Dock Levellers

Dock Levellers 

Technical Details 

■ Overview 

HLS-2 

HTL-2 

1 

1 

6.2 

Frame and box models 

6.2 

6 

Frame and box models 

6 

2 

6.1 

1 Basic frame 

2 Platform 

3 Dock leveller (HTL-2) or telescopic lip (HTL-2) 

4 Toe Guards 4 

5 Maintenance Strut 

2 

5 

5 

6.1 

3 

3 

Hörmann Loading Technology CHE 02-05 - Subject to Changes Dock Levellers - 16 

4 

4 

6.2 

1 5 

Pit model 

6.2 

6 

1 5 

Pit model 

2 3 

6 

2 3 

7 7 

6 Electro-hydraulic unit 

6.1 Main cylinder 

6.2 Hinged lip or telescopic cylinder 

7 Tailboard slot cover HTL-2 

6.1 

6.1 

Dock-Levellers - 16.



■ Basic Frame 

Self-supporting steel frame, welded with 

reinforcement profiles for the 2 main cylinders, 

matched to the respective load capacity. 

Calculation according to the Finite Element Method. 

Further execution dependent on the model: 

Frame and box models fitted with edge angles, 

closed at the sides, on box model also at the back. 

FR and box model with side adjustment angles 

and anchors all round, FA model with anchors at 

back only. 

■ Platform 

Profiled, slip-resistant steel (chequer plate), S 235 JR, 

standard material thickness 6/8 mm with 

reinforcement profiles S 355 JO. If required, 

e.g. when forklift trucks with PU tyres are involved, 

also available with 8/10 cm thick chequer plate. 

The construction conforms to EN 1398, 

being designed for handling equipment with 

a load on 1 axle over 2 contact surfaces, 

150 x 150 mm, at a distance of 1 m apart. 

Smaller contact surfaces, for example, 

as presented by so called reach trucks with 

hard PU tyres exert increased pressure on 

the platform which can cause permanent 

damage (deformation) to the platform 

surface. 

■ Hinges 

At the front end: 2 hinge axles, Ø 28 mm 

At the back end: 3 hinge axles in sockets 

Ø 60.3 x 14.2 mm. 

■ Safety marking 

Yellow/black markings applied to the lateral edge 

of the platform and the inside of the basic frame 

clearly show when the dock leveller has travelled 

up or down. 

■ Hinged lip / telescopic lip 

Made of profile, slip-resistant steel, 

Material S 355 JO, in a standard thickness of 

12/14 mm. The slightly inclined lip provides a good 

area of support when loading above the horizontal, 

thereby avoiding a "level crossing effect". 

Type R - straight: standard 

version for dock levellers up 

to 2000 mm wide 

Type S - tapered: standard 

version for dock levellers 

from 2100 mm wide 

Type SG - with separate 

segments: optional 

Hinged lip 

405 mm long, with open, 

self-cleaning 

orthotropically designed 

lip hinge, i.e. with 

150 mm long specially 

arranged supporting hinge 

strips (S355 JO). 

In the home position the 

hinged lip engages 

behind a locking device 

which also prevents 

intruders from using 

the dock leveller to gain 

access. 

Telescopic lip 

Reach 500 or 1000 mm long (short designation 

corresponding to HTL-2-5 or -10) 

The telescopic lip is guided by trapezoidal tubular 

profiles underneath the platform. 

The complete telescopic lip has a length of twice 

the reach + 350 mm. For this reason a 2 m long 

dock leveller HTL-2 with a reach of 1000 mm 

cannot be supplied. 

Dock-Levellers - 17. 

Hörmann Loading Technology CHE 02-05 - Subject to Changes Dock Levellers - 17



■ Toe guards 

Made of galvanized steel, telescopic. 

Toe guards prevent feet from getting trapped 

between the loading platform and the dock leveller. 

■ Maintenance strut 

Made of galvanized steel. 

The maintenance strut serves to secure and 

support the platform during maintenance 

checks and repairs. 

■ Front cover 

Hörmann HTL-2 dock levellers are supplied with 

a front cover in black flap material as a standard 

feature. 

■ Surface 

The steel surfaces are sand-blasted or stained 

and coated with a two-component PU paint, 

in a choice of traffic black (RAL 9017) or ultramarine 

blue (RAL 5002). 

On request, a galvanized version or one coated in 

a chosen colour to RAL is also possible. 

■ Electro-hydraulic unit 

Hörmann dock levellers feature an electro-hydraulic 

unit with 2 main cylinders which move the platform 

and a further cylinder for the hinged or telescopic 

lip. The main cylinders are attached to the left and 

right near the outer edge, whereby in the event of 

an emergency STOP any deforming can be 

counteracted as far as possible to do so. 

Power rating: 400 V / 50 Hz 

Motor output: 1.1 kW 

Safety elements: electronic emergency STOP 

valve, hose break valves, 

thermal and short-circuit fuse, 

restart lock following a power 

failure or emergency STOP 

■ Controls - from June 2005! 

Depending on requirements, Hörmann dock 

levellers can be equipped with 

- basic controls 420S/420T or 

- multiple controls 445S/445T or 460S/460T. 

All the controls are ideal for combining with 

Hörmann door controls: 

For the control of the dock door and dock 

leveller only 1 feeder cable is required! 

Housing identical in appearance and 

dimensions 

Uniform easy-to-follow menu prompting 

Same control for three-phase current and 

alternating current 

Same comprehensive accessories, 

e.g. signal lights, photocells 

All the dock leveller controls offer the option of 

mutual safeguarding of the dock door and dock 

leveller to prevent damage. For this, see section 

"Dock Leveller and Dock Door". 

The functions and options of the various controls 

are listed in the following overview as well as 

described in detail in the corresponding instructions. 

Hörmann Loading Technology CHE 02-05 - Subject to Changes Dock-Levellers Dock Levellers - 18. 

18



Overview of Basic controls Multiple controls 

4xxS: controls for HLS-2 

4xxT: controls for HLS-2 

1) Connection kit required 

420 S 420 T 445 S 445 T 460 S 460 T 

Separate control unit housing ✗ ✗ ✗ ✗ ✗ ✗ 

Protection category IP 65 ✗ ✗ ✗ ✗ ✗ ✗ 

Mains supply 400V / 230 V ✗ ✗ ✗ ✗ ✗ ✗ 

Main switch / emergency-STOP switch ✗ ✗ ✗ ✗ ✗ ✗ 

Membrane keypad integrated into 

the housing cover ✗ ✗ ✗ ✗ ✗ ✗ 

Can be combined 

with Hörmann controls ✗ ✗ ✗ ✗ ✗ ✗ 

Prepared for dock leveller 

release function ✗ ✗ ✗ ✗ ✗ ✗ 

Prepared for door 

release function ✗ ✗ ✗ ✗ 

Menu readout and programming 

via double 7 segment display ✗ ✗ ✗ ✗ 

Service menu with maintenance 

cycles and operating hours counter 

as well as error analysis ✗ ✗ ✗ ✗ 

Power-ON and error/malfunction 

display includes readout 

of last 5 error messages ✗ ✗ ✗ ✗ 

Connection option 

for wheel chock with sensor ✗ ✗ ✗ ✗ ✗ ✗ 

Connection option for proximity switch 1) 1) ✗ ✗ ✗ ✗ 

Connection option for signal lights 

system, photocell, registering 

driver's arrival etc. ✗ ✗ ✗ ✗ 

Option for control of an inflatable 

dock shelter/seal with or 

without roll-down flap. ✗ ✗ 

Semi-automatic operation: 

door closes when the dock leveller 

is in the home position ✗ ✗ 





■ Load capacity/rated load 

As standard 60 kN to EN 1398. 

Higher load capacities (for HLS-2 to180 kN, 

for HTL-2 to 150 kN) optional. 

The required load capacity is determined by the 

overall weight of 

• the handling equipment 

• the payload 

• the auxiliary devices used 

Never be tempted to take into 

account the supposed "actual" 

loading weight instead of the 

maximum load capacity of the forklift truck! 

We know from experience that the maximum load 

capacity of the forklift truck is always used to the full. 

Despite the short-term advantages when ordering 

a standard dock leveller, an undersized product will in 

the long term inevitably lead to complaints as a result 

of overloading. 

In addition to that, the type and quality of the 

forklift truck tyres is also a key factor. 

By way of comparison: 

In accordance with the European Standard 1398, 

the rated load stated on the type plate is based on 

handling equipment with 

- a load on one axle 

- 2 contact areas 150 x 150 mm 

- a distance of 1 m. 

These trucks have pneumatic tyres or “superelastic 

tyres”. 

Other, hard (PU) tyres, e.g. in Vulkollan, have 

smaller contact surfaces and therefore apply greater 

pressure to the platform. As a result, given the 

corresponding overall weight, this can cause the 

chequer plate of the dock leveller to deform. Such 

tyres are used, for e.g., on so called reach trucks. 

It should be made known in advance if forklift 

trucks with harder tyres are to be used. 

In such cases it may be necessary to choose a 

stronger platform or a dock leveller with a higher 

load capacity. 

Type Forklift truck Powered high-lift truck Reach truck 

with tandem rollers with single rollers 

Tyres inflated/ PU/ Vulkollan PU/ Vulkollan PU/ Vulkollan 

Super-elastic 

• Rated load 60 kN 

Permissible total weight* (dock leveller in operating position) 

Chequer plate 6/8 6t 5t 4t 3t 


• Rated load 90 kN 


* Note: When exceeded, there is a risk of tyre tracks. The rated load is not affected. 





■ Further technical features 

Height compensation 

DIN EN 1398 a well as ZH 1/156 permit a 

maximum gradient of 12.5%. 

Torsional flexibility / twist capability 

Thanks to precisely dimensioned profiles on the 

bottom platform edge and double cylinder 

hydraulics a high degree of twist can be achieved 

without impairing the stability. 

Temperature 

The dock leveller and the hydraulic oil used as 

standard are suitable for temperatures ranging 

between approx. –15°C and +50°C. In the case of 

lower temperatures, adjustments are necessary, 

above all it is important to use another type of oil. 

In doing so, bear in mind the effect of wind. 

Weights 

The weights of the dock leveller, depending on 

the type, installation model and size, are listed in 

the tables of the following drawings: 

V3042 HLS… Dimensions and Weights HLS-2 

V3042 HTL… Dimensions and Weights HTL-2 

■ Optional extras 

Weather seals 

A weather seal can be attached to the outside of 

the platform to prevent drafts entering the building 

through the gap between the base frame/pit and 

the platform. 

Anti-slip coating 

In certain circumstances, such as in meat 

processing, it may be necessary to provide 

special anti-slip protection. 

For this purpose, a special anti-slip coating is 

available which is applied to the platform. 

Made up of a two-component epoxy resin, it is 

particularly hard-wearing and chemically resistant 

which, in respect of goods traffic, is exactly what 

is called for. 

Note: on a galvanized surface the anti-slip coating 

does not adhere particularly well. 

In such cases, the surface must be pretreated. 

Thermal insulation 

Hinged lip dock levellers can be supplied with 

a 30 mm thick insulation layer underneath the 

platform. Providing thermal insulation for telescopic 

dock levellers is not quite so straightforward, so 

a specific enquiry must be made to establish the 

feasibility and costs. 


21


Dock Leveller and Door 

■ Interlocking of door/dock leveller 

ALWAYS NECESSARY: Prevent the dock leveller 

being raised when the door is closed. 

Otherwise in the case of a manually operated door, 

the latching will be excessively strained or damaged. 

With a closed power-operated door, the operator 

would block the spring axle. 

The rise of the dock leveller could cause the cables 

to fall from the cable drum. 

On a door with door security kit, this would be 

considerably strained or damaged. 

Solution: the dock leveller 

release function 

The door's end-of-travel signalling 

ensures that the dock leveller 

cannot be operated when the 

door is closed. 

An additional PCB is required for 

the door controls. 

The dock leveller controls are 

already prepared for this function. 

Drawback: if the motor fails, no signal is issued 

and the dock leveller cannot be operated. 

The alternative would be to install a proximity 

switch in the door's clear opening. This would then 

guarantee release even without function of the 

controls and on manually operated doors. 

On manually operated doors a fuse-disconnecting 

switch can also be installed on the door. Careful 

consideration must, however, be given to where 

this will be positioned, e.g. on the shoot bolt or at 

the top. 

If it is installed at the very top of the door and the 

door travels back a short distance once having 

reached the end-of-travel position, it is possible that 

the switch will switch back on again unintentionally, 

thus preventing operation of the dock leveller. 

If it is installed lower down, there is a risk that forklift 

trucks will drive into a door that has not fully opened. 

OPTIONAL: Preventing the door from closing 

while the dock leveller is still in a working 

position. 

Depending on the site conditions, it can prove 

practical to fit a device to ensure that the door 

does not close until the dock leveller is in the home 

position. 

If, for e.g., the door is closed by central or remote 

control while loading is still taking place, there is a 

risk that the door will sustain collision damage. 

Solution: door release function 

This ensures that the door can 

only be closed when the dock 

leveller is in the home position. 

For this, a proximity switch is 

attached to the dock leveller. 

The door controls are not 

released until this has been 

activated. 

Hörmann multiple controls are 

already prepared for this door release function. 

Basic controls require a connection kit in order to 

allow connection of the proximity switch. 

This function is also necessary together with 

semi-automatic operation. With multiple controls 

using semi-automatic operation the door closes 

automatically following clearance of the dock 

leveller. 


22


Particular Benefits 

■ TÜV-tested safety 

■ 28 standard sizes: 4 widths, 7 lengths 

■ As standard load capacity up to 60 kN 

■ Installation models for any situation: frame, box and pit model, 

renovation adapters for different pit sizes 

■ Extremely large working range above and below the horizontal 

■ Extended loading surface thanks to the inclination of the lip 

■ Open, self-cleaning lip hinge on HLS-2 

■ Long hinged lip on HLS-2, 405 mm 

■ HTL-2 telescopic lip supports with 132 mm high trapezoidal sections 

■ High-grade selection of materials and dimensioning on all hinges 

■ Effective telescopic toe guards 

■ Electric motor precabled and connected to the dock leveller 

■ Can be combined with door controls 

■ Door and dock leveller with mutual safeguard 

■ Expert testing and maintenance for the complete loading station 

including dock shelters/seals and doors possible 


Änderungen vorbehalten CHE 02-05 23


Special Solutions 

■ Hörmann DOBO System: first dock, then open the doors 

The Difference 

In contrast to conventional loading situations, 

with the DOBO system the lorry can dock while 

the doors are still closed. The doors can be 

opened after the vehicle has docked. 

Field of Application 

The DOBO System is the ideal solution 

- for the absolutely hygienic transportation of fish, 

meat and other chilled goods. 

- for customs purposes in those situations where 

the doors must remain closed until the customs 

officers arrive. 

- to prevent pilfering. 

In detail 

The Hörmann DOBO System (docking before 

opening) provides a cavity on the left and right of 

the dock leveller (pit model) for parking the lorry 

doors. 

When in the home position, the dock leveller is 

already at its lowest position below the horizontal 

plane. In this way the doors can be opened 

unimpeded. 

Hörmann dock levellers of the HLS-2 type with 

hinged lip are specifically modified for this purpose. 

For HTL-2 dock levellers with a telescopic lip no 

changes to the structural design are required. 

Combining the DOBO System with a loading 

house is recommended. The building itself then 

stays as it is - no structural alterations are 

necessary. 

Drawing 

405002 Pit dimensions for pit model 

“P” for the DOBO System 





■ Hörmann Dock Leveller HTLV-2 

With multifunctional three-segment telescopic lip for lorries and delivery vans 

With HTLV-2 type dock levellers you have the 

choice: the three-segment telescopic lip can be 

extended to cover the entire width or simply 

switched over to allow use of the 1 metre wide 

middle section only. 

In a delivery van situation, the weight is compensated 

over the 1000 mm wide telescopic lip via an 

ingenious hydraulic system (patent pending). 

As a result, there is no overloading of the delivery 

van due to the combined weight on the dock 

leveller of the handling equipment and load. 

In a lorry situation, the 500 mm long 

three-segment telescopic lip can be infinitely 

extended over its full width (2000 mm). 

The dock leveller can now bear a dynamic load of 

up to 60 kN. 

The platform of the dock leveller therefore becomes 

a multifunctional loading station! 

Since the deck of the delivery van is lower than 

that of a lorry, the HTLV-2 dock leveller has a larger 

working area below the horizontal than conventional 

dock levellers. This is achieved by dispensing with 

the usual front girder with supporting members. 

Instead, 2 hydraulically controlled bolts at the sides 

support the platform in the home position. 

Dock Levellers of the HTLV-2 type are available as 

frame or box models. 

Dimensions and working range: 

Ordering size: 2000 x 3000 mm 

Overall height: 795 mm 

Width of 

telescopic lip: 2000: 500/1000/500 mm 

Working range: 565 mm below the horizontal, 

465 mm above the horizontal 

Rated load: 60 kN lorry 

20 kN delivery van 





■ Hörmann Dock Leveller HTLP-2 

With parallel connection to lorries for forklift trucks and stacker lift trucks 

A reliable system 

With the HTLP-2 dock leveller, the transport vehicle 

always stands horizontal throughout the loading 

process. 

Thanks to the parallel guidance in the front section of 

the dock leveller, you can load high goods into the 

lorry using a forklift truck as well as access the very 

last pallet using a simple stacker lift truck. 

The 500 mm long telescopic lip with 2 separate 

slide-in segments is infinitely extendable, so precise 

positioning is guaranteed. 

The self-supporting base frame, the chequer-plated 

platform with a high degree of twist, 2 main cylinders 

with automatic emergency-STOP valves plus simple 

operation make loading a safe and straightforward 

procedure. 

Installation methods 

HTLP-2 dock levellers are available as a frame 

model, i.e. with self-supporting frame, or as a box 

model for particularly quick and straightforward 

installation. 

Dimensions and levelling: 

Ordering size: 2400 x 4700 mm 

Parallel section: 1200 mm 

Length of gradient: 3500 mm 

Overall height: 900 mm 

Length of 

telescopic lip: 500 mm 

Levelling: 440 mm below the horizontal 

400 mm above the horizontal 

Rated load: 60 kN

Dock Levellers

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