Poweramp VS Manual Sept2012
Contents
1. VERTICAL LIPS 2003 to Present 6 WIDE 40K W O Gussets 40 45K WO Gussets 90K W Gussets 16 0595 0387 0595 1107 0595 1107 18 0595 0388 0595 1108 0595 1108 20 0595 0389 0595 1109 0595 1109 6 5 WIDE 16 0595 0390 0595 1110 0595 1110 18 0595 0391 0595 1111 0595 1111 20 9222 0382 0595 1112 0595 1112 7 WIDE 16 0595 0393 0595 1113 0595 1113 18 0595 0394 0595 1114 0595 1114 20 0595 0395 0595 1115 0595 1115 VERTICAL PLATFORMS 2003 to Present 6 WIDE 40K W O Gussets 40 45K WO Gussets 90K W Gussets 5 9515 0843 9515 1077 9515 1121 6 9515 0844 9515 1074 9515 1124 8 9515 1065 9515 1071 CALL 6 5 WIDE 5 9515 0845 9515 1078 9515 1122 6 9515 0846 9515 1075 9515 1125 8 9515 1066 9515 1072 CALL 7 WIDE 5 9515 0849 9515 1079 9515 1123 6 9515 0848 9515 1076 9515 1126 8 9515 1067 9515 1073 CALL 4111 0008 Sept 2012 37 PARTS Lip and Platform 38 4111 0008 Sept 2012 PARTS Item Quantity Part Number Description A 1 See Table page 37 Lip Weldment Call on 2002 and older levelers B 1 See Table page 37 Platform Welded Assembly Call on 2002 and older levelers 9202 0050 Pin Lip Hinge 6 W 9202 0051 Pin Lip Hinge 6 5 W 9202 0052 Pin Lip Hinge 7 W C 9202 0053 Pin Lip Hinge EW SS 9202 0054 Pin Lip Hinge 6 5 W SS 9202 0055 Pin Lip Hinge 7W SS 9202 0040 Rear Hinge Pin S S 9202 02. position during installation They will keep the leveler in the upright position once the hinge pins are installed until the storage prop and hoist cylinder are installed and the leveler is ready for testing Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death 4111 0008 Sept 2012 11 IMPORTANT HI D Ke GA O UN Ve o Yi gt N gt ke O c Ki Ces amp be B GA UN ab gt ke O B e D ab te O ab Q O O O B D 2 O O D O c QD O O D Yi c C C bel Ben D D 2 O ab Q gt E bel c ab 2 oO ab O c Bn ab Q O Benn Q O cC lt D ab K UN O O O D o o 2 O Remove any control panel bumpers or pelletizing that may be banded to the dock leveler 1 Do not remove banding on hoist cylinder or storage prop at this time 2 Make sure the mounting hardware of lifting bracket s A is snug The brackets should pivot relatively freely on the mounting cap screw DO NOT over tighten NOTE Overall length of lifting chain and bracket A must be kept to a minimum to prevent interference between the lifting equipment and and the building ceiling or door as the dock leveler is lowered into the pit A and to S 3 Attach lifting chain to lifting bracket hav
3. This page was intentional left blank 4111 0008 Sept 2012 9 INSTALLATION Prepare Pit A Distance Pit Width B Distance Dock Floor to Pit Front and Rear Floor All Four Corners 1 2 Taper Rear to Front Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before installation has been completed Failure to follow the installation instructions can result in damage to dock leveler the facilities and or serious personal injury or death Only trained installation professionals with the proper equipment should install this product Before lowering the dock leveler into the pit the following must be performed 1 Remove all debris from the pit and sweep the pit clean 2 Check the entire dock leveler pit for proper construction according to approved certified pit drawings Make sure pit is square has the proper depth and taper by making the following measurements 10 C Distance Pit Length D Distance Pit Corner to Corner Top Both Sides of Pit Bottom and Both Sides Measure pit width distance A at both front and rear of pit e Measure dock floor to pit floor distance B on both sides of the rear embed channel and at front if applicable e Measure pit floor taper rear to front cannot exceed 1 2 total taper Measure pit length distance C at both sides Measure corner to corner cris cross distan
4. Breather Reservoir E 4 21010011 Hex Head Capscrew F 4 2101 0058 Lock Washer G 4 2101 0060 Flat Washer 9394 0014 Motor Assembly 115V 1 Ph 9394 0015 Motor Assembly 460V 3 Ph 9394 0033 Motor Assembly 208V 1 Ph H 1 9394 0034 Motor Assembly 230V 1 Ph 9394 0035 Motor Assembly 575V 3 Ph 9394 0043 Motor Assembly 208V 3 Ph 9394 0044 Motor Assembly 230V 3 Ph 1 9301 0132 Pump 1 75Gpm L 1 9904 0090 Hose 17 50 Lg 8 Jic Swivel Both Ends 5 6 LG M 1 9904 0059 Hose 35 00 Lg 6 Jic Swivel Both Ends 8 LG 1 9904 0137 Hose 60 00 Lg 6 Jic Swivel Both Ends N 1 9904 0103 Hose 10 50 Lg 8 ORB to 8 Jic Swivel O 1 9904 0059 Hose 35 00 Lg 6 Jic Swivel Both Ends P 1 9904 0083 Hose 44 50 Lg 6 Jic Swivel Both Ends Q 2 9904 0102 Hose 21 00 Lg 8 ORB to 8 Jic Swivel H 1 9301 0115 Fitting 90 Deg 6 ORB To 8 Jic S 1 9301 0116 Fitting 90 Deg 8 ORB To 8 Jic T 1 8583 0089 Vertical Valve Assembly 1 Provide dock leveler serial number platform size and lip size when calling or faxing orders 2 Provide length and width of inspection plate opening when calling or faxing orders 4111 0008 Sept 2012 41 Centra Power Hydraulic Components 42 4111 0008 Sept 2012 PARTS Item Quantity Part Number Description A 1 0525 0085 Lip Cylinder B 1 0525 0066 Hoist Cylinder 10 and 12 Pits 0525 0104 Hoist Cylinder 15 Pits C 1 9904 0059 Hose 35 00 Lg 6 Jic Swiv
5. M 2 4301 0003 Cable Assembly Dual Coil Includes Screw N 1 4301 0004 Cable Assembly Single Coil Includes Screw O 1 8585 0099 Valve Manifold V8 W PowerHold Centra Power Only Coils Included A L Included in in 8585 0099 4111 0008 Sept 2012 49 PARTS Centra Power VS Manifold W Powerhold Lower Platform m N Restraint Pressure Restraint Valve GON K Pump Psi 1 d Return to Tank Restraint Return J Hoist Cyl Blind End C Lip Valve Pressure Relief GU D E Lower Platform To Tank PAO Float Valve H Hoist Cylinder Rod End J Diverter Valve LXA Item Quantity Part Number Description A 2 8581 0005 Valve Cartridge 3 Way Delta B 1 8581 0105 Valve Cartridge Direct Acting Relief Relief C 1 8581 0092 Valve Cartridge Fixed 5 GPM Flow Control Valve D 1 8581 0139 Valve Cartridge Orifice Check Lip Flow Control Internal E 1 8581 0010 Valve Cartridge 2 Way N C Poppet F 1 8581 0102 Valve Cartridge 2 Way Bi Directional G 2 8581 001 1 Valve Cartridge 4 Way H 1 8581 0088 Valve Cartridge Fixed 2 GPM Flow Control Valve 1 9301 0109 Fitting Male 6 Orb X 6 Jic J 4 9301 0113 Fitting Elbow 90 Deg Male 6 Orb X 6 Jic K 2 9301 0116 Fitting Elbow 90 Deg Male 8 Orb X 8 Jic L 6 8581 0004 Delta Coil 115V Includes 1 2 UNF Jam Nut M 3 4301 0003 Cable Assembly Dual Coal In
6. be approximately 2 in 51 mm N from top of reservoir M with platform stored and the lip in the flooded position 5 Add hydraulic fluid if necessary Use only recommended fluid Pg 23 6 Install breather cap 7 Turn ON electrical power to the leveler 8 Return the lip to the raised position 25 ADJUSTMENTS SC Adjust Main Pressure Relief When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the a maintenance prop Failure to do this may result in serious personal injury or death 31V Id JAVN Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before n maintenance is complete Failure to do this may OE tr result in serious personal injury or death NOTE The main pressure relief may need to be Pressure increased if the platform does not rise or A Motor D Jam Nut rises slowly and the system operates in B Pump E Acorn Nut pressure relief mode See Troubleshooting C Main Pressure Relief section To adjust the main pressure relief The main pressure relief may need to be decreased if the pump motor loads down when platform starts to raise from the lowered position See Troubleshooting section 1 Raise the platform fully and engage the maintenance prop in the service positio
7. chocked unless the truck restraint is used Never remove the wheel chocks until loading unloading is finished and truck driver has been given permission to leave Make sure platform lip rests on the truck trailer bed with at least 4 in 102 mm of overlap Maintain a safe distance from side edges of leveler during the loading unloading process Failure to follow these instructions may result in serious personal injury or death The dock leveler operating instructions are divided into the two methods of loading and unloading e For ramp loading and unloading see Ramp Loading Unloading Instructions on page 20 e For end loading and unloading see End Loading Unloading Instructions on page 21 4111 0008 Sept 2012 OPERATION 10 in 254 mm LEE EE Y 8 in 203 mm The VS hydraulic dock leveler is designed to compensate for a maximum 10 in 254 mm above and 8 in 203 below dock difference between the loading dock and the truck bed DO NOT use the dock leveler if the truck trailer bed is more than 10 in above 8 in below higher or lower than the dock floor Based on a 5 ft or 6 ft long leveler service height may vary with design specifications DO NOT overload the dock leveler DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave equipment or material unattended on the dock leveler Failure to follow these instructions may result in personal injury and or
8. for high resistance or no connection Heverse any two legs at the branch circuit disconnect Check wiring to motor for high resistance Check for loose or corroded connections Check if gauge of wires to motor are of correct size and specification for load requirement Replace if necessary Heplace motor Defective motor capacitor Replace motor 31 Platform does not Heavy object s on platform Remove object s from platform rise Pump operates in pressure relief mode NOTE For safety reasons the dock leveler is designed to lift only the platform s own weight Dock leveler binds Check for visible obstructions that could cause binding Remove obstructions If no obstructions found call Poweramp Technical Services See inside back cover for phone number and address Pressure relief set too low Increase pressure relief See Adjust Main Pressure Helief in the Adjustment section NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Platform rises slowly Low hydraulic fluid Add fluid as needed See Periodic Maintenance in the Maintenance section Contaminated hydraulic Clean and inspect valves Flush contaminated oil system from hydraulic system Fill system with new oil See Periodic Mai
9. single phase not energizing Three phase units only No voltage is present on Platform does not rise or one line lower Motor hums but does not run NOTE A motor that is missing voltage on one line is said to be single phased Three phase units only Phase reversed Platform does not rise Motor runs in reverse Single phase units only Line voltage too low Platform does not rise or lower Motor energizes but does not run Defective motor centrifugal switch 4111 0008 Sept 2012 TROUBLESHOOTING Heset overload relay three phase or replace fuse s single phase Determine cause of overload NOTE When replacing fuse s the new fuse must have the same specification as the old fuse Check voltage at starter or relay coil If voltage is present and starter or relay does not energize replace starter or relay If voltage is not present check all components in series with the starter or relay coil Check for blown fuses at branch circuit disconnect Heplace fuse Determine cause of blown fuse Check motor starter as follows 1 Disconnect wires at load side of starter 2 Energize the starter 3 4 Measure line to line voltage at load side of Measure line to line voltage at line side of starter starter Line side and load side voltages should be approximately the same Replace starter if voltage values are considerably different from one another Check all wiring to motor
10. 041 Hear Hinge Pin Stainless Steel E 6 2101 0245 Cotter Pin F 1 9515 Imbed Call G 2 9222 0221 Maintenance Prop H 4 2101 0262 Bolt 5 8 11 UNC X 1 75 Grade 8 4 2101 0042 Nut 5 8 11 UNC Grade 5 J 1 0525 0085 Lip Cylinder K 1 9202 0004 Pin Lip Cyl 3 4 Dia x 4 3 8 Lg L 2 2101 0049 Hairpin Clip M 1 2401 0004 Grommet N 1 0525 0066 Hoist Cylinder O 1 9202 0038 Pin Hoist Cyl 49 64 Dia 10 1 4 Lg P 4 2101 0093 Washer flat 3 4 Q 1 8581 0023 Prop Kicker R 4 2101 0153 Hex Head Cap Screw 1 4 20 UNC x 1 2 Lg S 4 2101 0005 Washer 1 4 in Lock T 2 9225 0016 Storage Prop U 1 9202 0067 Hoist Cyl Pin Rod End V 1 2101 0259 Ring Clip Rue W 2 2101 0046 Cotter Pin X 1 0522 0005 Clevis Pin Y 1 2101 0045 Cotter Pin 4111 0008 Sept 2012 39 PARIS gt SC Vertical Leveler Hydraulic Components Sight Glass Fluid should cover half the sight glass Fluid level must be checked with leveler in the stored position with the lip folded 40 4111 0008 Sept 2012 o PARTS SC Vertical Leveler Hydraulic Components Item Quantity Part Number Description A 1 0525 0085 Lip Cylinder B 1 0525 0066 Hoist Cylinder 10 and 12 Pits 0525 0104 Hoist Cylinder 15 Pits C 1 9394 0024 Reservoir Short 5 6 Lg Includes Hoses 9904 0102 amp 9904 0103 9394 0053 Heservoir Long 8 Lg Includes Hoses 9904 0102 amp 9904 0103 D 1 9301 0199
11. 1 0008 Sept 2012 Safety Decal s A DANGER CRUSH HAZARD DO NOT WORK UNDER DOCK LEVELER unless all maintenance props have been properly positioned Side maintenance props must be positioned as shown in figure A below Prop locking pin must be positioned as shown in figure B below Refer to owner s user s manual for proper procedure Failure to do so will result in death or serious injury FIG A Storage Position FIG B LS e Maintenance Position Safety Decal on Leveler Frame A DANGER CRUSH HAZARD DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance prop Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury Safety Decal on Platform Cylinder 4111 0008 Sept 2012 AA DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is safely supported by maintenance prop Place barriers on drive way and dock floor to indicate service work being performed Refer to owner s user s manual for proper maintenance procedures Failure to comply will result in death or serious injury Safety Decal on Hear Platform A DANGER If for any reason the platform is raised by means other than the hydraulic system i e Fork truck or c
12. 5 Valve Cartridge 3 Way Delta C 1 We Fitting Plug D 1 8581 0088 Valve Cartridge Flow 2GPM E 2 0521 0017 Fitting Elbow 90 Deg Male F 1 9904 0120 Fitting Elbow 45 Deg Male 8 Orb X 8 Jic G 1 9904 0116 Fitting Elbow 90 Deg Male 8 Orb X 8 Jic H 1 8581 0004 Delta Coil 115V Includes 1 2 UNF Jam Nut 1 4301 0001 Cable Assembly 48 Lg Includes Screw J 1 8583 0045 Centra Power valve Assembly A G Included in in 8583 0045 Not Sold Separate 4111 0008 Sept 2012 47 PARTS VS Manifold W O Powerhold Centra Power Diverter Valve Lower Platform LEI kK Pump Psi UM K Return to Tank u ON Q Hoist Cyl Blind End J Hoist Cyl Blind End DXJ Lip Cylinder e Lip Valve Pressure Relief SD E Lower Platform Hoist Cylinder Rod End J FX Float Valve Item Quantity Part Number Description A 2 8581 0005 Valve Cartridge 3 Way Delta B 1 8581 0105 Valve Cartridge Direct Acting Relief Relief D 1 8581 0139 Valve Cartridge Orifice Check Lip Flow Control Internal E 1 8581 0010 Valve Cartridge 2 Way N C Poppet F 1 8581 0102 Valve Cartridge 2 Way Bi Directional G 1 8581 0011 Valve Cartridge 4 Way H 1 8581 0088 Valve Cartridge Fixed 2 GPM Flow Control Valve J 3 9301 0113 Fitting Elbow 90 Deg Male 6 Orb X 6 Jic K 2 9301 0116 Fitting Elbow 90 Deg Male 8
13. A Division of Systems Inc VS SERIES Gm l Dock Leveler Owner s User s Manual POWERAMP Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 257 7399 www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0008 Copyright 2008 September 2012 Page Safety Recognize Safety Information ee esee 1 General Operational Safety Precautions 1 Operational Safety Precautions cessere esee 2 Maintenance Safety Precautions eese 4 E LEE eege 5 Owners Users Responsibility eee e ERR ess 6 Introduction General Informall n octo id eius c aR Ra 6 Dock Leveler Stock Specifications 6 Component lIdentification 1 cce eceee eere ee eeeeen ee 7 Installation Prepare PIN waar em 8 Prepare Dock Leveler irasos onki aa a AEA SaS 9 Install Dock Leveler sinna a Ea E AAA 10 Install Control Panel and Wiring 13 Put New Leveler Into Service ss 15 Operation ISIC ORV Em 16 Operating Instructions ENEE 22 Ramp Loading Unloading Instruct
14. HIRD PARTIES FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY VS SERIES LEVELER In addition to the Standard Product Warranty provided with all Poweramp Products Systems Inc guarantees materials components and workmanship to be free of defects for the following extended periods e Structural Warranty VS For a period of five 5 years from the date of shipment this warranty specifically applies to the deck section lip section rear hinge assembly and front hinge assembly only Hydraulic Warranty VS For a period of five 5 years from date of shipment this warranty specifically applies to the hydraulic pump and motor all hydraulic cylinders hydraulic pressure lines and fittings only
15. Hoist Cyl HT LU Rod End CO v K B pos M 5 c 10 fb Ke A A IE X d LX Item Quantity Part Number Description A 1 8581 0005 Valve Cartridge 3 Way Delta B 1 8581 0102 Valve Cartridge 2 Way Bi Dr Delta C 1 8581 001 1 Valve Cartridge 4 Way 2 Pos Delta D 1 8581 0010 Valve Cartridge 2 Way N C Poppet Delta E 1 8581 0105 Valve Cartridge Relief F 1 id Valve Manifold G 1 ii Fitting Plug H 2 9301 0111 Fitting 6 ORB X 8 Jic 3 9301 0113 Fitting 90 Deg 6 ORB X 6 Jic J 4 8581 0004 Delta Coil 115V Includes 1 2 UNF Jam Nut K 2 4301 0001 Cable Assy 48 Lg Includes Screw L 2 4301 0003 Cable Assy 48 Lg Includes Screw Two Coil M 1 8581 0139 Orifice Check Lip Flow Control N 1 8585 0089 Vertical Valve Assembly A 1 amp M Included in in 8583 0089 Not Sold Separate 46 4111 0008 Sept 2012 Centra Power Manifold 3 Return From Dock leveler F 4 Pressure To Dock leveler 2 Return To Pump Station WE amp xu E 1 Pressure From e Pump Station X 4b Lo 903 m el 6 Item Quantity Part Number Description A 1 iis Valve Manifold B 1 8581 000
16. LLATION Install Control Panel and Wiring c SSE The electrical i i Ze power must be OFF prior to electrical A ees SARS installation For maximum protection use an OSHA NV U approved locking device to lock out all power if sources Only the person installing the equipment should have the key to unlock the power source Failure to follow these instructions may result in serious personal injury or death DO NOT make any final electrical connections until all welding has been completed Failure to do this may result in serious personal injury or death All electrical work including the installation of the disconnect panel control panel and final connections to the pit junction box must be B Control Panel C Distance 48 in 14 630 mm performed by a certified electrician and conform to all local and applicable national codes A Disconnect Panel provided by others 1 Mount the push button control panel B so bottom 9 Lower dock leveler check to make sure the of control panel to dock floor distance C is 48 in leveler goes into float mode about 15 above 1219 2 mm dock floor allow to dock to float to full below position Make sure the dock makes contact with 2 Install electrical disconnect panel A if not already pit floor Push and hold the RAISE button until installed the leveler turns off and the Blue stored light comes on 3 Install and connect the control wiring 6 Ch
17. Orb X 8 Jic L 5 8581 0004 Delta Coil 115V Includes 1 2 UNF Jam Nut M 2 4301 0003 Cable Assembly Dual Coil Includes Screw N 1 4301 0004 Cable Assembly Single Coil Includes Screw O 1 8585 0098 Valve Manifold VG W O PowerHold Centra Power Only Coils Included A L Included in in 8585 0098 48 4111 0008 Sept 2012 PARTS VS Manifold W Powerhold EXL Lower Platform J Hoist Cyl Blind End Restraint Pressure J Restraint Valve LX G C kK Pump Psi NEZ d d Pressure Relief K Return to Tank H E ower Platform Hoist Cylinder Rod End J Restraint Return XL Float Valve E To Tank Item Quantity Part Number Description A 1 8581 0005 Valve Cartridge 3 Way Delta B 1 8581 0105 Valve Cartridge Direct Acting Relief Relief C 1 8581 0092 Valve Cartridge Fixed 5 GPM Flow Control Valve D 1 8581 0139 Valve Cartridge Orifice Check Lip Flow Control Internal E 1 8581 0010 Valve Cartridge 2 Way N C Poppet F 1 8581 0102 Valve Cartridge 2 Way Bi Directional G 2 8581 0011 Valve Cartridge 4 Way H 1 8581 0088 Valve Cartridge Fixed 2 GPM Flow Control Valve 1 9301 0109 Fitting Male 6 Orb X 6 Jic J 4 9301 0113 Fitting Elbow 90 Deg Male 6 Orb X 6 Jic K 2 9301 0116 Fitting Elbow 90 Deg Male 8 Orb X 8 Jic L 5 8581 0004 Delta Coil 115V Includes 1 2 UNF Jam Nut
18. S Power Pack Assembly Item Quantity Part Number Description A 2 2101 0039 Nylon Lock Nut 5 16 18 UNC B 2 9301 0029 Seal Thread C 1 9302 0014 Reservoir D 1 9301 0199 Breather Cap 3 8 NPT Male E 1 9301 0027 O Ring Reservoir F 2 9302 0012 Tie Rod Reservoir 1 9301 Pump Only G 4 2101 0039 Cap Screw 5 16 18 UNC x 3 1 2 in Grade 5 1 9301 0028 Gasket Pump 1 9303 0002 Coupling Assembly H 1 9302 0017 Plate Drive J 1 9904 0001 Hose K 1 0521 0017 90 Elbow 3 8 NPT Male x 8 JIC Male L 1 0521 0007 90 Elbow 1 4 NPT Male x 1 4 Tube M 1 3411 Motor Only N 1 0521 0015 Straight Fitting 3 8 NPT Male x 8 JIC Male P 1 0521 0014 Ball Check Q 1 9301 0024 Guide Check Ball H 1 9302 0009 opring Relief Valve S 1 9303 0003 Screw Adjusting T 2 9301 0014 Washer Nylon 11 16 in OD x 1 2 in ID U 1 9301 0015 Nut Jam 1 2 20 UNF V 1 9301 0016 Nut Acorn 1 2 20 UNF W 1 0521 0016 45 Elbow 3 8 NPT Male x 8 JIC Male X 1 9301 0009 Strainer Suction Y 1 9301 0082 Magnet Z 1 9301 0008 Pipe Nipple 3 8 NPT x 3 in AA 2 9301 0003 Washer Aluminum 9 16 in OD x 3 8 in ID x 1 16 in AB 2 9301 0004 Screw Socket Head 3 8 16 UNC x 1 3 4 in AC 2 2101 0063 Nut Jam 5 16 18 UNC 1 9395 Power Pack Complete Includes All Items Except L N and W 1 Provide dock leveler serial number and type of installation when calling or
19. and you no longer need to hold the lower button This feature is designed into the operation of the leveler to allow for the floating vertical motion of the trailer during loading and unloading Lip Lower and lip Raise K To lower the lip the vertical leveler must be in the lower mode Press the lower leveler and lip at the same time and the motor will shut off and the lip will lower To raise the lip the leveler must be in the raise mode Press the raise 18 KW SMS NN NK i F te J Raise Button EE H Solenoid K Lip Button I Lip Cylinder L Lower Button button and the lip button the motor will still run and the lip will will raise The Lip push button is inactive while the leveler is in the float mode Also when leveler is stored Some models are equipped with multiple cylinders 4111 0008 Sept 2012 Operating Instructions otay clear of dock leveler when freight carrier is entering or leaving dock area DO NOT move or use the dock leveler if anyone is under or in front of leveler Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Failure to follow these instructions may result in severe personal injury or death Only trained personnel should operate the dock leveler DO NOT use a broken or damaged dock leveler Make sure proper service and maintenance procedures have been performed on leveler before using Truck trailer wheels must be
20. arts Break Down Warranty Information and Manufacturers Contact Information The owner user shall be responsible to verify that this information is available and received as well as proper instructions training and familiarity of the equipment for all operators has been completed Owner s User s shall actively maintain update and re train all operators on safe working habits and operations of the equipment 3 9 It is recommended when the transportation vehicle is positioned correctly in the dock opening and in contact with both bumpers there shall be a minimum of 4 00 inches 100mm overlap of the leveling device and the transportation vehicle at all times during the loading and unloading process Name plates placards decals instructions and posted warnings shall not be obscured from the view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for any replacements Manufacturer s recommended periodic maintenance and inspection procedures in effect at the date of shipment shall be followed at all times Written documentation of maintenance replacement parts or damage should be retained In the event of damage notification to 9 the manufacturer is requested Any modifications or alterations of loading dock equipment shall only be done with prior written approval from the original equipment manufacturer When industrial moving devices are being used in the loading or unload
21. ce D at both sides Take measurements at dock floor level and at pit floor level NOTE If any measurement are off by more than 1 8 in 3 18 mm in depth width and squareness 1 4 in 0 in 6 32mm contact Poweramp Technical Services before proceeding Make sure the field junction box for the dock leveler E and floor embed plate F is at the correct location per pit diagrams 4111 0008 Sept 2012 INSTALLATION Prepare Dock Leveler A Lifting Bracket B Maintenance Props Poweramp dock levelers are designed with installation in mind Each unit is shipped with lifting 7 bracket s A fastened to the platform The dock leveler is heavy Use a lifting device and chains with the appropriate lifting capacity and reach Always use the lifting brackets provided with the unit whenever lowering or lifting a dock leveler into DO NOT remove the Maintenance Props at this or out of a pit time They should be rotated to the lowered
22. cludes Screw O 1 8585 0097 Valve Manifold VS W PowerHold Centra Power Only Coils Included A L Included in 8585 0097 50 4111 0008 Sept 2012 PARTS 4111 0008 Sept 2012 51 PARTS J J 4 3J 34 Platform Cylinder Repair Parts arrel Lg Item Quantity Part Number Description l A 1 9301 0109 Fitting Conn Str Thread 90 DEG Male B 1 9303 0025 Down Speed Control Valve Assy C 1 0521 0073 Grease Zerk D 1 2101 0093 Hex Nut E 1 9461 0002 Rod End F 1 0525 0066 Hoist Cylinder 10 and 12 Pits 15 3 4 Barrel Lg 1 0525 0104 Hoist Cylinder 15 Pits 23 Barrel Lg G 1 1751 0138 Decal Note No seal kit is available for this cylinder Provide dock leveler serial number when calling or faxing orders Not Sold Separately 52 4111 0008 Sept 2012 Ci PARTS Lip Cylinder Repair Parts ROSAS NAIA OA SS ANS SAX IS SSS GT E SUM cl ASN WARES AAA SANS XGA NSSS pe Item Quantity Part Number Description A 1 0525 0014 Seal Kit 1992 and earlier 0525 0059 Seal Kit 1992 and Newer B 1 0525 0085 VS Lip Cylinder Provide dock leveler serial number when calling or faxing orders Not Sold Separately 4111 0008 Sept 2012 53 Remote Mount Power Pack Assembly 54 4111 0008 Sept 2012 TC PART
23. d DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury IMPORTANT The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 0008 Sept 2012 General Operational Safety Precautions Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or guard is removed or disconnected Never remove DANGER WARNING or CAUTION signs or Decal s on the equipment unless replacing them Do not start the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone Hemove any tools or foreign objects from the operating zone before starting Keep the operating zone free of obstacles that could cause a person to trip or fall Operational Safety Precautions wor Stay clear of dock leveling device when freight carrier is entering or leaving area Do not move or use the dock leveling device if anyone is under or in front of it Ke
24. damage to equipment 4 DANGER Ld Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do nof open cover without appropriate PPE Refer to NFPA ZOE for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death 19 OPERATION Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 21 1 Check to make sure truck trailer is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the truck trailer wheels or use the truck restraint if available A LOWER Button 4 Lower the platform lip onto truck trailer as follows a Lower platform by pushing and holding LOWER button b Make sure that the lip is fully extended and supported on the truck trailer along the entire width of the platform with at least 4 in 102 mm of lip contacting the truck bed 20 Tere 5 Proceed with loading or unloading the truck trailer 6 If end loading is necessary see End Loading Unloading Instructions on page 21 B RAISE Button C STORED Button ra When loading or unloading is finished raise the platform by pushing and holding RAISE button When fully raised
25. e 26 Both valves must be energized Check power to the all spool valves they should have a magnetic pull Pump Motor must be running Remove and clean spool valves or replace with new or good working valves Pump Motor must be running 33 Storage Limit Switch Item Quantity Part Number Description A 2 2101 0027 Screw 3110 32 UNF x 1 75 Lg B 1 0961 0130 Arm Limit Switch C 1 0961 0186 Limit Switch 34 4111 0008 Sept 2012 E PARTS Solenoid Prop Kicker Item Quantity Part Number Description A 3 2101 0153 Bolt 1 4 UNC 1 2 Lg B 3 2101 0005 Washer Lock 1 4 C 1 8581 0023 Solenoid Prop Kicker J Box A C Item Quantity Part Number Description A 1 2751 0042 J Box Fiber Glass 5 x 5 Includes Cover B 1 0961 0054 Mercury Switch C 1 3051 0025 Rectifier Bridge 4111 0008 Sept 2012 35 PARIS gt Storage Prop Assembly Item Quantity Part Number Description A 1 9222 0097 Yoke Upper Arm Prop B 3 0522 0005 Clevis Pin 3 4 Dia x 2 2 4 Lg C 1 ii Upper Weldment D 1 e Lower Weldment E 1 9201 0006 Prop lock Pin and Clip F 3 2101 0047 Cotter Pin H 1 9225 0016 Storage Prop Assembly Not Sold Separate 36 4111 0008 Sept 2012 PARTS Lip and Platform See drawing on page 38
26. e hoist cylinder and below the upper hose The Down speed flow control is pre set at 1 1 2 turns out from fully closed To adjust the speed control a Loosen the allen head set screw b To decrease the lowering speed turn knurled knob screw A clockwise c To increase the lowering speed turn knurled adjusting screw A counterclockwise d Tighten the set screw when once desired down speed has been set 4111 0008 Sept 2012 ADJUSTMENTS Maintenance Prop Adjustment Maintenance Prop Adjustments 1 Raise platform fully and engage the maintenance prop in the service position If dock leveler has not been used recently cycle leveler once 2 Turn OFF all electrical power to the dock leveler Attach safety lockout and tagout devices 3 Adjust yoke on maintenance till you have minimum 1 approximately of free play 4 in the prop 4 When the play in the prop is correct only 1 1 2 threads max will be exposed through the yoke If more threads exposed the maintenance prop must be shorted Max Threads Exposed 1 1 2 When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before mai
27. e the equipment and WILL void warranty specifications to those in the following list will result i Use of hydraulic fluids with equivalent specifications in abnormal operation of the dock leveler and We to those listed here are acceptable voiding of warranty Failure to follow these instructions may result in serious personal injury or death 4111 0008 Sept 2012 23 MAINTENANCE Regular maintenance must be performed on a weekly and quarterly schedule Weekly Maintenance e Operate the dock leveler through the complete operating cycle to maintain lubrication NOTE Make sure the limit switch is clear of debris Inspect the platform hinge and the lip hinge areas The hinge areas must be kept free of dirt and debris Build up of foreign material in the hinge areas will cause abnormal operation IMPORTANT Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler Quarterly Maintenance e Lubricate the following areas with light weight machine oil A Lip hinge area unless equipped with grease fittings apply oil to the top of the entire length of lip hinge when platform is in the stored position and lip is folded B Platform hinge area apply oil to top of all platform hinges when platform is in the stored position C Apply a light oil to the Storage prop pins D Grease the hoist cylinder grease fitting E Apply a light oil to the Lip Cylinder pi
28. eck the lip operation Lower dock leveler 4 Connect the dock leveler power cable to the field check to make sure the leveler goes into float wires in the pit junction box Refer to the electrical mode about 15 above dock floor allow to dock drawings supplied with the dock leveler to float to below dock Push and hold the RAISE button until the leveler turns off and the Blue stored light comes on 4111 0008 Sept 2012 15 DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death IMPORTANT DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground welding equipment to the dock leveler frame NEVER to the platform Failure to follow these instructions may damage the motor hoist cylinder wiring and or control panel Following start up or if the platform is raised using an external lifting device or the hyd
29. el Both Ends 5 6 LG 9904 0137 Hose 60 00 Lg 6 Jic Swivel Both Ends 8 LG D 1 9904 0083 Hose 44 00 Lg 6 Jic Swivel Both Ends E 1 9904 0059 Hose 35 00 Lg 6 Jic Swivel Both Ends F 1 9904 0082 Hose 21 00 Lg 8 Jic Swivel Both Ends G 1 9904 0090 Hose 17 50 Lg 8 Jic Swivel Both Ends H 1 8585 0089 Vertical Valve Assembly 1 8583 0045 Centra Power Valve Assembly 4111 0008 Sept 2012 43 PARTS Centra Power KS4 Hydraulic Components Item Quantity Part Number Description A 1 0525 0085 Lip Cylinder B 1 0525 0066 Hoist Cylinder 10 and 12 Pits 0525 0104 Hoist Cylinder 15 Pits 1 9904 0061 Hose 72 00 Lg 8 To 6 Jic Swivel Both Ends 5 6 LG C 1 9904 0062 Hose 96 00 Lg 8 To 6 Jic Swivel Both Ends 8 LG 1 9904 0140 Hose 140 00 Lg 8 To 6 Jic Swivel Both Ends 8 LG 1 Provide length and diameter of hose when calling or faxing orders Provide length of lip cylinder when calling or faxing orders 3 Provide dock leveler serial number voltage and phase when calling or faxing orders 44 4111 0008 Sept 2012 4111 0008 Sept 2012 45 VS Manifold Pressure Relief Return To Tank ON Pump Psi H C Lip Valve A Tage I Hoist Cyl Bind End H qE f
30. ep hands and feet clear of pinch points Avoid putting any part of your body near moving parts L T afe way to operate this equipment Read and understand the manufacturer s s If you have any questions ask your supervisor tex Chock restrain all freight carriers Never remove the wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away IN Tee Do not use a broken or damage dock leveling device Make sure proper service and maintenance procedures have been performed before using CM re _ or Make sure lip overlaps onto trailer at least 4 in 102 mm Keep a safe distance from both side edges 4111 0008 Sept 2012 WE Do not use dock leveling device if freight carrier is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device 4111 0008 Sept 2012 3 SAFETY 4 5 D h5 Maintenance Safety Precautions ALWAYS stand clear of dock leveler and lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death ALWAYS disconnect electrical power source and ground wire before welding on dock leveler DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Alwa
31. ervice Dock Leveler Safely A Tagout Device When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death B Lockout Device C Maintenance Props D Storage Prop Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 22 When maintenance is to be performed on the dock leveler First install the SAFETY bolt in the storage prop D Second support the platform with maintenance props C Cautio
32. essure Relief E Jam Nut decreased if the pump motor loads down C Pump Motor F Acorn Nut when platform starts to raise from the lowered position See Troubleshooting 1 The leveler must be in the stored position and the section maintenance prop in the service position 2 Turn OFF all electrical power to the dock leveler Attach safety lockout and tagout devices 3 Remove acorn nut F 4 Loosen jam nut E 5 Adjust allen head adjusting screw D as follows e Turn clockwise to increase pressure relief e Turn counterclockwise to decrease pressure relief 6 While holding the adjusting screw tighten jam nut and install the acorn nut 7 Turn ON electrical power to the dock leveler 8 Check leveler operation 9 Repeat steps 1 9 as necessary 4111 0008 Sept 2012 27 ADJUSTMENTS Adjustment Set Screw Screw 28 Stored Limit Switch Adjustment 1 Loosen Set Screw 2 With roller arm contacting storage prop rotate adjustment screw counter clockwise until a Click noise is heard 3 Tighten set screw head cap screw 4 Readjust as needed to leveler allow to store 3 to 5 degrees from vertical 5 After adjusting the stored limit switch check for correct play in the prop Down Speed Control Adjustment If the dock leveler lowers to slow the down speed control requires adjustment The speed control adjusting screw A The set screw is located on the hoist cylinder B directly abov
33. faxing orders Provide dock leveler serial number voltage and phase when calling or faxing orders 4111 0008 Sept 2012 99 56 4111 0008 Sept 2012 Customer Information MISCELLANEOUS NOTE Hefer to illustration for left right orientation of dock leveler The model serial number decal A is located on the right platform joist near the front lip of dock leveler When you receive your VS dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keeping of the numbers in the event the model serial number decal A becomes lost or damaged Also write down Systems Inc s job number the company that installed the dock leveler and the original owner s name This will all help to identify the specific dock leveler if more information is required When ordering use part numbers and description to help identify the item ordered Do not use item numbers These are only for locating the position of the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER For service call or contact Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0008 Sept 2012 Serial No Systems Inc Job No Original Owner Information Date of Installation 57 STANDARD PRODUCT WARRANTY SYSTEMS INC warrants that its products will be free from defects in design materials and workmanship for a
34. ing of product from the transportation vehicle this vehicle shall have the brakes and wheel chocks applied appropriately or all other positive restraining device shall be fully utilized Loading dock safety equipment should never be used outside of its intended use range or capacity Please consult the manufacturer if you have any questions as to the use range or capacity of the equipment When selecting loading dock safety equipment it is important to consider not only present requirements but also future plans and any possible adverse conditions environments or USE 4111 0008 Sept 2012 General Information Congratulations on your choice of a Poweramp Vertical Storing dock leveler This manual covers the VS Vertical Storing series hydraulic dock leveler Designed by Poweramp to be a marvel of simplicity and efficiency your dock leveler when properly installed will provide many years of trouble free performance with an absolute minimum of maintenance Its revolutionary hydraulic system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended The VS series dock leveler comes equipped with an electrical control panel which allows push button operation of the dock leveler functions Each VS dock leveler unit and control panel has been factory prewired and tested to ensure satisfactory operation To illu
35. ing the a lifting device i e hoist or fork truck appropriate lifting capacity and reach x aa onu iu ra nae a EEE RE REE RR EER D LE ERR D NE DA E QA A QR E QA B ona om um Em T E 2 PTT T a LEE CN C RE CR CR EON ENERO EE EE Mae bob E LM M ak ah ml ml m mL CL m m m m u s CL cL c m m m s ah sj Li dee Eet EE NNN NNN NNN NNN RIO RR MOTOR d nnt C m i e tsi e t su dv GE TEE A DPA MH UR is C I P D P Dh Uh I D PS a e ON D D gti UN a DEL E D DONE DEN EE DN NE Ir E are Hac la PROC ML td ur M a c n tu NENNEN C OR UO ON RN NNN ONU OO OR SO NO ORO eee De E M T E E NE i MOS E SUR E IM E C E MIS RS M A Dd Beete rrr tr rr rM L Cana a EE ae a t o a UL OR D EE QoS E NES I NI GUT Ma ESL D Maintenance props in lowered location during installation and service Sept 2012 4111 0008 12 Install Dock Leveler IMPORTANT The minimum size of the shim that contacts the leveler frame i e the top shim of each shim stack must be at least 4 1 2 x 4 1 2 in 114 3 x 114 3 mm to support the full width of the hoist cylinder storage prop weldment Use the thickest shim stock possible for stability and weld penetration purposes DO NOT use multiple layers of 1 8 in 3 18 mm or thinner shim stock 4 Before installing the leveler the Imbed channel must be shimmed and welded to the Imbed on the pit floor A Distance Leveler Frame F Pyramid Preferred Height G Stepped Acceptable B Shim L
36. ions 18 End Loading Unloading Instructions 19 Maintenance Service Dock Leveler Safely eese eeeuss 20 Periodic Maintenance REE REENEN RER eene nnn nnn 21 Adjustments Adjust Main Pressure Relief SC 23 Adjust Main Pressure relied Remote System 24 Purging Hydraulic System rici Lec ece cc crore err rend eg eedeeg 14 Bi c 25 Hode Eye Adjustments eec tere reri aaa 15 Troubleshooting elle EN e e dr e mor 27 Parts Frame and Platform MEE 35 MISC PAS inaa 32 Hydraulic Valve Bleus vegeeseseeeee Geesen gege eege 42 Hoist Cylinder Repair Parts es eee eere eere 48 Lip Cylinder Repair Parts 1 ee eeee esee eee 49 Power Pack Assembly e eere erre rene eere enne nnn 50 Miscellaneous Customer Information eege eege 52 Lc Back Cover Recognize Safety Information Safety Alert Symbol The Safety Alert Symbol identifies important safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury or death Follow the instructions in the safety message The use of the wor
37. l the pin lube pin can be installed 9 After pin has been installed store maintenance Props and locking pin test the leveler for operation 4111 0008 Sept 2012 17 OPERATION Theory I DA ok ee l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l LL A Control Box B Platform C PowerPack D Hoist Cylinder F Limit Switch G Reservoir When a button is pushed on the control panel this activates an electric motor C which drives a hydraulic pump The hydraulic pump forces oil into the platform cylinder s D causing the platform to rise or lower Releasing the button will stop the platform from moving except in the float mode To lower the Vertical leveler the lower button will be pushed The leveler will first come toward the operator A electrical solenoid L will kick the Storage prop The solenoid will hold the Storage prop out for a period of time to allow the leveler to lower The leveler will start to lower down to the truck When the lever is about 12 to 15 above dock height the leveler goes into float mode You will also hear the motor make a different sound
38. ls not energized Lip does not lower Bad spool valve Platform does not lower Blue stored light not on Leveler pump runs but Platform does not lower Leveler pump runs prop Storage Prop kicker works but Platform does not lower Leveler pump runs prop D and E Coils not kicker works but Platform energized does not lower Bad spool valve 4111 0008 Sept 2012 Prop kicker does not kick Add fluid as needed See Periodic Maintenance in the Maintenance section Hemove and clean spool valve or replace with new or good working valve Add fluid as needed See Periodic Maintenance in the Maintenance section In correct adjustment on the Adjust the limit switch so the plate form leans 3 deg toward the door see adjustments Check power to the spool valve should have a magnetic pull when energized Pump Motor must be running Hemove and clean spool valve or replace with new or good working valve Pump Motor must be running All three valves must be energized Check power to the all spool valves they should have a magnetic pull Pump Motor must be running Remove and clean spool valves or replace with new or good working valves Pump Motor must be running Limit switch not adjusted correctly see adjusts Possible bad switch stored limit switch Possible prop kicker Solenoid not working Possible Mercury switch not working Not enough slop in the maintenance prop see pag
39. n 2 Turn OFF all electrical power to the dock leveler Attach safety lockout and tagout devices 3 Remove acorn nut E 4 Loosen jam nut D 5 Adjust allen head adjusting screw C Under acorn nut e Turn clockwise to increase pressure relief e Turn counterclockwise to decrease pressure relief 6 While holding the adjusting screw tighten jam nut and install the acorn nut 7 Turn ON electrical power to the dock leveler 8 Disengage the maintenance prop 9 Check leveler operation 10 Repeat steps 1 9 as necessary 26 4111 0008 Sept 2012 ADJUSTMENTS Adjust Main Pressure Relief Remote Mount When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the O work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death NOTE The main pressure relief may need to be C E s increased if the platform does not rise or rises slowly and the system operates in pressure relief mode See Troubleshooting section e 3 A Reservoir D Hex Adjusting Screw The main pressure relief may need to be B Main Pr
40. n The lip may fold down after the platform has rested on the maintenance prop Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout device B and tagout device A Only the person servicing the equipment should have the capability to remove the lockout devices The tagout devices must inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to OSHA regulation 1910 147 4111 0008 Sept 2012 MAINTENANCE Periodic Maintenance A Lip Hinge Area C Storage Prop E Lip Cylinder B Platform Pins D Hoist Cylinder To ensure normal operation of the dock leveler use only Aircraft Hydraulic Fluid designed to meet or exceed military specification MIL L 5606 It is Before performing any maintenance under the recommended that the following hydraulic fluids be dock leveler lock the electrical power source in used OFF position and lock the maintenance prop in the service position using an approved locking device See Service Dock Leveler Safely in this section Ultra Vis Hvi 15 Flomite 530 ZF Aero Shell Fluid 4 or Fluid 41 Mobile Aero HFA Mil H5606G or Aero HF Texaco Aircraft Hydraulic Oil 15 or 5606 Exxon Univis J13 IMPORTANT These fluid brands can be mixed together Mixing Use of fluids that do not have equivalent with fluids that do not meet or exceed MIL L 5606 E et may damag
41. ns NOTE Apply grease to lip hinge grease fittings if equipped 24 Yearly Maintenance e Lubricate the following areas with light weight machine oil A Lip hinge area unless equipped with grease fittings apply oil to the top of the entire length of lip hinge when platform is in the stored position and lip is folded B Platform hinge area apply oil to top of all platform hinges when platform is in the stored position C Apply a light oil to the Storage prop pins D Grease the hoist cylinder grease fitting E Apply a light oil to the Lip Cylinder pins F Change hydraulic oil may be required more often depending upon conditions NOTE Apply grease to lip hinge grease fittings if equipped 4111 0008 Sept 2012 Checking Fluid Levels Reservoir on Remote Pumps 4111 0008 Sept 2012 MAINTENANCE N Lt CD Mj d Pressure CH aja Return OX cc M Reservoir P Breather Cap N 2 in 51 mm From Top of Q Fluid Level Reservoir IMPORTANT A low fluid level or the use of hydraulic fluids not equivalent to the fluid types recommended will cause abnormal operation of the leveler and WILL void warranty e Check reservoir fluid level Q 1 The leveler must be in the stored position with the lip lowered 2 Turn OFF all electrical power to the leveler 3 Remove breather cap P 4 Measure fluid level The fluid level should
42. ntenance in the Maintenance section Damaged or restricted Heplace damaged hose s Remove restriction hydraulic hose s Pressure relief set too low Increase pressure relief See Adjust Main Pressure Helief in the Adjustment section NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Decrease pressure relief See Adjust Main Pressure Helief in the Adjustment section Pump motor loads down Pressure relief set too high when platform starts to raise from the lowered position NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel 32 4111 0008 Sept 2012 Platform does not rise to Low hydraulic fluid full height Platform does not rise Col energized on the float Remove wire of terminal strip to the float coil If Coil leveler raises possible bad PLY or relay Bad spool valve i Low hydraulic fluid Platform Does not rise to full height Limit switch C Coil not energized Lip does not extend Bad spool valve D and E Coi
43. ntenance is complete Failure to do this may result in serious personal injury or death 4111 0008 Sept 2012 29 TROUBLESHOOTING Troubleshooting When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before 4 DANGER Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before maintenance is complete Failure to do this may i l X working on or inside Do not result in serious personal injury or death open cover without appropriate PPE Refer to NFPA 7OE for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death Before performing the detailed troubleshooting procedures check the following items first e Check all fuses inside the control panel s Replace e Make sure the correct voltages are present at the any blown fuse s with a fuse of equal specification proper locations inside the control panel s 30 4111 0008 Sept 2012 Platform does not rise Motor overload device or lower Motor does not tripped or fuse blown energize Motor starter three phase or motor relay
44. ocation Under H Offset Not Acceptable Maintenance Prop Straight Not Acceptable Standard Dock Leveler Only C Dock Floor D Rear Imbed Frame E Imbed Frame Maintenance Prop 4111 0008 Sept 2012 Shim Stacking Methods Q S 13 The dock leveler is heavy Use chains and a lifting device with the appropriate lifting capacity and reach Failure to do so may result in damage to dock leveler and or serious personal injury or death A Bottle Jack A Rear Imbed C Maintenance Props E lifting Lug B Dock Leveler D Hinge Pins F Storage Prop 5 Lube the three rear hinge pins using grease Install 7 Once the three hinge pins are installed Install the the three pins in the rear imbed only through out Storage prop Install latch pin the first hinge tube 8 Make all hydraulic connections 6 lower the Vertical leveler down centering the leveler s three hinge pins with the imbeds three 9 Make all electrical connection pins Note Do not connect hoist cylinder at this time e Insert the pins Start with on outside first second Systems must be bleed before connected see install the center pin and than the last out side page 16 hinge pin e Optional use Us a bottle jack to align the rear of the dock leveler to the imbed channel 14 4111 0008 Sept 2012 INSTA
45. period of one 1 year from the date of shipment All claims for breach of this warranty must be made within 30 days after the defect is or can with reasonable care be detected In no event shall any claim be made more than 30 days after this warranty has expired In order to be entitled to the benefits of this warranty the product must have been properly installed maintained and operated in accordance with all manufacturers recommendations and or specified design parameters and not otherwise have been subject to abuse misuse misapplication acts of nature overloading unauthorized repair or modification application in a corrosive environment or lack of maintenance Periodic lubrication adjustment and inspection in accordance with all manufacturers recommendations are the sole responsibility of the Owner User In the event of a defect as determined by SYSTEMS INC covered by this warranty SYSTEMS INC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS SUBSIDARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUDING T
46. rane a hazardous condition may exist because the main hoist cylinder will have air on the load bearing end The cylinder will not support the platform which can fall rapidly potentially causing injuries to anyone under the platform Be sure the leveler is restrained per instructions in the owner s user s manual When repairs service is complete unit must be operated in the raised direction only until visible movement of platform indicates cylinder is full If alternate lifting means are still available use to return platform to original lowered position and then raise unit hydraulically Safety Decal on Rear Platform OWNER S USER S RESPONSIBILITIES 1 The owner user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle The owner user should therefore train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer s recommendations and industry standards Before operation of the equipment all operators shall read understand and be familiar with all functions of equipment as described in the owner s user s manual The manufacturer shall provide to the initial purchaser all necessary information with regards to Safety Information Operation Installation and Safety Precautions Recommended Initial and Periodic Inspections Procedures Planned Maintenance schedule Product Specifications Troubleshooting Guide P
47. raulic system is opened to atmosphere air will enter into the hydraulic system Whenever this happens purge air from hydraulic system fully Failure to do this may result in damage to the equipment serious injury or death 16 Purging air from the VS hydraulic system 1 10 11 12 Begin by supporting the leveler in the stored position with the storage prop and maintenance props Lock out the storage prop with the locking bolt Lock out and tag out the leveler Disconnect the lower hoist cylinder mounting pin Hemove one of two screws holding the stored limit switch Swivel stored limit switch away from storage prop SEE PAGE 28 Open down speed flow control valve counter clockwise Down speed control valve is located on hoist cylinder SEE PAGE 28 Hestore power to the leveler Confirm the blue stored indicator light is no longer illuminated Cycle the hoist cylinder up and down at least 6 times using the leveler s own hydraulic power Connect the hoist cylinder to the base of the Imbed is channel Adjust down speed flow control to factory settings The settings are 1 1 2 turns out from fully closed Maintenance props must be moved back to the working positions The lip cylinder is self purging Lower the leveler to a 45 degree angle Cycle lip by pressing the lower and lip button together to lower the lip Press the raise and lip button together to raise the lip WARNING Stay clear of lip a
48. strate which connections are to be made in the field at installation electrical drawings are included with each order or by contacting Poweramp Technical Services Once again thank you and congratulations on your purchase of a Poweramp hydraulic dock leveler 4111 0008 Sept 2012 INTRODUCTION Dock Leveler Stock Specifications Models Nominal SizeW x L VS 65 6 x 5 VS 66 6 x 6 VS 68 6x8 VS 655 66 x 5 VS 656 6 6 x 6 VS 658 DG x 8 VS 75 f x VS 76 7x6 VS 78 7x8 VS dock levelers are available in the following sizes weight capacities and options Width VS 6 ft 1828 8 mm 6 1 2 ft 1981 2 mm 7 ft 2133 6 mm Length 5 ft 1524 mm 6 ft 1828 8 mm 8 ft 2438 mm Capacity CIR 40 000 Ib 18 144 kg 45 000 Ib 20 412 kg 50 000 Ib 22 680 kg CIR Comparative Industry Rating Call Poweramp to discuss available powerpack mounting configurations voltages phases and options to meet your specific needs INTRODUCTION Component Identification A Lip G Trombetta Valve Prop Kicker Behind Prop Assy B Deck H Storage Prop Assembly with Lock Out Pin included F C Lip Cylinder I Hinge Pin D Flow Control Valve J Stored Limit Switch E Hoist Cylinder K Maintenance Props F Storage Prop Yoke Some models are equipped with multiple hoist cylinders Powerpack may be mounted on underside of leveler or remotely 4111 0008 Sept 2012 INTRODUCTION
49. t all times as it may fall if air is present in the system Make sure all air is purged from the hydraulic cylinders after set up and any time air is introduced to the system Failure to do this may result in serious personal injury or death 4111 0008 Sept 2012 CIN TAAL LATION Put New Dock Leveler Into Service 1 Disconnect the external lifting device and chains from the lifting brackets 2 Complete all welding 3 Install hydraulic hoses and fill system 4 Connect all electrical connections 5 Purge System see Purging pg 16 4 Test leveler for operation Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or CEA MAY Tes pit Rod Eye adjustment amp New installation 1 Support the leveler with the maintenance props Lock out the storage prop with the locking bolt 2 Lock out and tag out the leveler 3 Remove lower hoist cylinder mounting pin 4 Remove one of two screws holding the stored limit switch Swivel stored limit switch away from storage prop 5 Hestore power to the leveler Confirm the blue stored indicator light is no longer illuminated 6 Cycle the hoist cylinder up and down at least once to make cylinder is fully extended 7 Rod eye should be adjusted so the center of the rod Eye is half way below the center of the hole of the imbed After adjusted tighten jam nut 8 To center the rod eye with the embed tap the lower button unti
50. the leveler will shut off and the Blue stored light will come on 8 Remove chocks from truck trailer wheels or release the truck restraint if used 9 Indicate to driver that truck may leave the dock e End Loading Unloading Platform at Cross Traffic Position 4111 0008 Sept 2012 Operating Instructions Continued Below Dock End Loading Unloading Instructions 1 Check to make sure truck trailer is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the truck trailer wheels or use the truck restraint if available 4 Lower platform and lower the lip Lower platform until the legs on the bottom of the eveler makes ontact with the pit loor B RAISE Button D LIP Button 5 Proceed with loading or unloading End Loading Unloading Platform at Below Dock Position 4111 0008 Sept 2012 OPERATION Dock Leveler Loading Unloading Instructions y NOTE Optional Lip Keepers Check to make sure truck trailer is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the truck trailer wheels or use the truck restraint if available 4 Lower platform and lower lip until lip makes contact with the Lip Keepers 5 Proceed with loading or unloading 21 MAINTENANCE S
51. ys ground to the dock leveler frame Hydraulic and electrical power must be OFF when servicing the equipment For maximum protection use an OSHA approved locking device to lock out all power sources Only the person servicing the equipment should have the key to unlock the device Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete The storage maintenance props 2 must be in the Maintenance position when working under the dock leveler and the storage prop must have a grade 5 or better in the locking hole For maximum protection use an OSHA approved locking device to lock out the main power supply Only the person servicing the equipment should have the key to unlock the device 4 411
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