Home

XL Owner`s/User Manual

Contents

1. PSI to Logic Block 4111 0036 September 2015 48 Logic Block Assembly PARTS Logic Block and Lever Arm Item Quantity Part Number Description A i 9574 0001 Spool Valve Logic Block Standard 9574 0002 Spool Valve Logic Block Cold Weather B i 5455 0001 Lever Arm Standard 5455 0004 Lever Arm Cold Weather Logic Block Cable Assembly Item Quantity Part Number Description C 1 7955 0001 Cable Subassembly Logic Block D 2 2101 0059 Washer 1 4 in E 1 9572 0004 Spring F 1 8102 0001 Weight Logic Block Cable G 2 2101 0032 Set Screw Socket Head 1 4 20 UNC x 3 8 in 1 5265 0002 Cable Weight Assembly Logic Block Includes Items C H Logic Block Assembly Item Quantity Part Number Description J 2 9301 0112 Fitting 8 ORB Male x 8 JIC Male K 1 9572 0002 Plug Spool Valve L 2 9572 0003 Gasket Spool Valve M 1 9572 0004 Spring Spool Valve N 1 9572 0013 Dowel Pin Cold Weather Wash Down Feature Only P 1 N Logic Block Complete Includes Items A and K N Q 1 2101 0014 Cap Screw 5 16 18 UNC x 2 in R 1 2101 0039 Nylon Lock Nut 5 16 18 UNC Dual Lanyard Assembly Optional Item Quantity Part Number Description S 1 4261 0004 Ring Pull T 1 7952 0002 Clasp Cable U 1 7955 0001 Cable Subassembly V 1 8102 0002 Weight 1 5265 0001 Cable Assembly
2. POWERAMP XL SERIES MOCE AVENA Owner s User s Manual POWERAMP Division of Systems Inc e W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 lt fax 262 255 5917 www poweramp com techservices docksystemsinc com Printed in U S A Manual No 4111 0036 Copyright 2015 September 2015 Table of Contents Page Safety Recognize Safety Information ssssssssssss esse ses ss esse eesess esse enesenn enen 1 General Operational Safety Precautions c cccceesseesseesseeeeeesees 1 Operational Safety PreCautiOns cccccccssseeecsesseeeeesseeseeesseeseeensees 2 Maintenance Safety PreCautiOns cccccsssccsseseesseesesseeseeseeseeseeeseeseas d galei DISCOS HHT 5 Owners Users Responsibilities sss sss ssssss sss e esse senenn ennenen 6 Introduction General lnformatioan s sss sssssssssss css s cesse eee eee eenn eenn ennenen 7 Dock Leveler Stock Specifications ssssssssss esse sss esse sese ses esse enea 7 Component ldentrfication ssssssssssssss sss sss esse sees essen ennenen ee 8 Installation Prepa 1 TT 9 Prepare Dock Leveler ccccsscesscssseeesseesseenseeesseesseenseeeseeaseeaseonseees 10 Install Dock Leveler cssssssssssssssssssesssessesene enesenn enean enean e 12 Install Control Panel and Wiring ss ssssssssssssssssssssssssessssess enen 18 Put New Leveler Into ServiCe cccsseccsseeceseecenseeeeseeeseeenseeeeneees 19 istal lt ras HHHH 20 NTT
3. Unsupported dock leveler 2 or ramps can lower unexpectedly trained operators malfunctioning dock leveler Report Before allowing vehicle to leave operating dock leveler or beginning to Maintenance Service the dock always e Ensure that no equipment material or people are on the bumpers Return the dock leveler to its trailer bed reposition vehicle stored position at dock level Failure to follow posted instructions will result in death or serious injury Cal 262 255 1510 for replacement placards waming labek or owner sluser s manuais prop forward of bar to support lip Refer to owner s user s manual for proper use Failure to comply will result in death or serious injury SAFETY INFORMATION supports the ramp before driving on ramy Operation 1 Read and follow all instructions and warnings in the owner s user s 7 Stay clear of hinges and front and manual sides of moving dock leveler Use of dock leveler restricted to Never use damaged j Always chock trailer wheels or problems immediately to supervisor engage truck restraint before load or unload 1 Read and follow all instructions Never use hands or equipment to warnings and maintenance schedules move the ramp of lip in the owner s user s manual Before activating dock leveler 2 Maintenance Service of dock leveler Ensure trailer is backed in against restricted to trained personnel Place barriers on the driveway and on Remove
4. 2 0191 0053 Rubber Seal Left or Right Side 8 Levelers 1 25 4 mm 2 0191 0054 Rubber Seal Left or Right Side 10 or 12 Levelers 1 25 4 mm 2 0193 0009 Neoprene Seal Short Vertical RH 6 Tall UP To 55K B 0193 0010 Neoprene Seal Short Vertical LH 6 Tall UP To 550K 2 0193 0011 Neoprene Seal Short Vertical RH 8 Tall 60K and above 0193 0012 Neoprene Seal Short Vertical RH 8 Tall 60K and above C AR 2101 0039 Nylon Lock Nut 5 16 18 UNC Side Weather Seal w o Toe Guard D AR 2101 0011 Cap Screw 5 16 18 UNC x 1 in Side Weather Seal w o Toe Guard F 2 0192 0052 W S Rubber End Cap G 1 Call Rear Brush Weather Seal One Size Fits All H 1 0191 0056 Weather seal Cup N a a a a Provide dock leveler serial number and size of platform when calling or faxing orders AR As Required 4111 0036 September 2015 55 FAILURE TO FOLLOW RESULT IN DEATH OR OTHER SERIOUS INJURY NOTES ADANGER e Read and follow ajl instructions warnings and maintenance schedules in the manual and on placards Operation and servicing of dock leveler is restricted to authorized personnel Always chock transport vehicle wheels or engage vehicle restraint and set parking brakes before operating dock leveler or beginning to load or unload Before activating dock leveler ensure lip avoids contact with transport vehicle sides and cargo If lip does not lower to transport vehicle bed reposition transport vehicle
5. C i 9511 0004 J Box Standard 4 x 4 in Metal Box 9512 0429 J Box Cold Weather 5 x 5 in Plastic Box D 1 0961 0014 Micro switch with Harness Dual Lanyard Feature Only E 1 1751 0736 Decal Arc Flash D D D Provide dock leveler serial number voltage phase and options when calling or faxing controller orders 4111 0036 September 2015 41 PARTS Frame and Platform 42 4111 0036 September 2015 Frame and Platform PARTS Item Quantity Part Number Description A 1 O595 ___ 1 Lip Welded Assembly B 1 7823 __ 2 Plate Inspection C 1 9515 __ 1 Platform Welded Assembly 9202 0050 x 1 Pin Lip Hinge 2003 and Newer Pin D 1 9202 0051 6 1 2 x 1 Pin Lip Hinge 2003 and Newer Pin 9202 0052 7 x 1 Pin Lip Hinge 2003 and Newer Pin l i 8435 _ 1 Frame Standard 8435 _ 1 Frame CleanPit F 2 9201 0006 Prop Pin and Clip G 3 9202 0002 Rear Hinge Pin 9202 0009 Rear Hinge Pin Stainless Steel H 6 2101 0047 Cotter Pin 1 4 x 2 in AR 2101 0039 Nylon Lock Nut 5 16 18 UNC J AR 2101 0011 Cap Screw 5 16 18 UNC x 1 in K 2 5275 0001 Toe Guard Linkage L 6 2101 0089 Cap Screw 3 8 16 UNC x 2 0 in N 12 2101 0060 Washer 3 8 in Flat N 6 2101 0040 Nylon Lock Nut 3 8 16 UNC O 1 0015 __ 1 Folding or Sliding Toe Guard Left P 1 0015 __ 1 Folding or Sliding Toe guard Right Q 2 0523 0024 Lip Lifter Short Cas
6. Ensure the transport vehicle floor supports extended lip or the leveler frame lip keepers or below dock endload supports supports the ramp before driving on ramp Stay clear of hinges and front and sides of moving dock leveler Never use hands or equipment to move the ramp or lip Never use damaged or malfunctioning dock leveler Report problems immediately to supervisor Always store dock leveler and remove people material and equipment from ramp before vehicle leaves the dock DO NOT ENTER PIT unless dock leveler is securely supported by the maintenance prop Disconnect power and follow proper lockout tagout procedures for the dock leveler before entering the dock leveler pit or doing any repair or inspection under the dock leveler THESE INSTRUCTIONS COULD Scan to view our owner s user s manuals online www DockSystemsinc com 1 800 643 5424 Call for additional placards or manuals or with questions POWERAMP MCGUIRE DLM SYSTEMS INC Loading Dock Equipment OPERATING INSTRUCTIONS POWERED DOCK LEVELERS EE pe OQ NORMAL OPERATION 1 Raise the platform by depressing and holding the RAISE button 2 Hold the RAISE button until the lip is fully extended then release the RAISE button The platform will lower until lip is resting on the transport vehicle STORING LEVELER Depress the RAISE button until the lip is completely folded When the lip is folded release the RAISE button The platform will lo
7. Includes Items S V W 1 5405 0001 Lever Arm X 1 2101 0068 Cap Screw 5 16 18 UNC x 1 3 4 in Y 2 2101 0039 Nylon Lock Nut 5 16 18 UNC Z 5 2101 0163 Flat Washer 5 16 in AA 1 2101 0015 Cap Screw 5 16 18 UNC x 3 1 4 in Must provide serial number or Job number 4111 0036 September 2015 49 PARTS Power Pack Assembly Breather line M 50 4111 0036 September 2015 Power Pack Assembly PARTS 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 0015 Reservoir D 1 9301 0199 Breather Cap 3 8 NPT Male E 1 9301 0027 O Ring Reservoir F 2 9302 0013 Tie Rod Reservoir 1 9301 __ 1 Pump Only G 4 2101 0016 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 2 Motor Only N 1 0521 0015 Straight Fitting 3 8 NPT Male x 8 JIC Male E 1 0521 0014 Ball Check Q 1 9301 0024 Guide Check Ball R 1 9302 0009 Spring 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 0
8. Lanyard Lever Pivot An inspection plate is provided in the platform floor for ease of maintenance and pit inspection K Lip Lifter and Lift Cylinder Pin Block F Platform Cylinder Trunnion J Lip Cylinder to Platform Frame Pin L Toe Guard Pivots C Inspection Plate To ensure normal operation of the dock leveler use only aircraft hydraulic fluid designed to meet or exceed military specification MIL H 5606 G It is recommended that the following hydraulic fluids be used e ULTRA VIS HVI 15 e Aero Shell Fluid 4 or Fluid 41 Mobile Aero HFA Mil HS606A or Aero HF e Texaco Aircraft Hydraulic Oil 15 or 5606 e Exxon Univis J13 These fluid brands can be mixed together Mixing with fluids that do not meet or exceed MIL H 5606 G may damage the equipment and WILL void warranty Use of hydraulic fluids with equivalent specifications to those listed here are acceptable 4111 0036 September 2015 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 To thoroughly inspect the platform hinge area put the platform in the full below dock position 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 NOTICE Failure to properly lubricate the d
9. Product Warranty is extended to two 2 years from date of shipment e Structural Warranty For a period of seven 7 years from the date of shipment this warranty specifically applies to the deck section lip section frame rear hinge assembly and front hinge assembly only e Hydraulic Warranty For a period of seven 7 years from date of shipment this warranty specifically applies to the hydraulic pump and motor all hydraulic cylinders hydraulic pressure lines and fittings and fluid logic control assembly only
10. TTT 21 Operation HGG E E S 23 Operating Instructions ssssssssss ses sss sees sees ss see sss sees eenn eenn 24 Ramp Loading Unloading Instructions ccccsseeesseeeeeseeseeeees 25 End Loading Unloading INStructiOns cccccessseeeesseeeeeseeseenees 26 Maintenance Service Dock Leveler Safely ssssssssssss esse esesess essen ennenen neee 27 Periodic Maintenance sss ssss sss ssssss sese sesss essen ennenen ennenen nee 28 Adjustments Adjust Main Pressure Relief ccccssssecsssseeessseeeeeseeeeesseeeeaseeeensees 31 Adjust Cable Weight and Down Speed Control sssseeesseeseees 32 Adjust Auto Return To Dock ARTDI sss ssssssssssssssss sese ene 33 Troubleshooting Troubleshooters iaa 36 Parts CONOIS cect este este rene ee et epee ec ee EEE EREE 41 Frame and Platform sssssss sss esse sss ssss sese esse esse essen ennenen neee nee 42 Hydraulic Components sssssssssssssssss sese cesses sees ennes 44 Hoist Cylinder Repair Parts cccccssssccsssssessensessesseesenseesnseesoeseeees 46 Lip Cylinder Repair Parts ss sss sss sssss sese sesss essen enen ennenen nee 47 Logic Block Assembly saisiccenieteeciccncnncccsennccasuctencscwuesanncceuiiewnssdeedsneweee 48 Power Pack Assembly sssnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn 50 E Slop and Lip 1 HHHH 52 Weather Seals c ccsccsecsecssecseeneeneeeeseneeneenseeesensensecsunesenseueeenseuensenees 54 Miscellaneous C
11. XL 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 PR series dock leveler comes equipped with an electrical control panel which allows push button operation of the dock leveler functions Each PR dock leveler unit and control panel has been factory prewired and tested to ensure satisfactory operation To illustrate which connections are to be made in the field at installation electrical drawings are included with each order or by contacting Technical Services Once again thank you and congratulations on your purchase of a Poweramp hydraulic dock leveler 4111 0036 September 2015 INTRODUCTION Dock Leveler Stock Specifications XL dock levelers are available in the following sizes weight capacities and options Width XL 8 ft 2438 mm 8 1 2 ft 2590 mm 9 ft 2743 mm Length 8 ft 2438 mm 10 ft 8048 mm 12 ft 83658 mm Capacity CIR 45 000 Ib 20 411 kg 50 000 Ib 22 679 kg 60 000 Ib 27 215 kg 80 000 Ib 36 287 kg i eS he aae CIR Comparative Industry Rating Call Poweramp to discuss available voltages ph
12. all standard models add shims at front shim locations C and D so front of dock leveler will stay level with dock floor when leveler is resting fully on shims For CleanPit models add shims only at front shim locations D so front of dock leveler will stay level with dock floor when leveler is resting fully on shims INSTALLATION IIs f Vj z Xv S A ANR a G 3 8 in 6 in 9 5 mm A Front of Dock Pit B Dock Leveler Frame C Side Pit Curb Angle D Gap 3 4 in 19 mm Minimum 8 With rear hinge frame angle F tight against rear pit curb angle G perform check the following e Pry between the platform and rear hinge frame angle at locations E to make sure rear edge of platform is parallel to the rear hinge frame angle F e Gap D must exist equally along both sides of leveler so weather seal if equipped will not bind during dock leveler operation 14 152 mm E Pry Locations F Rear Hinge Frame Angle G Rear Pit Curb Angle H Flare Bevel Weld Typical To Fit Spacing 9 If gap D cannot be obtained equally at both sides of leveler grind or add material at the rear edge of rear hinge frame angle F as needed 10 Allow the dock leveler to rest fully on the shim stacks Check that a smooth and level transition exists between the dock floor and the dock leveler platform Add or remove shims as necessary until a smooth transition is obtained 11 I
13. and Down Speed Control in the Adjustment section NOTE Extreme cold weather OR incorrect fluid may cause platform to lock Adjustment is same 39 PARTS Front Side Back Inside Cc O Q ia A D oO 0 Q a CA O a 03 J D Q z lolala N EI SSR O x lt 03 D E o L DOD O x lt b oO 0 S lt D Z D z s s i S OD 2 00 0 gt O GQ 5 D OD No OoWNQqooeee EL costo S55 G OO u G OlS oo N 9 O 2 2 5 2 lt x p Se LE ee Iei es i 2 5 mm Qd d O B L Z tTtaaa Q E x xi ce O r EEE Oooo onw 3 23 3 3 OIrTrTIrTCELULLVN LLAMMAMM m p g daie Wt LQ c ON dH 46 HH OO ON ri rr O E OOO rrer ooo O SP Pl Pl KOI KO LK lO lS gt ree l re l re l re r e CW f t CO wi T C9 C C9 C9 GOLO LO LO LO ba O Tr rilir r r OCD OD OD O a E NEEL ee O gt oS Fe Sla ele L a L D a O 4111 0036 September 2015 40 Controls PARTS AA DANGER Ay Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer to NFPA 70E for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Sever Injury or Death Item Quantity Part Number Description A 1 0615 0040 Proximity Switch with Harness ARTD Feature Only B 1 Push Button Controller
14. any end loads if required dock floor to indicate service work is Check trailer alignment to avoid lip tle ida a interference Iflip does not lower to AOA Ensure that truck bed supports intenance prop extended lp or the leveler frame 5 Ifelectrically powered tum off and use OSHA lockout tagout procedures decal placed in same position on both sides 1751 0329 x2 decal placed in same position on both sides 1751 0330 x2 decal placed in same position on both sides 1751 0138 1751 0729 ADANGER 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 ADANGER Do not work under dock leveler unless this maintenance prop has been secured in the upright position See owner s user s manual for proper procedures Failure to comply CRUSH HAZARD will result in death or serious injury 1751 0731 1751 0726 1751 0729 A DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch and insert through the maintenance prop housing Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury 1751 0731 A DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is safely supported by maintenance prop Place barr
15. series with the starter or relay coil This page intentionally left blank 36 4111 0036 September 2015 TROUBLESHOOTING Three phase units only No voltage is present on Check for blown fuses at branch circuit disconnect Platform does not rise one line Replace fuse Determine cause of blown fuse Motor hums but does not run N OTE A motor that is Check motor starter as follows missing voltage on one line 4 Disconnect wires at load side of starter is said to be single phased gt Ep ergize the starter 3 Measure line to line voltage at line side of starter 4 Measure line to line voltage at load side of 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 for high resistance or no connection Three phase units only Phase reversed Reverse any two legs at the branch circuit Platform does not rise disconnect Motor runs in reverse Single phase units only Line voltage too low Check wiring to motor for high resistance Check for Platform does not rise loose or corroded connections Check if gauge of Motor energizes but wires to motor are of correct size and specification does not run for load requirement Replace if necessary Defective motor centrifugal Replace motor switch Defective motor capacitor Replace motor Dock leveler equipped The auto return proximity Adj
16. 009 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 1 Power Pack Complete Includes All Items Except L N and W 1 Provide dock leveler serial number and type of installation when calling or faxing orders 2 Provide dock leveler serial number voltage and phase when calling or faxing orders 4111 0036 September 2015 51 PARTS E Stop amp Lip To Hoist Cylinder To Lip Cylinder from Logic Block ae from logic Block A Psi lip out valve to Return To Tank from lip cylinder E Stop Valve A Hoist Cylinder to Lip out Valve GU ETA E Stop CD Pressure line Li t pat Return Logic block to E Stop Valve Item Quantity Part Number Description A 1 8583 0063 Valve Block E Stop and Lip Out B 1 4305 0263 Cable Harness 2 coils C 2 8581 0005 Cartridge Vale 3 Way included when ordering 8583 0063 D 2 8581 0004 Coil E 2 2101 0077 Hex Head cap Screw F 4 8581 0005 Washer Flat G 2 2101 0039 Nylon Lock Nut 5 16 18 UNC H AR 9904 0106 Hyd Hose Provide dock leveler serial number and size of platform when calling or faxing orders Provide hose lengths and fitting sizes 52 4111 0036 September 2015 PARTS E Stop amp Lip out KS5 and KS6 To Hoist Cylind
17. 14 3 mm and each successive lower shim being larger so the shims can be welded together using a fillet weld DO NOT use offset method Q or straight method R NOTE Toassistin obtaining an accurate measurement of distance K use a string G pulled tight across the pit opening directly over the shim locations 3 Verify that each shim stack is at the correct height by measuring distance K top of shim stack L to dock floor Distance K must equal the dock leveler height A 4111 0036 September 2015 INSTALLATION 4 For all standard models put a 1 4 in 6 6 mm thick shim at locations C and D For Clean Pit models put a 1 4 in 6 6 mm thick shim at locations D only NOTE A 1 4 in 6 6 mm thick shim at locations C and D is used only as a starting point The final shim stack height will be determined after dock leveler is lowered into the pit 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 5 Using an appropriate lifting device connected to the lifting brackets lower dock leveler into the pit so rear hinge frame angle H is tight against rear pit curb angle F across full width of the leveler frame 6 Allow rear of dock leveler to rest on the rear shims while keeping the front of the dock leveler level with the dock floor 7 For
18. 36 September 2015 INSTALLATION 1 Remove any control panel and bumpers that may be banded to the frame of the dock leveler DO NOT remove the shipping bands B around the platform lip and leveler frame at this time NOTICE DO NOT overtighten the lifting bracket hardware Overtightening can damage the weather seal if equipped NOTE Overall width of platform and lifting brackets A must be kept to a minimum to prevent interference between the lifting brackets and the pit walls as the dock leveler is lowered into the pit 2 Make sure the mounting hardware of lifting brackets A is snug The brackets should pivot relatively freely on the mounting cap screw DO NOT overtighten 3 Attach lifting chains to lifting brackets A and to a lifting device i e hoist or fork truck having the appropriate lifting capacity and reach 4 Remove wood blocks that are attached to the leveler frame before putting the dock leveler into the pit 4111 0036 September 2015 11 INSTALLATION Install Dock Leveler Shim Stacking Methods A Distance Leveler Frame H Rear Hinge Frame Angle Height I Shims Location Under B Shim Locations Under Hoist Cylinder Rear Vertical Supports J Distance Dock Floor to C Shim Location Under Pit Floor Maintenance Prop K Distance Top of Shim Standard Dock Leveler Stack to Dock Floor Only L Shim Stack D Shim Locations Under M Dock Leveler
19. Frame Lip Keepers N Pyramid Preferred E Dock Floor P Stepped Acceptable F Rear Pit Curb Angle Q Offset Not Acceptable G String R Straight Not Acceptable S Shim between lip keeper curb angle when required 12 4111 0036 September 2015 NOTE Poweramp dock levelers are designed with a nominal 1 2 in 12 7 mm shimming distance to allow for pit inconsistencies 1 Determine height of shim stack L for each shim location B by performing the following a Measure leveler frame height distance A b Measure dock floor to pit floor distance J at each shim location B Write down the dimensions obtained at each location c Subtract distance A from distance J to obtain the shim height Repeat for each shim location NOTICE 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 frame rail and to provide a shelf for a fillet weld Use the thickest shim stock possible for stability and weld penetration purposes DO NOT use multiple layers of 1 8 in 8 18 mm or thinner shim stock 2 Using the results obtained in step 1 create the individual shim stacks on the pit floor at locations B Build each shim stack L using the pyramid method N preferred or stepped method P with the top shim having a minimum size of 4 1 2 x 4 1 2 in 114 3 x 1
20. Lip Maintenance Prop B Tag Out Device C Lock Out Device E 3 Styles of Lock 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 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 4111 0036 September 2015 Whenever maintenance is to be performed under the dock leveler platform support the platform with maintenance prop E Position the maintenance prop behind front header plate F while staying
21. NG or CAUTION signs decals or placards 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 Remove 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 SAFETY Operational Safety Precautions Learn the safe way to operate this equipment Read and understand the manufacturer s instructions If you have any questions ask your supervisor DANGER wor MTT Stay clear of dock leveling device when transport Chock restrain all transport vehicles Never remove vehicle is entering or leaving area the wheel chocks until loading or unloading is finished and transport driver has been given permission to drive away a x eal S Do not use a broken or damage dock leveling Do not move or use the dock leveling device if device Make sure proper service and maintenance anyone is under or in front of it procedures have been performed before using Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Make sure lip overlaps onto transport vehicle bed at least 4 in 102 mm Keep a safe distance from both side edges 2 4111 0036 September 2015 SAFETY wer Do not use dock leveling device if transport vehicles bed is too high or too low Do not overlo
22. T contact the switch otherwise damage to switch will occur Readjust switch and or target if necessary then recheck for interference 34 6 Turn ON electrical power to the dock leveler 7 Disengage the maintenance prop 8 Turn the ARTD switch on control panel to the ON position 9 Raise the platform until the lip is fully extended then allow the platform to drift to the below dock position After approximately 6 seconds the platform must return to the cross traffic position 10 Adjust the proximity switch and target as necessary Make small adjustments then operate the dock leveler to check results Do this until satisfied with the ARTD operation Use the following illustrations to assist in fine tuning and or diagnosing the ARTD operation Cross Traffic Position Lip Keeper NOTE The platform lip is fully folded when the platform is at the cross traffic stored position lip engaged with keepers or when platform is resting on the maintenance prop Whenever the platform lip is at the cross traffic position the following conditions will exist for a normally operating ARTD e Target not in the sensing area of proximity switch Proximity switch OFF open no signal sent to control panel Proximity switch indicator light is OFF Platform stays at this position unless the operator activates the leveler 4111 0036 September 2015 Full Below Dock Position Lip Keeper Whenever the pla
23. ad 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 0036 September 2015 3 SAFETY DANGER 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 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 A maintenance prop permanently attached and hinged to the unit with means for lock out tag out requirements per OSHA 1910 147 is included with each pit style dock leveler In addition it is recommended and good safety practice to use an additional means to support the dock platform and lip anytime when physically working in front of or under the dock leveler This additional means may include but not limited to a boom truck fork truck stabilizing bar or equivalent 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 Always ground to the dock leveler frame Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or deat
24. ases and options to meet your specific needs INSTALLATION Component Identification One hoist cylinder and lip cylinder shown for clarity A Lip D Powerpack Motor Pump Reservoir G Main Frame J Toe Guard 2 used B Platform E Logic Block H Lip Keepers 4 used K Raise Button C Lip Cylinder s F Platform Cylinder s I Maintenance Prop L ARTD Switch option 8 4111 0036 September 2015 Prepare Pit INSTALLATION A Distance Pit Width B Distance Dock Floor to Pit C Distance Pit Length D Distance Pit Corner to Corner Top Front and Rear Floor All Four Corners 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 NOTICE DO NOT remove the shipping bands around the dock leveler lip until instructed to do so 4111 0036 September 2015 Both Sides of Pit Bottom and Both Sides 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 Check the entire dock leveler pit for proper construction acc
25. clear of the lip The lip will fold down after the platform has rested on the maintenance prop Lock the maintenance prop in the service upright position using an OSHA approved lockout device C and tagout device D 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 146 Refer to OSHA regulation 1910 147 27 MAINTENANCE Periodic Maintenance One hoist cylinder and lip Cylinder shown for clarity A Lip Hinge Area B Valve Lever Pivot on Logic E Platform Hinge Area Before performing any maintenance under the dock leveler lock the electrical power source in OFF position and lock the maintenance prop in the service position using an approved locking device See Service Dock Leveler Safely in this section Failure to follow these instructions may result in serious personal injury or death NOTICE Use of fluids that do not have equivalent specifications to those in the following list will result in abnormal operation of the dock leveler and voiding of warranty 28 G Toe Guard Hinges H Platform Cylinder to Platform Pin D Dual
26. d 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 SUBSIDIARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUDING THIRD PARTIES FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERRUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY XL 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 Standard
27. d shorten the lifespan of the affected components 12 With the rear hinge frame angle F tight against the rear pit curb angle G weld the rear hinge frame angle F to the rear pit curb angle G using a 3 8 in 9 5 mm flare bevel skip weld each weld being 6 in 152 mm long Start at each end with a 6 in 152 mm long weld Space all the other welds out evenly leaving approximately 6 in 152 mm space between each weld 13 Weld front of dock leveler frame B to shims located under the keepers then weld the shims to the front pit curb steel 14 With leveler welded into place remove the shipping bands from around lip and leveler frame If the platform is raised using an external lifting device or the hydraulic system is opened to atmosphere air will enter into the hydraulic system Whenever this happens always cycle the leveler at least 4 times using the leveler s own hydraulic power system before allowing the leveler to be put into service This is to make sure all air is purged from the hydraulic cylinders Failure to do this may result in serious personal injury or death 15 Using an external lifting device i e crane or fork truck attached to the platform lifting brackets slowly raise the platform Check for binding as platform is being raised 16 If binding occurs lower the platform Reposition leveler and or add or remove shims as necessary Slowly raise platform again If platf
28. ed before being placed back in service Any modifications or alterations of loading dock equipment shall only be done with prior written approval from the manufacturer and the same shall be at least as safe as the original equipment was prior to the modification and shall also satisfy all safety requirements of the manufacturer for the particular application of the leveling device When industrial moving devices are being used in the loading or unloading 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 It is recommended that trailers with air ride Suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize trailer bed drop Loading dock safety equipment should never be used outside of its intended use vertical working range or capacity Please consult the manufacturer if you have any questions as to the use vertical working range or capacity of the equipment Only properly trained and authorized personnel should operate 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 environmental factors or usage 4111 0036 September 2015 General Information Congratulations on your choice of a Poweramp dock leveler This manual covers the
29. er After all electrical connections in the pit have been made disengage the maintenance prop and lower the platform using the external lifting device connected to the platform lifting brackets All electrical work including the installation of the disconnect panel control panel and final connections to the pit junction box must be performed by a certified electrician and conform to all local and applicable national codes 4111 0036 September 2015 Put New Dock Leveler Into Service 1 Disconnect the external lifting device and chains from the lifting brackets 2 Check that the leveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly lf an excessive transition exists between the dock floor and leveler and or lip does not contact both lip keepers evenly contact Poweramp Technical Services for further instructions 3 Install the dock bumpers as required Always stand clear of the dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death 4 Turn the main electrical power ON 5 Raise the leveler platform fully by pushing and holding the RAISE button or lightly pulling and holding the dual lanyard pull ring located in a recess at the rear of the plaltform NOTE The platform of a properly operating dock leveler will automatically stop rising when it reaches approximately 2 3 inches from
30. er from logic Block To Lip Cylinder from A H Logic Block PSI Lip out valve to lip cylinder j Hoist cylinder H a amp Return To Tank from N A Hook Block i 7 me as eg EGF A G B PSI from pump to Hook block E Stop Ha PSI to E stop Lip Out OL Return E Stop To Hook Block Pressure hose to Logic block Item Quantity Part Number Description A 1 8583 0063 Valve Block E Stop and Lip Out B 1 4305 0263 Cable Harness 2 coils C 2 8581 0005 Cartridge Vale 3 Way included when ordering 8583 0063 D 2 8581 0004 Coil E 2 2101 0077 Hex Head cap Screw F 4 8581 0005 Washer Flat G 2 2101 0039 Nylon Lock Nut 5 16 18 UNC H AR 9904 0106 Hyd Hose Provide dock leveler serial number and size of platform when calling or faxing orders Provide hose lengths and fitting sizes 4111 0036 September 2015 72 PARTS Weather Seal Rubber Style I iT 0 C V AR As Required NOTE Kits are for existing dock leveler without weather seal N Provide dock leveler serial number and size of platform when calling or faxing orders 54 4111 0036 September 2015 Weather Seal Brush Style PARTS Item Quantity Part Number Description 2 0191 0045 Brush Seal and Track Left or Right 8 Levelers 1 25 4 mm A 2 0192 Brush Seal and Track Left or Right Side 1 1 2 in 1 25 4 mm
31. f leveler cannot be squared and or made level as instructed in steps 8 10 contact Technical Services 4111 0036 September 2015 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 NOTICE 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 NOTE The illustration on the previous page shows a typical weld pattern The weld pattern will vary slightly depending on size of dock leveler 4111 0036 September 2015 INSTALLATION NOTICE DO NOT weld continuously along the full length of the rear hinge frame angle This can put unnecessary stress on the leveler components causing the leveler to malfunction an
32. facturers Contact Information as well as tables to identify the grade slope for all variations of length or configuration of the dock leveling device and information identifying the maximum uncontrolled drop encountered when sudden removal of support while in the working range of the equipment It is recommended that 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 The Owner User must review all name plates placards decals instructions and posted warnings and place the same in view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for any replacements Manufacturers 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 the manufacturer is required Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main support while under load such as what might occur when a transport vehicle pulls out from under the leveling device shall be removed from service inspected by a manufacturer s authorized representative and repaired or replaced as need
33. form steps 5 7 at least four times to purge any air that may be in the hydraulic system and to ensure proper operation 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 10 When the platform lowers to the full below dock position wait 5 seconds after the lip has folded to allow lip cylinder to fully retract Push and hold the RAISE button or lightly pull and hold the dual lanyard pull ring until the platform rises just enough to clear the lip keepers then release the RAISE button or pull ring to allow the platform to lower to the cross traffic stored position lip engages lip keepers NOTE For dock levelers equipped with the Auto Return To Dock ARTD the platform will automatically return to the cross traffic position if the ARTD is enabled When the platform is at the full below dock position there is a six second delay before the platform will automatically rise to the cross traffic position 11 Perform steps 5 7 at least four times to purge any air that may be in the hydraulic system and to ensure proper operation INSTALLATION The XL dock leveler uses spring loaded bumpers the bumpers must be mounded in line with the bumper pads NOTE The bumper must be mounted to a poured concert wall Bumpers are welded two the curb angle Curb Angle Bottoms held
34. g is finished 26 A ARTD Switch B Dual Lanyard Pull Ring 6 Turn the ARTD switch A on the control panel to the OFF position 7 Raise the platform and extend the lip just enough to clear the lip keepers by lightly pulling then firmly pulling the dual lanyard pull ring B 8 When the platform lip clears the lip keepers release pull ring A The platform will drift down to the full below dock position 9 Proceed with loading or unloading NOTE When end unloading is finished and access to the rest of the transport vehicle is still required the platform lip will need to be extended See Ramp Loading Unloading Instructions on page 23 for further instructions 10 When the loading or unloading is finished return the dock leveler platform to the cross traffic stored position by performing one of the following e Turn the ARTD switch A to the ON position After approximately six seconds the platform will automatically rise to the cross traffic position OR e Lightly pull dual lanyard pull ring B to raise the platform When the platform lip clears the lip Keepers release the pull ring and allow the platform to lower to the cross traffic position 11 Remove chocks from transport vehicle wheels or release the vehicle restraint if used 12 Indicate to the driver that the transport vehicle may leave the dock 4111 0036 September 2015 Service Dock Leveler Safely MAINTENANCE A
35. g the dual lanyard pull ring F This activates an electric motor D which in turn drives a hydraulic pump The hydraulic pump forces oil into the platform cylinder s H causing the platform to rise Releasing the RAISE button or pull ring allows the platform to lower When the platform rises to the point where there is 1 3 in 25 4 76 2 mm of travel left in the platform cylinder a cable P pulls valve lever L down When the cable force exceeds the force necessary to shift the spool valve inside logic block G the spool shifts causing oil to be redirected to the lip cylinder s C This causes the platform to stop rising and lip A to extend When the lip has fully extended the platform will continue to rise until it reaches the full raised position 4111 0036 September 2015 The dual lanyard feature provides dual function operation One function raises the platform The other function extends the lip Lightly pulling dual lanyard pull ring F lifts dual lanyard lever M causing the contacts of dual lanyard switch N to close The closed contacts activates electric motor D which causes the platform to rise operation is the same as when using the RAISE button Releasing pull ring F causes lever M to open the dual lanyard switch contacts which de activates the electric motor and allows the platform to lower When pull ring F is firmly pulled the pull ring cable lifts lever M which in tu
36. h 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 stand clear of dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death 4 DANGER Ld Are Flash and Shock Hazard PPE Personal Protection Equipment Required D e enegre equipment betore working on or inside Do mot open cover without appropriate PPE Refer to NFPA 70E for PPE requirements Ths panel may contain mare than ane Power SUDE Hazardous Voltage Will Cause Sever injury or Death 4111 0036 September 2015 SAFETY Safety Decals Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily leg ible If any are missing or require replacement please call 1 800 643 5424 for replacements AA DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar Do not force maintenance 1751 0727 1751 0730 x2 A DANGER dock leveler
37. heck reservoir fluid level Q 1 Put the dock leveler platform at the full below dock position 2 Turn OFF all electrical power to the leveler 3 Remove inspection plate C 4 Remove breather cap P 5 Measure fluid level The fluid level should be approximately 2 in 51 mm N from top of reservoir M with platform at the below dock position 6 Add hydraulic fluid if necessary Use only recommended fluid 7 Install breather cap and inspection plate 8 Turn ON electrical power to the leveler 9 Return the platform to the cross traffic position 29 MAINTENANCE This page intentionally left blank 30 4111 0036 September 2015 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 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 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 pos
38. ice position Allow platform to rest on the prop so the lip will fully fold until it contacts the lip stops Turn OFF all electrical power to the dock leveler Attach safety lockout and tagout devices 33 ADJUSTMENTS NOTICE Anytime proximity switch and target are adjusted always check for interference between target and switch before operating the leveler Damage to switch will occur if the target contacts the switch The maximum torque for proximity switch lock nuts is 27 Nem 29 lb ft Damage to switch will occur if maximum torque is exceeded A 1 4 in 6 4 mm Approximate B Target C 1 in 25 4 mm Approximate D Lock Nuts E Proximity Switch NOTE Distances A and C are typical factory settings Use these dimensions only as a starting point when adjusting the proximity switch and target especially if switch and or target have been replaced When dimensions A and C are obtained the proximity switch and target may need finer adjustments to get the ARTD to operate satisfactorily 3 Loosen lock nuts D Adjust proximity switch E to obtain distance A Tighten lock nuts 4 Bend target B as needed to obtain distance C Recheck distance A and readjust if necessary NOTE Atleast two people may be required to manually move the lip 5 After adjusting proximity switch and target slowly move the lip up by hand while observing the target and proximity switch The target MUST NO
39. ide of platform Use of two steel supports having sufficient strength is acceptable in serious personal injury or death Standard models only DO NOT use the maintenance prop to support the raised platform until the maintenance prop has been properly shimmed and welded The shims must be welded to each other the leveler frame and to the front pit curb steel Failure to do this may result in serious personal injury or death b Remove maintenance prop D from the shipping location on dock leveler 49 All model levelers Install shims at locations B frame using the pyramid or stepped shimming method 7 l Both platform cylinder trunnions must be solidly c Position base of maintenance prop D so center of prop is approximately 8 1 2 in 216 mm E to left of dock leveler center Adjust position of prop base so opposite end of prop will go between the platform joists A when prop is fully raised The prop must not contact the joists wiring or other components Tack weld the prop base to front pit curb steel Raise the prop to the upright position to make sure the prop does not contact a platform joist The prop must rest against the inside corner of the lip hinge header When proper operation of the prop is confirmed finish weld the prop base to the front pit curb steel Move the maintenance prop to the service upright position Remove the temporary supports installed in step a of this procedure a
40. iers on driveway 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 1751 0728 4111 0036 September 2015 OWNER S USER S RESPONSIBILITIES 10 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 manufacturers recommendations and industry standards Effective operator training should also focus on the owner s user s company policies and operating conditions Maintaining updating and re training all operators on safe working habits and operation of the equipment regardless of previous experience should be done on a regular basis and should include an understanding and familiarity with all functions of the equipment Owner s user s shall actively maintain update and retrain all operators on safe working habits and operations of the equipment The manufacturer shall provide to the initial purchaser all necessary information regarding Safety Information Operation Installation and Safety Precautions Recommended Initial and Periodic Inspections Procedures Planned Maintenance Schedule Product Specifications Troubleshooting Guide Parts Break Down Warranty Information and Manu
41. in place with 2 5 8 4 3 4 anchors Drive 20 4111 0036 September 2015 PLACARD Placard installation Instructions Owner is responsible for the installation and placement of product placards Make sure placard is in plain view of dock leveler operations Suggested placement of placard is near control box attached to electrical conduit by using nylon tie If there is no control box present mount placard on wall to the immediate left of leveler at eye level PIS SENS ontrol Bov C C sh JA r 5 E tk XT NZ al WN a pie MRY 4111 0036 September 2015 21 OPERATION This page intentionally left blank 22 4111 0036 September 2015 OPERATION Theory One hoist cylinder and lip Cylinder shown for clarity J Raise Button K ARTD Switch L Valve Lever A Lip B Platform C Lip Cylinder s M Dual Lanyard Lever N Dual Lanyard Switch P Cable E Inspection Plate F Dual Lanyard Pull Ring G Logic Block D Electric Motor H Platform Cylinder s The XL dock leveler uses hydraulic logic and one button operation for ease of use The dock leveler can be operated remotely using the RAISE button J on the control panel or operated locally using the dual lanyard pull ring F located in a recess at the rear of the platform Platform B is raised by pushing and holding the RAISE button J or lightly pulling and holdin
42. ition 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 NOTE The main pressure relief may need to be increased if the platform does not rise or rises slowly and the system operates in pressure relief mode See Troubleshooting section The main pressure relief may need to be decreased if the pump motor loads down when platform reaches the full raised position See Troubleshooting section 4111 0036 September 2015 ADJUSTMENTS A Reservoir B Main Pressure Relief C Pump Motor D Hex Adjusting Screw E Jam Nut F Acorn Nut To adjust the main pressure relief 1 Raise the platform fully and engage the 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 hex adjusting screw D as follows e Turn clockwise to increase pressure relief e Turn counterclockwise to decrease pressure relief 6 Tighten the jam nut and install the acorn nut 7 Turn ON electrical power to the dock leveler 8 Disengage the maintenance prop 9 Check leveler o
43. its full raised height at which point the lip extends When the lip is fully extended the platform will continue to rise until it reaches the full raised position If the lip does not extend or extend fully see Platform Rises to Full Height But Lip Does Not Fully Extend in the Troubleshooting section 6 Release the RAISE button or pull ring to lower the platform As long as there is no truck present at the dock the platform will lower to the full below dock position as the lip folds 7 NOTE If a truck is present the platform will lower until the lip rests on the truck trailer bed See Operating Instructions in Operation section 4111 0036 September 2015 INSTALLATION 8 When the platform lowers to the full below dock position wait 5 seconds after the lip has folded to allow lip cylinder to fully retract Push and hold the RAISE button or lightly pull and hold the dual lanyard pull ring until the platform rises just enough to clear the lip keepers then release the RAISE button or pull ring to allow the platform to lower to the cross traffic stored position lip engages lip keepers NOTE For dock levelers equipped with the Auto Return To Dock ARTD the platform will automatically return to the cross traffic position if the ARTD is enabled When the platform is at the full below dock position there is a six second delay before the platform will automatically rise to the cross traffic position 9 Per
44. m 1 Check to make sure transport vehicle 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 transport vehicles wheels or use the vehicle restraint if available A RAISE Button B Dual Lanyard Pull Ring 4 Extend the platform lip onto transport vehicle as follows a Raise the platform by depressing and holding RAISE button A or lightly pulling and holding dual lanyard pull ring B b Hold the RAISE button or pull ring until the lip is fully extended then release the RAISE button or pull ring The platform will lower until the lip is resting on the transport vehicles bed c Make sure that the lip is fully extended and supported on the transports vehicle along the entire width of the platform with at least 4 in 102 mm of lip contacting the transport vehicles bed 4111 0036 September 2015 OPERATION U Tete Proceed with loading or unloading the transport vehicle If end loading is necessary see End Loading Unloading Instructions on page 24 A RAISE Button C Dual Lanyard Pull Ring B ARTD Switch 7 When loading or unloading is finished raise the platform by depressing and holding RAISE button A or lightly pulling and holding dual lanyard pull ring C Depress the RAISE button or pull ring until the lip folds enough to clear the transport vehicles bed the
45. n release the RAISE button or pull ring The lip will fold and the platform will return to the cross traffic position Remove chocks from transport vehicles wheels or release the vehicle restraint if used Indicate to driver that transport vehicle may leave the dock 25 OPERATION Operating Instructions End Loading Unloading Instructions NOTE If ramp loading is required see Ramp Loading Unloading Instructions on page 23 End loading or unloading can be done with the dock at the cross traffic position or below dock position depending on the height of the transport vehicles bed 1 Check to make sure transport vehicle 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 transport vehicle wheels or use the vehicle restraint if available eX End Loading Unloading Platform at Cross Traffic Position 4 If transport vehicle bed is at or above dock floor level leave leveler at the cross traffic position and proceed with loading or unloading End Loading Unloading Platform at Below Dock Position 5 If transport vehicle bed is below the dock floor level perform steps 6 12 Whenever end loading or unloading with the platform in the below dock position make sure the ARTD switch is in the OFF position DO NOT turn the ARTD switch to the ON position until end loading or unloadin
46. nd lower the platform onto the prop using the external lifting device Confirm the prop is properly engaged DO NOT disconnect the external lifting device at this time For left right orientation of dock leveler see inside back cover of this manual 4111 0036 September 2015 20 21 shimmed the entire length of the trunnion Make sure the trunnions are level from side to side as well as from front to back Finish weld all shims using a fillet weld e Weld all shims within each shim stack to each other then weld the shim stack to the leveler frame e Weld the front leveler frame shim stacks to the front pit curb steel When all welding has been completed paint all the welds and shims NOTE Clean Pit models are shipped with a T frame 22 C installed This temporary frame holds the leveler frame at the correct dimensions until the leveler is permanently anchored into place Only then should it be removed There are six cap screws and nuts that fasten the T frame to the rest of the leveler frame Tack welds may also be used For CleanPit models only remove the T frame C INSTALLATION Install Control Panel and Wiring The electrical power must be OFF prior to electrical installation For maximum protection use an OSHA approved locking device to lock out all power sources Only the person installing the equipment should have the key to unlock the power source Failure to follow these instructio
47. nosing and adjusting the switch NOTE Some proximity switches have an indicator light at the back of the housing and some have the light at the side of the housing 4111 0036 September 2015 ADJUSTMENTS Adjust the ARTD as Follows 1 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 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 Raise platform fully and engage the maintenance prop in the serv
48. ns 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 When drilling access hole in the control box DO NOT penetrate too deep components may be damaged DO NOT turn control upside down to drill any access holes To prevent damaged to electrical components from debris cover components prior to drilling Seal all conduit entrances to prevent moisture from entering the control box DO NOT use compressed air to clean control box Recommended to vacuum debris from inside A DANGER Ly Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer fo NFPA 70E for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Sever Injury or Death 18 A Disconnect Panel provided by others B Control Panel C Distance 48 in 14 630 mm Mount the pushbutton control panel B so bottom of control panel to dock floor distance C is 48 in 1219 2 mm 2 Install electrical disconnect panel A if not already installed 3 Install and connect the control wiring 4 Connect the dock leveler power cable to the field wires in the pit junction box Refer to the electrical drawings supplied with the dock level
49. oading unloading process Failure to follow these instructions may result in serious personal injury or death 24 L in 305 mm Pee 0 mais eae E d The PR hydraulic dock leveler is designed to compensate for a maximum 12 in 805 mm of height difference between the loading dock and the transport vehicle DO NOT use the dock leveler if the transport vehicles bed is more than 12 in 305 mm higher or lower than the dock floor Ts in 305 mm 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 damage to equipment 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 23 s For end loading and unloading see End Loading Unloading Instructions on page 24 4111 0036 September 2015 Operating Instructions Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 24 For ramp loading or unloading the XL dock leveler can be operated by using either the RAISE button on the control panel or the dual lanyard pull ring located in a recess at the rear of the platfor
50. ock 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 at the full below dock position and lip is folded D Dual lanyard lever pivot E Platform hinge area apply oil to top of all platform hinges when platform is at the full below dock position G Toe guard hinges along full length of top and bottom hinges H Platform cylinder to platform frame pin J Lip cylinder to platform frame pin K Lip lifter and lift cylinder pin Lubricate the following areas with white lithium grease B Valve lever pivot and top of logic block spool valve E All platform cylinder trunnions L Toe guard cams where toe guard strut contacts cams NOTE Apply grease to lip hinge grease fittings if equipped Yearly Maintenance e Follow Quarterly Maintenance A Change hydraulic oil may be required more often depending upon conditions 4111 0036 September 2015 MAINTENANCE P Breather Cap Q Fluid Level M Reservoir N 2 in 51 mm From Top of Reservoir NO EOF 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 C
51. on Lock Nut 5 16 18 UNC N 1 9575 _ 3 Logic Block P 4 2101 0050 Clip Hairpin Q 2 9202 0005 Pin 1 x 3 3 4 in R 8 2101 0009 Cap Screw 5 16 18 UNC x 3 4 in S 4 7942 0006 Platform Cylinder Hold Down 0525 0043 Cylinder Platform 15 1 2 in 394 mm Barrel Length F 2 0525 0044 Cylinder Platform 17 1 2 in 445 mm Barrel Length 0525 0045 Cylinder Platform 19 1 2 in 495 mm Barrel Length 0525 0046 Cylinder Platform 21 1 2 in 546 mm Barrel Length U 2 9301 0120 Elbow 45 8 ORB Male x 8 JIC Male V 2 9904 ___ 1 Hose Logic Block to Platform Cylinder W 1 9904 ___1 Hose Logic Block to Pump Return Port X 4 2101 0040 Nylon Lock Nut 3 8 16 UNC Y 4 2101 0060 Washer 3 8 in Z 2 9455 _ 2 Hold Down Lip Cylinder AA 2 0522 0002 Spring AB 2 0521 0007 Elbow 90 1 4 NPT Male x 1 4 Tube AC 2 2101 0011 Cap Screw 5 16 18 UNC x 1 in AD 1 9395 __ 3 Power Pack Complete AE 1 0521 0016 Elbow 45 3 8 NPT Male x 8 JIC Male AF 1 0521 0015 Straight Fitting 3 8 NPT Male x 8 JIC Male AG 6 2101 0039 Nylon Lock Nut 5 16 18 UNC in AH 1 9392 0042 Mounting Bar AJ 1 0521 0007 Elbow 90 1 4 NPT Male x 1 4 Tube AK 4 2101 0011 Cap Screw 5 16 18 UNC x 1 in AL 1 R509 ___ Tube Vent 3 8 OD x 1 16 in Wall AM 2 9301 0155 Tee 8 orom 8 Jic 8 Jic AN 2 9301 0127 Run Tee 80rbm 8 Jic 8Jic 1 Provide length and diameter of hose when calling or faxing orders 2 Provide length of lip cylinder when calling or faxing orders 3 Provide dock leveler
52. ording to approved certified pit drawings Make sure pit is square by making the following measurements e Measure pit width distance A at both front and rear of pit e Measure dock floor to pit floor distance B at all four corners s Measure pit length distance C at both sides e Measure corner to corner criss cross distance D at both sides Take measurements at dock floor level and at pit floor level lf any measurement is off by more than 1 8 in 3 18 mm contact Poweramp Technical Services before proceeding Make sure the field junction box for the dock leveler E is at the correct location per pit diagrams INSTALLATION Prepare Dock Leveler A Lifting Bracket 2 used B Shipping Bands Poweramp dock levelers are designed with installation in mind Each unit is shipped with lifting brackets A fastened to the platform side joists 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 or out of a pit Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death 10 NOTICE DO NOT remove the shipping bands B around the platform lip and leveler frame at this time The shipping bands are needed to hold the leveler together during the installation process 4111 00
53. orm still binds contact Technical Services for further instructions INSTALLATION One hoist cylinder and lip Cylinder shown for clarity CleanPit Model Shown A Platform Joists C T Frame CleanPit Only E Distance 8 1 2 in 216 mm Approx Center of Leveler B Shim Locations Under Platform D Maintenance Prop CleanPit to Center of Prop Mounting Plate Cylinder Trunnions Model Shown NOTE For Clean Pit models proceed to step 17 17 Standard models only a Install shims under maintenance prop D where prop attaches to leveler frame Make sure prop is solidly shimmed b Raise maintenance prop D to the service upright position and lock prop in this position using an OSHA approved locking device c Proceed to step 18 16 4111 0036 September 2015 INSTALLATION Closely follow the step by step instructions for installing the CleanPit maintenance prop Failure to Make sure all personnel are outside of the leveler operating zone and clear of the platform lip before activating the leveler Failure to do this may result install the maintenance prop correctly may result in failure of prop during use damage to equipment and or serious personal injury or death 18 Clean Pit models only a Temporarily support platform in the full raised position using an external lifting device Provide addition support using two 4 x 4 in 102 x 102 mm wood beams of sufficient length one at each s
54. per front hose connection NOTE If the platform lowers too fast the platform will stop lowering and lock in safety mode Use 1 4 turn increments when adjusting the down speed control Check platform lowering speed after each adjustment To adjust the speed control a Loosen the jam nut b To decrease the lowering speed turn adjusting screw A clockwise c To increase the lowering speed turn adjusting screw A counterclockwise d Tighten the jam nut NOTE Extreme cold and or incorrect fluid may also cause cylinder to lock Adjust down speed to decrease lowering speed 4111 0036 September 2015 Adjust Auto Return To Dock ARTD A Cable E Target B Proximity Switch F Lip Hinge Tube C Bracket G Platform Lip D Lock Nuts H Indicator Light Standard PR levelers are equipped with the Auto Return To Dock ARTD unless leveler is interlocked with a truck restraint The ARTD allows the platform to automatically return to the cross traffic stored position after the truck departs The ARTD uses a proximity switch B located under the platform and a piece of angled steel called the target E that is attached to the lip hinge tube F The proximity switch provides a six second delay after the platform has lowered to the full below dock position after which the platform will return to the cross traffic position The switch also contains an indicator light H that can be used for diag
55. peration 10 Repeat steps 1 9 as necessary 31 ADJUSTMENTS Adjust Cable Weight and Down Speed Control C Valve Lever D Cable A Speed Control Adjusting Screw B Logic Block Cable Weight Adjustment If the platform lip does not extend or extends too soon cable weight F may need adjustment The cable weight is attached to cable D and is located underneath the platform directly behind logic block B The factory setting causes the lip to fully extend when 1 3 in 25 4 76 2 mm of travel is left in the platform cylinder NOTE To prevent the cable weight from accidentally falling off the cable when adjusting the weight attach a locking pliers or similar device to the cable just below the cable weight If adjustment requires that the weight be moved down allow sufficient distance between pliers and weight before adjusting To adjust the cable weight a Loosen do not remove set screws H If set screws are removed balls G may fall out b To make lip extend sooner slide the weight up c To make lip extend later slide the weight down d Tighten set screws 32 E Locking Pliers F Cable Weight G Steel Ball 2 used H Set Screw 2 used Down Speed Control Adjustment If the dock leveler did not lower it is possible that the speed control requires adjustment The speed control adjusting screw A is a hex screw located in logic block B directly behind the up
56. ping 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 0036 September 2015 Dock Leveler Information Serial No Systems Inc Job No Original Owner Information Address Address 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 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 an
57. rn pushes lever L down thus causing the spool valve in logic block G to shift When this happens oil is redirected to the lip cylinder s causing the platform to stop rising and the lip to extend This function can be used to put the platform at the full below dock position without fully raising the platform NOTE The ARTD switch K if equipped must be in the OFF position for the platform to stay at the below dock position Some models are equipped with multiple cylinders 23 OPERATION DANGER Stay clear of dock leveler when transport vehicle 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 Transport vehicle wheels must be chocked unless the vehicle restraint is used Never remove the wheel chocks until loading unloading is finished and transport vehicles driver has been given permission to leave Make sure platform lip rests on the transport vehicles bed with at least 4 in 102 mm of overlap Maintain a safe distance from side edges of leveler during the l
58. ront 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 Before performing the detailed troubleshooting procedures check the following items first e Check all fuses inside the control panel s Replace any blown fuse s with a fuse of equal specification e Make sure the correct voltages are present at the proper locations inside the control panel s Platform does not rise Motor overload device Reset overload relay three phase or replace Motor does not energize tripped or fuse blown 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 Motor starter three phase Check voltage at starter or relay coil or motor relay single phase not energizing e If voltage is present and starter or relay does not energize replace starter or relay If voltage is not present check all components in
59. serial number voltage and phase when calling or faxing orders 4111 0036 September 2015 45 PARTS Platform Cylinder Repair Parts Wear Ring Backup Ring Galo Excluder Ring alaa iois Retaining Ring RMMALVOLHN LAA OAS AAD Sil peal V gt Barrel Length Item Quantity Part Number Description A 0525 0048 Seal Kit 1992 and Newer 0525 0013 Seal Kit 1991 and Older B 1 0525 0043 Cylinder Platform 15 1 2 in 894 mm Barrel Length 0525 0044 Cylinder Platform 17 1 2 in 445 mm Barrel Length 0525 0045 Cylinder Platform 19 1 2 in 495 mm Barrel Length 0525 0046 Cylinder Platform 21 1 2 in 546 mm Barrel Length C 1 1751 0138 Decal Provide dock leveler serial number when calling or faxing orders 46 4111 0036 September 2015 PARTS Lip Cylinder Repair Parts Spring Spring Guide Washer l mil 7 H i DO il DW T WA YAM G Ka PETE Barrel Length Piston Seal 3 Piece Retaining Ring Wear Ring Item Quantity Part Number Description A 0525 0059 Seal Kit 1992 and Newer 0025 0014 Seal Kit 1991 and Older B l 0525 0086 Lip Cylinder Complete 14 in Barrel Length 0525 0087 Lip Cylinder Complete 20 in Barrel Length Provide dock leveler serial number when calling or faxing orders 4111 0036 September 2015 mh PARTS Logic Block Assembly Lip Cylinder Main Cylinder SN
60. tform lip is at the full below dock position the following conditions will exist for a normally operating ARTD e Proximity switch senses target Proximity switch ON closed signal sent to the control panel Proximity switch indicator light is ON Platform will automatically rise after approximately a six second delay then returns to the cross traffic position 4111 0036 September 2015 ADJUSTMENTS Lip Fully Extended Position Whenever the platform lip is at the fully extended position the following conditions will exist for a normally operating ARTD Target not in the sensing area of proximity switch Proximity switch OFF open no signal sent to the control panel Proximity switch indicator light is OFF If the platform lip is resting on the truck bed the platform will stay at this position unless the operator activates the leveler 35 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 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 f
61. ting 0523 0154 Lip Lifter Long Weldment R 1 1751 0010 Decal Model Serial ID S 2 2101 0046 Cotter Pin 1 4 x 1 1 4 in y 9225 ___ 1 Prop Rod Standard Only 9225 1 Prop Rod CleanPit Only U i 0015 0001 Toe Guard Pivot LH 0015 0003 Toe Guard Pivot LH 26 deep pit v i 0015 0002 Toe Guard Pivot RH 0015 0004 Toe Guard Pivot RH 26 deep pit AR As Required 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 0036 September 2015 43 PARTS Hydraulic Components Af f Lip Hose Return Hose Hoist Hose One hoist cylinder and lip Cylinder shown for clarity 44 4111 0036 September 2015 Hydraulic Components PARTS Item Quantity Part Number Description A 2 0522 0005 Clevis Pin B 2 2101 0045 Cotter Pin C 2 0522 0156 Yoke D 2 0521 0005 Roll Pin 2 0525 0086 Lip Cylinder 13 3 4 in 349 mm Barrel Length 0525 0087 Lip Cylinder 20 1 8 in 511 mm Barrel Length F 2 9202 0004 Pin 3 4 x 4 38 in G 4 2101 0049 Clip Hairpin H 2 9301 0111 Fitting 6 ORB Male x 8 JIC Male J 2 9904 ___1 Hose Logic Block to Lip Cylinder K 1 9904 _ 1 Hose Pump Pressure Port to Logic Block L 2 2101 0015 Cap Screw 5 16 18 UNC x 3 1 4 in M 2 2101 0039 Nyl
62. tton is pushed Platform rises after lip is fully extended Platform locks into safety as platform lowers Lip drops to vertical position 4111 0036 September 2015 Low hydraulic fluid Logic block valve lever cable weight too low on cable Logic block spool valve stuck in the up position or valve lever binding so that the lever will not push the spool down Logic block spool valve stuck in the down position or valve lever binding causing lever to prematurely push the spool down Platform lowering speed is too fast Add fluid as needed See Periodic Maintenance in the Maintenance section Adjust cable weight See Adjust Cable Weight and Down Speed Control in the Adjustment section Apply penetrating oil to spool area and valve lever pivot at top of logic block lf necessary disconnect the valve lever from logic block Move spool valve up and down until spool valve slides freely If the spool valve cannot be made to slide freely replace spool valve Lubricate valve lever pivot with white lithium grease Apply penetrating oil to spool area and valve lever pivot at top of logic block lf necessary disconnect the valve lever from logic block Move spool valve up and down until spool valve slides freely If the spool valve cannot be made to slide freely replace spool valve Lubricate valve lever pivot with white lithium grease Adjust platform down speed control See Adjust Cable Weight
63. ush contaminated oil system from hydraulic system Fill system with new oil See Periodic Maintenance in the Maintenance section Damaged or restricted Replace damaged hose s Remove restriction hydraulic hose s Pressure relief set too low Increase pressure relief See Adjust Main Pressure Relief 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 Pump motor loads down Pressure relief set too high when platform reaches the full raised position Decrease pressure relief See Adjust Main Pressure Relief 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 38 4111 0036 September 2015 TROUBLESHOOTING Symptom Possible Cause Platform does not rise to Low hydraulic fluid Add E as needed See Periodic Maintenance in full height the Maintenance section Platform DOES rise to full height but lip DOES NOT extend or extend fully Lip does not extend Lip extends almost immediately when the RAISE bu
64. ust proximity switch and target as necessary with ARTD Platform switch not sensing target See Adjust Auto Return To Dock ARTD in the does not automatically correctly Adjustment section return to the cross traffic position or operates Defective proximity switch Replace switch abnormally Broken wire Loose or Repair or replace wires and connections as corroded wire connections necessary 4111 0036 September 2015 37 TROUBLESHOOTING Platform does not Heavy object s on platform Remove object s from platform rise Pump operates in pressure relief mode 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 Relief 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 Fl
65. ustomer Information sss ssssssssss sss ss cesses ecce se essen ennenen neee 57 VUE Ta AT TT Back Cover Recognize Safety Information Safety Alert Symbol The Safety Alert Symbol identifies import safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury of death Follow the instructions in the safety message DANGER The use of the word 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 NOTICE The use of the word NOTICE is to draw attention to a procedure that needs to be followed to prevent machine damage SAFETY INSTRUCTIONS Indicates a type of safety sign or separate panel on a safety sign where safety related instructions or procedures as described 4111 0036 September 2015 SAFETY General Operational Safety Precautions Read and understand the Owners s Users s manual 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 WARNI
66. wer returning to the cross traffic position BELOW DOCK ENDLOADING e HYDRAULIC ONLY Depress and hold the RAISE button until the leveler is fully raised As the lip starts to extend release the RAISE button The leveler will lower to the below dock position provided the lip extension allows the lip to clear the lip keepers AIR POWERED ONLY Depress and hold the RAISE button until the leveler is 12 above dock level Pull the below dock level chain until the leveler passes the below dock position HYDRAULIC WITH INFINITE LIP CONTROL If equipped raise the platform by depressing and holding the RAISE button When the lip is just above the lip keepers simultaneously depress and hold the RAISE button and the LIP OUT button until lip has extended beyond the lip keepers Release both buttons regarding proper use maintenance and repair of dock leveler U751 0674RevA NOTE If equipped depressing E STOP button will stop platform from lowering Item Quantity Part Number Description A 1 1751 0874 Placard 56 4111 0036 September 2015 Customer Information MISCELLANEOUS NOTE Refer 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 XL dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe kee

Download Pdf Manuals

Related Search

Related Contents

Samsung GT-E2120 Korisničko uputstvo  TERMOIDEA MANUALE INSTALLAZIONE MINI EOLO 28 KW  取扱説明書 - 三菱電機  Contenuto 90-91.pmd  XTZ Room Analyzer II Manual  ANEXOS PONTIFICIA UNIVERSIDAD CATÓLICA DEL PERÚ    TCP-U90F/ U80/U700  10 - Ташев Галвинг ООД  User Manual  

Copyright © All rights reserved. Failed to retrieve file