Poweramp VH Manual July2015
Contents
1. 26 A SAE Cap Screw C Main Pressure Relief B Hex Adjusting Screw D Reservoir To adjust the main pressure relief If leveler is in conjunction with PowerHook see PowerHook manual Raise the platform fully and engage the maintenance prop in the service position Turn OFF all electrical power to the dock leveler Attach safety lockout and tagout devices Remove SAE plug A Adjust hex adjusting screw B in small 1 4 turn increments as follows e Turn clockwise to increase pressure relief e Turn counterclockwise to decrease pressure relief Tighten the jam nut and install the SAE plug Turn ON electrical power to the dock leveler Disengage the maintenance prop Check leveler operation Repeat steps 1 8 as necessary 4111 0002 May 2015 July 2015 ADJUSTMENTS Adjust Cable Weight and Down Speed Control e ru 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 2 3 in 50 8 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 weight2. when platform reaches the full raised position 4111 0002 May 2015 July 2015 TROUBLESHOOTING Heavy object s on platform Remove object s from platform For safety reasons the dock leveler is designed to lift only the platform s own weight Check for visible obstructions that could cause binding Remove obstructions If no obstructions found call Systems Inc Technical Services See inside back cover for phone number and address 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 Low hydraulic fluid Add fluid as needed See Periodic Maintenance in the Maintenance section Clean and inspect valves Flush contaminated oil from hydraulic system Fill system with new oil See Periodic Maintenance in the Maintenance section Heplace damaged hose s Remove restriction 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 t
3. 43 PARTS Power Pack Assembly Metal Reservoir Return Line E HY 9 Pressure Line Item Quantity Part Number Description A 1 9395 1 Heservoir Pump and Motor B 1 0521 0007 Elbow 1 4 NPT Male x 1 4 Tube C 1 9301 0199 Breather Cap 3 8 NPT Male D 2 0521 0201 Elbow 8 ORB x 8 JIC Male E 1 3411 Motor Only F 4 2101 0016 Cap Screw 5 16 18 UNC x 3 1 2 in Grade 5 G 1 9301 0190 O Ring Not Shown Seal Between Reservoir and Manifold H 1 9301 0159 Metal Reservoir 1 Provide dock leveler serial number voltage phase and type of installation when calling or faxing orders 44 4111 0002 May 2015 July 2015 PARTS Power Pack Assembly Plastic Reservoir Return Line E E W H Pressure Line Item Quantity Part Number Description A 1 9395 ___1 Reservoir Pump and Motor B 1 0521 0007 Elbow 1 4 NPT Male x 1 4 Tube C 1 9301 0218 Breather Cap Push In D 2 9301 0201 Elbow 8 ORB x 8 JIC Male E 1 3411 _ _ Motor Only F 4 2101 0225 Cap Screw 1 4 20 UNC x 1 2 in G 1 9301 0226 O Ring Not Shown Seal Between Reservoir and Manifold H 1 9301 0224 Plastic Reservoir 1 2401 0001 Grommet for breather Reservoir Provide dock leveler serial number voltage phase and type of installation when calling or faxing orders 4111 0002 May 2015 45 July 2015 PARTS Power Pack Assembly Low Amp
4. Scan to view our owner s user s POWERAMP MCGUIRE manuals online DLM www DockSystemslinc com SYSTEMS INC 1 800 643 5424 Loading Dock Equipment Call for additional placards or manuals or with questions regarding proper use maintenance and repair of dock leveler 1751 0874 Rev A OPERATING INSTRUCTIONS POWERED DOCK LEVELERS NORMAL OPERATION 1 Raise the platform by depressing and holding the RAISE button OQ 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 lower returning to the cross traffic position BELOW DOCK ENDLOADING 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 OQ lip extension allows the lip to clear the lip keepers AIR POWERED ONLY Depress and hold the RAISE button until the leveler is 12 o above dock level Pull the below dock level chain until the leveler passes the below a dock position e HYDRAULIC WITH INFINITE LIP CONTROL If equipped raise the platform ee by depressing and holding the RAISE button When the lip is just above the lip keepers simultaneously depress
5. 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 A DANGER Aw Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De onongizo equipment polo working on or inside Do not oman cover withioul OCH PRE Redes to HPA TOE WE PPE recjuieernenis This geared Tri Gonia msoeec Thon one DORG SOUTE Hazardous Voltage Will Cause Sever 4111 0002 May 2015 July 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 1 75 1 0727 Do not force maintenance 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 1751 0730 x2 ADANGER Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always e Ensure that no equipment material or people are on the dock leveler e Return the dock leveler to its stored position at dock level s Failure to follow posted instructions will result in death or seri
6. 12 Perform step 7 if not equipped with ARTD OPERATION Operating Instructions Stay clear of dock leveler when transport vehicle is 12 in 305 mm entering or leaving dock area ere WU UL Y DO NOT move or use the dock leveler if anyone is ge under or in front of leveler o e Lo in 305 mm The VH hydraulic dock leveler is designed to Failure to follow these instructions may result in compensate for a maximum 12 in 305 mm of severe personal injury or death height difference between the loading dock and the transport vehicles bed DO NOT use the dock leveler if the transport vehicles bed is more than 12 in 805 mm higher or lower than the dock floor Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Only trained personnel should operate the dock service height may vary with design specifications leveler DO NOT overload 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 DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave equipment or material unattended Transport vehicle wheels must be chocked unless on the dock leveler the vehicle restraint is used Never remove the wheel chocks until loading unloading is finished Failure to follow these instructions may result in and transport vehicles driver has been given perso
7. Lip Hinge Tube C Bracket G Platform Lip D Lock Nuts H Indicator Light VH levelers are equipped with the optional Auto Return To Dock ARTD if leveler not interlocked with a vehicle restraint The ARTD allows the platform to automatically return to the cross traffic stored position after the transport vehicle 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 diagnosing 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 28 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 t
8. 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 114 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 To assist in 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 12 4 For all VH models put a 1 4 in 6 6 mm thick shim at locations C and D 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
9. Block 9575 0010 Logic Block Cold Weather P 2 2101 0050 Clip Hairpin 7 8 in dia Q 2 9202 0005 Pin 1 x 3 3 4 in H 4 2101 0009 Cap Screw 5 16 18 UNC x 3 4 in S 2 8431 0022 Platform Cylinder Hold Down 1 0525 0043 Cylinder Platform 15 1 2 in 394 mm Barrel Length T 1 0525 0044 Cylinder Platform 17 1 2 in 445 mm Barrel Length 1 0525 0045 Cylinder Platform 19 1 2 in 495 mm Barrel Length 1 0525 0046 Cylinder Platform 21 1 2 in 546 mm Barrel Length U 1 9904 0089 Hose Logic Block to Platform Cylinder 6 8 levelers 9904 0075 Hose Logic Block to Platform Cylinder 10 levelers V 1 9301 0120 Elbow 45 8 ORB Male x 8 JIC Male W 1 9904 0106 Hose Logic Block to Pump Return Port X 2 2101 0040 Nylon Lock Nut 3 8 16 UNC Y 2 2101 0060 Washer 3 8 in Z 1 9455 _ 2 Hold Down Lip Cylinder AA 1 0522 0002 Spring AB 1 0521 0007 Elbow 90 1 4 NPT Male x 1 4 Tube AC 4 2101 0011 Cap Screw 5 16 18 UNC x 1 in AD 4 2101 0058 Washer 5 16 AF 6 2101 0039 Nylon Lock Nut 5 16 18 UNC in AG 2 9391 0116 Elbow 8 ORB Male x 8 JIC Male AH 1 9395 3 Power Pack Complete AJ 1 0521 0007 Elbow 90 1 4 NPT Male x 1 4 Tube AK 1 H509 Tube Vent 3 8 OD x 1 16 in Wall AM 1 0522 0186 Lip Lifter Short Casting 0523 0024 Lip Lifter Long Weldment AN 0521 0017 Elbow 3 8NPT Male x Male x 8 JIC Male 1 Provide length and diameter of hose when calling or faxing orders 2 Provide length of lip cylinder when calling or faxing orders 3 Pr
10. Draw Return Line Or O Pressure Line D E 11 2 Amps Q 120 volts Item Quantity Part Number Description A 1 0521 0007 Elbow 1 4 NPT Male x 1 4 Tube B 1 9301 0218 Breather Cap Push In C 2 0521 0201 Elbow 8 ORB x 8 JIC Male D 1 9301 0226 O Ring Not Shown Seal Between Reservoir and Manifold E 1 9301 0224 Plastic Reservoir F 1 2401 0001 Grommet Reservoir G 1 9301 0227 Suction Filter Not Shown In Side reservoir H 1 9395 0404 Complete PPAC 115 Volt 46 4111 0002 May 2015 July 2015 Weather Seal Brush Style Weather Seal Kits Item Quantity Part Number Description A 1 0195 0021 Brush Kit Includes Seal and Track 1 1 2 in 82 Lg Both Sides B 1 0195 0033 Rubber Kit Includes Seal and Track 1 1 2 in 82 Lg Both Sides Individual Replacement Seals Item Quantity Part Number Description C 1 0192 0098 Brush Refill 1 1 2 in 82 Lg D 1 0192 0085 Rubber Refill 1 1 2 in 82 Lg E 1 0192 0146 Heplacement Channel Ka S g D Item Quantity Part Number Description G 1 0195 0044 Rear Powerseal Brush Seal 0195 0046 Foam Seal Fits 6 self adhesive backing F 1 0195 0047 Foam Seal Fits 6 1 2 self adhesive backing 0195 0048 Foam Seal Fits 7 self adhesive backing Provide dock leveler serial number and size of platform when calling or faxing orders Provi
11. F Platform Cylinder s THEORY The VH dock leveler uses hydraulic logic and one button operation for ease of use Platform B is raised by depressing and holding the RAISE button K This activates an electric motor D which in turn drives a hydraulic pump The hydraulic pump forces oil into the platform cylinder s F causing the platform to rise Releasing the RAISE button allows the platform to lower J Toe Guards K Raise Button L ARTD Switch option G Main Frame H Lip Keepers 4 used Maintenance Prop 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 pulls the valve lever up When the cable force exceeds the force necessary to shift the spool valve inside logic block E 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 0002 May 2015 July 2015 INSTALLATION Prepare Pit A Distance Pit Width B Distance Dock Floor to Pit C Distance Pit Length D Distance Pit Corner to Corner Front and Rear Floor All Four Corners Both Sides of Pit Top Bottom and Both Sides Before lowering the dock leveler into the pit the f Post safety warnings and barricade the work followin
12. July 2015 INSTALLATION Install Dock Leveler A Distance Leveler Frame Height B Shim Locations Under Rear Vertical Supports C Shim Location Under Maintenance Prop Same as D D Shim Locations Under Lip Keepers E Dock Floor F Rear Pit Curb Angle G String H Rear Hinge Frame Angle 4111 0002 May 2015 July 2015 Shim Stacking Methods c OR lt T m 5 I Shims Location under Hoist Cylinder J Distance Dock Floor to Pit Floor K Distance Top of Shim Stack to Dock Floor L Shim Stack M Dock Leveler Frame N Pyramid Preferred P Stepped Acceptable Q Offset Not Acceptable R Straight Not Acceptable S Shim between lip keeper curb angle when required INSTALLATION NOTE Poweramp dock levelers are designed with a nominal 172 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 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
13. MAINTENANCE Periodic Maintenance A Lip Hinge Area C Platform Hinge Area B Valve Lever Pivot on Logic Block 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 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 Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler 24 D Platform Cylinder Trunnion E Platform Cylinder to Platform Pin F Lip Cylinder to Platform Frame Pin G Lip Lifter and Lift Cylinder Pin To ensure normal operation of the dock leveler use only aircraft hydraulic fluid designed to meet or exceed military specification MIL H 5606G It is recommended that the following hydraulic fluids be used e ULTRA VIS HVI 15 e Aero Shell Fluid 4 or Fluid 41 e 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 5606G may damage the equipment and WILL void warranty Use of hydraulic fluids with equivalent specification
14. 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 C b To make lip extend sooner slide the weight up c To make lip extend later slide the weight down d Tighten set screws 4111 0002 May 2015 July 2015 E Locking Pliers F Cable Weight G 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 upper 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 downspeed to decrease lowering speed 27 ADJUSTMENTS Adjust Auto Return To Dock ARTD A Cable E Target B Proximity Switch F
15. 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 Depress the RAISE button B till the lip clears the keepers OR e Turn the ARTD switch A to the ON position After approximately six seconds the platform will automatically rise 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 0002 May 2015 July 2015 Service Dock Leveler Safely PPL Pindmaa Protection Equa rnent Recuced E ET ET wii ore nace Core a Cp el oer ee A Maintenance Prop B Tag Out 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 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
16. 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 all VH 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 4111 0002 May 2015 July 2015 III LLL G 3 8 in 6 in 9 5 mm 152 mm A Front of Dock Pit C Side Pit Curb Angle E B Dock Leveler Frame D Gap 3 4 in 19 mm F Minimum 8 With rear hinge frame angle F tight against rear 9 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 4111 0002 May 2015 July 2015 INSTALLATION INNA SSSSS Pry Locations Rear Hinge Frame Angle G Rear Pit Curb Angle H Flare Bevel Weld Typical To Fit Spacing If gap D cannot be obtained equally at both sides of leveler grind or add material at the rear edge
17. 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 Heset 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 f 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 4111 0002 May 2015 34 July 2015 TROUBLESHOOTING Three phase units only Platform does not rise Motor hums but does not run Three phase units only Platform does not rise Motor runs in reverse Single phase units only Platform does not rise Motor energizes but does not run Dock leveler equipped with ARTD Platform does not automatically return to the cross traffic position or operates abnormally 32 No voltage is present on Check for blown fuses at branch circuit disconnect one line Replace fuse Determine cause of blown fuse NOTE A motor that is Check motor starter as follows Hie voltage on one line 1 Disconnect wires at load side of star
18. the platform lip is resting on the transport vehicles bed the platform will stay at this position unless the operator activates the leveler 4111 0002 May 2015 July 2015 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 TROUBLESHOOTING 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 Before performing the detailed troubleshooting procedures check the following items first e Check all fuses inside
19. to drilling Q Seal all conduit entrances to prevent moisture from entering the control box DO NOT use compressed air to clean control box For left right orientation of dock leveler see inside back cover of Recommended to vacuum debris from inside this manual 16 4111 0002 May 2015 July 2015 INSTALLATION Placard Installation Instructions e Owner is responsible for the installation and placement of product placards e Make sure placard is in plain view of dock leveler operations e 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 Tr a REE Seka Seana BORG RT SS NTP Ee Se u 4 88 Jj NN 4111 0002 May 2015 17 July 2015 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 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 discon
20. Cotter Pin 1 4 x 1 1 4 in 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 For left right orientation of dock leveler see inside back cover of this manual 4111 0002 May 2015 37 July 2015 PARTS Hydraulic Components Hoist Cylinder Hose Pressure Hose 38 4111 0002 May 2015 July 2015 Hydraulic Components PARTS Item Quantity Part Number Description A 1 0522 0005 Clevis Pin B 1 2101 0045 Cotter Pin C 1 0522 0156 Yoke D 1 0521 0005 Roll Pin E 1 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 1 9202 0004 Pin 3 4 x 4 38 in G 2 2101 0049 Clip Hairpin 5 8 in dia H 1 9301 0111 Fitting 6 ORB Male x 8 JIC Male 9904 0089 Hose Logic Block to Lip Cylinder 6 leveler long or short lip cylinders J 1 9904 0075 Hose Logic Block to Lip Cylinder 8 leveler long or short lip cylinders 9904 0076 Hose Logic Block to Lip Cylinder 10 leveler long or short lip cylinders K 1 9904 0106 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 Nylon Lock Nut 5 16 18 UNC N 1 9575 0007 Logic
21. F 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 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 INTERUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY VH 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 For a period of five 5 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 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 and fluid logic control assembly only
22. RAfjjp VH SERIES POWERAMPP Division of Systems Inc e W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 e fax 262 255 5917 e www docksystemsinc com e techservices docksystemsinc com Printed in U S A Manual No 4111 0002 Copyright 2015 May 2015 July 2015 Table of Contents Page Safety Recognize Safety Information sccccsssseesseseesseeseeeeeseeseesseeneneeenens 1 General Operational Safety Precautions 1 Operational Safety Precautions eeeeeeee KEE 2 Maintenance Safety Precautions eesseeeess 4 Safety ele pet ee 5 Owner s User s Responsibilities sees 6 Introduction General Inf rmalo M ren ioe aan ea a a a iaa aA OAN ahi 7 Dock Leveler Stock Specifications 7 Component Identification ccce ecce eere eere enne 8 iin 8 Installation wlan 9 Prepare Dock L6eveler 5 n a o omia s Una ue e aaa aS PRESE 10 Install DOCK 48 7 l tr t 11 Install Control Panel and Wiring 18 Put New Leveler Into Service sese 19 Operation Operating Instructions e ee eeeee ee eeee
23. 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 15 If binding occurs lower the platform Reposition leveler and or add or remove shims as necessary Slowly raise platform again If platform still binds contact Technical Services for further instructions 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 4111 0002 May 2015 July 2015 INSTALLATION ic dE ES C Removable Frame Section D Maintenance Prop 16 All VH models a Install shims under maintenance prop D where prop attaches to leveler frame Make sure prop is solidly shimmed b Using the appropriate lifting device attached to the platform lifting lugs slowly raise the dock to the fully open position c Raise maintenance prop D to the service upright position and lock prop in this position using an OSHA approved locking device d Proceed to step 17 Two people are required to engage the maintenance prop one person to operate the lifting device the other person to engage the maintenance prop INSTALLATION Make sure the platform is properly supported in the raise
24. and hold the RAISE button and the LIP OUT button until lip has extended beyond the lip keepers Release both buttons NOTE If equipped depressing E STOP button will stop platform from lowering Item Quantity Part Number Description A 1 1751 0874 Placard 48 4111 0002 May 2015 July 2015 MISCELLANEOUS Customer Information NOTE Refer to illustration for left right orientation of Dock Leveler Information dock leveler Model The model serial number decal A is located on the right platform joist near the front lip Serial No of dock leveler Systems Inc Job No When you receive your VH dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keeping of the __ Original Owner Information numbers in the event the model serial number decal A becomes lost or damaged Name Al s Address SO 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 Installer Information When ordering use part numbers and description Name to help identify the item ordered Do not use item numbers These are only for locating the position of Address the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER Date of Installation For service call or contact Systems Inc P O Box 309 Ge
25. ase 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 0002 May 2015 J uly 2015 M Reservoir N 3 in 76 5mm From Top of Reservoir MAINTENANCE P Breather Cap Q Fluid Level DANGER WE ia 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 Check reservoir fluid level Q 1 Put the dock leveler platform at the full above dock position 2 Turn OFF all electrical power to the leveler 3 Remove breather cap P 4 Measure fluid level The fluid level should be approximately 3 in 76 5 mm N from top of reservoir M with platform raised on the maintenance prop 5 Add hydraulic fluid if necessary Use only recommended fluid 6 Install breather cap and inspection plate 7 Turn ON electrical power to the leveler 8 Return the platform to the cross traffic position 25 ADJUSTMENTS Adjust Main Pressure Relief When service und
26. 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 eX End Loading Unloading Platform at Cross Traffic Position 4 f transport vehicles 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 f transport vehicles bed is below the dock floor level and the dock is equipped with the optional lip out button 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 unloading is finished 22 A ARTD Switch 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 dressing RAISE button B and LIP OUT button C simultaneously 8 When the platform lip clears the lip keepers release RAISE button B and LIP OUT button C 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 Hamp Loading Unloading Instructions on page 23 for
27. ather 5 x 5 in Plastic Box D 1 1751 0736 Decal Arc Flash Provide dock leveler serial number voltage phase and options when calling or faxing controller orders 4111 0002 May 2015 35 July 2015 PARTS Frame and Platform 36 4111 0002 May 2015 July 2015 Frame and Platform PARTS Item Quantity Part Number Description A 1 0595 1 Lip Welded Assembly B 1 823 Platform Welded Assembly 9202 0050 Pin Lip Hinge 1 Dia 70 50 LG 1 9202 0051 Pin Lip Hinge 1 Dia 76 75 LG 9202 0052 Pin Lip Hinge 1 Dia 81 50 LG 1 0014 0142 Toe Guard Sliding Left Upper 6 Foot VH3 1 0014 0140 Toe Guard Sliding Left Lower 6 Foot VH3 1 0014 0145 Toe Guard Sliding Left Upper 8 Foot VH3 1 0014 0143 Toe Guard Sliding Left Lower 8 Foot VH3 1 0014 0141 Toe Guard Sliding Right Upper 6 Foot VH3 E 1 0014 0140 Toe Guard Sliding Right Lower 6 Foot VH3 1 0014 0144 Toe Guard Sliding Right Upper 8 Foot VH3 1 0014 0143 Toe Guard Sliding Right Lower 8 Foot VH3 F 3 9202 0002 Rear Hinge Pin 9202 0009 Rear Hinge Pin Optional Stainless Steel G 6 2101 0047 Cotter Pin 1 4 x 2 in H 1 0015 Frame VH 1 9225 Maintenance Prop Rod J 1 9201 0001 Prop Pin amp Clip K AR 2101 0039 Nylon Lock Nut 5 16 18 UNC L AR 2101 0163 Washer 5 16 in Flat M AR 2101 001 1 Cap Screw 5 16 18 UNC x 1 in N 1 1751 0010 Decal Model Serial ID O 2 2101 0046
28. c Block Assembly eturn To Tank A to Logic Block H MOON s X To Hoist Cyl July 2015 4111 0002 May 2015 42 Logic Block Assembly PARTS Logic Block and Lever Arm Item Quantity Part Number Description A 1 9574 0001 Spool Valve Logic Block Standard 9574 0002 Spool Valve Logic Block Cold Weather 5402 0007 Lever Arm Standard B 1 5402 0008 Lever Arm Standard Centra Power 5455 0006 Lever Arm Cold Weather 5455 0007 Lever Arm Cold Weather Centra Power 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 opring F 1 8102 0001 Weight Logic Block Cable G 2 2101 0032 Set Screw Socket Head 1 4 20 UNC x 3 8 in H 1 5265 0002 Cable Weight Assembly Logic Block Includes Items C H Logic Block Assembly Item Quantity Part Number Description J 2 9301 0112 Elbow 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 9575 0007 Logic Block Complete Includes Items A and K N Q 1 2101 0098 Cap Screw 5 16 18 UNC x 1 3 4 in R 1 2101 0039 Nylon Lock Nut 5 16 18 UNC o 2 9301 0112 8 ORBM JICM SAE Straight 4111 0002 May 2015 July 2015
29. d position before entering the pit to finish weld the shims Failure to do this may result in serious personal injury or death 17 All model levelers Install shims at locations B using the pyramid or stepped shimming method Both platform cylinder trunnions must be solidly shimmed the entire length of the trunnion Make 19 When all welding has been completed paint all sure the trunnions are level from side to side as the welds and shims well as from front to back NOTE VH models are shipped with a front frame 18 Finish weld all shims using a fillet weld section C installed This temporary frame holds the leveler frame at the correct e Weld all shims within each shim stack to each dimensions until the leveler is permanently other then weld the shim stack to the leveler anchored into place Only then should it be frame removed Weld the front leveler frame shim stacks to the There are four cap screws and nuts that front pit curb steel fasten the T frame to the rest of the leveler frame Tack welds may also be used 20 For all VH models remove the Shipping Bar C by grinding the tack welds that hold it in place during transport Paint after Shim Stacking Methods N P 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
30. de width of weatherstrip when replacing existing seals 4111 0002 May 2015 47 July 2015 PLACARD ADANGER Read and follow all 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 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 FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR OTHER SERIOUS INJURY
31. 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 DANGER bk Le A d i Te Ane 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 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
32. eee rne e nennen nennt 20 Ramp Loading Unloading Instructions 21 End Loading Unloading Instructions 22 Maintenance Service Dock Leveler Safely sees 23 Periodic Maintenance ege eege EES 24 Adjustments Adjust Main Pressure Relief sese 26 Adjust Cable Weight and Down Speed Control 27 Adjust Auto Return To Dock ARTD 28 Troubleshooting Tro blesho oting Mam Ee 31 Parts CONTE ONS Rees LN E M TUN 35 Frame and Plal fOr ME 36 Hydraulic eu le e E E 38 Hoist Cylinder Repair Parts ccccssssecsssseesesseeseaseesenseeeeeseeeseaseees 40 Lip Cylinder Repair Parts ciii eoeii vclit rece e ere oov eee Ex EE R deos puc URES 41 LOGIC ele t le TEE 42 Power Pack Greet leede 44 Weather Sedlgu iio iere ei oriri a Co 2E ese E euo a Eb aea EE Eo ER SERE cons EROR 47 Miscellaneous xav tee PAC AN Ossie ET MS 48 Customer Information ccccccesesseceeeesseeseeenseeeceenseeeeoenseessennseeseoenes 49 Warn anty A Back Cover Recognize Safety Information Safety Alert Symbol The Safety Alert Symbol identifies NOTICE safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal inj
33. eepers evenly If an excessive transition exists between the dock floor and leveler and or lip does not contact both lip keepers evenly contact Systems Inc Technical Services for further instructions 3 Install the dock bumpers as required 4 Turn the main electrical power ON Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or death may result 5 Raise the leveler platform fully by depressing and holding the RAISE button NOTE The platform of a properly operating dock leveler will automatically stop rising when it reaches approximately 2 3 inches from 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 Hises to Full Height But Lip Does Not Fully Extend in the Troubleshooting section 6 Release the RAISE button to lower the platform As long as there is no transport vehicle present at the dock the platform will lower to the full below dock position as the lip folds NOTE lf a transport vehicle is present the platform will lower until the lip rests on the transport vehicles bed See Operating Instructions in Operation section 4111 0002 May 2015 July 2015 INSTALLATION 7 When the platform lowers to the full below dock position wait 6 seconds after the lip has folded to a
34. er pivot at top of logic block If 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 If 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 and Down Speed Control in the Adjustment section NOTE Extreme cold weather OR incorrect fluid may cause platform to lock Adjustment is same 4111 0002 May 2015 July 2015 PARTS Controls RY A DANGER AY Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open without appropriate PPE Refer to NFPA ZOE for PPE requirements This panel may contain more than one power soumce 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 C 1 9511 0004 J Box Standard 4 x 4 in Metal Box 9512 0429 J Box Cold We
35. er 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 transport vehicles with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize transport vehicle 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 0002 May 2015 July 2015 General Information Congratulations on your choice of a Poweramp dock leveler This manual covers the VH 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 a
36. er 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 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
37. g must be performed area at dock level and ground level to prevent 1 unauthorized use of the dock leveler before installation has been completed 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 by making the following measurements Failure to follow the installation instructions can result in damage to dock leveler the facilities and or serious personal injury or death 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 e 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 DO NOT remove the shipping bands around the i is off b han 1 8 i dock leveler lip until instructed to do so any measurement Is o ve mo d e 3 18 mm contact Technical Services before proceeding 3 Make sure the field junction box for the dock leveler E is at the correct location per pit diagrams 4111 0002 May 2015 9 July 2015 INSTALLATION Prepare Dock Leveler 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 1 Remove any control panel and bumper
38. gnize 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 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 Manufacturers 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 whe
39. he control panel Decrease 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 33 TROUBLESHOOTING Platform does not rise to Low hydraulic fluid Add fluid 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 button is depressed Platform rises after lip is fully extended Platform locks into safety as platform lowers Lip drops to vertical position 34 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 lev
40. he 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 service 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 4111 0002 May 2015 July 2015 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 Ib ft Damage to switch will occur if maximum torque is exceeded A 3 16 in 4 8 mm C 1 in 25 4 mm Approximate Approximate B Target D Lock Nuts E Proximity Switch NOTE Distances A and C are typical factory setti
41. 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 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 29 ADJUSTMENTS Full Below Dock Position Lip Keeper Whenever the platform lip is at the full below dock position the following conditions will exist for a normally operating ARTD 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 30 Lip Fully Extended Position Whenever the platform lip is at the fully extended 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 the control panel Proximity switch indicator light is OFF If
42. llow lip cylinder to fully retract Depress and hold the RAISE button until the platform rises just enough to clear the lip keepers then release the RAISE button 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 8 Perform 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 9 Raise the platform fully Hold the platform at this position using the RAISE button and move the maintenance prop to the service upright position Helease the RAISE button to allow the platform to lower until it is resting on the maintenance prop 10 With the maintenance prop supporting the platform remove the lifting brackets and front shipping bar in between lip keepers 11 Dress and hold the RAISE button until the maintenance prop drops to its stored position Helease the RAISE button and allow the platform to lower fully
43. n 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 transport vehicle along the entire width of the platform with at least 4 in 102 mm of lip contacting the transport vehicles bed 4111 0002 May 2015 July 2015 OPERATION Tete Proceed with loading or unloading the transport vehicle If end loading is necessary see End Loading Unloading Instructions on page 22 A RAISE Button B ARTD Switch 7 When loading or unloading is finished raise the platform by depressing and holding RAISE button A Hold the RAISE button until the lip folds enough to clear the transport vehicle bed then release the RAISE button 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 21 OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE If ramp loading is required see Ramp Loading Unloading Instructions on page 20 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
44. n 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 needed 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 manufactur
45. nal injury and or damage to equipment permission to leave The dock leveler operating instructions are Make sure platform lip rests on the transport divided into the two methods of loading and vehicles bed with at least 4 in 102 mm of unloading overlap e For ramp loading and unloading see Ramp Maintain a safe distance from side edges of leveler Loading Unloading Instructions on page 21 during the loading unloading process 3 3 E e For end loading and unloading see End Loading Unloading Instructions on page 22 Failure to follow these instructions may result in serious personal injury or death 20 4111 0002 May 2015 July 2015 Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 22 For ramp loading or unloading the VH dock leveler can be operated by using the RAISE button on the control panel 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 4 Extend the platform lip onto transport vehicle as follows a Raise the platform by depressing and holding RAISE button A b Hold the RAISE button until the lip is fully extended then release the RAISE butto
46. nd operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended The VH series dock leveler comes equipped with an electrical control panel which allows push button operation of the dock leveler functions Each VH 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 0002 May 2015 July 2015 INTRODUCTION Dock Leveler Stock Specifications VH dock levelers are available in the following sizes weight capacities and options Width VH 6 ft 1828 8 mm 6 1 2 ft 1981 2 mm 7 ft 2133 6 mm Length 6 ft 1828 8 mm 8 ft 2438 mm 10 ft 3048 mm 12 ft 8658 mm Capacity CIR 25 000 Ib 11 340 kg 30 000 Ib 13 608 kg 35 000 Ib 15 876 kg 40 000 Ib 18 144 kg 45 000 Ib 20 412 kg 50 000 Ib 22 680 kg 60 000 Ib 27 216 kg m dcm cm c CIR Comparative Industry Rating Call Poweramp to discuss available voltages phases and options to meet your specific needs INTRODUCTION Component Identification A Lip D Powerpack Motor Pump Reservoir B Platform E Logic Block C Lip Cylinder s
47. nect 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 AA DANGER 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 ZOE 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 push button control panel B so bottom of control panel to dock floor distance C is 48 in 122 cm Install electrical disconnect panel A if not already installed Install and connect the control wiring Connect the dock leveler power cable to the field wires in the pit junction box Refer to the electrical drawings supplied with the dock leveler 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 4111 0002 May 2015 July 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 k
48. ngs 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 At least 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 NOT contact the switch otherwise damage to switch will occur Readjust switch and or target if necessary then recheck for interference 4111 0002 May 2015 July 2015 ADJUSTMENTS 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
49. of rear hinge frame angle F as needed 10 Allow the dock leveler to rest fully on the shim 11 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 If leveler cannot be squared and or made level as instructed in steps 8 10 contact Technical Services 13 INSTALLATION DO NOT weld continuously along the full length of the rear hinge frame angle This can put DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded unnecessary stress on the leveler components causing the leveler to malfunction and shorten the lifespan of the affected components 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 11 With the rear hinge frame angle F tight against proceeding with grinding or welding the rear pit curb angle G weld the rear hinge frame angle F to the rear pit curb angle G Always keep a fire extinguisher of the proper type using a 3 8 in 9 5 mm flare bevel skip weld nearby when grinding or welding each weld being 6 in 152 mm long Failure to follow these instructions may result in Start at each end with a 6 in 152 mm long serious personal injury or death weld S
50. ous injury 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 DANGER CRUSH HAZARD 1 75 1 01 38 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 1751 0729 ADANGER CRUSH HAZARD 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 will result in death or serious injury 1751 0729 AA DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch 1 75 1 073 1 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 ISTA 4 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 1 75 1 0726 safely supported by maintenance prop Place barriers 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 1781 0726 4111 0002 May 2015 5 July 2015 OWNER S USER S RESPONSIBILITIES 10 The owner user should reco
51. ovide dock leveler serial number voltage and phase when calling or faxing orders 4111 0002 May 2015 July 2015 39 PARTS Platform Cylinder Repair Parts Wear Ring Excluder Ring Retaining Ring IN LK e KSE SV D GO o OQ 235302 o ER t D 9 ococo cr ssa cc 2 0 oxi oc DOS gt Zn om O c3o027 momo oun SO Item Quantity Part Number Description A 1 0525 0048 Seal Kit 1992 and Newer 0525 0013 oeal Kit 1991 and Older 0525 0043 Cylinder Platform 15 1 2 in 394 mm Barrel Length B 1 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 40 4111 0002 May 2015 July 2015 PARTS Lip Cylinder Repair Parts Spring Spring Guide Washer ee y Gel Sal Ro mn SH KZ LLLLL ELA E t I qM MM Piston Seal 3 Piece Retaining Ring Wear Ring Item Quantity Part Number Description A 1 0525 0059 Seal Kit 1992 and Newer 0025 0014 oeal Kit 1991 and Older B 1 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 0002 May 2015 41 July 2015 PARTS Logi
52. pace all the other welds out evenly leaving approximately 6 in 152 mm space between each weld 12 Weld front of dock leveler frame B to shims DO NOT connect the dock leveler electrical wiring located under the keepers then weld the shims and ground connections until all welding has been to the front pit curb steel completed 13 With leveler welded into place remove the DO NOT ground welding equipment to any shipping bands from around lip and leveler frame 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 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 NOTE The illustration on the previous page shows a typical weld pattern The weld pattern Whenever this happens always cycle the leveler Will vary slightly depending on size of dock at least 4 times using the leveler s own hydraulic leveler 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 14 4111 0002 May 2015 July 2015 A Platform Joists B Shim Locations Under Platform Cylinder Trunnions 14 Using
53. 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 0002 May 2015 July 2015 MAINTENANCE Side View C Lock Out Device D Header 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 Whenever maintenance is to be performed under the dock leveler platform support the platform with maintenance prop A Position the maintenance prop behind front header plate D while staying 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 B and tagout device C 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 C 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 23
54. rmantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0002 May 2015 49 July 2015 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 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 O
55. s to those listed here are acceptable 4111 0002 May 2015 July 2015 Regular maintenance must be performed on a weekly and quarterly schedule Follow all safety precautions 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 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 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 C Platform hinge area apply oil to top of all platform hinges when platform is at the full below dock position E Platform cylinder to platform frame pin F Lip cylinder to platform frame pin G 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 D All platform cylinder trunnions NOTE Apply gre
56. s 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 te ix E SC DO NOT overtighten the lifting bracket hardware Overtightening can damage the weather seal if equipped A Lifting Bracket 2 used B Shipping Bands Poweramp dock levelers are designed with NOTE Overall width of platform and lifting brackets installation in mind Each unit is shipped with lifting A must be kept to a minimum to prevent brackets A fastened to the platform side joists 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 The dock leveler is heavy Use a lifting device and brackets A is snug The brackets should pivot chains with the appropriate lifting capacity and relatively freely on the mounting cap screw reach DO NOT overtighten Always use the lifting brackets provided with the 3 Attach lifting chains to lifting brackets A and to unit whenever lowering or lifting a dock leveler into a lifting device i e hoist or fork truck having the or out of a pit appropriate lifting capacity and reach Failure to follow these instructions may result in 4 Remove wood blocks that are attached to the damage to dock leveler and or serious personal leveler frame before putting the dock leveler into injury or death the pit 10 4111 0002 May 2015
57. ter is said to be single phased 2 Energize the starter 3 Measure line to line voltage at line side of starter 4 Measure line to line voltage at load side of starter 5 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 Phase reversed Reverse any two legs at the branch circuit disconnect Line voltage too low 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 Defective motor centrifugal Replace motor switch Defective motor capacitor Replace motor The auto return proximity Adjust proximity switch and target as necessary switch not sensing target See Adjust Auto Return To Dock ARTD in the correctly Adjustment section Defective proximity switch Replace switch Broken wire Loose or Repair or replace wires and connections as corroded wire connections necessary 4111 0002 May 2015 July 2015 Platform does not rise Pump operates in pressure relief mode Dock leveler binds Pressure relief set too low Platform rises slowly Contaminated hydraulic system Damaged or restricted hydraulic hose s Pressure relief set too low Pump motor loads down Pressure relief set too high
58. u have any questions ask your supervisor we eer 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 vehicles driver has been given permission to drive away NT ee Do not use a broken or damaged 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 CM ke _ or Keep hands and feet clear of pinch points Avoid Make sure lip overlaps onto transport vehicles bed putting any part of your body near moving parts at least 4 in 102 mm Keep a safe distance from both side edges 2 4111 0002 May 2015 July 2015 SAFETY WE Do not use dock leveling device if transports vehicles bed 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 0002 May 2015 3 July 2015 SAFETY Maintenance Safety Precautions 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
59. ury or death Follow the instructions in the safety message 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 The use of the word NOTICE is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 0002 May 2015 July 2015 SAFETY General Operational Safety Precautions Read and understand the Owner s User 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 WARNING or CAUTION signs or decals 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 yo
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