VH SERIES Dock Leveler Owner’s/User’s Manual Poweramp • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022 800.643.5424 • fax: 262.257.7399 • www.docksystemsinc.com • techservices@docksystemsinc.com Printed in U.S.A. Copyright © 2002 Manual No.
Table of Contents Safety Page Recognize Safety Information.............................................................. General Operational Safety Precautions............................................. Operational Safety Precautions............................................................ Maintenance Safety Precautions.......................................................... Safety Decals..........................................................................................
SAFETY Recognize Safety Information Safety-Alert Symbol The Safety-Alert Symbol identifies important safety messages on equipment, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message. General Operational Safety Precautions Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler.
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. Stay clear of dock leveling device when freight carrier is entering or leaving area. Chock/restrain all freight carriers. Never remove the wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away.
SAFETY Do not use dock leveling device if freight carrier is too high or too low. Do not overload the dock leveling device. Do not operate any equipment while under the influence of alcohol or drugs. Do not leave equipment or material unattended on dock leveling device.
SAFETY Maintenance Safety Precautions 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. Hydraulic and electrical power must be OFF when servicing the equipment.
SAFETY Safety Decals Every 90 days (quarterly) inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible. If any are missing or require replacement, please call 1-800-643-5424 for replacements. 5.06" DANGER 2.40" 1751-0727 CRUSH HAZARD Maintenance prop must support leveler behind bar. 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.
OWNER’S/USER’S RESPONSIBILITIES 1. The owner/ user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle. The owner/ user should, therefore, train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer’s recommendations and industry standards.
INTRODUCTION General Information 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 (3658 mm) Congratulations on your choice of a Poweramp dock leveler. This manual covers the VH series hydraulic dock leveler.
INTRODUCTION Component Identification B K A G E C L F D H A — Lip B — Platform C — Lip Cylinder(s)* I D — Powerpack (Motor/Pump/Reservoir) E — Logic Block F — Platform Cylinder(s)* G — Main Frame H — Lip Keepers (4 used) I — Maintenance Prop J —Toe Guard (2 used) K —Raise Button L —ARTD Switch (option) THEORY The VH 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 .
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INSTALLATION Prepare Pit A C B D A—Distance (Pit Width) (Front and Rear) B— Distance (Dock Floor-to-Pit 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.
INSTALLATION Prepare Dock Leveler IMPORTANT A 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 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. IMPORTANT B A— Lifting Bracket (2 used) DO NOT overtighten the lifting bracket hardware.
INSTALLATION Install Dock Leveler Shim Stacking Methods N A A P Q R C B D 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 12 G— String H— Rear Hinge Frame Angle J— Distance (Dock Floor-toPit 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
INSTALLATION 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). 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.
INSTALLATION A B C C D D E F G A— Front of Dock Pit B— Dock Leveler Frame 3/8 in. (9.5 mm) 6 in. (152 mm) 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: • 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).
INSTALLATION IMPORTANT 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.
INSTALLATION A B D C A— Platform Joists B— Shim Locations (Under Platform Cylinder Trunnions) C— Removable Frame Section D— Maintenance Prop 14. 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. Two people are required to engage the maintenance prop: one person to operate the lifting device, the other person to engage the maintenance prop. 15.
INSTALLATION Make sure the platform is properly supported in the raised position before entering the pit to finish weld the shims. Failure to do this may result in serious personal injury or death. 18. 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 sure the trunnions are level from side-to-side as well as from front-to-back. 19.
INSTALLATION Install Control Panel and Wiring A 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. B C DO NOT make any final electrical connections until all welding has been completed.
INSTALLATION 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. If 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. 4. Turn the main electrical power ON.
OPERATION Operating Instructions Stay clear of dock leveler when freight carrier is entering or leaving dock area. 12 in. (305 mm) 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.
OPERATION 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 truck/trailer is positioned squarely against dock bumpers. 2. Instruct driver to remain at the dock until the loading or unloading process has been completed. 3.
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 truck/trailer bed. 1. Check to make sure truck/trailer is positioned squarely against dock bumpers. 2. Instruct driver to remain at the dock until the loading or unloading process has been completed. 3.
MAINTENANCE Service Dock Leveler Safely A B Side View A E C A— Lip Maintenance Prop B —Tag Out Device C — Lock 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.
MAINTENANCE Periodic Maintenance A B F C E G D A— Lip Hinge Area B— Valve Lever Pivot on Logic Block C— Platform Hinge Area D— Platform Cylinder Trunnion 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.
MAINTENANCE Regular maintenance must be performed on a weekly and quarterly schedule. N P Q Weekly Maintenance • 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.
ADJUSTMENTS Adjust Main Pressure Relief A When service under the dock leveler is required, always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop. Failure to do this may result in serious personal injury or death. B D C 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.
ADJUSTMENTS Adjust Cable Weight and Down Speed Control D C G H F E B A A— Speed Control Adjusting Screw B— Logic Block C—Valve Lever D— Cable E— Locking Pliers F— Cable Weight G—Steel Ball (2 used) H— Set Screw (2 used) Cable Weight Adjustment Down Speed Control 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).
ADJUSTMENTS Adjust Auto Return To Dock (ARTD) Adjust the ARTD as Follows: C D E F 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.
ADJUSTMENTS IMPORTANT 6. Turn ON electrical power to the dock leveler. 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. 7. Disengage the maintenance prop. The maximum torque for proximity switch lock nuts is 27 N•m (29 lb-ft). Damage to switch will occur if maximum torque is exceeded. 9.
ADJUSTMENTS Full Below-Dock Position Lip Fully Extended Position Lip Keeper 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. 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).
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.
TROUBLESHOOTING Symptom Three-phase units only: Platform does not rise. Motor hums, but does not run. Possible Cause Solution No voltage is present on one line. Check for blown fuses at branch circuit disconnect. Replace fuse. Determine cause of blown fuse. NOTE: A motor that is missing voltage on one line is said to be single-phased. Check motor starter as follows: 1. Disconnect wires at load side of starter. 2. Energize the starter. 3. Measure line-to-line voltage at line side of starter. 4.
TROUBLESHOOTING Symptom Platform does not rise. Pump operates in pressure relief mode. Possible Cause Solution Heavy object(s) on platform. Remove object(s) from platform. NOTE: For safety reasons, the dock leveler is designed to lift only the platform’s own weight. Dock leveler binds. Check for visible obstructions that could cause binding. Remove obstructions. If no obstructions found, call Poweramp Technical Services. See inside back cover for phone number and address.
TROUBLESHOOTING Symptom Possible Cause Solution Platform does not rise to Low hydraulic fluid. full height. Add fluid as needed. See Periodic Maintenance in the Maintenance section. Platform DOES rise to full height, but lip DOES NOT extend or extend fully. Low hydraulic fluid. Add fluid as needed. See Periodic Maintenance in the Maintenance section. Logic block (valve) lever cable weight too low on cable. Adjust cable weight.
PARTS Controls B A C Item Quantity Part Number A B 1 1 C 1 0615-0040 * 9511-0004 9512-0429 Description Proximity Switch with Harness (ARTD Feature Only) Push Button Controller J-Box, Standard (4 x 4 in. Metal Box) J-Box, Cold Weather (5 x 5 in. Plastic Box) * Provide dock leveler serial number, voltage, phase, and options when calling or faxing controller orders.
PARTS Frame and Platform A T B S U M R K P N L D Q C J E G F H V 36 4111-0002 — Sept 2010
PARTS Frame and Platform Item Quantity Part Number A B 1 1 1 0595-____1 7823-____2 9202-0050 9202-0051 9202-0052 Lip, Welded Assembly Platform, Welded Assembly Pin, Lip Hinge, 1” Dia 70.50 LG Pin, Lip Hinge, 1” Dia 76.75 LG Pin, Lip Hinge, 1” Dia 81.
PARTS Hydraulic Components G J AK B F H E P AA R C AB Q W Z S AM Y V AG A D X AE AG U AC N AJ AD T M L AH K AF 38 4111-0002 — Sept 2010
PARTS Hydraulic Components Item Quantity Part Number A B C D 1 1 1 1 E 1 F G H J K L M N 1 2 1 1 1 2 2 1 1 0522-0005 2101-0045 0522-0156 0521-0005 0525-0086 0525-0087 9202-0004 2101-0049 9301-0111 9904-0074 9904-0106 2101-0015 2101-0039 9575-0007 9575-0010 Clevis Pin Cotter Pin Yoke Roll Pin Lip Cylinder, 13-3/4 in. (349 mm) Barrel Length Lip Cylinder, 20-1/8 in. (511 mm) Barrel Length Pin, 3/4 x 4.38 in. Clip, Hairpin, 5/8 in. dia.
PARTS Platform Cylinder Repair Parts A B C 1 B 1 C 1 ! DANGER A Part Number 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.
PARTS Lip Cylinder Repair Parts A B Item Quantity A 1 B 1 Part Number 0525-0059 0025-0014 0525-0086 0525-0087 Description Seal Kit 1992 and Newer Seal Kit 1991 and Older Lip Cylinder, Complete, 14 in. Barrel Length Lip Cylinder, Complete, 20 in. Barrel Length *Provide dock leveler serial number when calling or faxing orders.
PARTS Logic Block Assembly C B D E F G H To Lip Cyl A L J R Return To Tank To Hoist Cyl.
PARTS Logic Block Assembly Logic Block and Lever Arm Item Quantity A 1 B 1 Part Number 9574-0001 9574-0002 5402-0007 5402-0008 5455-0006 5455-0007 Description Spool Valve, Logic Block, Standard Spool Valve, Logic Block, Cold Weather Lever Arm, Standard Lever Arm, Standard, Centra-Power Lever Arm, Cold Weather Lever Arm, Cold Weather, Centra-Power Logic Block Cable Assembly Item C D E F G H Quantity 1 2 1 1 2 2 1 Part Number 7955-0001 2101-0059 9572-0004 8102-0001 9552-0001 2101-0032 5265-0002 Des
PARTS Power Pack Assembly, Metal Reservoir Return Line D E B C G F A H Pressure Line 1 2 Item Quantity Part Number A B C D E F G H 1 1 1 2 1 4 1 1 9301-____ 0521-0007 9301-0199 0521-0017 3411-____ 2 2101-0016 9301-0190 9301-0159 1 Description Reservoir, Pump with Motor Drive Plate 90° Elbow, 1/4 NPT Male x 1/4 Tube Breather Cap, 3/8 NPT Male 90° Elbow, 3/8 NPT Male x #8-JIC Male Motor Only Cap Screw, 5/16-18 UNC x 3-1/2 in.
PARTS Power Pack Assembly, Plastic Reservoir Return Line D B C A E G F A H Pressure Line 1 2 Item Quantity Part Number A B C D E F G H 1 1 1 2 1 4 1 1 9391-____* 0521-0007 9301-0218 0521-0017 3411-____ 2 2101-0225 9301-0226 9301-0224 Description Reservoir, Pump with Motor Drive Plate 90° Elbow, 1/4 NPT Male x 1/4 Tube Breather Cap, Push In 90° Elbow, 3/8 NPT Male x #8-JIC Male Motor Only Cap Screw, 5/16-18 UNC x 3-1/2 in.
PARTS Weather Seal, Rubber Style B A C Item Quantity Part Number A B C 3 1 1 1 1 0192-____* 0192-____* 0192-____* 0195-____* 0195-____* Description Foam Seal, Rear Hinge Rubber Seal, Right Side Rubber Seal, Left Side Kit, Side, Rubber Weather Seal Kit, Rear, Rubber Weather Seal AR = As Required NOTE: Kits are for existing dock leveler without weather seal. * Provide dock leveler serial number and size of platform when calling or faxing orders.
PARTS Weather Seal, Brush Style A B C D C E G H F J Item Quantity Part Number A B C D E AR AR AR 1 1 1 1 1 1 1 1 1 1 1 2101-0012 0193-0001 2101-0039 0194-____* 0194-____* 0192-____* 0192-____* 0192-____* 0192-____* 0192-____* 0192-____* 0192-____* 0192-____* 0195-____* Cap Screw, 5/16-18 UNC x 1-1/4 in. (For Bar) Bar, Rear Hinge Brush Seal Nylon Lock Nut, 5/16-18 UNC (For Bar) Brush Assembly, Right Rear Hinge Brush Assembly, Left Rear Hinge Brush Seal and Track, Left Side, 1 in.
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MISCELLANEOUS Customer Information A Dock Leveler Information 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 VH dock leveler, write down the dock leveler model and serial number in the form provided. This will help ensure safe keeping of the numbers in the event the model/serial number decal (A) becomes lost or damaged.
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.