VS 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 © 2008 Manual No.
Table of Contents Page Safety Recognize Safety Information ............................................................. General Operational Safety Precautions ............................................ Operational Safety Precautions........................................................... Maintenance Safety Precautions ......................................................... Safety Decal’s ........................................................................................
SAFETY Recognize Safety Information General Operational Safety Precautions 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. 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 stand clear of dock leveler and lip when working in front of the dock leveler. Failure to do this may result in serious personal injury or death. ALWAYS disconnect electrical power source and ground wire before welding on dock leveler. 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.
SAFETY Safety Decal’s 4.00" ! DANGER ! DANGER CRUSH HAZARD DO NOT WORK UNDER DOCK LEVELER unless all maintenance props have been properly positioned. Side maintenance props must be positioned as shown in figure “A” below. Prop locking pin must be positioned as shown in figure “B” below. Refer to owner’s/user’s manual for proper procedure. Failure to do so will result in death or serious injury. Storage Position 6.25" FIG.
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 Models VS-65 VS-66 VS-68 VS-655 VS-656 VS-658 VS-75 VS-76 VS-78 Nominal Size W x L 6’ x 5’ 6’ x 6’ 6’ x 8’ 6’6” x 5’ 6’6” x 6’ 6’6” x 8’ 7’ x 5’ 7’ x 6’ 7’ x 8’ VS dock levelers are available in the following sizes, weight capacities, and options: Congratulations on your choice of a Poweramp Vertical Storing dock leveler. This manual covers the VS (Vertical Storing) series hydraulic dock leveler.
INTRODUCTION Component Identification A B C D E K F G H I G J A. B. C. D. E. F. Lip Deck Lip Cylinder Flow Control Valve Hoist Cylinder* Storage Prop Yoke G. H. I. J. K. Trombetta Valve-Prop Kicker (Behind Prop Assy) Storage Prop Assembly with Lock-Out Pin included (F) Hinge Pin Stored Limit Switch Maintenance Props * Some models are equipped with multiple hoist cylinders. *Powerpack may be mounted on underside of leveler or remotely.
INTRODUCTION This page was intentional left blank 4111-0008 — Sept 2012 9
INSTALLATION Prepare Pit A B C D C A B A—Distance (Pit Width) (Front and Rear) B— Distance (Dock Floor-to-Pit C— Distance (Pit Length) Floor) (All Four Corners) 1/2” (Both Sides of Pit) Taper Rear to Front Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before installation has been completed.
INSTALLATION Prepare Dock Leveler A B A— Lifting Bracket The dock leveler is heavy. Use a lifting device and chains with the appropriate lifting capacity and reach. B — Maintenance Props Poweramp dock levelers are designed with installation in mind. Each unit is shipped with lifting bracket(s) (A) fastened to the platform. IMPORTANT Always use the lifting brackets provided with the unit whenever lowering or lifting a dock leveler into or out of a pit.
INSTALLATION IMPORTANT Installation of VS levelers from inside is recommended due to combined height of leveler and proper lifting equipment may be greater than outside door height. 1. Remove any control panel, bumpers or pelletizing that may be banded to the dock leveler. Do not remove banding on hoist cylinder or storage prop at this time. 2. Make sure the mounting hardware of lifting bracket(s) (A) is snug. The brackets should pivot relatively freely on the mounting cap screw. DO NOT over tighten. 3.
INSTALLATION Install Dock Leveler Shim Stacking Methods E F G H I B C IMPORTANT The minimum size of the shim that contacts the leveler frame (i.e., the top shim of each shim stack) must be at least 4-1/2 x 4-1/2 in. (114.3 x 114.3 mm) to support the full width of the hoist cylinder / storage prop weldment. Use the thickest shim stock possible for stability and weld penetration purposes. DO NOT use multiple layers of 1/8 in. (3.18 mm) or thinner shim stock. D 4.
INSTALLATION The dock leveler is heavy. Use chains and a lifting device with the appropriate lifting capacity and reach. Failure to do so may result in damage to dock leveler and/or serious personal injury or death. E B C C F A A— Rear Imbed B— Dock Leveler D Bottle Jack C— Maintenance Props D— Hinge Pins 5. Lube the three rear hinge pins using grease Install the three pins in the rear imbed only through out the first hinge tube. E— lifting Lug F— Storage Prop 7.
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. B C 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.
INSTALLATION Purging air from the VS hydraulic system. 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 Put New Dock Leveler Into Service 1. Disconnect the external lifting device and chains from the lifting brackets. 2. Complete all welding. 3. Install hydraulic hoses and fill system. 4. Connect all electrical connections. 5. Purge System(see Purging pg 16). 4 Test leveler for operation. Always stand clear of platform lip when working in front of the dock leveler. Serious personal injury or death may result. Rod Eye adjustment & New installation. 1.
OPERATION Theory A J I B K G L C F A — Control Box B — Platform C — PowerPack H D D — Hoist Cylinder F — Limit Switch G — Reservoir H — Solenoid I— Lip Cylinder J — Raise Button K — Lip Button L— Lower Button When a button is pushed on the control panel this activates an electric motor (C) which, drives a hydraulic pump. The hydraulic pump forces oil into the platform cylinder(s) (D), causing the platform to rise or lower.
OPERATION Operating Instructions Stay clear of dock leveler when freight carrier is entering or leaving dock area. 10 in. (254 mm) DO NOT move or use the dock leveler if anyone is under or in front of leveler. 8 in. (203 mm) 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 21. 1. Check to make sure truck/trailer is positioned squarely against dock bumpers. 2. Instruct driver to remain at the dock until the loading or unloading process has been completed. 5. Proceed with loading or unloading the truck/trailer. 3. Chock the truck/trailer wheels or use the truck restraint if available. 6.
OPERATION Operating Instructions—Continued Below Dock End Loading/Unloading Instructions Dock Leveler Loading/Unloading Instructions 1. Check to make sure truck/trailer is positioned squarely against dock bumpers. 2. Instruct driver to remain at the dock until the loading or unloading process has been completed. 3. Chock the truck/trailer wheels or use the truck restraint if available. 4. Lower platform and lower the lip.
MAINTENANCE Service Dock Leveler Safely D A B C A— Tagout Device B — Lockout Device C —Maintenance Props 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 E A E D C B A— Lip Hinge Area B— Platform Pins C— Storage Prop D— Hoist Cylinder 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. Weekly Maintenance • Operate the dock leveler through the complete operating cycle to maintain lubrication. NOTE: Make sure the limit switch is clear of debris. • Inspect the platform hinge and the lip hinge areas. The hinge areas must be kept free of dirt and debris. Build-up of foreign material in the hinge areas will cause abnormal operation.
MAINTENANCE Checking Fluid Levels Reservoir on Remote Pumps Q N P M Pressure Return M — Reservoir N — 2 in. (51 mm) (From Top of Reservoir) P — Breather Cap Q — Fluid Level IMPORTANT A low fluid level or the use of hydraulic fluids not equivalent to the fluid types recommended, will cause abnormal operation of the leveler and WILL void warranty. • Check reservoir fluid level (Q): 1. The leveler must be in the stored position with the lip lowered. 2. Turn OFF all electrical power to the leveler. 3.
ADJUSTMENTS SC Adjust Main Pressure Relief When service under the dock leveler is required, always lock all electrical disconnects in the OFF position after raising the platform and engaging the 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.
ADJUSTMENTS Adjust Main Pressure Relief Remote Mount F E D 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 A 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 Stored Limit Switch Adjustment 1. Loosen Set Screw 2. With roller arm contacting storage prop, rotate adjustment screw counter clockwise until a “Click noise is heard. 3. Tighten set screw head cap screw. 4. Readjust as needed to leveler allow to store 3 to 5 degrees from vertical. 5. After adjusting the stored limit switch check for correct play in the prop.
ADJUSTMENTS Maintenance Prop Adjustment Maintenance Prop Adjustments 1. Raise platform fully and engage the maintenance prop in the service position (If dock leveler has not been used recently cycle leveler once). 2. Turn OFF all electrical power to the dock leveler. Attach safety lockout and tagout devices. 1” 3. Adjust yoke on maintenance till you have minimum. 1“ approximately, of free play in the prop”. 4. When the play in the prop is correct only 1-1/2 threads max will be exposed through the yoke.
TROUBLESHOOTING 1.50" Troubleshooting DANGER 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. 3.00" 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.
TROUBLESHOOTING Symptom Possible Cause Platform does not rise Motor overload device or lower. Motor does not tripped or fuse blown. energize. Solution Reset overload relay (three-phase) or replace fuse(s) (single-phase). Determine cause of overload. NOTE: When replacing fuse(s), the new fuse must have the same specification as the old fuse. Symptom Motor starter (three-phase) Check voltage at starter or relay coil. or motor relay (single-phase) not energizing.
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. Pressure relief set too low.
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 not rise. Coil energized on the float coil. Remove wire of terminal strip to the float coil, If leveler raises possible bad PLY or relay Bad spool valve. Remove and clean spool valve or replace with new or good working valve. Platform Does not rise to Low hydraulic fluid. full height.
PARTS Storage Limit Switch A Item Quantity Part Number A B C 2 1 1 2101-0027 0961-0130 0961-0186 34 C B Description Screw #10-32 UNF x 1.
PARTS Solenoid Prop Kicker C Item Quantity Part Number A B C 3 3 1 2101-0153 2101-0005 8581-0023 A B Description Bolt 1/4 UNC 1/2 Lg.
PARTS Storage Prop Assembly A C E D F B Item Quantity Part Number A B C D E F H 1 3 1 1 1 3 1 9222-0097 0522-0005 ** ** 9201-0006 2101-0047 9225-0016 Description Yoke, Upper Arm Prop Clevis Pin 3/4 Dia x 2-2/4 Lg.
PARTS Lip and Platform See drawing on page 38 A B 6’ WIDE 16” 18” 20” 6.5’ WIDE 16” 18” 20” 7’ WIDE 16” 18” 20” 6’ WIDE 5 6 8 6.
PARTS Lip and Platform A C Y X W J B K L M O G T R S I Q N U V H D E P F 38 4111-0008 — Sept 2012
PARTS Item Quantity Part Number A B 1 1 See Table page 37 C 1 D 3 E F G H I J K L M N O P Q R S T U V W X Y 6 1 2 4 4 1 1 2 1 1 1 4 1 4 4 2 1 1 2 1 1 4111-0008 — Sept 2012 Description 9202-0050 9202-0051 9202-0052 9202-0053 9202-0054 9202-0055 9202-0040 Lip, Weldment - Call on 2002 and older levelers Platform, Welded Assembly - Call on 2002 and older levelers Pin, Lip Hinge 6’W Pin, Lip Hinge 6.5’W Pin, Lip Hinge 7’W Pin, Lip Hinge 6’W, SS Pin, Lip Hinge 6.
PARTS SC Vertical Leveler Hydraulic Components A Sight Glass. Fluid should cover half the sight glass. Fluid level must be checked with leveler in the stored position with the lip folded.
PARTS SC Vertical Leveler Hydraulic Components Item Quantity Part Number A 1 B 1 0525-0085 0525-0066 0525-0104 Lip, Cylinder Hoist Cylinder 10” and 12” Pits Hoist Cylinder 15” Pits C 1 D E F G 1 4 4 4 H 1 I L N 1 1 1 1 1 9394-0024 9394-0053 9301-0199 21010011 2101-0058 2101-0060 9394-0014 9394-0015 9394-0033 9394-0034 9394-0035 9394-0043 9394-0044 9301-0132 9904-0090 9904-0059 9904-0137 9904-0103 Reservoir Short (5’-6’ Lg) Includes Hoses 9904-0102 & 9904-0103 Reservoir Long (8’ Lg) Includ
PARTS PARTS Centra Power Hydraulic Components A C E F H D G I 42 B 4111-0008 — Sept 2012
PARTS Item Quantity Part Number A 1 B 1 C 1 D E F G H I 1 1 1 1 1 1 0525-0085 0525-0066 0525-0104 9904-0059 9904-0137 9904-0083 9904-0059 9904-0082 9904-0090 8585-0089 8583-0045 4111-0008 — Sept 2012 Description Lip, Cylinder Hoist Cylinder 10” and 12” Pits Hoist Cylinder 15” Pits Hose, 35.00” Lg, #6 Jic Swivel Hose, 60.00” Lg, #6 Jic Swivel Hose, 44.00” Lg, #6 Jic Swivel Hose, 35.00” Lg, #6 Jic Swivel Hose, 21.00” Lg, #8 Jic Swivel Hose, 17.
PARTS Centra Power KS4 Hydraulic Components Item Quantity Part Number A 1 B 1 C 1 1 1 0525-0085 0525-0066 0525-0104 9904-0061 9904-0062 9904-0140 Description Lip, Cylinder Hoist Cylinder 10” and 12” Pits Hoist Cylinder 15” Pits Hose, 72.00” Lg, #8 To #6 Jic Swivel Both Ends (5’-6’ LG) Hose, 96.00” Lg, #8 To #6 Jic Swivel Both Ends (8’ LG) Hose, 140.00” Lg, #8 To #6 Jic Swivel Both Ends (8’- LG) A B C 1 Provide length and diameter of hose when calling or faxing orders.
4111-0008 — Sept 2012 45
PARTS VS Manifold Pressure Relief L E G F I Return To Tank H Hoist Cyl Rod End Pump Psi H “C” Lip Valve A C “E” Lower Platform M I D “D” Lower Platform Lip Cyl I K Hoist Cyl Bind End “B” Float Valve B L K K Item Quantity A B C 1 1 1 8581-0005 8581-0102 8581-0011 Part Number Valve Cartridge 3-Way Delta Valve Cartridge 2-Way Bi-Dr Delta Valve Cartridge 4-Way 2 Pos Delta Description D E F G H I J K L M 1 1 1 1 2 3 4 2 2 1 8581-0010 8581-0105 ** ** 9301-0111 9301-0113 8581-0004 4301-00
PARTS Centra Power Manifold 3. Return From Dock leveler 2. Return To Pump Station 4. Pressure To Dock leveler F I B E G A 1.
PARTS VS Manifold W/O Powerhold Lower Platform L E J Hoist Cyl Blind End J Hoist Cyl Blind End D J Lip Cylinder Centra Power L A Diverter Valve A L “C” Lip Valve K Pump Psi B Pressure Relief H K Return to Tank G L “E” Lower Platform Hoist Cylinder Rod End J F L Float Valve M N Item Quantity Part Number Description A B D E F G H J K 2 1 1 1 1 1 1 3 2 8581-0005 8581-0105 8581-0139 8581-0010 8581-0102 8581-0011 8581-0088 9301-0113 9301-0116 Valve Cartridge 3-Way Delta Valve Cartridge - Direct
PARTS VS Manifold W/ Powerhold E L Lower Platform Restraint Pressure J J Hoist Cyl Blind End Restraint Valve L G D J Lip Cylinder C A L “C” Lip Valve K Pump Psi B Pressure Relief H K Return to Tank G L “E” Lower Platform I Restraint Return F L Float Valve To Tank Hoist Cylinder Rod End J M N Item Quantity Part Number Description A B C D E F G H I J K 1 1 1 1 1 1 2 1 1 4 2 8581-0005 8581-0105 8581-0092 8581-0139 8581-0010 8581-0102 8581-0011 8581-0088 9301-0109 9301-0113 9301-0116 Valve C
PARTS Centra Power VS Manifold W/ Powerhold E L Lower Platform Restraint Pressure J M Restraint Valve G L J Hoist Cyl Blind End D J Lip Cylinder C A L “C” Lip Valve K Pump Psi B Pressure Relief K Return to Tank G L “E” Lower Platform Restraint Return I To Tank F L Float Valve H Hoist Cylinder Rod End J Description Diverter Valve L A Item Quantity Part Number A B C D E F G H I J 2 1 1 1 1 1 2 1 1 4 8581-0005 8581-0105 8581-0092 8581-0139 8581-0010 8581-0102 8581-0011 8581-0088 9301-0109 930
PARTS 4111-0008 — Sept 2012 51
PARTS Platform Cylinder Repair Parts B D G C E Control Box Size: Decal Size: 4 x 2 File Name: 1751-0138 Rev A ! DANGER CRUSH HAZARD DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance prop. Refer to owner’s/user’s manual for proper maintenance procedure. Failure to comply will result in death or serious injury. A F Barrel Lg.
PARTS Lip Cylinder Repair Parts Item A Quantity 1 B 1 Part Number 0525-0014 0525-0059 0525-0085 Description Seal Kit 1992 and earlier Seal Kit 1992 and Newer VS Lip Cylinder *Provide dock leveler serial number when calling or faxing orders.
PARTS Remote Mount Power Pack Assembly J L K M H D G E F C AC AB N P Q B AA R Z S Y W T A X U T V 54 4111-0008 — Sept 2012
PARTS Power Pack Assembly Item Quantity Part Number A B C D E F 2 2 1 1 1 2 1 4 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 2 1 2101-0039 9301-0029 9302-0014 9301-0199 9301-0027 9302-0012 9301-____ 1 2101-0039 9301-0028 9303-0002 9302-0017 9904-0001 0521-0017 0521-0007 3411-____ 2 0521-0015 0521-0014 9301-0024 9302-0009 9303-0003 9301-0014 9301-0015 9301-0016 0521-0016 9301-0009 9301-0082 9301-0008 9301-0003 9301-0004 2101-0063 9395-____ 1 G H J K L M N P Q R S T U V W X Y Z AA AB AC 1 2 Description N
NOTES 56 4111-0008 — Sept 2012
MISCELLANEOUS Customer 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. Dock Leveler Information Model ___________________________________ Serial No. ________________________________ Systems, Inc., Job No. ______________________ When you receive your VS dock leveler, write down the dock leveler model and serial number in the form provided.
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.
