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Poweramp VS series Owner's And User's Manual

Dock leveler
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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.poweramp.com • techservices@poweramp.com
Printed in U.S.A.
Manual No. 4111-0008
Copyright
2017
April 2017
©
June 2017

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Summary of Contents for Poweramp VS series

  • Page 1 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.poweramp.com • techservices@poweramp.com Printed in U.S.A. Manual No. 4111-0008 Copyright 2017 April 2017 ©...

  • Page 2: Table Of Contents

    Table of Contents Page Precautions Recognize Precautionary Information ..........1 General Operational Precautions ............1 Operational Precautions ..............2 Maintenance Precautions ..............4 Precaution Decal’s ................5 Owners/Users Responsibility .............. 6/7 Introduction General Information ................7 Dock Leveler Stock Specifications ............. 7 Component Identification ..............

  • Page 3: Precautions

    PRECAUTIONS Recognize Precautionary Information General Operational Precautions Safety - Alert Symbol The Safety-Alert Symbol This is the safety alert symbol. It is used to alert you to the potential physical injury hazard. Obey all safety messages Read and understand the Owner’s/User’s manual and that follow this symbol to avoid possible death or become thoroughly familiar with the equipment and injury.

  • Page 4: Operational Precautions

    PRECAUTIONS Operational Safety Precautions Operational Precautions Learn the safe way to operate this equipment. Read and understand the manufacturer’s instructions. If you have any questions, ask your supervisor. Chock/restrain all transport vehicles, Never Stay clear of dock leveling device when transport Stay clear of dock leveling device when transport remove the wheel chocks until loading or vehicle is entering or leaving area.
  • Page 5 PRECAUTIONS Operational Precautions Do not use dock leveling device if transport vehicle 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.

  • Page 6: Maintenance Precautions

    PRECAUTIONS Maintenance Precautions 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.

  • Page 7: Precaution Decal's

    PRECAUTIONS Precautionary Decal’s CRUSH HAZARD CRUSH HAZARD Before doing any maintenance, repair or adjustments on the Before doing any maintenance, repair or adjustments on the dock leveler, first store the leveler in a vertical position with lip dock leveler, first store the leveler in a vertical position with lip extended, then ensure all maintenance props are in extended, then ensure all maintenance props are in maintenance positions and properly secured, and then...

  • Page 8: Owners/Users Responsibility

    OWNER’S/USER’S RESPONSIBILITIES 1) The manufacturer shall provide to the initial an understanding and familiarity with all functions of purchaser and make the following information the equipment. Owners/users shall actively maintain, readily available to the owners/users and their update and retrain all operators on safe working agents, all necessary information regarding Safety habits and operations of the equipment.

  • Page 9: Introduction

    The VS series dock leveler comes equipped with an electrical control panel, which allows push button 10) Manufacturer’s recommended maintenance and operation of the dock leveler functions.

  • Page 10: Component Identification

    INTRODUCTION Component Identification A Lip G Prop Kicker (Behind Prop Assy) B Deck Storage Prop Assembly with Prop Lock Pin included C Lip Cylinder Hinge Pins D Flow Control Valve J Stored Limit Switch E Hoist Cylinder* K Maintenance Props(2) Storage Prop Yoke * Some models are equipped with multiple hoist cylinders.

  • Page 11: Installation

    INSTALLATION Prepare Pit A—Distance (Pit Width) B— Distance (Dock Floor-to-Pit C— Distance (Pit Length) D— Distance (Pit Corner-to-Corner) (Top, (Front and Rear) Floor) (All Four Corners) 1/2” (Both Sides of Pit) Bottom, and Both Sides) Taper Rear to Front • Measure pit floor taper, rear to front cannot exceed 1/2”...

  • Page 12: Prepare Dock Leveler

    Prepare Dock Leveler A— Lifting Bracket 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. The dock leveler is heavy. Use a lifting device and chains with the appropriate lifting capacity and reach.

  • Page 13: Install Dock Leveler

    INSTALLATION 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.
  • Page 14 INSTALLATION Install Dock Leveler Shim Stacking Methods 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.
  • Page 15 INSTALLATION The dock leveler is heavy. Use a lifting device and chains with the appropriate lifting capacity and reach. Always use the lifting brackets provided with the unit whenever lowering or lifting a dock leveler into or out of a pit. Bottle Jack A Rear Embed C Maintenance Props...

  • Page 16: Install Control Panel And Wiring

    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. DO NOT make any final electrical connections until all welding has been completed.
  • Page 17 INSTALLATION Placard Installation Instructions • Owner/Users are responsible for the installation and placement of product placards. • Make sure placard is in plain view of dock leveler and/or vehicle restraint operations. • Suggested placement of placard is near control box attached to electrical conduit by using nylon tie.

  • Page 18: Put New Leveler Into Service

    INSTALLATION Put New Dock Leveler Into Service 1. Disconnect the external lifting device and chains DO NOT grind or weld if hydraulic fluid or other from the lifting brackets. flammable liquid is present on the surface to be ground or welded. 2.

  • Page 19: Purging Hydraulic System

    INSTALLATION Purging Air From The VS Hydraulic System. 1. The unit must be supported in the stored position with the storage prop and maintenance props in their in service positions. Lock out the storage prop with the prop pin and clip. 2.

  • Page 20: Operation Theory

    OPERATION Theory Control Box Hoist Cylinder Solenoid Lip Button Platform Limit Switch Lip Cylinder Lower Button Power Pack Reservoir Raise Button When the leveler is operated an electric motor is To lower the lip the vertical leveler must not be in the activated (C) which, drives a hydraulic pump.

  • Page 21: Operating Instructions

    OPERATION Operating Instructions 10 in. (254 mm) Stay clear of dock leveler when transport vehicle carrier is entering or leaving dock area. 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.

  • Page 22: Ramp Loading/Unloading Instructions

    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 transport vehicle is positioned squarely against both dock bumpers. 2. Instruct driver to remain at the dock until the loading or unloading process has been completed.

  • Page 23: End Loading/Unloading Instructions

    OPERATION Operating Instructions—Continued Below Dock End Loading/Unloading Instructions Dock Leveler Loading/Unloading Instructions 1. Check to make sure the transport vehicle is positioned squarely against both dock bumpers. 2. Instruct driver to remain at the dock until the loading or unloading process has been completed.

  • Page 24: Maintenance

    MAINTENANCE Service Dock Leveler 1.50" CRUSH HAZARD DO NOT WORK UNDER OR IN FRONT OF DOCK LEVELER Arc Flash and unless ALL props have been properly positioned and secured. First position Shock Hazard PPE [Personal Protection side maintenance prop(s) and secure with screw Equipment] Required and nut as shown in figure “A”...

  • Page 25: Periodic Maintenance

    MAINTENANCE Periodic Maintenance Lip Hinge Area Storage Prop Lip Cylinder Platform Pins Hoist Cylinder To ensure normal operation of the dock leveler, use only Aircraft Hydraulic Fluid designed to meet or When service under the dock leveler is required, exceed military specification MIL-H-5606-G. It is always lock all electrical disconnects in the OFF recommended that the following hydraulic fluids be position after raising the platform and engaging the...
  • Page 26 MAINTENANCE Regular maintenance must be performed on a weekly and quarterly schedule. Follow all safety precautions. Weekly Maintenance CRUSH HAZARD • Operate the dock leveler through the complete DO NOT WORK UNDER OR IN FRONT OF DOCK LEVELER unless ALL props have been operating cycle, making sure the dock leveler floats properly positioned and secured.
  • Page 27 MAINTENANCE Checking Fluid Levels on Reservoir for Remote Pumps • 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, Lock out/Tag out. Pressure 3.

  • Page 28: Adjustments

    ADJUSTMENTS PPAC Pressure Relief The pressure relief on the remote PPACs are factory adjusted. Consult Factory. 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.

  • Page 29: Adjust Main Pressure Relief

    ADJUSTMENTS Adjust Unit Pressure Slotted Adjusting Screw 1. The leveler must be in the stored position and the Jam Nut maintenance prop in the service position. 2. Turn OFF all electrical power to the dock leveler. Pressure Relief Attach safety lockout and tagout devices. 3.

  • Page 30: Limit Switch

    ADJUSTMENTS Stored Limit Switch Adjustment Follow all safety precautions. 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 5 Degrees from vertical leaning toward the overhead door.
  • Page 31 ADJUSTMENTS Storage Prop Adjustment Storage Prop Adjustments Follow all safety precautions. 1. Raise platform fully and engage the storage 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.
  • Page 32 TROUBLESHOOTING 1.50" 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 props. Arc Flash and Shock Hazard PPE [Personal Protection Always post safety warnings and barricade the work area at dock level and ground level to prevent Equipment] Required unauthorized use of the dock leveler before...

  • Page 33: Troubleshooting

    TROUBLESHOOTING Symptom Possible Cause Solution Motor overload device Reset overload relay (three-phase) or replace 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. Platform does not rise or lower.
  • Page 34 TROUBLESHOOTING Symptom 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 Technical Services.
  • Page 35 TROUBLESHOOTING Symptom Possible Cause Solution Low hydraulic fluid. Add fluid as needed. See Periodic Maintenance in Platform does not rise to the Maintenance section. full height. Coil energized on the float Remove wire of terminal strip to the float coil, If coil.

  • Page 36: Parts

    PARTS Storage Limit Switch Item Quantity Part Number Description 2101-0027 Screw #10-32 UNF x 1.75 Lg 0961-0130 Arm, Limit Switch 0961-0186 Limit Switch Click for manuals and videos http://www.docksystemsinc.com/Parts-Service 4111-0008 — April 2017 June 2017...
  • Page 37 PARTS Solenoid Prop Kicker Item Quantity Part Number Description 2101-0153 Bolt 1/4 UNC 1/2 Lg. 2101-0005 Washer, Lock 1/4 8581-0023 Solenoid Prop Kicker J-Box Item Quantity Part Number Description 2751-0042 J Box Fiber Glass 5” x 5“ (Includes Cover) 0961-0054 Mercury Switch 3051-0025 Rectifier Bridge...
  • Page 38 PARTS PARTS Storage Prop Assembly File Name: 1751-0229 Rev E Decal Size: 4 x 1 Item Quantity Part Number Description 9225-0016 Storage Prop Assembly Complete 9222-0097 Yoke, Upper Arm Prop 0522-0005 Clevis Pin 3/4 Dia x 2 Lg. Upper Weldment Lower Weldment 2101-0254 Prop Lock Pin and Clip...

  • Page 39: Frame And Platform

    PARTS Lip and Platform See drawing on page 38 VERTICAL LIPS 2003 to Present 6’ WIDE 40K W/O Gussets 45K Gussets 50K W/Gussets 16” 0595-0387 0595-1107 0595-1107 18” 0595-0388 0595-1108 0595-1108 20” 0595-0389 0595-1109 0595-1109 6.5’ WIDE 16” 0595-0390 0595-1110 0595-1110 18”...
  • Page 40 PARTS Lip and Platform 4111-0008 — April 2017 June 2017...
  • Page 41 PARTS Item Quantity Part Number Description Lip, Weldment - Call on 2002 and older levelers See Table page 37 Platform, Welded Assembly - Call on 2002 and older levelers See Table page 37 9202-0050 Pin, Lip Hinge 6’W 9202-0051 Pin, Lip Hinge 6.5’W 9202-0052 Pin, Lip Hinge 7’W 9202-0053...

  • Page 42: Hydraulic Components

    PARTS SC Vertical Leveler Hydraulic Components Sight Glass. Fill reservoir thru allen Fluid should cover half the sight glass. plug not the breather Fluid level must be checked with leveler in the stored position with the lip folded. 4111-0008 — April 2017 June 2017...
  • Page 43 PARTS SC Vertical Leveler Hydraulic Components Item Quantity Part Number Description 0525-0085 Lip Cylinder Without Fittings 0526-0016 Lip Cylinder With Fittings 0525-0127 Hoist Cylinder 5’ or 6 Lg. 0525-0126 Hoist Cylinder 8’ Lg. 15” Pits 0525-0125 Hoist Cylinder 8’ Lg. 10” or 12” Pits 9394-0024 Reservoir Short (5’-6’...
  • Page 44 PARTS Centra Power Hydraulic Components 4111-0008 — April 2017 June 2017...
  • Page 45 PARTS Item Quantity Part Number Description 0525-0085 Lip Cylinder Without Fittings 0526-0016 Lip Cylinder With Fittings 0525-0127 Hoist Cylinder 5’ or 6 Lg. 0525-0126 Hoist Cylinder 8’ Lg. 15” Pits 0525-0125 Hoist Cylinder 8’ Lg. 10” or 12” Pits 9904-0059 Hose, 35.00”...
  • Page 46 PARTS Centra Power KS4 Hydraulic Components Item Quantity Part Number Description 0525-0085 Lip Cylinder Without Fittings 0526-0016 Lip Cylinder With Fittings 0525-0127 Hoist Cylinder 5’ or 6 Lg. 0525-0126 Hoist Cylinder 8’ Lg. 15” Pits 0525-0125 Hoist Cylinder 8’ Lg. 10” or 12” Pits 9904- Hose, 9904...
  • Page 47 PARTS This page was left intentional left blank 4111-0008 — April 2017 June 2017...

  • Page 48: Hydraulic Valve Components

    PARTS VS Manifold Pressure Relief Hoist Cyl Rod End Return To Tank Pump Psi “C” Lip Valve “E” Lower Platform “D” Lower Platform Lip Cyl Hoist Cyl Blind End “B” Float Valve Item Quantity Part Number Description 8585-0089 Vertical Valve Assembly 8581-0005 Valve Cartridge 3-Way Delta 8581-0102...
  • Page 49 PARTS Centra Power Manifold 3. Return From Dock leveler 2. Return To Pump Station 4. Pressure To Dock leveler 1. Pressure From Pump Station Item Quantity Part Number Description 8583-0045 Centra Power Valve Assembly Valve Manifold 8581-0005 Valve Cartridge 3-Way Delta Fitting, Plug 8581-0088 Valve Cartridge - Flow 2GPM...
  • Page 50 PARTS VS Manifold CP W/O Powerhold Lower Platform Hoist Cyl Blind End Centra Power Lip Cylinder Diverter Valve “C” Lip Valve Pressure “E” Lower Platform Pressure Relief Float Valve (HB) Return to Tank Hoist Cylinder Rod End Item Quantity Part Number Description Valve, Assy.
  • Page 51 PARTS VS Manifold Remote W/ Powerhold Lower Platform Restraint Pressure Lip Cylinder Hoist Cyl Blind End “C” Lip Valve Pressure “E” Lower Platform REMOVE LARGE PLUG (9301-0229) Restraint Valve REMOVE SMALL PLUG @ BOTTOM OF CAVIT Return to Tank Pressure Relief REPLACE WITH 4-WAY CARTIAGE VALVE (C) Restraint Return (HB)
  • Page 52 PARTS 4111-0008 — April 2017 June 2017...
  • Page 53 PARTS This page was left intentional left blank 4111-0008 — April 2017 June 2017...

  • Page 54: Hoist Cylinder Repair Parts

    PARTS Platform Cylinder Repair Parts Barrel Lg. Item Quantity Part Number Description 9301-0109 Fitting Connection Str Thread 90 DEG Male 1751-0138 Decal 0521-0073 Grease Zerk 2101-0159 Hex Nut 9461-0002 Rod End 0525-0125* Hoist Cylinder 8’Lg, 10” or 12” Pits 0525-0126* Hoist Cylinder 8’Lg, 15”...

  • Page 55: Lip Cylinder Repair Parts

    PARTS Lip Cylinder Repair Parts SECTION A-A 13.75” Item Quantity Part Number Description 0522-0191 Yoke (included in 0525-0085) 0521-0005 Roll pin (included in 0525-0085) 0525-0014 Seal Kit 1992 and earlier 0525-0059 Seal Kit 1992 and newer 0525-0085 Lip Cylinder Without Fittings E-F 0526-0016 Lip Cylinder With Fittings E-F 9301-0109...

  • Page 56: Power Pack Assembly, Remote

    PARTS Remote Mount Power Pack Assembly Pressure Return 4111-0008 — April 2017 June 2017...
  • Page 57 PARTS Power Pack Assembly Item Quantity Part Number Description 2101-0039 Nylon Lock Nut, 5/16-18 UNC 9301-0029 Seal, Thread 9302-0014 Reservoir 9301-0199 Breather Cap, 3/8 NPT Male 9301-0027 O-Ring (Reservoir) 9302-0012 Tie Rod (Reservoir) 9301-____ Pump Only 2101-0039 Cap Screw, 5/16-18 UNC x 3-1/2 in., Grade 5 9301-0028 Gasket, Pump 9303-0002...
  • Page 58 NOTES 4111-0008 — April 2017 June 2017...

  • Page 59: Miscellaneous

    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 left platform joist near the front (lip) of Serial No. ________________________________ dock leveler. Systems, Inc., Job No.

  • Page 60: Warranty

    PROFIT, INTERRUPTION OF BUSINESS OR LOSS OF GOODWILL. PRODUCT SPECIFIC WARRANTY “VS” SERIES LEVELER In addition to the “Standard Product Warranty” provided with all Poweramp® Products, Systems Inc., guarantees materials, components and workmanship to be free of defects for the following extended periods: • Structural Warranty (VS) –...

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