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Poweramp PR Owner's Manual

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PR SERIES
Dock Leveler
Owner's Manual
POWERAMP • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022
800.643.5424 • fax: 262.255.4199 • www.poweramp.com • techservices@poweramp.com
Printed in U.S.A.
Manual No. 4111-0001
Rev. June 2003
Copyright
2002
©

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  • Page 1 PR SERIES Dock Leveler Owner’s Manual POWERAMP • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022 800.643.5424 • fax: 262.255.4199 • www.poweramp.com • techservices@poweramp.com Printed in U.S.A. Manual No. 4111-0001 Rev. June 2003 Copyright 2002...

  • Page 2: Table Of Contents

    Table of Contents Page Safety Recognize Safety Information ....... 1 General Operational Safety Precautions .

  • Page 3: Safety

    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 Read and understand the operating instructions and the instructions in the safety message.

  • Page 4: Operational Safety Precautions

    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 Chock/restrain all freight carriers. Never remove carrier is entering or leaving area.
  • Page 5 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.

  • Page 6: Maintenance Safety Precautions

    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.

  • Page 7: Safety Decals

    SAFETY Safety Decals Safety Decal on Leveler Frame Safety Decal on Platform Cylinder 4111-0001 — June 2003...
  • Page 8 SAFETY This page intentionally left blank 4111-0001 — June 2003...

  • Page 9: Introduction

    INTRODUCTION General Information Dock Leveler Stock Specifications PR dock levelers are available in the following sizes, weight capacities, and options: Width: PR 6 ft (1828.8 mm) 6-1/2 ft (1981.2 mm) 7 ft (2133.6 mm) Width: PR-XL 8 ft (2438.4 mm) 8-1/2 ft (2590.8 mm)

  • Page 10: Component Identification

    INTRODUCTION Component Identification A — Lip D — Powerpack (Motor/Pump/Reservoir) G — Dual-Lanyard Pull Ring K — Maintenance Prop B — Platform E — Inspection Plate H — Platform Cylinder(s)* L — Lip Keepers (2 used) C — Lip Cylinder(s)* F —...

  • Page 11: Installation

    If any measurement is off by more than 1/8 in. DO NOT remove the shipping bands around the (3.18 mm), contact Poweramp Technical Services dock leveler lip until instructed to to so. before proceeding.

  • Page 12: Prepare Dock Leveler

    Prepare Dock Leveler A— Lifting Bracket (2 used) B — Shipping Bands Poweramp dock levelers are designed with installation in mind. Each unit is shipped with lifting The dock leveler is heavy. Use a lifting device and brackets (A) fastened to the platform side joists.
  • Page 13 INSTALLATION 1. Remove any control panel and bumpers that may be banded to the frame of the dock leveler. DO NOT remove the shipping bands (B) around the platform lip and leveler frame at this time. IMPORTANT DO NOT overtighten the lifting bracket hardware. Overtightening can damage the weather seal, if equipped.

  • Page 14: Install Dock Leveler

    INSTALLATION Install Dock Leveler Shim Stacking Methods A— Distance (Leveler Frame G— String Height) H— Rear Hinge Frame Angle B— Shim Locations (Under J— Distance (Dock Floor-to-Pit Rear Vertical Supports) Floor) C— Shim Location (Under K— Distance (Top of Shim Maintenance Prop) Stack-to-Dock Floor) (Standard Dock Leveler...
  • Page 15 INSTALLATION NOTE: Poweramp dock levelers are designed with a 4. For all standard models, put a 1/4 in. (6.6 mm) nominal 1/2 in. (12.7 mm) shimming distance thick shim at locations (C and D) . to allow for pit inconsistencies.
  • Page 16 • Gap (D) must exist equally along both sides of leveler so weather seal (if equipped) will not 11. If leveler cannot be squared and/or made level as bind during dock leveler operation. instructed in steps 8 — 10, contact Poweramp Technical Services. 4111-0001 — June 2003...
  • Page 17 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 Poweramp Technical Services for further instructions. 4111-0001 — June 2003...
  • Page 18 INSTALLATION CleanPit Model Shown A— Platform Joists C— T- Frame (CleanPit Only) E— Distance [8-1/2 in. (216 mm) Approx] B— Shim Locations (Under Platform D— Maintenance Prop (CleanPit (Center of Leveler to Center of Prop Cylinder Trunnions) Model Shown) Mounting Plate) NOTE: For CleanPit models, proceed to step 17.
  • Page 19 INSTALLATION Closely follow the step-by-step instructions for Make sure the platform is properly supported in the installing the CleanPit maintenance prop. Failure to raised position before entering the pit to finish weld install the maintenance prop correctly may result in the shims.

  • Page 20: 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. Failure to follow these instructions may result in serious personal injury or death.

  • Page 21: Put New Leveler Into Service

    (stored) position (lip floor and leveler and/or lip does not contact both engages lip keepers). lip keepers evenly, contact Poweramp Technical Services for further instructions. NOTE: For dock levelers equipped with the Auto Return To Dock (ARTD), the platform will 3.
  • Page 22 INSTALLATION This page intentionally left blank 4111-0001 — June 2003...

  • Page 23: Operation

    P — Cable D — Electric Motor H — Platform Cylinder(s)* The PR dock leveler uses hydraulic logic and The dual lanyard feature provides dual function one-button operation for ease of use. operation. One function raises the platform. The other function extends the lip.

  • Page 24: Operating Instructions

    Keep hands and feet clear of pinch points. Avoid putting any part of your body near moving parts. The PR 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.

  • Page 25: Ramp Loading/Unloading Instructions

    Ramp Loading/Unloading Instructions NOTE: If end unloading is required, see End Loading/Unloading Instructions on page 24. For ramp loading or unloading, the PR dock leveler can be operated by using either the RAISE button on the control panel or the dual lanyard pull ring located in a recess at the rear of the platform.

  • Page 26: End Loading/Unloading Instructions

    OPERATION Operating Instructions—Continued End Loading/Unloading Instructions NOTE: If ramp loading is required, see Ramp Loading/Unloading Instructions on page 23. End loading or unloading can be done with the dock at the cross-traffic position or below-dock position, depending on the height of the truck/trailer bed.

  • Page 27: Maintenance

    MAINTENANCE Service Dock Leveler Safely Side View A— Tagout Device B — Lockout Device C — Lockout Device D — Tagout Device E — Maintenance Prop F — Header Plate When service under the dock leveler is required, Always post safety warnings and barricade the always lock all electrical disconnects in the OFF work area at dock level and ground level to prevent position after raising the platform and engaging the...

  • Page 28: Periodic Maintenance

    MAINTENANCE Periodic Maintenance An inspection plate is provided in the platform floor for ease of maintenance and pit inspection. A— Lip Hinge Area D— Dual-Lanyard Lever Pivot G — Toe Guard Hinges K— Lip Lifter and Lift B— Valve Lever Pivot on Logic E—...
  • Page 29 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: To thoroughly inspect the platform hinge area, put the platform in the full below-dock position.
  • Page 30 MAINTENANCE This page intentionally left blank 4111-0001 — June 2003...

  • Page 31: Adjustments

    ADJUSTMENTS 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...

  • Page 32: Adjust Cable Weight And Down Speed Control

    ADJUSTMENTS Adjust Cable Weight and Down Speed Control A— Speed Control Adjusting C—Valve Lever E— Locking Pliers G—Steel Ball (2 used) Screw D— Cable F— Cable Weight H— Set Screw (2 used) B— Logic Block Cable Weight Adjustment Down Speed Control Adjustment If the platform lip does not extend, or extends too If the dock leveler did not lower, it is possible that the soon, cable weight (F) may need adjustment.

  • Page 33: Adjust Auto Return To Dock (Artd)

    D— Lock Nuts H— Indicator Light Standard PR levelers are equipped with the Auto Return To Dock (ARTD) unless leveler is interlocked with a truck restraint. Always stand clear of the dock leveler lip when working in front of the dock leveler.
  • Page 34 ADJUSTMENTS IMPORTANT 6. Turn ON electrical power to the dock leveler. Anytime proximity switch and target are adjusted, 7. Disengage the maintenance prop. always check for interference between target and switch before operating the leveler. Damage to 8. Turn the ARTD switch (on control panel) to the switch will occur if the target contacts the switch.
  • Page 35 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 •...
  • Page 36 ADJUSTMENTS This page intentionally left blank 4111-0001 — June 2003...

  • Page 37: Troubleshooting

    TROUBLESHOOTING Troubleshooting When service under the dock leveler is required, Always stand clear of the dock leveler lip when always lock all electrical disconnects in the OFF working in front of the dock leveler. position after raising the platform and engaging the The maintenance prop MUST be in the service maintenance prop.
  • Page 38 TROUBLESHOOTING Symptom Possible Cause Solution Three-phase units only: No voltage is present on Check for blown fuses at branch circuit disconnect. Platform does not rise. one line. Replace fuse. Determine cause of blown fuse. Motor hums, but does not run. NOTE: A motor that is Check motor starter as follows: missing voltage on one line...
  • Page 39 Dock leveler binds. Check for visible obstructions that could cause binding. Remove obstructions. If no obstructions found, call Poweramp Technical Services. See inside back cover for phone number and address. Pressure relief set too low. Increase pressure relief. See Adjust Main Pressure Relief in the Adjustment section.
  • Page 40 TROUBLESHOOTING Symptom Possible Cause Solution 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 Low hydraulic fluid. Add fluid as needed. See Periodic Maintenance in full height, but lip DOES the Maintenance section.

  • Page 41: Parts

    PARTS Controls Item Quantity Part Number Description 0961-0085 Proximity Switch with Harness (ARTD Feature Only) Push Button Controller 9511-0004 J-Box, Standard (4 x 4 in. Metal Box) 9512-0429 J-Box, Cold Weather (5 x 5 in. Plastic Box) 0961-0014 Microswitch with Harness (Dual Lanyard Feature Only) * Provide dock leveler serial number, voltage, phase, and options when calling or faxing controller orders 4111-0001 —...

  • Page 42: Frame And Platform

    PARTS Frame and Platform 4111-0001 — June 2003...
  • Page 43 PARTS Frame and Platform Item Quantity Part Number Description 0595-____ Lip, Welded Assembly 7823-____ Plate, Inspection 9515-____ Platform, Welded Assembly 9202-____ Pin, Lip Hinge 0015-____ Toe Guard Welded Assembly, Left 8435-____ Frame, Standard 8435-____ Frame, CleanPit 2101-0039 Nylon Lock Nut, 5/16-18 UNC 9222-0382 Lockout Strap, Maintenance Prop 2101-0163...

  • Page 44: Hydraulic Components

    PARTS Hydraulic Components 4111-0001 — June 2003...
  • Page 45 PARTS Hydraulic Components Item Quantity Part Number Description 0522-0005 Clevis Pin 2101-0045 Cotter Pin 0522-0156 Yoke 0521-0005 Roll Pin 0525-0086 Lip Cylinder, 13-3/4 in. (349 mm) Barrel Length 0525-0087 Lip Cylinder, 20-1/8 in. (511 mm) Barrel Length 9202-0004 Pin, 3/4 x 4.38 in. 2101-0049 Clip, Hairpin 9301-0111...

  • Page 46: Hoist Cylinder Repair Parts

    PARTS Platform Cylinder Repair Parts Item Quantity Part Number Description 0522-0120 Gland 0521-0104 Rod Step Seal 0521-0008 O-Ring 0521-0009 Backup Ring 0521-0103 Wear Ring (Slydring) 0521-0105 Excluder Plus Seal 0521-0013 Retaining Ring 0525-0043 Cylinder, Platform, 15-1/2 in. (394 mm) Barrel Length 0525-0044 Cylinder, Platform, 17-1/2 in.

  • Page 47: Lip Cylinder Repair Parts

    PARTS Lip Cylinder Repair Parts Item Quantity Part Number Description 0524-0077 Cylinder Barrel Assembly 0521-0109 Wear Ring 0521-0110 Piston Seal, 3-Piece 0524-0051 Piston Assembly 0521-0050 Spring 0522-0091 Spring Guide 2101-0085 Flat Washer, 2-1/4 in. OD x 1-3/16 in. ID x 9/64 in. Thk. 0524-0068 Cylinder Head 0521-0004...

  • Page 48: Logic Block Assembly

    PARTS Logic Block Assembly PR 4111-0001 — September 2002...
  • Page 49 PARTS Logic Block Assembly Logic Block and Lever Arm Item Quantity Part Number Description 9574-0001 Spool Valve, Logic Block, Standard 9574-0002 Spool Valve, Logic Block, Cold Weather 5402-0007 Lever Arm, Standard 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...

  • Page 50: Power Pack Assembly

    PARTS Power Pack Assembly 4111-0001 — June 2003...
  • Page 51 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 2101-0016 Cap Screw, 5/16-18 UNC x 3-1/2 in., Grade 5 9301-0028 Gasket, Pump 9303-0002...

  • Page 52: Weather Seal, Rubber Style

    PARTS Weather Seal, Rubber Style Item Quantity Part Number Description 0192-____* Foam Seal, Rear Hinge 0192-____* Rubber Seal, Rear (Flat, Bend to Fit) 0192-____* Rubber Seal, Left Side 0192-____* Neoprene Seal, Short Vertical, Right 0192-____* Neoprene Seal, Short Vertical, Left 2101-0039 Nylon Lock Nut, 5/16-18 UNC (Side Weather Seal w/o Toe-Guard) 2101-0011...

  • Page 53: Weather Seal, Brush Style

    PARTS Weather Seal, Brush Style Item Quantity Part Number Description 2101-0012 Cap Screw, 5/16-18 UNC x 1/4 in. (For Bar) 0193-0001 Bar, Rear Hinge Brush Seal 2101-0039 Nylon Lock Nut, 5/16-18 UNC (For Bar) 0194-____* Brush Assembly, Right Rear Hinge 0194-____* Brush Assembly, Left Rear Hinge 0192-____*...
  • Page 54 PARTS This page intentionally left blank 4111-0001 — June 2003...

  • Page 55: Miscellaneous

    Serial No. ________________________________ of dock leveler. Systems, Inc., Job No. ______________________ When you receive your PR 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.

  • Page 56: Warranty

    Systems, Inc., guarantees the materials, components, and workmanship in your Poweramp dock leveler to be of the highest quality and to be free of defects in material and workmanship for a period of Seven (7) Years from date of shipment, specifically the deck section, lip section, frame, rear hinge, front hinge.

This manual is also suitable for:

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