Poweramp RCR Series Owner & User Manual

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RCR Series

Dock Leveler

Owner's/User's Manual

Older model shown.

Poweramp • Division of Systems, LLC • W194 N11481 McCormick Drive • Germantown, WI 53022

800.643.5424 • fax: 262.255.5917 • www.poweramp.com • techservices@poweramp.com

Printed in U.S.A.

Manual No. 4111-0044

June 2021

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Page 1 RCR Series Dock Leveler Owner’s/User’s Manual Older model shown. Poweramp • Division of Systems, LLC • W194 N11481 McCormick Drive • Germantown, WI 53022 800.643.5424 • fax: 262.255.5917 • www.poweramp.com • techservices@poweramp.com Printed in U.S.A. Manual No. 4111-0044 © 2021 Systems, LLC - All Rights Reserved...
Page 2: Table Of Contents
Table of Contents Page Precautions Recognize Precautionary Information ..........1 General Operational Precautions ............1 Operational Precautions ..............2 Safety Decals ..................4 Placard ....................5 Owner’s/User’s Responsibilities............6 Introduction General Information ................8 Component Identification ..............9 Installation Installation Precautions ..............12 Fixed RCR Installation .................
Page 3: Precautions
PRECAUTIONS Recognize Precautionary Information General Operational Precautions Safety-Alert Symbol The Safety-Alert Symbol is a graphic representation intended to convey a safety message without the Read and understand the Owner’s/User’s Manual and use of words. When you see this symbol, be alert become thoroughly familiar with the equipment and to the possibility of death or serious injury.
Page 4: Operational Precautions
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. Stay clear of dock leveling device when transport Chock/restrain all transport vehicles. Never vehicle is entering or leaving area. remove the wheel chocks or release the restraining device until loading or unloading is finished, and transport driver has been given...
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: Safety Decals
PRECAUTIONS Safety Decals RCR Series 1751-0397 Rev A 1751-0397 1751-1272 CRUSH HAZARD CRUSH HAZARD DO NOT WORK UNDER OR IN FRONT OF DO NOT WORK UNDER OR IN FRONT OF RAIL RAMP RAIL RAMP unless ALL props have been properly unless ALL props have been properly positioned and secured.
Page 7: Placard
PRECAUTIONS Placard O P E R AT I N G DANGER INSTRUCTIONS RAIL RAMP LEVELERS • 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 NORMAL OPERATION To lower the rail ramp, Press and hold the LOWER personnel.
Page 8: Owner's/User's Responsibilities
OWNER’S/USER’S RESPONSIBILITIES 1) The manufacturer shall provide to the initial the owner’s/user’s company policies, operating purchaser and make the following information conditions and the manufacturer’s specific readily available to the owners/users and their instructions provided with the dock leveling agents, all necessary information regarding device.
Page 9 OWNER’S/USER’S RESPONSIBILITIES 7) Loading dock safety equipment should never 11) Loading dock devices that are structurally be used outside of its vertical working range, or damaged or have experienced a sudden loss of outside the manufacturer’s rated capacity. It shall support while under load, such as might occur also be compatible with the loading equipment when a transport vehicle is pulled out from under...
Page 10: Introduction
7 ft (2134 mm) manual describes these changes where applicable. 7-1/2 ft (2286 mm) 8 ft (2438.4 mm) The RCR series dock leveler comes equipped 8-1/2 ft (2590 mm) with an electrical control panel, which allows push 9 ft (2743 mm) button operation of the dock leveler functions.
Page 11: Component Identification
INTRODUCTION Component Identification (Fixed RCR) Inspect package and all components. Report any missing or damaged items immediately and note on the shipping Bill Of Lading (BOL). L o a d i n g D o c FINAL ASSEMB AMER MATERIAL DRAWN BY CHECKED MarkS...
Page 12 INTRODUCTION Component Identification (RCR w/Manual Side Shift) Inspect package and all components. Report any missing or damaged items immediately and note on the shipping Bill Of Lading (BOL). ITEM P O W E R A M P M C G U I R E D L M L o a d i n g D o c k E q u i p m e n t FINAL ASSEMBLY, RAIL RAMP...
Page 13 INTRODUCTION Component Identification (RCR w/Hydraulic Side Shift) Inspect package and all components. Report any missing or damaged items immediately and note on the shipping Bill Of Lading (BOL). P O W L o a d i n g D o c k E q u i p m e FINAL ASSEMBLY, RAIL RAM EASTERDAY FARMS, 50K MATERIAL...
Page 14: Installation
INSTALLATION Installation Precautions It is recommended and good safety practice to use an additional means to support the dock platform CRUSH HAZARD DO NOT WORK UNDER OR IN FRONT OF and lip anytime when physically working in front of RAIL RAMP unless ALL props have been properly or under the dock leveler.
Page 15: Fixed Rcr Installation
INSTALLATION Fixed RCR Installation Figure 7 L o a d i n g D o c k E q 5. Lube the rear hinge pins using grease. Install the Installation of Platform to Embed FINAL ASSEMBLY, RA hinge pins in one side of the rear embed hinge tubes, AMERICOLD leaving room for the platform hinge tubes.
Page 16: Rcr W/Side Shift Installation
INSTALLATION RCR w/Side Shift Installation Figure 8 6-1/2” 6-1/2” 10” Channel 10” Channel P O W E R A M C G U I Figure 10 L o a d i n g D o c k E q u i p m e n t FINAL ASSEMBLY, RAIL RAMP A —...
Page 17 INSTALLATION RCR w/Side Shift Installation (continued) P O W E R A M P Figure 11 M C G U I R E D L M L o a d i n g D o c k E q u i p m e n t A —...
Page 18 INSTALLATION RCR w/Side Shift Installation Pictures Older model shown. Figure 14 Figure 14 shows the carriage being installed into the roller track; Figure 15 provides a side view of this process. The crane is positioned inside the building as the combined height of the leveler and lifting equipment is greater than the outside door height.
Page 19 INSTALLATION RCR w/Side Shift Installation Pictures Older model shown. Figure 16 Installation of RCR levelers from inside is recommended, as combined height of leveler and proper lifting equipment may be greater than Figure 16 shows the leveler platform being installed outside door height.
Page 20: Install Control Panel And Wiring
INSTALLATION Install Control Panel and Wiring Make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes. A hard hat or other applicable head protection should always be worn when working under or around a dock leveler.
Page 21 INSTALLATION Placard Installation Instructions 1. Installers and/ or Owner’s/ User’s are responsible for the installation and placement of product placards. 2. Placard must be in plain view of dock leveler and/ or vehicle restraint operations. 3. Suggested placement of placard is near control box, attached to the wall or electrical conduit using a cable tie.
Page 22: Purging Air From Rcr Hydraulic System & Adjusting Rod Eye
INSTALLATION Purging Air From RCR Hydraulic System & Adjusting Yoke If the equipment being serviced is a new start- up, opened to atmosphere, or lifted manually, air will enter into the hydraulic system. Whenever this happens, air must be fully purged from the hydraulic system.
Page 23: Put New Dock Leveler Into Service
INSTALLATION Put New Dock Leveler Into Service A hard hat or other applicable head protection should always be worn when working under or around a dock leveler. Always stand clear of platform lip when working in front of the dock leveler. 1.
Page 24: Operation
OPERATION Operational Precautions Stay clear of dock leveler when transport vehicle is entering or leaving dock area. 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.
Page 26: Ramp Loading/Unloading
OPERATION Operating Instructions Ramp Loading/Unloading 1. Before activating dock leveler, ensure lip will avoid contact with transport vehicle frame, sides and cargo during dock leveler activation. If contact is likely or observed, reposition transport vehicle. 2. Instruct driver to remain at the dock until the loading or unloading process has been completed.
Page 27: End Loading/Unloading
OPERATION Operating Instructions (continued) Below Dock End Loading/Unloading 6. When loading or unloading is finished, raise the platform by Pressing and holding RAISE (B) button 1. Before activating dock leveler, ensure lip will avoid until unit is about 45 degrees forward, then press contact with transport vehicle frame, sides and cargo the LIP button (C) simultaneously and the lip will fold during dock leveler activation.
Page 28: Optional Side Shift
OPERATION Operating Instructions (continued) Optional Side Shift Note: Levelers with optional Side Shift function identically to regular levelers, except that the leveler can be hydraulically shifted from side to side for optional positioning. 1. Before activating dock leveler, ensure lip will avoid contact with transport vehicle frame, sides and cargo Figure 26 during dock leveler activation.
Page 29: Maintenance
MAINTENANCE Maintenance Precautions Figure 27 Figure 28 A— Lock Out Device B —Tag Out Device C — Maintenance Props When working with electrical or electronic controls, make sure that the power source has been tagged (B) and locked out (A) according to OSHA regulations * It is recommended and good safety practice to use and approved local electrical codes (see Figure 27).
Page 30: Periodic Maintenance
MAINTENANCE Periodic Maintenance P O W E R A M P Figure 29 M C G U I R E D L M A— Lip Hinge Area C— Upper Hoist Cylinder Pin E — Lip Cylinder Pins G— Lower Hoist Cylinder Pin L o a d i n g D o c k E q u i p m e n t B—...
Page 31 MAINTENANCE Quarterly Maintenance • Complete Weekly Maintenance. • Lubricate the following areas with light weight 2 in. machine oil (see Figure 29): (A) — Lip hinge area unless equipped with grease fittings (apply oil to the top of the entire length of lip hinge when platform is in the stored position and lip is folded) Pressure...
Page 32: Adjustments
ADJUSTMENTS Adjust Flow Control 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 is not limited to a boom truck, fork truck, stabilizing bar or equivalent.
Page 33: Adjust Main Pressure Relief
ADJUSTMENTS Adjust Main Pressure Relief Main Pressure Relief Adjustment Note: The main pressure relief valve (A, Figure 32) may need to be increased if the platform does not rise or rises slowly and the system operates in pressure relief mode. The main pressure relief may need to be decreased if the pump motor loads down when platform reaches the full raised position.
Page 34: Troubleshooting
TROUBLESHOOTING 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 is not limited to a boom truck, fork truck, stabilizing bar or equivalent.
Page 35 TROUBLESHOOTING Symptom Possible Cause Solution Check for blown fuses at branch circuit disconnect. Replace fuse. Determine cause of blown fuse. Check motor starter as follows: 1. Disconnect wires at load side of starter. 2. Energize the starter. No voltage is present on 3.
Page 36 TROUBLESHOOTING Symptom Possible Cause Solution Remove object(s) from platform. Heavy object(s) on platform. Note: For safety reasons, the dock leveler is designed to lift only the platform’s own weight. Check for visible obstructions that could cause Dock leveler binds. binding. Remove obstructions. If no obstructions found, contact Systems, LLC Technical Services.
Page 37 TROUBLESHOOTING Symptom Possible Cause Solution Platform does not rise to Add hydraulic fluid, see pages 28-29 for proper fluid Low hydraulic fluid. full height. level and type. Remove and clean spool valve, or replace with new Platform does not rise. Faulty spool valve.
Page 39: Platform Hydraulic Hoses
PARTS Platform Hydraulic Hoses Item Quantity Part Number Description 0521-0162 Fitting, Tee #6 JIC As Req. 9904-____ Hose, Lip Cylinder As Req. 9904-____ Hose, Hoist Cylinder Blind End As Req. 9904-____ Hose, Hoist Cylinder Rod End 9904-____ Hose, Hoist Cylinder Blind End Tee to Valve Block 9904-____ Hose, Hoist Cylinder Rod End Tee to Valve Block 9904-____...
Page 41 PARTS Carriage, Lip and Platform Item Quantity Part Number Description 0595-____ Lip, Weldment 9516-____ Platform, Welded Assembly 9202-____ Pin, Lip Hinge 9202-0040 Rear Hinge Pin As Req. 9202-0041 Rear Hinge Pin Stainless Steel As Req. 2101-0047 Cotter Pin, 1/4 x 2.00” 8436-____ Carriage Assembly (Not required with fixed applications) 9511-0042...
Page 42: Hydraulic Side Shift
PARTS Hydraulic Side Shift S Y S T L o a d i n g MATERIAL DRAWN BY TOLERANCES (UNLESS OTHERWISE NOTED)  FRACTIONAL: 1/32" DECIMAL: .00 =  .01"  .000 = .005" ANGULAR:   This print is the property of Systems, Inc. and represents a of use and/or manufacture and/or sale.
Page 43: Carriage
PARTS Carriage A B C Torque Specifications: 1-7/8” or 2” Roller: 65-75 ft/lbs. 3” Roller: 170 ft/lbs. Item Quantity Part Number Description 9461-0004 Cam Roller 1-7/8” Dia. (before 2004) 9461-0007 Cam Roller 2” Dia. (after 2004) 2101-0199 Nut, Hex 7/8”-14 (One Per 9461-0007 Cam Roller) 2101-0200 Washer, Lock 7/8”...
Page 44: Valve Blocks
PARTS Vertical Valve Block Assembly—Platform Mounted Pump/ Motor (RV) Pressure Relief (HR) Hoist Cyl (R) Return To Tank Rod End (P) Pump Psi (F valve) Lip Valve (J1 valve) Lower Platform (J2 valve) (LP) Lower Platform Lip Cyl (HB) Hoist Cyl Blind End (FRV) Platform Relief Valve Item...
Page 45 PARTS Vertical Valve Block Assembly—Remote Mounted Pump/ Motor (RV) Pressure Relief (HR) Return Hoist Cyl To Tank Rod End (P) Pump Psi (F valve) Lip Valve (J1 valve) Lower Platform (LP) (J2 valve) Lip Cyl Lower Platform (HB) Hoist Cyl Bore End (FRV) Platform Relief Valve Item...
Page 46 PARTS Side Shift Diverter Valve Block To Side Shift Valve Pressure From Pump To Leveler Manifold Item Quantity Part Number Description 8583-0013 Valve, RCR, Leveler/Side-Shift Diverter - Complete 8581-0005 Valve Cartridge 3-Way 9301-0113 Fitting 90 Deg #6 ORB X #6 JIC 9301-0115 Fitting 90 Deg #6 ORB X #8 JIC 9301-0116...
Page 47 PARTS Side Shift Directional Valve Block To Rod End of Cylinder To Blind End of Cylinder Pressure From Diverter Valve Return To Tank Item Quantity Part Number Description 8583-0014 Valve, RCR, Side-Shift - Complete 8581-0011 Valve Cartridge 4-Way 9301-0113 Fitting 90 Deg #6 ORB X #6 JIC 9301-0115 Fitting 90 Deg #6 ORB X #8 JIC 4111-0044 —...
Page 48: Powerpacks
PARTS Remote Mounted PPAC VS Hydraulic Components (P) Pump Pressure (R) Return (F) Solenoid Valve (LP) Lip Cylinder (RV) System Relief Valve (HB) Bore End of Hoist Cyl (HR) Rod End of Hoist Cyl (FRV) Platform Relief Valve (J2) Solenoid Valve (J1) Solenoid Valve 4111-0044 —...
Page 49 PARTS Remote Mounted PPAC VS Hydraulic Components Item Quantity Part Number Description 9396-0051 PPAC ASSY, VS, REM Mount, RV Float 2101-0077 Screw, HHCS, 5/16-18 UNC X 3 2101-0102 Screw, RHMS, 8-32 UNC X 3/4 2101-0163 Washer - Flat - Zinc Plated, 5/16” DIA 2101-0187 Screw, HHCS - Grade 5, 5/16-18 UNC X 1 2101-0214...
Page 51 PARTS Remote Mount Valve Block w/Side Shift Assembly Hydraulic Schematic Item Quantity Part Number Description 0521-0022 Fitting, Tee, Run Swivel #8 JICF #8 JICM 2101-0011 Hex Head Cap Screw 5/16-18 x 1”, Grade 2 2101-0039 Nylon Lock Nut 5/16-18 2101-0077 Screw, HHCS, 5/16-18 x 3 2751-0080 J-Box, Fiber Glass 5”...
Page 52: Hoist Cylinder Parts
PARTS Hoist Cylinder Parts Seal kits are not available for vertical hoist cylinders. Barrel Lg. Item Quantity Part Number Description 0525-0132* Hoist Cylinder, Complete Assy* 0525-0133* Hoist Cylinder, Complete Assy* 0525-0134* Hoist Cylinder, Complete Assy* 9301-0109 Fitting, #6 ORBM x #6 JICM 1751-0138 Decal, Cylinder Fluid 0521-0073...
Page 53: Lip Cylinder Parts
PARTS Lip Cylinder Parts ITEM PART NO. 0521-0028 FITTING - BREATHER - B 0521-0238 CYL,LIP,SHORT,2.5" BOR 9301-0109 FITTING CON STR THRD GRAY PAINT USED TO SIGNIFY NO SPRING IN CYLINDER ASSEMBLY (BLACK PAINT USED TO SIGNIFY A SPRING IS IN CYLINDER ASSEMBLY) 13.75”...
Page 54: Powerpack Assembly
PARTS Remote Mount Powerpack Assembly Pressure Return MATE DRAW Leveler pressure is set by relief valve on valve block. Remote mount powerpack pressure is factory set. (UNL FRACTI DECIMA .00 = Typical cookpot-style remote mount Powerpack shown for reference purposes only. .000 Contact Systems, LLC Technical Services with serial number for exact breakdown.
Page 55 PARTS Remote Mount Powerpack Assembly (continued) Item Quantity Part Number Description 9395-____ Powerpack, Complete (Includes All Items Except L, N, and W) 2101-0039 Nut, Nylon Lock, 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)
Page 56 PARTS Powerpack Assembly (Carriage Mounted w/Single Hoist/Single Lip Cylinder) Return Line Pressure Line Item Quantity Part Number Description 9395-____ Powerpack, Complete 0521-0007 Elbow, 1/4 NPT Male x 1/4 Tube 9301-0218 Breather Cap, Push In 9301-0120 Fitting 45 Degree, #8 ORB x #8-JIC Male 3411-____ Motor Only 2101-0225...
Page 57: Flow Control Valve
PARTS Flow Control Valve Quantity Part Number Description 9303-0025 Flow Control Valve (Down Speed) *Provide dock leveler serial number when e-mailing, calling or faxing orders. 4111-0044 — June 2021 © 2021 Systems, LLC...
Page 59: Customer Information
MISCELLANEOUS Customer Information Figure 34 Figure 33 NOTE: Refer to Figure 33 for left/right orientation of dock Dock Leveler Information leveler and Figure 34 for example of decal. The LEVELER model/serial number decal is Model ___________________________________ located on the left platform joist near the front (lip) of dock leveler (A).
Page 60: Warranty
STANDARD PRODUCT WARRANTY SYSTEMS, LLC 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.

Poweramp RCR Series Owner & User Manual

Precautions

Introduction

Installation

Operation

Maintenance

Adjustments

Troubleshooting

Parts

Miscellaneous

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