Poweramp VH SERIES HYDRAULIC User Manual

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Page 1

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

Manual No. 4111-0002

January 2012

Page 2

Table of Contents

Page

Safety

Recognize Safety Information ............................................................. 1

General Operational Safety Precautions ............................................ 1

Operational Safety Precautions ........................................................... 2

Maintenance Safety Precautions ......................................................... 4

Safety Decals ......................................................................................... 5

Owner’s User’s Responsibilities ......................................................... 6

Introduction

General Information .............................................................................. 7

Dock Leveler Stock Specifications ..................................................... 7

Component Identification ..................................................................... 8

Theory ................................................................................................... 8

Installation

Prepare Pit .............................................................................................10

Prepare Dock Leveler .......................................................................... 11

Install Dock Leveler ............................................................................. 12

Install Control Panel and Wiring ........................................................ 18

Put New Leveler Into Service.............................................................. 19

Operation

Operating Instructions ........................................................................ 20

Ramp Loading/Unloading Instructions ........................................ 21

End Loading/Unloading Instructions ........................................... 22

Maintenance

Service Dock Leveler Safely ............................................................... 23

Periodic Maintenance .......................................................................... 24

Adjustments

Adjust Main Pressure Relief ............................................................... 26

Adjust Cable Weight and Down Speed Control ................................ 27

Adjust Auto Return To Dock (ARTD) ................................................. 28

Troubleshooting

Troubleshooting ................................................................................... 31

Parts

Controls ................................................................................................ 35

Frame and Platform ............................................................................. 36

Hydraulic Components ........................................................................ 38

Hoist Cylinder Repair Parts ................................................................ 40

Lip Cylinder Repair Parts .................................................................... 41

Logic Block Assembly ....................................................................... 42

Power Pack Assembly ......................................................................... 44

Weather Seals ...................................................................................... 46

Miscellaneous

Customer Information ......................................................................... 49

Warranty ................................................................................ Back Cover

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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.

The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death.

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.

Never operate a dock leveler while a safety device or guard is removed or disconnected.

Never remove DANGER, WARNING, or CAUTION signs or decals on the equipment unless replacing them.

The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death.

The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury.

IMPORTANT

The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage.

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Do not start the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone.

Remove any tools or foreign objects from the operating zone before starting.

Keep the operating zone free of obstacles that could cause a person to trip or fall.

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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.

Do not move or use the dock leveling device if anyone is under or in front of it.

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

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.

Do not use a broken or damage dock leveling device. Make sure proper service and maintenance procedures have been performed before using.

Make sure lip overlaps onto trailer at least 4 in. (102 mm).

Keep a safe distance from both side edges.

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Do not use dock leveling device if freight carrier is too high or too low.

SAFETY

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.

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SAFETY

Maintenance Safety Precautions

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. Only the person servicing the equipment should have the key to unlock the device.

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.

DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded

Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete.

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.

Failure to follow these instructions may result in serious personal injury or death.

ALWAYS stand clear of dock leveler lip when working in front of the dock leveler. Failure to do this may result in serious personal injury or death.

The maintenance prop must be in the upright “service” position when working under the dock leveler. For maximum protection, use an OSHA approved locking device to lock the maintenance prop in the service position. Only the person servicing the equipment should have the key to unlock the device.

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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.

1751-0727

SAFETY

DANGER

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.

1751-0727

1751-0730 (x2)

DANGER

Unsupported dock leveler ramps can lower unexpectedly.

Before allowing vehicle to leave the dock always:

! Ensure that no equipment,

material or people are on the dock leveler.

! Return the dock leveler to its

Failure to follow posted instructions will result in death or serious injury.

stored position at dock level.

(decal placed in same position on both sides)

SAFETY INFORMATION

Operation

1. Read and follow all instructions and warnings in the owner’s/user’s manual.

2. Use of dock leveler restricted to trained operators

3. Always chock trailer wheels or engage truck restraint before operating dock leveler or beginning to load or unload.

4. Never use hands or equipment to move the ramp or lip

5. Before activating dock leveler: ¥ Ensure trailer is backed in against bumpers.

¥ Remove any end loads if required. ¥ Check trailer alignment to avoid lip

interference. If lip does not lower to trailer bed, reposition vehicle.

6. Ensure that truck bed supports extended lip or the leveler frame

Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.

1751-0329 (x2)

DO NOT

FORK THIS SIDE

(decal placed in same position on both sides)

1751-0330 (x2)

(decal placed in same position on both sides)

DANGER

CRUSH HAZARD

1751-0138

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.

1751-0729

CRUSH HAZARD

Do not work under dock leveler unless this maintenance prop has been secured in the upright position. See owner’s/user’s manual for proper procedures. Failure to comply will result in death or serious injury.

1751-0731

DANGER

CRUSH HAZARD

Rotate prop to maintenance position.

Open the pin latch and insert through the maintenance prop housing. Close the pin latch to secure prop. Use every time dock leveler is serviced. Failure to comply will result in death or serious injury.

supports the ramp before driving on ramp.

7. Stay clear of hinges and front and sides of moving dock leveler.

8. Never use damaged or malfunctioning dock leveler. Report problems immediately to supervisor.

Maintenance/Service

1. Read and follow all instructions, warnings and maintenance schedules in the owner’s/user’s manual.

2. Maintenance/Service of dock leveler restricted to trained personnel.

3. Place barriers on the driveway and on dock floor to indicate service work is being performed.

4. DO NOT ENTER PIT unless dock leveler is securely supported by maintenance prop.

5. If electrically powered turn off and use OSHA lockout/tagout procedures.

FORK

HERE

1751-0729

1751-0731

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1751-0726

DANGER

CRUSH HAZARD

DO NOT ENTER PIT unless dock leveler is safely supported by maintenance prop. Place barriers on driveway and dock floor to indicate service work being performed. Refer to owner’s/user’s manual for proper maintenance procedures. Failure to comply will result in death or serious injury.

1751-0726

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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. Effective operator training should also focus on the owner’s/user’s company policies and operating conditions. Maintaining, updating and re training all operators on safe working habits and operation of the equipment, regardless of previous experience, should be done on a regular basis and should include an understanding and familiarity with all functions of the equipment. Owner’s/user’s shall actively maintain, update and retrain all operators on safe working habits and operations of the equipment.

2. The manufacturer shall provide to the initial purchaser all necessary information regarding Safety Information, Operation, Installation and Safety Precautions, Recommended Initial and Periodic Inspections Procedures, Planned Maintenance Schedule, Product Specifications, Troubleshooting Guide, Parts Break Down, Warranty Information, and Manufacturers Contact Information, as well as tables to identify the grade(slope) for all variations of length or configuration of the dock leveling device and information identifying the maximum uncontrolled drop encountered when sudden removal of support while in the working range of the equipment.

3. It is recommended that when the transportation vehicle is positioned correctly in the dock opening and in contact with both bumpers, there shall be a minimum of 4.00 inches (100mm) overlap of the leveling device and the transportation vehicle at all times during the loading and unloading process.

4. The Owner/User must review all name plates, placards, decals, instructions and posted warnings and place the same in view of the operator or maintenance personnel for whom such warnings are intended for. Contact manufacturer for any replacements.

5. Manufacturer’s recommended periodic maintenance and inspection procedures in effect at the date of shipment shall be followed at all times. Written documentation of maintenance, replacement parts or damage should be retained. In the event of damage notification to the manufacturer is required.

6. Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main support while under load (such as what might occur when a transport vehicle pulls out from under the leveling device) shall be removed from service, inspected by a manufacturer’s authorized representative, and repaired or replaced as needed before being placed back in service.

7. Any modifications or alterations of loading dock equipment shall only be done with prior written approval from the manufacturer and the same shall be at least as safe as the original equipment was prior to the modification and shall also satisfy all safety requirements of the manufacturer for the particular application of the leveling device.

8. When industrial moving devices are being used in the loading or unloading of product from the transportation vehicle, this vehicle shall have the brakes and wheel chocks applied appropriately or all other positive restraining device shall be fully utilized. It is recommended that trailers with air-ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize trailer bed drop.

9. Loading dock safety equipment should never be used outside of its intended use, vertical working range, or capacity. Please consult the manufacturer if you have any questions as to the use, vertical working range or capacity of the equipment. Only properly trained and authorized personnel should operate the equipment.

10. When selecting loading dock safety equipment, it is important to consider not only present requirements but also future plans and any possible adverse conditions, environmental factors or usage.

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INTRODUCTION

General Information

Congratulations on your choice of a Poweramp dock leveler. This manual covers the VH series hydraulic dock leveler.

Designed by Poweramp to be a marvel of simplicity and efficiency, your dock leveler, when properly installed, will provide many years of troublefree performance with an absolute minimum of maintenance. Its revolutionary hydraulic system efficiently controls and operates every function. To obtain maximum performance and longest possible use, a simple program of preventive maintenance is recommended.

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)

Capacity (CIR*)

25,000 lb (11 340 kg) 30,000 lb (13 608 kg) 35,000 lb (15 876 kg) 40,000 lb (18 144 kg) 45,000 lb (20 412 kg) 50,000 lb (22 680 kg) 60,000 lb (27 216 kg)

* CIR (Comparative Industry Rating)

Call Poweramp to discuss available voltages, phases and options to meet your specific needs.

The VH series dock leveler comes equipped with an electrical control panel, which allows push button operation of the dock leveler functions. Each VH dock leveler unit and control panel has been factory prewired and tested to ensure satisfactory operation.

To illustrate which connections are to be made in the field at installation, electrical drawings are included with each order or by contacting Poweramp Technical Services.

Once again, thank you and congratulations on your purchase of a Poweramp hydraulic dock leveler.

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INTRODUCTION

Component Identification

A — Lip B — Platform C — Lip Cylinder(s)*

D — Powerpack (Motor/Pump/Reservoir) E — Logic Block F — Platform Cylinder(s)*

THEORY

The VH dock leveler uses hydraulic logic and onebutton operation for ease of use.

The dock leveler can be operated remotely using the RAISE button (J) on the control panel .

Platform (B) is raised by pushing and holding the RAISE button (K). This activates an electric motor (D) which, in turn, drives a hydraulic pump. The hydraulic pump forces oil into the platform cylinder(s) (F), causing the platform to rise. Releasing the RAISE button allows the platform to lower.

G — Main Frame H — Lip Keepers (4 used) I — Maintenance Prop

J —Toe Guard (2 used) K —Raise Button L —ARTD Switch (option)

When the platform rises to the point where there is 1 — 3 in. (25.4 — 76.2 mm) of travel left in the platform cylinder, a cable pulls the valve lever up. When the cable force exceeds the force necessary to shift the spool valve inside logic block (E), the spool shifts, causing oil to be redirected to the lip cylinder(s) (C). This causes the platform to stop rising and lip (A) to extend. When the lip has fully extended, the platform will continue to rise until it reaches the full raised position.

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INTRODUCTION

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INSTALLATION

Prepare Pit

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.

C— Distance (Pit Length) (Both Sides of Pit)

D— Distance (Pit Corner-to-Corner) (Top,

Bottom, and Both Sides)

Before lowering the dock leveler into the pit, the following must be performed:

1. Remove all debris from the pit and sweep the pit clean.

2. Check the entire dock leveler pit for proper construction according to approved/certified pit drawings. Make sure pit is square by making the following measurements:

Only trained installation professionals with the proper equipment should install this product.

IMPORTANT

DO NOT remove the shipping bands around the dock leveler lip until instructed to do so.

• Measure pit width distance (A) at both front and rear of pit.

• Measure dock floor-to-pit floor distance (B) at all four corners.

• Measure pit length distance (C) at both sides.

• Measure corner-to-corner (criss-cross) distance (D) at both sides. Take measurements at dock floor level and at pit floor level.

If any measurement is off by more than 1/8 in.

(3.18 mm), contact Poweramp Technical Services before proceeding.

3. Make sure the field junction box for the dock leveler (E) is at the correct location per pit diagrams.

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INSTALLATION

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 brackets (A) fastened to the platform side joists.

IMPORTANT

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

DO NOT overtighten the lifting bracket hardware. Overtightening can damage the weather seal, if equipped.

NOTE: Overall width of platform and lifting brackets

(A) must be kept to a minimum to prevent interference between the lifting brackets and the pit walls as the dock leveler is lowered into the pit.

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.

Failure to follow these instructions may result in damage to dock leveler and/or serious personal injury or death.

2. Make sure the mounting hardware of lifting brackets (A) is snug. The brackets should pivot relatively freely on the mounting cap screw. DO NOT overtighten.

3. Attach lifting chains to lifting brackets (A) and to a lifting device (i.e., hoist or fork truck) having the appropriate lifting capacity and reach.

4. Remove wood blocks that are attached to the leveler frame before putting the dock leveler into the pit.

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INSTALLATION

Install Dock Leveler

Shim

Stacking Methods

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

G— String H— Rear Hinge Frame Angle J— Distance (Dock Floor-to-

Pit 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 (Not Acceptable) R — Straight (Not Acceptable)

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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). b. Measure dock floor-to-pit floor distance (J)

at each shim location (B). Write down the dimensions obtained at each location.

c. Subtract distance (A) from distance (J) to obtain

the shim height. Repeat for each shim location.

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 frame rail and to provide a shelf for a fillet weld.

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.

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. The final shim stack height will be determined after dock leveler is lowered into the pit.

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.

5. Using an appropriate lifting device connected to the lifting brackets, lower dock leveler into the pit so rear hinge frame angle (H) is tight against rear pit curb angle (F) across full width of the leveler frame.

6. Allow rear of dock leveler to rest on the rear shims while keeping the front of the dock leveler level with the dock floor.

2. Using the results obtained in step 1, create the individual shim stacks on the pit floor at locations (B). Build each shim stack (L) using the pyramid method (N) (preferred) or stepped method (P) with the top shim having a minimum size of 4-1/2 x 4-1/2 in. (114.3 x 114.3 mm) and each successive lower shim being larger so the shims can be welded together using a fillet weld. DO NOT use offset method (Q) or straight method (R).

NOTE: To assist in obtaining an accurate

measurement of distance (K), use a string (G) pulled tight across the pit opening, directly over the shim locations.

3. Verify that each shim stack is at the correct height by measuring distance (K) [top of shim stack (L) to dock floor]. Distance (K) must equal the dock leveler height (A).

7. For all VH models, add shims at front shim locations (C and D) so front of dock leveler will stay level with dock floor when leveler is resting fully on shims.

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INSTALLATION

A— Front of Dock Pit B— Dock Leveler Frame

3/8 in. (9.5 mm)

C— Side Pit Curb Angle D— Gap [3/4 in. (19 mm)

Minimum]

6 in. (152 mm)

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).

• Gap (D) must exist equally along both sides of leveler so weather seal (if equipped) will not bind during dock leveler operation.

E— Pry Locations F— Rear Hinge Frame

Angle

G— Rear Pit Curb Angle H— Flare Bevel Weld, Typical

(To Fit Spacing)

9. If gap (D) cannot be obtained equally at both sides of leveler, grind or add material at the rear edge of rear hinge frame angle (F) as needed.

10. Allow the dock leveler to rest fully on the shim

stacks. Check that a smooth and level transition exists between the dock floor and the dock leveler platform. Add or remove shims as necessary until a smooth transition is obtained.

11. If leveler cannot be squared and/or made level

as instructed in steps 8 — 10, contact Poweramp Technical Services.

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DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded.

Always keep a fire extinguisher of the proper type nearby when grinding or welding.

INSTALLATION

IMPORTANT

DO NOT weld continuously along the full length of the rear hinge frame angle. This can put unnecessary stress on the leveler components, causing the leveler to malfunction and shorten the lifespan of the affected components.

11. With the rear hinge frame angle (F) tight against the rear pit curb angle (G), weld the rear hinge frame angle (F) to the rear pit curb angle (G) using a 3/8 in. (9.5 mm) flare bevel skip weld — each weld being 6 in. (152 mm) long.

Failure to follow these instructions may result in serious personal injury or death.

IMPORTANT

DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed.

DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler. Always ground welding equipment to the dock leveler frame, NEVER to the platform.

Failure to follow these instructions may damage the motor, hoist cylinder, wiring, and/or control panel.

NOTE: The illustration on the previous page shows

a typical weld pattern. The weld pattern will vary slightly depending on size of dock leveler.

Start at each end with a 6 in. (152 mm) long

weld. Space all the other welds out evenly leaving approximately 6 in. (152 mm) space between each weld.

12. Weld front of dock leveler frame (B) to shims located under the keepers, then weld the shims to the front pit curb steel.

13. With leveler welded into place, remove the shipping bands from around lip and leveler frame.

If the platform is raised using an external lifting device or the hydraulic system is opened to atmosphere, air will enter into the hydraulic system.

Whenever this happens, always cycle the leveler at least 4 times using the leveler’s own hydraulic power system before allowing the leveler to be put into service. This is to make sure all air is purged from the hydraulic cylinders. Failure to do this may result in serious personal injury or death.

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INSTALLATION

A— Platform Joists B— Shim Locations (Under Platform Cylinder Trunnions)

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.

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.

16. All VH models: a. Install shims under maintenance prop (D)

where prop attaches to leveler frame. Make sure prop is solidly shimmed.

C— Removable Frame Section D— Maintenance Prop

Two people are required to engage the maintenance prop: one person to operate the lifting device, the other person to engage the maintenance prop.

DO NOT use the maintenance prop to support the raised platform until the maintenance prop has been properly shimmed and welded. The shims must be welded to each other, the leveler frame, and to the front pit curb steel. Failure to do this may result in serious personal injury or death.

b. Using the appropriate lifting device, attached

to the platform lifting lugs, slowly raise the dock to the fully open position.

c. Raise maintenance prop (D) to the service

(upright) position and lock prop in this position using an OSHA approved locking device.

d. Proceed to step 18.

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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.

INSTALLATION

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. Finish weld all shims using a fillet weld.

• Weld all shims within each shim stack to each other, then weld the shim stack to the leveler frame.

• Weld the front leveler frame shim stacks to the front pit curb steel.

Shim

Stacking Methods

20. When all welding has been completed, paint all the welds and shims.

NOTE: VH models are shipped with a front frame

section (C) installed. This temporary frame holds the leveler frame at the correct dimensions until the leveler is permanently anchored into place. Only then should it be removed.

There are four cap screws and nuts that

fasten the T- frame to the rest of the leveler frame. Tack welds may also be used.

21. For all VH models, remove the Shipping Bar (C) by grinding the tack welds that hold it in place during transport. Paint after.

* For left/right orientation of dock leveler, see inside back cover of

this manual.

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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.

DO NOT make any final electrical connections until all welding has been completed. Failure to do this may result in serious personal injury or death.

All electrical work — including the installation of the disconnect panel, control panel, and final connections to the pit junction box — must be performed by a certified electrician and conform to all local and applicable national codes.

A— Disconnect Panel B— Control Panel

(provided by others) C— Distance, 48 in. (14 630 mm)

1. Mount the push button control panel (B) so bottom of control panel-to-dock floor distance (C) is 48 in. (1219.2 mm).

2. Install electrical disconnect panel (A) if not already installed.

3. Install and connect the control wiring.

4. Connect the dock leveler power cable to the field wires in the pit junction box. Refer to the electrical drawings supplied with the dock leveler.

5. After all electrical connections in the pit have been made, disengage the maintenance prop and lower the platform using the external lifting device connected to the platform lifting brackets.

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Put New Dock Leveler Into Service

INSTALLATION

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.

Always stand clear of platform lip when working in front of the dock leveler. Serious personal injury or death may result.

5. Raise the leveler platform fully by pushing and

holding the RAISE button .

NOTE: The platform of a properly operating dock

leveler will automatically stop rising when it reaches approximately 2 – 3 inches from its full raised height, at which point, the lip extends. When the lip is fully extended, the platform will continue to rise until it reaches the full raised position. (If the lip does not extend or extend fully, see Platform Rises to Full Height, But Lip Does Not Fully Extend in the Troubleshooting section.)

7. When the platform lowers to the full below-dock position, wait 5 seconds after the lip has folded to allow lip cylinder to fully retract. Push and hold the RAISE button until the platform rises just enough to clear the lip keepers, then release the RAISE button to allow the platform to lower to the crosstraffic (stored) position (lip engages lip keepers).

NOTE: For dock levelers equipped with the Auto

Return To Dock (ARTD), the platform will automatically return to the cross-traffic position if the ARTD is enabled. When the platform is at the full below-dock position, there is a six-second delay before the platform will automatically rise to the crosstraffic position.

8. Perform steps 5 – 7 at least four times to purge any air that may be in the hydraulic system and to ensure proper operation.

Unless the dock leveler is equipped with a tethered remote, two people are required to engage the maintenance prop: one person to operate the unit, the other person to engage the maintenance prop.

9. Raise the platform fully. Hold the platform at this position using the RAISE button and move the maintenance prop to the service (upright) position. Release the RAISE button to allow the platform to lower until it is resting on the maintenance prop.

6. Release the RAISE button to lower the platform. As long as there is no truck present at the dock, the platform will lower to the full below-dock position as the lip folds.

NOTE: If a truck is present, the platform will lower

until the lip rests on the truck/trailer bed. (See Operating Instructions in Operation section.)

4111-0002 — January 2012

10. With the maintenance prop supporting the platform, remove the lifting brackets and front shipping bar in between lip keepers.

11. If equipped with vertical weather seals, position the seals so that the seals are directly under and aligned with the overhead door.

12. Push and hold the RAISE button until the maintenance prop drops to its stored position. Release the RAISE button and allow the platform to lower fully.

13. Perform step 7 if not equipped with ARTD.

Page 22

OPERATION

Operating Instructions

Stay clear of dock leveler when freight carrier 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.

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. Make sure proper service and maintenance procedures have been performed on leveler before using.

Truck/trailer wheels must be chocked unless the truck restraint is used. Never remove the wheel chocks until loading/unloading is finished and truck driver has been given permission to leave.

12 in. (305 mm)

The VH hydraulic dock leveler is designed to compensate for a maximum ± 12 in.* (305 mm) of height difference between the loading dock and the truck bed. DO NOT use the dock leveler if the truck/trailer bed is more than 12 in. (305 mm) higher or lower than the dock floor.

*service height may vary with design specifications DO NOT overload the dock leveler. DO NOT operate any equipment while under the

influence of alcohol or drugs. DO NOT leave equipment or material unattended

on the dock leveler. Failure to follow these instructions may result in

personal injury and/or damage to equipment.

Make sure platform lip rests on the truck/trailer bed with at least 4 in. (102 mm) of overlap.

Maintain a safe distance from side edges of leveler during the loading/unloading process.

Failure to follow these instructions may result in serious personal injury or death.

The dock leveler operating instructions are divided into the two methods of loading and unloading:

• For ramp loading and unloading, see Ramp Loading/Unloading Instructions on page 21.

• For end loading and unloading, see End Loading/Unloading Instructions on page 22.

4111-0002 — January 2012

Page 23

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.

OPERATION

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.

A—RAISE Button

4. Extend the platform lip onto truck/trailer as follows: a. Raise the platform by pushing and holding

RAISE button (A).

b. Hold the RAISE button until the lip is fully

extended, then release the RAISE button. The platform will lower until the lip is resting on the truck/trailer bed.

c. Make sure that the lip is fully extended and

supported on the truck/trailer along the entire width of the platform with at least 4 in. (102 mm) of lip contacting the truck bed.

5. Proceed with loading or unloading the truck/trailer.

6. If end loading is necessary, see End Loading/ Unloading Instructions on page 22.

A—RAISE Button B—ARTD Switch

7. When loading or unloading is finished, raise the

platform by pushing and holding RAISE button (A).

Hold the RAISE button until the lip folds enough

to clear the truck/trailer bed, then release the RAISE button. The lip will fold and the platform will return to the cross-traffic position.

8. Remove chocks from truck/trailer wheels or release the truck restraint if used.

9. Indicate to driver that truck may leave the dock.

4111-0002 — January 2012

Page 24

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 belowdock 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. Chock the truck/trailer wheels or use the truck restraint if available.

End Loading/Unloading — Platform at Cross-Traffic Position.

4. If truck/trailer bed is at or above dock floor level, leave leveler at the cross-traffic position and proceed with loading or unloading.

A—ARTD Switch

6. Turn the ARTD switch (A) on the control panel to the OFF position, if equipped.

7. Push the Raise button (B) to the platform just enough to clear the lip keepers.

8. When the platform lip clears the lip keepers, push the Lip-Out button (C) just long enough to clear the lip keepers. Release Lip-Out button. The platform will drift down to the full below-dock position.

9. Proceed with loading or unloading.

NOTE: When end unloading is finished and access

to the rest of the truck/trailer is still required, the platform lip will need to be extended. See Ramp Loading/Unloading Instructions on page 19 for further instructions.

10. When the loading or unloading is finished,

return the dock leveler platform to the crosstraffic (stored) position by performing one of the following:

End Loading/Unloading — Platform at Below-Dock Position.

5. If truck/trailer bed is below the dock floor level, and the dock is equipped with the optional lip-out button, perform steps 6 –12.

Whenever end loading or unloading with the platform in the below-dock position, make sure the ARTD switch is in the OFF position. DO NOT turn the ARTD switch to the ON position until end loading or unloading is finished.

• Turn the ARTD switch (A) to the ON position, if equipped. After approximately six seconds, the platform will automatically rise to the crosstraffic position.

• Push the Raise button (B) until the lip clears the

lip keepers. Release Raise button, leveler will return to the stored or cross traffic position.

11. Remove chocks from truck/trailer wheels or release the truck restraint if used.

12. Indicate to the driver that the truck may leave the dock.

4111-0002 — January 2012

Page 25

Service Dock Leveler Safely

MAINTENANCE

A— Lip Maintenance Prop B —Tag Out Device C — Lock Out Device E.—3 Styles of Lock

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.

Side View

Always stand clear of the dock leveler lip when working in front of the dock leveler.

The maintenance prop MUST be in the service position when working under the dock leveler. For maximum protection, use an OSHA approved locking device to lock the maintenance prop in the service position. Only the person servicing the equipment should have the key to unlock the maintenance prop.

Unless the dock leveler is equipped with a tethered remote, two people are required to engage the maintenance prop: one person to operate the unit, the other person to engage the maintenance prop.

Failure to follow these instructions may result in serious personal injury or death.

4111-0002 — January 2012

Whenever maintenance is to be performed under the dock leveler platform, support the platform with maintenance prop (E). Position the maintenance prop behind front header plate (F) while staying clear of the lip. The lip will fold down after the platform has rested on the maintenance prop. Lock the maintenance prop in the service (upright) position using an OSHA approved lockout device* (C) and tagout device* (D).

Whenever servicing the dock leveler, lock the electrical power disconnect in the OFF position. Use only an OSHA approved lockout device* (B) and tagout device (A).

Only the person servicing the equipment should have the capability to remove the lockout devices. The tagout devices* must inform that repairs are in process and clearly state who is responsible for the lockout condition.

* Refer to OSHA regulation 1910.147.

Page 26

MAINTENANCE

Periodic Maintenance

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.

IMPORTANT

Use of fluids that do not have equivalent specifications to those in the following list will result in abnormal operation of the dock leveler and voiding of warranty.

E— Platform Cylinder-to-Platform Pin F— Lip Cylinder-to-Platform Frame Pin

G— Lip Lifter and Lift

Cylinder Pin

To ensure normal operation of the dock leveler, use only aircraft hydraulic fluid designed to meet or exceed military specification MIL-H-5606. It is recommended that the following hydraulic fluids be used:

• ULTRA-VIS-HVI-15

• Aero Shell Fluid 4 or Fluid 41

• Mobile Aero HFA Mil-HS606A or Aero HF

• Texaco Aircraft Hydraulic Oil 15 or 5606

• Exxon Univis J13 These fluid brands can be mixed together. Mixing

with fluids that do not meet or exceed MIL-H-5606G may damage the equipment and WILL void warranty. Use of hydraulic fluids with equivalent specifications to those listed here are acceptable.

4111-0002 — January 2012

Page 27

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.

• 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.

Quarterly Maintenance

IMPORTANT

Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler.

M - Reservoir P - Breather Cap N- 3 in. (76.5mm) From Top of

Reservoir

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):

• Lubricate the following areas with light weight machine oil:

(A)— Lip hinge area unless equipped with grease

fittings (apply oil to the top of the entire length of lip hinge when platform is at the full below-dock position and lip is folded)

(C)— Platform hinge area (apply oil to top of all

platform hinges when platform is at the full

below-dock position) (E)— Platform cylinder-to-platform frame pin (F)— Lip cylinder-to-platform frame pin (G)— Lip lifter and lift cylinder pin

• Lubricate the following areas with white lithium

grease:

(B)— Valve lever pivot and top of logic block spool

valve.

(D) — All platform cylinder trunnions

NOTE: Apply grease to lip hinge grease fittings if

equipped.

1. Put the dock leveler platform at the full abovedock position.

2. Turn OFF all electrical power to the leveler.

Failure to follow these instructions may result in serious personal injury or death.

4. Remove breather cap (P).

5. Measure fluid level. The fluid level should be approximately 3 in. (76.5 mm) (N) from top of reservoir (M) with platform raised on the maintenance prop.

6. Add hydraulic fluid if necessary. Use only recommended fluid.

4111-0002 — January 2012

7. Install breather cap and inspection plate.

8. Turn ON electrical power to the leveler.

9. Return the platform to the cross-traffic position.

Page 28

ADJUSTMENTS

Adjust Main Pressure Relief

Always stand clear of the dock leveler lip when working in front of the dock leveler.

Unless the dock leveler is equipped with a tethered remote, two people are required to engage the maintenance prop: one person to operate the unit, the other person to engage the maintenance prop.

Failure to follow these instructions may result in serious personal injury or death.

A— SAE Cap Screw B— Hex Adjusting Screw

C— Main Pressure Relief D—Reservoir

To adjust the main pressure relief:

1. Raise the platform fully and engage the maintenance prop in the service position.

2. Turn OFF all electrical power to the dock leveler. Attach safety lockout and tagout devices.

3. Remove SAE plug (A).

4. Adjust hex adjusting screw (B) in small 1/4 turn increments as follows:

• Turn clockwise to increase pressure relief.

NOTE: The main pressure relief may need to be

increased if the platform does not rise or rises slowly and the system operates in pressure relief mode. See Troubleshooting section.

The main pressure relief may need to be

decreased if the pump motor loads down when platform reaches the full raised position. See Troubleshooting section.

• Turn counterclockwise to decrease pressure relief.

5. Tighten the jam nut and install the SAE plug.

6. Turn ON electrical power to the dock leveler.

7. Disengage the maintenance prop.

8. Check leveler operation.

9. Repeat steps 1– 8 as necessary.

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Page 29

Adjust Cable Weight and Down Speed Control

ADJUSTMENTS

G H

A— Speed Control Adjusting

Screw

B— Logic Block

C—Valve Lever D— Cable

Cable Weight 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).

The factory setting causes the lip to fully extend when 1 – 3 in. (25.4 – 76.2 mm) of travel is left in the platform cylinder.

NOTE: To prevent the cable weight from accidentally

falling off the cable when adjusting the weight, attach a locking pliers or similar device to the cable just below the cable weight. If adjustment requires that the weight be moved down, allow sufficient distance between pliers and weight before adjusting.

To adjust the cable weight: a. Loosen (do not remove) set screws (H). If set

screws are removed, balls (G) may fall out. b. To make lip extend sooner, slide the weight up. c. To make lip extend later, slide the weight down. d. Tighten set screws.

E— Locking Pliers F— Cable Weight

G—Steel Ball (2 used) H— Set Screw (2 used)

Down Speed Control Adjustment

If the dock leveler did not lower, it is possible that the speed control requires adjustment. The speed control adjusting screw (A) is a hex screw located in logic block (B), directly behind the upper front hose connection.

NOTE: If the platform lowers too fast, the platform

will stop lowering and lock in “safety” mode.

Use 1/4 turn increments when adjusting the

down speed control. Check platform lowering speed after each adjustment.

To adjust the speed control:

a. Loosen the jam nut. b. To decrease the lowering speed, turn adjusting

screw (A) clockwise.

c. To increase the lowering speed, turn adjusting

screw (A) counterclockwise.

d. Tighten the jam nut.

NOTE: Extreme cold and/or incorrect fluid may also

cause cylinder to lock. Adjust downspeed to decrease lowering speed.

4111-0002 — January 2012

Page 30

ADJUSTMENTS

Adjust Auto Return To Dock (ARTD)

Adjust the ARTD as Follows:

A— Cable B— Proximity Switch C— Bracket D— Lock Nuts

E— Target F— Lip Hinge Tube G—Platform Lip H— Indicator Light

VH levelers are equipped with the optional Auto Return To Dock (ARTD) if leveler not interlocked with a truck restraint.

The ARTD allows the platform to automatically return to the cross-traffic (stored) position after the truck departs. The ARTD uses a proximity switch (B) located under the platform and a piece of angled steel called the target (E) that is attached to the lip hinge tube (F).

The proximity switch provides a six-second delay after the platform has lowered to the full below-dock position, after which, the platform will return to the cross-traffic position. The switch also contains an indicator light (H) that can be used for diagnosing and adjusting the switch.

Always stand clear of the dock leveler lip when working in front of the dock leveler.

Unless the dock leveler is equipped with a tethered remote, two people are required to engage the maintenance prop: one person to operate the unit, the other person to engage the maintenance prop.

NOTE: Some proximity switches have an indicator

light at the back of the housing and some have the light at the side of the housing.

Failure to follow these instructions may result in serious personal injury or death.

1. Raise platform fully and engage the maintenance prop in the service position. Allow platform to rest on the prop so the lip will fully fold until it contacts the lip stops.

2. Turn OFF all electrical power to the dock leveler. Attach safety lockout and tagout devices.

4111-0002 — January 2012

Page 31

ADJUSTMENTS

IMPORTANT

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.

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.

A— 1/4 in. (6.4 mm)

Approximate

B— Target

C— 1 in. (25.4 mm)

Approximate D— Lock Nuts E— Proximity Switch

6. Turn ON electrical power to the dock leveler.

7. Disengage the maintenance prop.

8. Turn the ARTD switch (on control panel) to the ON position.

9. Raise the platform until the lip is fully extended, then allow the platform to drift to the below-dock position.

After approximately 6 seconds, the platform must

return to the cross-traffic position.

10. Adjust the proximity switch and target as

necessary. Make small adjustments, then operate the dock leveler to check results. Do this until satisfied with the ARTD operation.

Use the following illustrations to assist in fine

tuning and/or diagnosing the ARTD operation.

Cross-Traffic Position

NOTE: Distances (A and C) are typical factory

settings. Use these dimensions only as a starting point when adjusting the proximity switch and target, especially if switch and/or target have been replaced.

When dimensions (A and C) are obtained,

the proximity switch and target may need finer adjustments to get the ARTD to operate satisfactorily.

3. Loosen lock nuts (D). Adjust proximity switch (E) to obtain distance (A). Tighten lock nuts.

4. Bend target (B) as needed to obtain distance (C). Recheck distance (A) and readjust if necessary.

NOTE: At least two people may be required to

manually move the lip.

5. After adjusting proximity switch and target, slowly move the lip up by hand while observing the target and proximity switch. The target MUST NOT contact the switch, otherwise, damage to switch will occur. Readjust switch and/or target if necessary, then recheck for interference.

Lip Keeper

NOTE: The platform lip is fully folded when the

platform is at the cross-traffic (stored) position (lip engaged with keepers) or when platform is resting on the maintenance prop.

Whenever the platform lip is at the cross-traffic position, the following conditions will exist for a normally operating ARTD:

• Target not in the sensing area of proximity switch.

• Proximity switch OFF (open) (no signal sent to control panel).

• Proximity switch indicator light is OFF.

• Platform stays at this position unless the operator activates the leveler.

4111-0002 — January 2012

Page 32

ADJUSTMENTS

Full Below-Dock Position

Lip Keeper

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).

• Proximity switch indicator light is ON.

Lip Fully Extended Position

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.

• Proximity switch OFF (open) (no signal sent to the control panel).

• Proximity switch indicator light is OFF.

• If the platform lip is resting on the truck bed, the platform will stay at this position unless the operator activates the leveler.

• Platform will automatically rise after approximately a six-second delay, then returns to the cross-traffic position.

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Page 33

TROUBLESHOOTING

Before performing the detailed troubleshooting procedures, check the following items first:

• Check all fuses inside the control panel(s). Replace any blown fuse(s) with a fuse of equal specification.

Always stand clear of the dock leveler lip when working in front of the dock leveler.

Unless the dock leveler is equipped with a tethered remote, two people are required to engage the maintenance prop: one person to operate the unit, the other person to engage the maintenance prop.

Failure to follow these instructions may result in serious personal injury or death.

• Make sure the correct voltages are present at the proper locations inside the control panel(s).

Symptom Possible Cause Solution

Platform does not rise. Motor does not energize.

Motor overload device tripped or fuse blown.

Motor starter (three-phase) or motor relay (singlephase) not energizing.

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.

Check voltage at starter or relay coil.

• If voltage is present and starter or relay does not energize, replace starter or relay.

• If voltage is not present, check all components in series with the starter or relay coil.

4111-0002 — January 2012

Page 34

TROUBLESHOOTING

Symptom Possible Cause Solution

Three-phase units only: Platform does not rise. Motor hums, but does not run.

No voltage is present on one line.

NOTE: A motor that is missing voltage on one line is said to be single-phased.

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.

3. Measure line-to-line voltage at line side of starter.

4. Measure line-to-line voltage at load side of starter.

5. Line-side and load-side voltages should be approximately the same. Replace starter if voltage values are considerably different from one another.

Check all wiring to motor for high resistance or no connection.

Three-phase units only: Platform does not rise. Motor runs in reverse

Single-phase units only: Platform does not rise. Motor energizes, but does not run.

Dock leveler equipped with ARTD: Platform does not automatically return to the cross-traffic position or operates abnormally.

Phase reversed. Reverse any two legs at the branch circuit

disconnect.

Line voltage too low. Check wiring to motor for high resistance. Check for

loose or corroded connections. Check if gauge of wires to motor are of correct size and specification for load requirement. Replace if necessary.

Defective motor centrifugal switch.

Defective motor capacitor. Replace motor.

The auto return proximity switch not sensing target correctly.

Defective proximity switch. Replace switch.

Broken wire. Loose or corroded wire connections.

Replace motor.

Adjust proximity switch and target as necessary. See Adjust Auto Return To Dock (ARTD) in the Adjustment section.

Repair or replace wires and connections as necessary.

4111-0002 — January 2012

Page 35

Symptom Possible Cause Solution

Platform does not rise. Pump operates in pressure relief mode.

TROUBLESHOOTING

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. Increase pressure relief. See Adjust Main Pressure

Relief in the Adjustment section.

NOTE: The pressure relief valve must not

be set at a level that causes the motor operating current to exceed the full load amp value* at any time, including when operating in pressure relief.

* The full load amp value can be found on the inside cover of the

control panel.

Platform rises slowly. Low hydraulic fluid. Add fluid as needed. See Periodic Maintenance in

the Maintenance section.

Contaminated hydraulic system.

Clean and inspect valves. Flush contaminated oil from hydraulic system. Fill system with new oil. See Periodic Maintenance in the Maintenance section.

Damaged or restricted

Replace damaged hose(s). Remove restriction.

hydraulic hose(s).

Pressure relief set too low. Increase pressure relief. See Adjust Main Pressure

Relief in the Adjustment section.

NOTE: The pressure relief valve must not

be set at a level that causes the motor operating current to exceed the full load amp value* at any time, including when operating in pressure relief.

* The full load amp value can be found on the inside cover of the

control panel.

Pump motor loads down when platform reaches

Pressure relief set too high. Decrease pressure relief. See Adjust Main Pressure

Relief in the Adjustment section.

the full raised position.

NOTE: The pressure relief valve must not

be set at a level that causes the motor operating current to exceed the full load amp value* at any time, including when operating in pressure relief.

* The full load amp value can be found on the inside cover of the

control panel.

4111-0002 — January 2012

Page 36

TROUBLESHOOTING

Symptom Possible Cause Solution

Platform does not rise to full height.

Low hydraulic fluid. 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.

Lip does not extend. Logic block spool valve

Lip extends almost immediately when the RAISE button is pushed. Platform rises after lip is fully extended.

Low hydraulic fluid. Add fluid as needed. See Periodic Maintenance in

Logic block (valve) lever cable weight too low on cable.

stuck in the up position or valve lever binding so that the lever will not push the spool down.

Logic block spool valve stuck in the down position or valve lever binding causing lever to prematurely push the spool down.

the Maintenance section.

Adjust cable weight. See Adjust Cable Weight and Down Speed Control in the Adjustment section.

Apply penetrating oil to spool area and valve lever pivot at top of logic block.

If necessary, disconnect the valve lever from logic block. Move spool valve up and down until spool valve slides freely. If the spool valve cannot be made to slide freely, replace spool valve.

Lubricate valve lever pivot with white lithium grease.

Apply penetrating oil to spool area and valve lever pivot at top of logic block.

If necessary, disconnect the valve lever from logic block. Move spool valve up and down until spool valve slides freely. If the spool valve cannot be made to slide freely, replace spool valve.

Platform locks into “safety” as platform lowers. Lip drops to vertical position.

Platform lowering speed is too fast.

Lubricate valve lever pivot with white lithium grease.

Adjust platform down speed control. See Adjust Cable Weight and Down Speed Control

in the Adjustment section.

NOTE: Extreme cold weather OR incorrect fluid may cause platform to lock. Adjustment is same.

4111-0002 — January 2012

Page 37

Controls

PARTS

Item Quantity Part Number Description

A 1 0615-0040 Proximity Switch with Harness (ARTD Feature Only) B 1 * 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)

D 1 1751-0736 Decal, Arrc Flash

Provide dock leveler serial number, voltage, phase, and options when calling or faxing controller orders.

4111-0002 — January 2012

Page 38

PARTS

Frame and Platform

4111-0002 — January 2012

Page 39

Frame and Platform

Item Quantity Part Number Description

A 1 0595-____ B 1 7823-____2 Platform, Welded Assembly

1 9202-0050 Pin, Lip Hinge, 1” Dia 70.50 LG

9202-0051 9202-0052 Pin, Lip Hinge, 1” Dia 81.50 LG

1 0014-0062 Toe Guard Welded Assembly, Left Upper 6 Foot VH3 1 0014-0066 Toe Guard Welded Assembly, Left Lower 6 Foot VH3

1 0014-0070 Toe Guard Welded Assembly, Left Upper 8 Foot VH3 1 0014-0074 Toe Guard Welded Assembly, Left Lower 8 Foot VH3

E 1 0015-____1 Frame, VH F 3 9202-0002 Rear Hinge Pin

G 6 2101-0047 Cotter Pin, 1/4 x 2 in.

H1 -

J1 - K 1 9225-____1 Maintenance Prop Rod L 1 9201-0001 Prop Pin & Clip

M AR 2101-0039 Nylon Lock Nut, 5/16-18 UNC

N-P AR 2101-0163 Washer, 5/16 in., Flat

Q AR 2101-0011 Cap Screw, 5/16-18 UNC x 1 in.

1 0014-0064 Toe Guard Welded Assembly, Right Upper 6 Foot VH3 1 0014-0068 Toe Guard Welded Assembly, Right Lower 6 Foot VH3

1 0014-0072 Toe Guard Welded Assembly, Right Upper 8 Foot VH3 1 0014-0076 Toe Guard Welded Assembly, Right Lower 8 Foot VH3

S 1 1751-0010 Decal, Model/Serial ID T 2 2101-0046 Cotter Pin, 1/4 x 1-1/4 in.

1 0521-0154 Lip Lifter Short 1 0523-0523 Lip Lifter Long

Lip, Welded Assembly

Pin, Lip Hinge, 1” Dia 76.75 LG

PARTS

AR = As Required

Provide dock leveler serial number, platform size, and lip size when calling or faxing orders.

Provide length and width of inspection plate opening when calling or faxing orders.

* For left/right orientation of dock leveler, see inside back cover of this manual.

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PARTS

Hydraulic Components

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Hydraulic Components

Item Quantity Part Number Description

A 1 0522-0005 Clevis Pin B 1 2101-0045 Cotter Pin C 1 0522-0156 Yoke D 1 0521-0005 Roll Pin

E1 F 1 9202-0004 Pin, 3/4 x 4.38 in.

G 2 2101-0049 Clip, Hairpin, 5/8 in. dia.

H 1 9301-0111 Fitting, #6-ORB Male x #8-JIC Male

J 1 9904-0074 Hose, Logic Block-to-Lip Cylinder K 1 9904-0106 Hose, Pump Pressure Port-to-Logic Block L 2 2101-0015 Cap Screw, 5/16-18 UNC x 3-1/4 in.

M 2 2101-0039 Nylon Lock Nut, 5/16-18 UNC

N 1 9575-0007 Logic Block

1 9575-0010 Logic Block, Cold Weather

P 2 2101-0050 Clip, Hairpin, 7/8 in. dia.

Q 2 9202-0005 Pin, 1 x 3-3/4 in.

R 4 2101-0009 Cap Screw, 5/16-18 UNC x 3/4 in. S 2 8431-0022 Platform Cylinder, Hold Down

1 0525-0043 Cylinder, Platform, 15-1/2 in. (394 mm) Barrel Length

1 0525-0044 Cylinder, Platform, 17-1/2 in. (445 mm) Barrel Length 1 0525-0045 Cylinder, Platform, 19-1/2 in. (495 mm) Barrel Length

1 0525-0046 Cylinder, Platform, 21-1/2 in. (546 mm) Barrel Length U 1 9904-0075 Hose, Logic Block-to-Platform Cylinder V 1 9301-0120 Elbow, 45° #8-ORB Male x #8-JIC Male

W 1 9904-0106 Hose, Logic Block-to-Pump Return Port

X 2 2101-0040 Nylon Lock Nut, 3/8-16 UNC Y 2 2101-0060 Washer, 3/8 in. Z 1 9455-____2 Hold-Down, Lip Cylinder

AA 1 0522-0002 Spring

AB 1 0521-0007 Elbow, 90° 1/4 NPT Male x 1/4 Tube AC 4 2101-0011 Cap Screw, 5/16-18 UNC x 1 in. AD 4 2101-0058 Washer, 5/16

AF 6 2101-0039 Nylon Lock Nut, 5/16-18 UNC in. AG 1 0521-0016 Elbow, 45° 3/8 NPT Male x #8-JIC Male AH 1 9395-____3 Power Pack Complete

AJ 1 0521-0007 Elbow, 90° 1/4 NPT Male x 1/4 Tube

AK 1 R509-____1 Tube, Vent (3/8 OD x 1/16 in. Wall) AM 1 0523-____ 2 Lip Lifter

0525-0086 Lip Cylinder, 13-3/4 in. (349 mm) Barrel Length 0525-0087 Lip Cylinder, 20-1/8 in. (511 mm) Barrel Length

PARTS

Provide length and diameter of hose when calling or faxing orders.

Provide length of lip cylinder when calling or faxing orders.

Provide dock leveler serial number, voltage, and phase when calling or faxing orders.

4111-0002 — January 2012

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PARTS

CRUSH HAZARD

DO NOT REMOV

safely supported b

owner’s/user’s ma

procedure. Failure

serious injury.

Platform Cylinder Repair Parts

Backup Ring

O-Ring

Rod Step Seal

Wear Ring

Excluder Ring

Retaining Ring

Item Quantity Part Number Description

0525-0048 Seal Kit 1992 and Newer 0525-0013 Seal Kit 1991 and Older

B 1 0525-0043 Cylinder, Platform, 15-1/2 in. (394 mm) Barrel Length

0525-0044 Cylinder, Platform, 17-1/2 in. (445 mm) Barrel Length 0525-0045 Cylinder, Platform, 19-1/2 in. (495 mm) Barrel Length

0525-0046 Cylinder, Platform, 21-1/2 in. (546 mm) Barrel Length

C 1 1751-0138 Decal

*Provide dock leveler serial number when calling or faxing orders.

4111-0002 — January 2012

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Lip Cylinder Repair Parts

PARTS

Spring

Spring Guide

Piston Seal, 3 Piece

Wear Ring

Item Quantity Part Number Description

0525-0059 Seal Kit 1992 and Newer 0025-0014 Seal Kit 1991 and Older 0525-0086 Lip Cylinder, Complete, 14 in. Barrel Length 0525-0087 Lip Cylinder, Complete, 20 in. Barrel Length

Washer

Retaining Ring

*Provide dock leveler serial number when calling or faxing orders.

4111-0002 — January 2012

Page 44

PARTS

Logic Block Assembly

To Lip Cyl

To Hoist Cyl.

Return To Tank

Pressure to Logic Block

4111-0002 — January 2012

Page 45

Logic Block Assembly

Logic Block and Lever Arm

Item Quantity Part Number Description

C 1 7955-0001 Cable Subassembly, Logic Block D 2 2101-0059 Washer, 1/4 in. E 1 9572-0004 Spring F 1 8102-0001 Weight, Logic Block Cable

G 2 2101-0032 Set Screw, Socket-Head, 1/4-20 UNC x 3/8 in.

H 1 5265-0002 Cable Weight Assembly, Logic Block (Includes Items C – H)

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

PARTS

Logic Block Assembly

Item Quantity Part Number Description

J 2 9301-0112 Fitting, #8-ORB Male x #8-JIC Male K 1 9572-0002 Plug, Spool Valve L 2 9572-0003 Gasket, Spool Valve

M 1 9572-0004 Spring, Spool Valve

N 1 9572-0013 Dowel Pin, Cold Weather/Wash Down Feature Only P 1 9575-0007 Logic Block, Complete (Includes Items A and K – N)

Q 1 2101-0098 Cap Screw, 5/16-18 UNC x 1-3/4 in.

R 1 2101-0039 Nylon Lock Nut, 5/16-18 UNC

4111-0002 — January 2012

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PARTS

Power Pack Assembly, Metal Reservoir

Return Line

Pressure Line

Item Quantity Part Number Description

A 1 9301-____ 1 Reservoir, Pump with Motor Drive Plate B 1 0521-0007 90° Elbow, 1/4 NPT Male x 1/4 Tube C 1 9301-0199 Breather Cap, 3/8 NPT Male D 2 0521-0017 90° Elbow, 3/8 NPT Male x #8-JIC Male E 1 3411-____ 2 Motor Only F 4 2101-0016 Cap Screw, 5/16-18 UNC x 3-1/2 in., Grade 5

G 1 9301-0190 O-Ring H 1 9301-0159 Metal Reservoir

Provide dock leveler serial number and type of installation when calling or faxing orders.

Provide dock leveler serial number, voltage, and phase when calling or faxing orders.

4111-0002 — January 2012

Page 47

PARTS

Power Pack Assembly, Plastic Reservoir

Return Line

G F

Pressure Line

Item Quantity Part Number Description

A 1 9301-0036 Reservoir, Pump with Motor Drive Plate

B 1 0521-0007 90° Elbow, 1/4 NPT Male x 1/4 Tube

C 1 9301-0218 Breather Cap,Push In

D 2 0521-0017 90° Elbow, 3/8 NPT Male x #8-JIC Male

E 1 3411-____ 2 Motor Only

F 4 2101-0225 Cap Screw, 5/16-18 UNC x 3-1/2 in., Grade 5 G 1 9301-0226 O-Ring

H 1 9301-0224 Plastic Reservoir

Provide dock leveler serial number and type of installation when calling or faxing orders.

Provide dock leveler serial number, voltage, and phase when calling or faxing orders.

4111-0002 — January 2012

Page 48

PARTS

Power Pack Assembly, Low Amp Draw

Return Line

Pressure Line

7.0 Amps @120 (volts consult factory)

Item Quantity Part Number Description

A 1 0521-0007 90° Elbow, 1/4 NPT Male x 1/4 Tube B 1 9301-0218 Breather Cap, Push In C 2 0521-0201 90° Elbow, #8 ORB x #8-JIC Male D 4 2101-0225 Cap Screw, 5/16-18 UNC x 3-1/2 in., Grade 5

E 1 9301-0226 O-Ring

F 1 9301-0224 Plastic Reservoir

G 1 9395-0404 Complete PPAC 115 Volt

Provide dock leveler serial number and type of installation when calling or faxing orders.

Provide dock leveler serial number, voltage, and phase when calling or faxing orders.

4111-0002 — January 2012

Page 49

Weather Seal, Brush Style

PARTS

Item Quantity Part Number Description

2 0195-0018 6’ Brush Seal and track, 1 in. (25 mm)

2 0195-0021 8’ Brush Seal and track, 1 in. (25 mm) 2 0195-0024 10’ Brush Seal and track, 1 in. (25 mm) 2 0195-0027 12’ Brush Seal and track, 1 in. (25 mm) 2 0195-0030 6’ Rubber Seal and track, 1 in (25 mm)

2 0195-0033 8’ Rubber Seal and track, 1 in (25 mm) 2 0195-0036 10’ Rubber Seal and track, 1 in (25 mm) 2 0195-0039 12’ Rubber Seal and track, 1 in (25 mm)

1 0192-____* Foam Seal kit, Rear Hinge 1 0195-0044 Rear Brush Weather Seal Fits all Sizes

AR = As Required NOTE: Brush or track can be purchased separately as replacement parts. Contact factory for part numbers. Kits are for existing dock leveler without weather seal.

Provide dock leveler serial number and size of platform when calling or faxing orders.

*Provide width of weatherstrip when replacing existing seals

4111-0002 — January 2012

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NOTES

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4111-0002 — January 2012

Page 51

Customer Information

MISCELLANEOUS

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.

Also, write down Systems, Inc.’s job number, the company that installed the dock leveler, and the original owner’s name. This will all help to identify the specific dock leveler if more information is required.

When ordering, use part numbers and description to help identify the item ordered. Do not use “item” numbers. These are only for locating the position of the parts. Always give dock leveler MODEL NUMBER and/or SERIAL NUMBER.

For service, call or contact:

Dock Leveler Information

Model ___________________________________

Serial No. ________________________________

Systems, Inc., Job No. ______________________

Original Owner Information

Name ___________________________________

Address _________________________________

________________________________

Installer Information

Name ___________________________________

Address _________________________________

_________________________________

Date of Installation ________________________

Systems, Inc. P.O. Box 309 Germantown, WI 53022

Phone: (800) 643-5424 Fax: (262) 255-5917

4111-0002 — January 2012

Page 52

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. In order to be entitled to the benefits of this warranty, the product must have been properly installed, maintained and operated in accordance with all manufacturer’s recommendations and/or specified design parameters and not otherwise have been subject to abuse, misuse, misapplication, acts of nature, overloading, unauthorized repair or modification, application in a corrosive environment or lack of maintenance. Periodic lubrication, adjustment and inspection in accordance with all manufacturers’ recommendations are the sole responsibility of the Owner/User.

In the event of a defect, as determined by SYSTEMS INC., covered by this warranty, SYSTEMS INC. shall remedy such defect by repairing or replacing any defective equipment or parts, bearing the cost for the parts, labor and transportation. This shall be exclusive remedy for all claims whether based on contract, negligence or strict liability.

WARRANTY LIMITATIONS

THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. SYSTEMS INC. AND ITS SUBSIDARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE, INCLUDING THIRD PARTIES, FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO, BREACH OF WARRANTY, LOSS OF USE, LOSS OF PROFIT, INTERUPTION OF BUSINESS OR LOSS OF GOODWILL.

PRODUCT SPECIFIC WARRANTY

“VH” 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 – For a period of five (5) years from the date of shipment, this warranty specifically applies to; the deck section, lip section, frame, rear hinge assembly and front hinge assembly only.

• Hydraulic Warranty – For a period of five (5) years from date of shipment, this warranty specifically applies to; the hydraulic pump and motor, all hydraulic cylinders, hydraulic pressure lines and fittings and fluid logic control assembly only.

Poweramp VH SERIES HYDRAULIC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual