Poweramp VS VERTICAL SPECIALTY User Manual

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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

VS SERIES

Dock Leveler

Owner’s Manual

Printed in U.S.A. Copyright

Manual No. 4111-0008

Revised April 2008

Page

Safety

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

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

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

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

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

Introduction

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Dock Leveler Stock Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation

Prepare Pit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Prepare Dock Leveler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Install Dock Leveler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Install Control Panel and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Put New Leveler Into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Operation

Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Ramp Loading/Unloading Instructions . . . . . . . . . . . . . . . . . . . . 18

End Loading/Unloading Instructions . . . . . . . . . . . . . . . . . . . . . 19

Maintenance

Service Dock Leveler Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Adjustments

Adjust Main Pressure Relief SC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Adjust Main Pressure relied Remote System . . . . . . . . . . . . . . . . . 24

Purging Hydralic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Rode Eye Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Parts

Frame and Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Misc Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Hydraulic Valve Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Hoist Cylinder Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Lip Cylinder Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Power Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Miscellaneous

Customer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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

Table of Contents

4111-0008 — April 2008

SAFETY

4111-0008 — April 2008

Recognize Safety Information

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.

General Operational Safety Precautions

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.

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.

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

IMPORTANT

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

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

SAFETY

4111-0008 — April 2008

Learn the safe way to operate this equipment. Read and understand the manufacturer's instructions. If you have any questions, ask your supervisor.

Operational Safety Precautions

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.

SAFETY

4111-0008 — April 2008

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

Do not overload the dock leveling device.

Do not operate any equipment while under the influence of alcohol or drugs.

Do not leave equipment or material unattended on dock leveling device.

SAFETY

4111-0008 — April 2008

Maintenance Safety Precautions

ALWAYS disconnect electrical power source and ground wire before welding on dock leveler.

DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler. Always ground to the dock leveler frame.

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

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

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

DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present. Stray sparks can ignite spills or leaks near the work area. Always clean up the oil leaks and spills before proceeding with grinding or welding.

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

Failure to follow these instructions 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 unit before maintenance is complete.

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.

The storage maintenance props (2) must be in the "Maintenance" position when working under the dock leveler and the storage prop must have a grade 5 or better in the locking hole. For maximum protection, use an OSHA approved locking device to lock out the main power supply. Only the person servicing the equipment should have the key to unlock the device.

SAFETY

4111-0008 — April 2008

Safety Decals

Safety Decal on Rear Platform

Safety Decal on Platform Cylinder

Safety Decal on Leveler Frame

INTRODUCTION

General Information

Models Nominal Size W x L

VS-65 6’ x 5’ VS-66 6’ x 6’ VS-68 6’ x 8’ VS-655 6’6” x 5’ VS-656 6’6” x 6’ VS-658 6’6” x 8’ VS-75 7’ x 5’ VS-76 7’ x 6’ VS-78 7’ x 8’

VS dock levelers are available in the following sizes, weight capacities, and options:

Width: VS

6 ft (1828.8 mm) 6-1/2 ft (1981.2 mm) 7 ft (2133.6 mm)

Length

5 ft (1524 mm) 6 ft (1828.8 mm) 8 ft (2438 mm)

Capacity (CIR*)

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

* CIR (Comparative Industry Rating)

Call Poweramp to discuss available powerpack mounting configurations, voltages, phases and

options to meet your specific needs.

The VS series dock leveler comes equipped with an electrical control panel, which allows push button operation of the dock leveler functions. Each VS 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.

Dock Leveler Stock Specifications

Congratulations on your choice of a Poweramp Vertical Storing dock leveler. This manual covers the VS (Vertical Storing) 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 trouble-free 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.

4111-0008 — April 2008

INTRODUCTION

Component Identification

* Some models are equipped with multiple hoist cylinders. *Powerpack may be mounted on underside of leveler or remotely.

A. Lip B. Deck C. Lip Cylinder D. Flow Control Valve E. Hoist Cylinder* F. Storage Prop Yoke

G. Trombetta Valve-Prop Kicker (Behind Prop Assy) H. Storage Prop Assembly with Lock-Out Pin incl (F) I. Hinge Pin J. Stored Limit Switch K. Maintenance Props

4111-0008 — April 2008

INSTALLATION

Prepare Pit

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, has the proper depth and taper by making the following measurements:

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

• Measure dock floor-to-pit floor distance (B) on both sides of the rear embed channel and at front if applicable.

• Measure pit floor taper, rear to front cannot exceed 1/2” total taper.

• 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.

NOTE” 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) and floor embed plate (F) is at the correct location per pit diagrams.

A—Distance (Pit Width)

(Front and Rear)

B— Distance (Dock Floor-to-Pit

Floor) (All Four Corners) 1/2” Taper Rear to Front

C— Distance (Pit Length)

(Both Sides of Pit)

D— Distance (Pit Corner-to-Corner)

(Top, Bottom, and Both Sides)

4111-0008 — April 2008

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.

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

INSTALLATION

Poweramp dock levelers are designed with installation in mind. Each unit is shipped with lifting bracket(s) (A) fastened to the platform.

Prepare Dock Leveler

A— Lifting Bracket B — Maintenance Props

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.

IMPORTANT

DO NOT remove the Maintenance Props at this time. They should be rotated to the lowered position during installation. They will keep the leveler in the upright position, once the hinge pins are installed, until the storage prop and hoist cylinder are installed and the leveler is ready for testing.

4111-0008 — April 2008

INSTALLATION

1. Remove any control panel, bumpers or palletizing that may be banded to the frame of the dock leveler. Do not remove banding on hoist cylinder or storage prop at this time.

NOTE: Overall length of lifting chain and bracket (A)

must be kept to a minimum to prevent interference between the lifting equipment and and the building ceiling or door as the dock leveler is lowered into the pit.

IMPORTANT

Installation of VS levelers from inside is recommended due to combined height of leveler and proper lifting equipment may be greater than outside door height.

Maintenance props in lowered location during installation and service.

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

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

4. Remove any shipping pallets that are attached to the leveler before beginning installation into the pit.

4111-0008 — April 2008

5. Before installing the leveler the Imbed channel must be shimmed and welded to the Imbed on the pit floor.

INSTALLATION

4111-0001 — March 2008

A— Distance (Leveler Frame

Height)

B— Shim Location (Under

Maintenance Prop) (Standard Dock Leveler

Only) C— Dock Floor D— Rear Imbed Frame E— Imbed Frame

(Maintenance Prop)

F— Pyramid (Preferred) G— Stepped (Acceptable) H— Offset (Not Acceptable) I — Straight (Not Acceptable)

Install Dock Leveler

IMPORTANT

The minimum size of the shim that contacts the leveler frame (i.e., the top shim of each shim stack) must be at least 4-1/2 x 4-1/2 in. (114.3 x 114.3 mm) to support the full width of the hoist cylinder / storage prop weldment.

Use the thickest shim stock possible for stability and weld penetration purposes. DO NOT use multiple layers of 1/8 in. (3.18 mm) or thinner shim stock.

Shim

Stacking Methods

4111-0008 — April 2008

INSTALLATION

A— Rear Imbed B— Dock Leveler

C— Maintenance Props D— Hinge Pins

E— lifting Lug F— Storage Prop

6. Lube the three rear hinge pins using grease Install the three pins in the rear imbed only through out the first hinge tube.

7. lower the Vertical leveler down centering the leveler’s three hinge pins with the imbeds three

pins.

• Insert the pins. Start with on outside first second install the center pin and than the last out side hinge pin.

• Optional use: Us a bottle jack to align the rear of the dock leveler to the imbed channel.

8. Once the three hinge pins are installed Install the Storage prop. Install latch pin

9. Make all hydraulic connections.

10. Make all electrical connection.

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.

4111-0008 — April 2008

INSTALLATION

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.

Install Control Panel and Wiring

A— Disconnect Panel B— Control Panel

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

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.

4111-0008 — April 2008

5. Lower dock leveler check to make sure the leveler goes into float mode (about 15” above dock floor) allow to dock to float to full below position. Make sure the dock makes contact with pit floor. Push and hold the RAISE button until the leveler turns off and the Blue stored light comes on.

6 Check the lip operation: Lower dock leveler

check to make sure the leveler goes into float mode (about 15” above dock floor) allow to dock to float to below dock. Push and hold the RAISE button until the leveler turns off and the Blue stored light comes on.

INSTALLATION

Purging air from the VS hydraulic system.

1. Begin by supporting the leveler in the stored position with the storage prop and maintenance props. Lock out the storage prop with the locking bolt.

2. Lock-out and tag-out the leveler.

3. Disconnect the lower hoist cylinder mounting pin.

4. Remove one of two screws holding the stored limit switch. Swivel stored limit switch away from storage prop.

5. Restore power to the leveler. Confirm the blue stored indicator light is no longer illuminated.

6. Cycle the hoist cylinder up and down at least 6 times using the leveler’s own hydraulic power.

7. Connect the hoist cylinder to the base of the Imbed is channel.

8. Move the maintenance props back to the working positions.

9. The lip cylinder is self purging. Lower the leveler to a 45 degree angle. Cycle lip by pressing the lower and lip button together to lower the lip. Press the raise and lip button together to raise the lip. WARNING: Stay clear of lip at all times as it may fall if air is present in the system.

10 Make sure all air is purged from the hydraulic

cylinders after set-up and any time air is introduced to the system. Failure to do this 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.

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.

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

Following start-up or 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, purge air from hydraulic system fully. Failure to do this may result in damage to the equipment, serious injury or death.

4111-0008 — April 2008

INSTALLATION

1. Disconnect the external lifting device and chains from the lifting brackets.

2. Complete all welding.

3. Install hydraulic hoses and fill system.

4. Connect all electrical connections.

5. Purge System(see Purging pg 14).

4 Test leveler for operation.

Put New Dock Leveler Into Service

Rod Eye adjustment & New installation.

1. Support the leveler with the maintenance props. Lock out the storage prop with the locking bolt.

2. Lock-out and tag-out the leveler.

3. Remove lower hoist cylinder mounting pin.

4. Remove one of two screws holding the stored limit switch. Swivel stored limit switch away from storage prop.

5. Restore power to the leveler. Confirm the blue stored indicator light is no longer illuminated.

6. Cycle the hoist cylinder up and down at least once to make cylinder is fully extended.

6. Rod eye should be adjusted so the center of the rod Eye is half way below the center of the hole of the imbed. After adjusted tighten jam nut.

6. To center the rod eye with the embed tap the lower button until the pin (lube pin) can be installed.

6. After pin has been installed store maintenance Props and locking pin test the leveler for operation.

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

4111-0008 — April 2008

OPERATION

When a button is pushed on the control panel this activates an electric motor (C) which, drives a hydraulic pump. The hydraulic pump forces oil into the platform cylinder(s) (D), causing the platform to rise or lower. Releasing the button will stop the platform from moving (except in the float mode).

To lower the Vertical leveler the lower button will be pushed. The leveler will first come toward the operator, A electrical solenoid (L) will kick the Storage prop. The solenoid will hold the Storage prop out for a period of time to allow the leveler to lower. The leveler will start to lower down to the truck. When the lever is about 12” to 15” above dock height the leveler goes into float mode. You will also hear the motor make a different sound and you no longer need to hold the lower button. This feature is designed into the operation of the leveler to allow for the floating/vertical motion of the trailer during loading and unloading.

Lip Lower and lip Raise (K). To lower the lip the vertical leveler must be in the lower mode. Press the lower leveler and lip at the same time and the motor will shut off and the lip will lower. To raise the lip the leveler must be in the raise mode. Press the raise button and the lip button the motor will still run and the lip will will raise. The Lip push button is inactive while the leveler is in the float mode. Also when leveler is stored.

Theory

* Some models are equipped with multiple cylinders.

A — Control Box B — Platform C — PowerPack

D — Hoist Cylinder F — Dual-Lanyard Pull Ring G — Reservoir

H — Solenoid I— Lip Cylinder J — Raise Button

K — Lip Button L— Lower Button M — Limit Switch

4111-0008 — April 2008

OPERATION

Operating Instructions

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 23.

• For end loading and unloading, see End

Loading/Unloading Instructions on page 24.

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.

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 VS 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.

12 in. (305 mm)

4111-0008 — April 2008

OPERATION

NOTE: If end unloading is required, see End

Loading/Unloading Instructions on page 19.

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.

Ramp Loading/Unloading Instructions

4. Lower the platform lip onto truck/trailer as follows:

a. Lower platform by pushing and holding LOWER button.

b. 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.

7. When loading or unloading is finished, raise the platform by pushing and holding RAISE button. When fully raised the leveler will shut off and the Blue stored light will come on.

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

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

A—RAISE Button

B—RAISE Button C—Stored Button

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

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

Operating Instructions—Continued

4111-0008 — April 2008

OPERATION

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

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

1. Check to make sure truck/trailer is positioned squarely against dock bumpers.

2. Instruct driver to remain at the dock until the loading or unloading process has been completed.

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

4. Lower platform and lower the lip. Lower platform until the legs on the bottom of the leveler makes contact with the pit floor.

5. Proceed with loading or unloading.

Below Dock End Loading/Unloading Instructions

NOTE: Optional Lip Keepers

1. Check to make sure truck/trailer is positioned squarely against dock bumpers.

2. Instruct driver to remain at the dock until the loading or unloading process has been completed.

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

4. Lower platform and lower lip until lip makes contact with the Lip Keepers.

5. Proceed with loading or unloading..

Operating Instructions—Continued

Dock Leveler Loading/Unloading Instructions

4111-0008 — April 2008

MAINTENANCE

Service Dock Leveler Safely

When maintenance is to be performed on the dock leveler, First install the SAFETY bolt in the storage prop. Second support the platform with maintenance props (D). Caution: The lip may will fold down after the platform has rested on the maintenance prop.

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.

A— Tagout Device B — Lockout Device C —SAFETY legs D — Maintenance Prop

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.

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.

4111-0008 — April 2008

MAINTENANCE

4111-0001 — September 2002

Periodic Maintenance

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

• Flomite 530 ZF

• Aero Shell Fluid 4 or Fluid 41

• Mobile Aero HFA Mil-H5606A 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-L-5606 may damage the equipment and WILL void warranty. Use of hydraulic fluids with equivalent specifications to those listed here are acceptable.

A— Lip Hinge Area B— platform Pins

C— Storage Prop D— Hoist Cylinder

E— Lip Cylinder

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.

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.

4111-0008 — April 2008

MAINTENANCE

Regular maintenance must be performed on a weekly and quarterly schedule.

Weekly Maintenance

• Operate the dock leveler through the complete operating cycle to maintain lubrication.

NOTE: Make sure the limit switch is clear of debris.

• Inspect the platform hinge and the lip hinge areas. The hinge areas must be kept free of dirt and debris. Build-up of foreign material in the hinge areas will cause abnormal operation.

Quarterly Maintenance

• 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 in the stored position and lip is folded)

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

platform hinges when platform is in the stored position)

(C)— Apply a light oil to the Storage prop pins.

(D)— Grease the hoist cylinder grease fitting

(E)— Apply a light oil to the Lip Cylinder pins.

NOTE: Apply grease to lip hinge grease fittings if equipped.

M — Reservoir N — 2 in. (51 mm) (From Top of

Reservoir)

P — Breather Cap Q — Fluid Level

• Check reservoir fluid level (Q):

1. The leveler must be in the stored position with the lip lowered.

2. Turn OFF all electrical power to the leveler.

3. Remove breather cap (P).

4. Measure fluid level. The fluid level should be approximately 2 in. (51 mm) (N) from top of reservoir (M) with platform at the below-dock position.

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

6. Install breather cap

7. Turn ON electrical power to the leveler.

8. Return the lip to the raised position.

IMPORTANT

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

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.

Pressure

Return

4111-0008 — April 2008

ADJUSTMENTS

SC Adjust Main Pressure Relief

A— Motor B— Pump C— Main Pressure Relief

D— Jam Nut E— Acorn Nut

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 starts to raise from the lowerd position. See Troubleshooting section.

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 acorn nut (E).

4. Loosen jam nut (D).

5. Adjust allen head adjusting screw (C) Under acorn nut:

• Turn clockwise to increase pressure relief.

• Turn counterclockwise to decrease pressure relief.

6. While holding the adjusting screw tighten jam nut and install the acorn nut.

7. Turn ON electrical power to the dock leveler.

8. Disengage the maintenance prop.

9. Check leveler operation.

10. Repeat steps 1– 9 as necessary.

Pressure

4111-0008 — April 2008

ADJUSTMENTS

To adjust the main pressure relief:

1. The leveler must be in the stored position and 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 acorn nut (F).

4. Loosen jam nut (E).

5. Adjust allen head adjusting screw (D) as follows:

• Turn clockwise to increase pressure relief.

• Turn counterclockwise to decrease pressure relief.

6. While holding the adjusting screw tighten jam nut and install the acorn nut.

7. Turn ON electrical power to the dock leveler.

8. Check leveler operation.

9. Repeat steps 1– 9 as necessary.

Adjust Main Pressure Relief Remote Mount

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 starts to raise from the lowerd position. See Troubleshooting section.

4111-0008 — April 2008

ADJUSTMENTS

Stored Limit Switch Adjustment

1. Loosen Set Screw

2. With roller arm contacting storage prop, rotate adjustment screw counter clockwise until a “Click” noise is heard.

3.Tighten set screw head cap screw.

4. Readjust as needed to leveler allow to store 3 to 5 deg from vertical.

5. After adjusting the stored limit switch check for

correct play in the prop.

Down Speed Control Adjustment

If the dock leveler lowers to slow, the down speed control, requires adjustment. The speed control adjusting screw (A) The set screw is located on the hoist cylinder (B), directly above hoist cylinder and below the upper hose.

The Down speed flow control is pre set at 1-1/2 turns out from fully clossed.

To adjust the speed control:

a. Loosen the allen head set screw.

b. To decrease the lowering speed, turn knurled

knob screw (A) clockwise.

c. To increase the lowering speed, turn knurled

adjusting screw (A) counterclockwise.

d. Tighten the set screw.

Adjustment

Screw

Set Screw

4111-0008 — April 2008

ADJUSTMENTS

Maintenance Prop Adjustment

Maintenance Prop Adjustments

1. Raise platform fully and engage the maintenance prop in the service position (If dock leveler has not been used recently cycle leveler once).

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

3. Adjust yoke on maintenance till you have min. 1“ of free play in the prop”.

4. When the play in the prop is correct only 1-1/2 threads max will be exposed through the yoke. If more threads exposed the maintenance prop must be shorted.

1”

Max Threads Exposed 1-1/2

4111-0008 — April 2008

TROUBLESHOOTING

Troubleshooting

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

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

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

TROUBLESHOOTING

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

Phase reversed. Reverse any two legs at the branch circuit

disconnect.

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

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.

Replace motor.

Defective motor capacitor. Replace motor.

Symptom Possible Cause Solution

Platform does not rise. Motor does not energize.

Motor overload device tripped or fuse blown.

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.

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

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.

4111-0008 — April 2008

TROUBLESHOOTING

Symptom Possible Cause Solution

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

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 hydraulic hose(s).

Replace damaged hose(s). Remove restriction.

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 starts to rasie from the lowerd position.

Pressure relief set too high. Decrease 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.

4111-0008 — April 2008

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 not rise. Coil energized on the float

coil.

Remove wire of terminal strip to the float coil, If leveler raises possible bad PLY or relay

Bad spool valve. Remove and clean spool valve or replace with new or

good working valve.

Platform Does not rise to full height.

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

the Maintenance section.

In correct adjustment on the Limit switch.

Adjust the limit switch so the plate form leans 3 deg toward the door (see adjustments) .

Lip does not extend. “C” Coil not energized Check power to the spool valve should have a

magnetic pull when energized (Pump Motor must be running)

Bad spool valve. Remove and clean spool valve or replace with new or

good working valve(Pump Motor must be running).

Lip does not lower. “C”, “D” and “E” Coils not

energized

All three valves must be energized. Check power to the all spool valves they should have a magnetic pull (Pump Motor must be running).

Bad spool valve. Remove and clean spool valves or replace with new

or good working valves.(Pump Motor must be running)

Platform does not lower. Blue stored light not on. Limit switch not adjusted correctly (see adjusts).

Possible bad switch stored limit switch

Leveler pump runs but Platform does not lower.

Prop kicker does not kick. Possible prop kicker Solenoid not working.

Possible Mercury switch not working.

Leveler pump runs prop kicker works but Platform does not lower.

Storage Prop Not enough slop in the maintenance prop

(see page 26).

Leveler pump runs prop kicker works but Platform does not lower.

“D” and “E” Coils not energized

Both valves must be energized. Check power to the all spool valves they should have a magnetic pull (Pump Motor must be running).

Bad spool valve. Remove and clean spool valves or replace with new

or good working valves.(Pump Motor must be running)

4111-0008 — April 2008

PART S

4111-0008 — April 2008

Item Quantity Part Number Description

A 3 2101-0153 Bolt 1/4 UNC 1/2 Lg. B 3 2101-0005 Washer, Lock 1/4 C 1 8581-0023 Selenoid Prop Kicker

Item Quantity Part Number Description

A 2 2101-0153 Screw #10-32 UNF x 1.75 Lg B 1 2101-0005 Clevis Pin 3/4 Dia x 2-2/4 Lg.

PART S

Item Quantity Part Number Description

A 1 2751-0042 J Box Fiber Glass 5” x 5“ (Includes Cover) B 1 0961-0054 Mercury Switch C 1 3051-0025 Rectifier Bridge

Item Quantity Part Number Description

A 1 9222-0097 Yoke, Upper Arm Prop B 3 0522-0005 Clevis Pin 3/4 Dia x 2-2/4 Lg. C 1 Upper Weldment (Not Sold Separately) D 1 Lower Weldment (Not Sold Separately) E 1 2101-0082 Hex Head Capscrew (Grade 5) 5/16-18 UNC 2-1/2 Lg F 1 2101-0039 Lock Nut 5/16 UNC

G 3 2101-0045 Cotter Pin

H 1 9225-0016 Storage Prop Assembly

4111-0008 — April 2008

VERTICAL LIPS 2003 to Present

6’ WIDE 40K W/O Gussets 40/45K WO Gussets

50K W/Gussets

16” 0595-0387 0595-1107

0595-1107

18” 0595-0388 0595-1108

0595-1108

20” 0595-0389 0595-1109

0595-1109

6.5’ WIDE 16” 0595-0390

0595-1110

18” 0595-0391 0595-1111

0595-1111

20” 9222-0382 0595-1112

0595-1112

7’ WIDE

16” 0595-0393 0595-1113

0595-1113

18” 0595-0394 0595-1114

0595-1114

20” 0595-0395 0595-1115 0595-1115

VERTICAL PLATEFORMS 2003 to Present

6’ WIDE 40K W/O Gussets 40/45K WO Gussets

50K W/Gussets

5 9515-0843 9515-1077

9515-1121

6 9515-0844 9515-1074

9515-1124

8 9515-1065 9515-1071

CALL

6.5’ WIDE 5 9515-0845

9515-1078

9515-1122

6 9515-0846 9515-1075

9515-1125

8 9515-1066 9515-1072

CALL

7’ WIDE

5 9515-0849 9515-1079

9515-1123

6 9515-0848 9515-1076

9515-1126

8 9515-1067 9515-1073 CALL

LIP and PLATFORM

4111-0008 — April 2008

Frame and Platform

K L

4111-0008 — April 2008

Item Quantity Part Number Description

A 1 See Table 1 Lip, Weldment - Call on 2002 and older levelers B 1 See Table 2 Platform, Welded Assembly - Call on 2002 and older levelers

C 1

9202-0050 Pin, Lip Hinge 6’W 9202-0051 Pin, Lip Hinge 6.5’W

9202-0052 Pin, Lip Hinge 7’W 9202-0053 Pin, Lip Hinge 6’W, SS 9202-0054 Pin, Lip Hinge 6.5’W, SS 9202-0055 Pin, Lip Hinge 7’W, SS

D 3 9202-0040 Rear Hinge Pin

9202-0041 Rear Hinge Pin Stainless Steel E 6 2101-0245 Cotter Pin F 1 9515-____

Imbed - Call

G 2 9222-0221 Maintiance Prop

H 4 2101-0020 Bolt 5/8-11 UNC X 1.75 Grade 5

I 4 2101-0042 Nut 5/8 UNC Grade 5

J 1 0525-0085 Lip Cylinder

K 1 9202-0004 Pin - Lip Cyl. 3/4 Dia. x 4-3/8 Lg.

L 2 2101-0049 Hairpin Clip

M 1 2401-0004 Grommet

N 1 0525-0066 Hoist Cylinder

O 1 9202-0038 Pin - Hoist Cyl. 49/64 Dia.10-1/4 Lg.

P 2 2101-0245 Cotter Pin 1/8Dia. x 1-1/4 Lg.

Q 1 8581-0023 Prop Kicker

R 4 2101-0153 Hex Head Cap Screw, 1/4-20 UNC x 1/2 Lg. S 4 2101-0005 Washer, 1/4 in., Lock T 1 9225-0016 maintenance Prop

U 1 9202-0039 Hoist Cly PinRod End V 2 2101-0245 Cottor Pin

W 2 2101-0046 Cottor Pin

Frame and Platform

4111-0008 — April 2008

SC Vertical Leveler Hydraulic Components

PART S

Sight Glass. Fluid should cover half the sight glass. Fluid level must be checked with leveler in the stored position with the lip folded.

4111-0008 — April 2008

PART S

Item Quantity Part Number Description

A 1 0525-0085 Lip, Cylinder

1 0525-0066 Hoist Cylinder 10” and 12” Pits 1 0525-0104 Hoist Cylinder 15” Pits

C 1

9394-0024 Reservoir Short (5’-6’ Lg) Includes Hoses 9904-0102 & 9904-0103

9394-0053 Reservoir Long (8’ Lg) Includes Hoses 9904-0102 & 9904-0103 D 1 9301-0199 Breather, Reservoir

E 4 21010011 Hex Head Capscrew F 4 2101-0058

Lock Washer

G 4 2101-0060 Flate Washer

1 9394-0014 Motor Assembly 115V 1 Ph 1 9394-0015 Motor Assembly 460V 3 Ph 1 9394-0033 Motor Assembly 208V 1 Ph 1 9394-0034 Motor Assembly 230V 1 Ph 1 9394-0035 Motor Assembly 575V 3 Ph 1 9394-0043 Motor Assembly 208V 3 Ph

1 9394-0044 Motor Assembly 230V 3 Ph I 1 9301-0132 Pump 1.75Gpm J - - Left Blank

K 6 2101-0089 Cap Screw, 3/8-16 UNC x 2.0 in. L 1 9904-0090 Hose, 17.50” Lg, #8 Jic Swivel Both Ends (5’-6’ LG)

1 9904-0059 Hose, 35.00” Lg, #6 Jic Swivel Both Ends (8’ LG)

1 9904-0137 Hose, 60.00” Lg, #6 Jic Swivel Both Ends

N 1 9904-0103 Hose, 10.50” Lg, #8 ORB to #8 Jic Swivel O 1 9904-0059 Hose, 35.00” Lg, #6 Jic Swivel Both Ends

P 1 9904-0083 Hose, 44.50” Lg, #6 Jic Swivel Both Ends Q 2 9904-0102 Hose, 21.00” Lg, #8 ORB to #8 Jic Swivel R 1 9301-0115

Fitting 90 Deg #6 ORB To #8 Jic S 1 9301-0116 Fitting 90 Deg #8 ORB To #8 Jic T 1 8583-0089 Vertical Valve Assembly

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.

SC Vertical Leveler Hydraulic Components

4111-0008 — April 2008

KS4 and Remote Mount Hydraulic Components

PART S

4111-0008 — April 2008

PART S

Item Quantity Part Number Description

A 1 0525-0085 Lip, Cylinder

1 0525-0066 Hoist Cylinder 10” and 12” Pits 1 0525-0104 Hoist Cylinder 15” Pits

C AR 9904-0061 Hose, 72.00” Lg, #8 To #6 Jic Swivel Both Ends (5’-6’ LG)

AR 9904-0062 Hose, 96.00” Lg, #8 To #6 Jic Swivel Both Ends (8’ LG) AR 9904-0140 Hose, 140.00” Lg, #8 To #6 Jic Swivel Both Ends (8’- LG)

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.

KS4 and Remote Mount Hydraulic Components

AR = As Required

4111-0008 — April 2008

PART S

Centra Power KS4 Hydraulic Components

4111-0008 — April 2008

Item Quantity Part Number Description

A 1 0525-0085 Lip, Cylinder

1 0525-0066 Hoist Cylinder 10” and 12” Pits 1 0525-0104 Hoist Cylinder 15” Pits

1 9904-0059 Hose, 35.00” Lg, #6 Jic Swivel Both Ends (5’-6’ LG) 1 9904-0137 Hose, 60.00” Lg, #6 Jic Swivel Both Ends (8’ LG)

D 1 9904-0083 Hose, 44.00” Lg, #6 Jic Swivel Both Ends

E 1 9904-0059 Hose, 35.00” Lg, #6 Jic Swivel Both Ends F 1 9904-0082

Hose, 21.00” Lg, #8 Jic Swivel Both Ends

G 1 9904-0090 Hose, 17.50” Lg, #8 Jic Swivel Both Ends H 1 8585-0089 Vertical Valve Assembly

I 1 8583-0045 Centra Power Valve Assembly

Centra Power KS4 Hydraulic Components

4111-0008 — April 2008

PART S

Item Quantity Part Number Description

A 1 8581-0005 Valve Cartridge 3-Way Delta B 1 8581-0102 Valve Cartridge 2-Way Bi-Dr Delta

C 1 8581-0011 Valve Cartridge 4-Way 2 Pos Delta D 1 8581-0010 Valve Cartridge 2-Way N.C. Poppet Delta

E 1 0521-0105 Valve Cartridge Relief F 1 Valve Manifold G 1 9301-0104 Fitting Plug H 2 9301-0111

Fitting #6 ORB X #8 Jic

I 3 9301-0113 Fitting 90 Deg #6 ORB X #6 Jic

J 4 8581-0004 Delta Coil 115V (Includes 1/2 UNF Jam Nut)

K 2 4301-0001

Cable Assy, 48" Lg (Includes Screw)

L 1 4301-0003

Cable Assy, 48" Lg (Includes Screw) Two Coil

*J 1 8585-0089 Vertical Valve Assembly

* A-I Included in in 8583-0089

Pump Psi

Return To Tank

“D” Lower Platform

“E” Lower Platform

Pressure Relief

“C” Lip Valve

Hoist Cyl Rod End

“B” Float Valve

Hoist Cyl Bind End

Lip Cyl

4111-0008 — April 2008

Item Quantity Part Number Description

A 1 Valve Manifold B 1 8581-0005 Valve Cartridge 3-Way Delta

C 1 Fitting, Plug D 1 8581-0088 Valve Cartridge - Flow 2GPM

E 2 0521-0017 Fitting Elbow 90 Deg Male F 1 9904-0120 Fitting Elbow 45 Deg Male, #8 Orb X #8 Jic

G 1 9904-0116 Fitting Elbow 90 Deg Male, #8 Orb X #8 Jic H 1 8581-0004

Delta Coil 115V (Includes 1/2 UNF Jam Nut)

I 1 4301-0001

Cable Assembly, 48" Lg (Includes Screw)

*J 1 8583-0045 Centra Power valve Assembly

* A-G Included in in 8583-0045

PART S

2. Return To Pump Station

1. Pressure From Pump Station

4. Pressure To Dockleveler

3. Return From Dockleveler

4111-0008 — April 2008

PART S

Platform Cylinder Repair Parts

Item Quantity Part Number

Description

A 1 ** Gland Base End B 1 ** Gland Rod End C 1 ** Cylinder Tube D 1 9301-0109 Fitting Conn Str Thread 90 DEG Male E 1 9303-0025 Down Speed Control Valve Assy

F 1 0521-0073 Grease Zerk G 1 ** Retaining Ring H 1 2101-0159 Hex Nut

I 1 9461-0002 Rod End

1 0525-0066* Hoist Cylinder 10” and 12” Pits 1 0525-0104* Hoist Cylinder 15” Pits

K 1 1751-0138 Decal

1 ** Seal Kit

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

**(Not Sold Separately)

4111-0008 — April 2008

PART S

Item Quantity Part Number Description

A 1 ** Cylinder Barrel Assembly B 1 ** Wear Ring C 1 ** Piston Seal, 3-Piece D 1 ** Piston Assembly E 1 ** Cylinder Head F 1 ** Retaining Ring

G 1 0521-0005 Roll Pin

H 1 0522-0156 Yo k e

I 1 0525-0085* Lip Cylinder, 13-3/4 in. (349 mm) Barrel Length (Complete)

J 1 0525-0014 Seal Kit (Includes Items B, C, E, and F) 1992 and earlier

K 1 0525-0059 Seal Kit (Includes Items B, C, E, and F) 1992 and Newer

Lip Cylinder Repair Parts

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

**(Not Sold Separately)

4111-0008 — April 2008

PART S

Remote Mount Power Pack Assembly

4111-0008 — April 2008

PART S

Power Pack Assembly

Item Quantity Part Number Description

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

B 2 9301-0029 Seal, Thread C 1 9302-0014 Reservoir D 1 9301-0199 Breather Cap, 3/8 NPT Male

E 1 9301-0027 O-Ring (Reservoir)

F 2 9302-0012 Tie Rod (Reservoir)

1 9301-____

Pump Only 4 2101-0039 Cap Screw, 5/16-18 UNC x 3-1/2 in., Grade 5 1 9301-0028 Gasket, Pump 1 9303-0002 Coupling Assembly

H 1 9302-0017 Plate, Drive

J 1 9904-0001 Hose K 1 0521-0017 90° Elbow, 3/8 NPT Male x #8-JIC Male L 1 0521-0007 90° Elbow, 1/4 NPT Male x 1/4 Tube

M 1 3411-____

Motor Only

N 1 0521-0015 Straight Fitting, 3/8 NPT Male x #8-JIC Male

P 1 0521-0014 Ball, Check

Q 1 9301-0024 Guide, Check Ball R 1 9302-0009 Spring, Relief Valve

S 1 9303-0003 Screw, Adjusting T 2 9301-0014 Washer, Nylon, 11/16 in. OD x 1/2 in. ID

U 1 9301-0015 Nut, Jam, 1/2-20 UNF

V 1 9301-0016 Nut, Acorn, 1/2-20 UNF

W 1 0521-0016 45° Elbow, 3/8 NPT Male x #8-JIC Male

X 1 9301-0009 Strainer, Suction Y 1 9301-0082 Magnet Z 1 9301-0008 Pipe Nipple, 3/8 NPT x 3 in.

AA 2 9301-0003 Washer, Aluminum, 9/16 in. OD x 3/8 in. ID x 1/16 in. AB 2 9301-0004 Screw, Socket Head, 3/8-16 UNC x 1-3/4 in. AC 2 2101-0063 Nut, Jam 5/16-18 UNC

1 9395-____

Power Pack Complete (Includes All Items Except L, N, and W)

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.

4111-0008 — April 2008

MISCELLANEOUS

Customer Information

NOTE: Refer to illustration for left/right orientation of

dock leveler.

The model/serial number decal (A) is located

on the right platform joist near the front (lip) of dock leveler.

When you receive your VS 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:

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

Phone: (800) 643-5424 Fax: (262) 257-7399

Dock Leveler Information

Model ___________________________________

Serial No. ________________________________

Systems, Inc., Job No. ______________________

Original Owner Information

Name ___________________________________

Address _________________________________

________________________________

Installer Information

Name ___________________________________

Address _________________________________

_________________________________

Date of Installation ________________________

4111-0008 — April 2008

NOTES

4111-0008 — April 2008

POWERAMP WARRANTY

VS SERIES LEVELER

Systems, Inc., guarantees the materials, components, and workmanship in your Poweramp dock leveler to be of the highest quality and to be free of defects in material and workmanship for a period of Five (5) Years from date of shipment, specifically the deck section, lip section, frame, rear hinge, front hinge.

Systems, Inc., further guarantees the hydraulic components on all Poweramp dock levelers for a period of Five (5) Years from date of shipment.

Specifically this guarantee applies to:

• Fluid logic control assembly

• All hydraulic cylinders

• Hydraulic pressure lines

• Hydraulic pump and motor.

The electrical components carry a One (1) year warranty.

In the event of any defect covered by this guarantee, Systems, Inc., will remedy said defect by repairing or replacing all defective parts, bearing all of the costs for parts, labor, and transportation.

All guarantee claims will be settled on a timely basis when defects are found to be from other than improper installation, operating contrary to instructions or beyond rated load capacities, abuse, careless or negligent use, or failure to maintain the unit as recommended by the owner's manual.

There are no guarantees, either expressed or implied, including any implied guarantees of merchantability or fitness for a particular purpose which shall extend beyond the guarantee periods indicated above. This guarantee is valid only if the unit(s) is unaltered from original condition as delivered from the factory and a survey is completed by a Poweramp representative.

Poweramp VS VERTICAL SPECIALTY User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual