Poweramp RCR Series, Owner & User Manual

Page 1: ...ems LLC All Rights Reserved Manual No 4111 0044 June 2021 Poweramp Division of Systems LLC W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www poweramp com techservices poweramp com Owner s User s Manual Older model shown ...

Page 2: ...ng Rod Eye 20 Put New Dock Leveler Into Service 21 Operation Operational Precautions 22 Ramp Loading Unloading 24 End Loading Unloading 25 Optional Side Shift 26 Maintenance Maintenance Precautions 27 Periodic Maintenance 28 Adjustments Adjust Flow Control 30 Adjust Main Pressure Relief 31 Troubleshooting Troubleshooting 32 Parts Platform Hydraulic Hoses 37 Carriage Lip and Platform 38 Hydraulic S...

Page 3: ... cause cancer or birth defects or other reproductive harm For more information go to www P65Warnings ca gov Safety Alert Symbol The Safety Alert Symbol is a graphic representation intended to convey a safety message without the use of words When you see this symbol be alert to the possibility of death or serious injury Follow the instructions in the safety message panel The use of the word DANGER ...

Page 4: ...nt of it Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Chock restrain all transport vehicles Never remove the wheel chocks or release the restraining device until loading or unloading is finished and transport driver has been given permission to drive away Do not use a broken or damaged dock leveling device or restraining device Make sure proper se...

Page 5: ...autions Do not use dock leveling device if transport vehicle is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device ...

Page 6: ...irst ensure all maintenance props are in maintenance positions and properly secured b Then engage prop lock pin in storage prop 5 Turn off power and use OSHA lockout tagout procedures Failure to follow posted instructions will result in death or serious injury Call 800 643 5424 for replacement placards warning labels or owner s user s manuals 1751 0807 Rev D SAFETY INFORMATION www Poweramp com 1 8...

Page 7: ...tly past the full vertical position release the RAISE button LIP OPERATION 1 To fold the lip the rail ramp must be in the lower mode With the LOWER button Pressed simultaneously Press the LIP button With both buttons Pressed the lip will fold 2 To extend the lip the rail ramp must be in the raise mode WiththeRAISEbuttonPressedsimultaneously Press the LIP button With both buttons Pressed the lip wi...

Page 8: ...he interface between the loading dock and the transport 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 operating conditions and the manufacturer s specific ...

Page 9: ... 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 t...

Page 10: ...atisfactory operation To illustrate which connections are to be made in the field at installation electrical drawings are included with each order or by contacting Systems LLC Technical Services RCR dock levelers are available in the following sizes weight capacities and options Width 6 ft 1829 mm 6 1 2 ft 1981 mm 7 ft 2134 mm 7 1 2 ft 2286 mm 8 ft 2438 4 mm 8 1 2 ft 2590 mm 9 ft 2743 mm Length Va...

Page 11: ...Valve E Platform Cylinder s F Lip Hinge Pin G Maintenance Props H Embed J Side End Load Support K Platform Hinge Pin L Lifting Bracket M Powerpack N Control Box Figure 4 INTRODUCTION TOLERANCES UNLESS OTHERWISE NOTED FRACTIONAL 1 32 DECIMAL 00 01 000 005 ANGULAR 1 MATERIAL DRAWN BY CHECKED DRAWIN MarkS 16 F FINAL ASSEMB S Y S L o a d i n g D o c This print is the property of Systems LLC and repres...

Page 12: ... 1 32 DECIMAL 00 01 000 005 ANGULAR 1 MATERIAL DRAWN BY CHECKED BY DRAWING NO DATE MarkS 9 23 2020 170381 ZD0 Side Shift RCR FINAL ASSEMBLY RAIL RAMP P O W E R A M P M C G U I R E D L M S Y S T E M S L o a d i n g D o c k E q u i p m e n t This print is the property of Systems LLC and represents a proprietary article in which Systems LLC retains any and patent and other rights including exclusive ...

Page 13: ...e mounted on underside of leveler or remotely Remote unit shown see pages 46 48 for Powerpack options B D F H J L C G E G K A R TOLERANCES UNLESS OTHERWISE NOTED FRACTIONAL 1 32 DECIMAL 00 01 000 005 ANGULAR 1 MATERIAL DRAWN BY CHECKED BY DRAWING NO DATE MarkS 9 170381 Z Side Shift R FINAL ASSEMBLY RAIL RAM P O W M C S Y S T E M S L o a d i n g D o c k E q u i p m e This print is the property of S...

Page 14: ... anytime when physically working in front of or under the dock leveler This additional means may include but is not limited to a boom truck fork truck stabilizing bar or equivalent Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before installation is complete A hard hat or other applicable head protection shoul...

Page 15: ...ng cap screw 4 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 5 Lube the rear hinge pins using grease Install the hinge pins in one side of the rear embed hinge tubes leaving room for the platform hinge tubes 6 Ensure maintenance props B are in the lowered position and tightly secured 7 Lower the RCR lev...

Page 16: ...rs depending on RCR model Manual Side Shift models a Weld on roller track stops K Figure 13 and proceed to step 8 Hydraulic Side Shift models a Install side shift cylinder mount G see supplied engineering drawings for exact mounting location Anchor to dock face or weld to embed b Install side shift cylinder H The dock leveler is heavy Use a lifting device and chains with the appropriate lifting ca...

Page 17: ...f RCR w Side Shift installation are shown on pages 15 16 A Roller Track B Hoist Cylinder Pin C Rear Hinge Pin D Lifting Brackets E Maintenance Props F Carriage G Side Shift Cylinder Mount H Side Shift Cylinder K Roller Track Stop Figure 11 Figure 12 Figure 13 INSTALLATION E TOLERANCES UNLESS OTHERWISE NOTED FRACTIONAL 1 32 DECIMAL 00 01 000 005 ANGULAR 1 MATERIAL DRAWN BY CHECKED BY DRAWING NO DAT...

Page 18: ... the roller track Figure 15 provides a side view of this process The crane is positioned inside the building as the combined height of the leveler and lifting equipment is greater than the outside door height The maintenance props are lowered and the platform is awaiting install INSTALLATION Figure 14 Figure 15 Older model shown ...

Page 19: ...aintenance props remain lowered to keep the platform upright Installation of RCR levelers from inside is recommended as combined height of leveler and proper lifting equipment may be greater than outside door height Overall length of lifting chain and bracket must be kept to a minimum to prevent interference between the lifting equipment and the building ceiling or door as the dock leveler is lowe...

Page 20: ...ntrol wiring to the field wires in the dock equipment junction boxes Refer to the electrical diagrams supplied with the dock equipment Note When installing electrical controls in a temperature controlled environment the installer must determine an appropriate means to isolate prevent thermal and vapor transfer through electrical conduit where conduit routing crosses temperature zones Systems LLC i...

Page 21: ...s user s manuals online www Loadin gDockSyste ms com WARNING CANCER AND REPRODUC TIVE HARM www P65Wa rnings ca gov OP E R AT I N G INSTRUCTIONS Read and follow all instructions warnings and maintenance schedules in the manual and on placards Operation and servicing of dock leveler is restricted to authorized personnel Always chock transport vehicle wheels or engage vehicle restraint and set parkin...

Page 22: ...en set screw C to turn knob Flow control valve location varies depending on options see Component Identification on pages 9 11 for location or contact Technical Services 6 With the cylinder pin s F removed from the embed carriage restore power to the dock leveler Then cycle the hoist cylinder s up and down at least six times using the leveler s own hydraulic power Ensure the cylinder rod s smoothl...

Page 23: ...allows the hoist cylinder to retract under a preset load Slowly driving a forklift s front wheels only onto the platform will cause the platform to lower b Make sure the platform lowers to the rail car while slowly driving a forklift s front wheels onto it See Figure 21 If the platform does not reach rail car check the adjustment of the yoke s to allow proper travel See pages 18 19 c Remove forkli...

Page 24: ...lip rests on the transport vehicles bed with at least 4 in 102 mm of overlap Maintain a safe distance from side edges of leveler during the loading unloading process Operational Precautions Stay clear of dock leveler when transport vehicle is entering or leaving dock area DO NOT move or use the dock leveler if anyone is under or in front of leveler Keep hands and feet clear of pinch points Avoid p...

Page 25: ...23 4111 0044 June 2021 2021 Systems LLC OPERATION This page intentionally left blank ...

Page 26: ...tton A until leveler reaches transport vehicle then allow leveler to descend into transport vehicle b Make sure that the lip is fully extended and supported on the transport vehicle along the entire width of the platform with at least 4 in 102 mm of lip contacting the transport vehicle bed See Figure 23 4 Proceed with loading or unloading the transport vehicle 5 When loading or unloading is finish...

Page 27: ...t Once the lip is pendant continue to press B until the Side End Load Supports make contact with transport vehicle b Make sure that the Side End Load Supports are fully extended and supported on the transport vehicle with at least 4 in 102 mm contacting the transport vehicle bed See Figure 25 5 Proceed with loading or unloading the transport vehicle 6 When loading or unloading is finished raise th...

Page 28: ...tion transport vehicle 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 If leveler is not centered with transport vehicle opening press the LEFT or RIGHT button see Figure 26 3 When the dock leveler is centered the leveler can be operated as normal 4 Proceed with loading or unloading instructions on pages 24 25 Note Side Shift function can be oper...

Page 29: ... front of the dock leveler Maintenance Precautions A Lock Out Device B Tag Out Device C Maintenance Props When working with electrical or electronic controls make sure that the power source has been tagged B and locked out A according to OSHA regulations and approved local electrical codes see Figure 27 When maintenance is to be performed on the dock leveler place the maintenance props C in their ...

Page 30: ... maintain lubrication Verify lip operates up and down Lock out and tag out the dock leveler then place the maintenance props in their service down position with hardware tightened by wrench Remove any debris or foreign objects from the lip hinge and rear hinge areas Inspect warning decals and placards Replace if damaged or missing Reference page 4 for decal placement TOLERANCES UNLESS OTHERWISE NO...

Page 31: ...for cracks Coils for cracks and or bent valves Lower pin and mounting holes Rear hinge pins and cotter pins Verify rue clip in manual lock position J box for water damage Inspect hoses cylinders fittings and powerpack Control box and conduit for damage M Reservoir N Breather Cap P Fluid Level Check reservoir fluid level P see Figure 30 1 The dock leveler must be in the stored position with the lip...

Page 32: ...oosen the allen head set screw C 5 Set adjusting knob B as follows To decrease the lowering speed adjust knob B clockwise To increase the lowering speed adjust knob B counterclockwise 6 Once ideal down speed flow control setting is achieved lock the adjustment in place by tightening the hex screw on the adjustment knob Note Do not overtighten the set screw 7 Turn ON electrical power to the dock le...

Page 33: ... may be located on the dock leveler platform or on the remote mount valve block Platform mounted valve block is shown see pages 50 52 for Powerpack options and Troubleshooting section on pages 36 39 for more information 1 Raise the platform fully engage the maintenance props in the service position and tighten all hardware with wrench 2 Turn OFF all electrical power to the dock leveler 3 Attach lo...

Page 34: ...on after raising the platform and engaging the maintenance prop 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 A hard hat or other applicable head protection should always be worn when working under or around a dock leveler Always stand clear of platform lip when working in front ...

Page 35: ...oltages 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 or lower Motor runs in reverse Phase reversed Reverse any two legs at the branch circuit disconnect Single phase units only Platform does not rise or lower Motor energizes ...

Page 36: ... type Contaminated hydraulic system Clean and inspect valves Flush contaminated oil from hydraulic system Fill system with new oil see pages 28 29 for proper fluid level and type Damage or blocked hydraulic hose s and or valve s Replace damaged hose s Check and remove blockage from hose s and or valve s Pressure relief set too low Increase pressure relief See page 30 for instruction Note The press...

Page 37: ...de D and E coils not energized Check power to the solenoid coil coil should have a magnetic pull when energized Faulty spool valve Remove and clean spool valve or replace with new valve Leveler does not side shift or is difficult to move Debris in roller track Remove debris from the track Grease cam rollers Leveler does not side shift hydraulically Diverter coil not energized Check power to the so...

Page 38: ...36 4111 0044 June 2021 2021 Systems LLC PARTS Platform Hydraulic Hoses C A G F E D B H ...

Page 39: ...q 9904 ____1 Hose Hoist Cylinder Rod End E 1 9904 ____1 Hose Hoist Cylinder Blind End Tee to Valve Block F 1 9904 ____1 Hose Hoist Cylinder Rod End Tee to Valve Block G 1 9904 ____1 Hose Lip Cylinder Tee to Valve Block H 1 2751 0035 J Box Fiber Glass 3 x 5 Includes Cover 1 Provide dock leveler serial number platform size and lip size when e mailing calling or faxing orders Platform Hydraulic Hoses...

Page 40: ...38 4111 0044 June 2021 2021 Systems LLC Carriage Lip and Platform PARTS U Q I B P H D E F A N C G J K L T L S V R M X W ...

Page 41: ...a x 4 3 8 Lg 1 per cylinder L As Req 2101 0049 Hairpin Clip 5 8 2 per cylinder M As Req 9301 0209 Fitting Straight Thread 6 ORBM 6 JICM 1 per cylinder N 2 0000 ____1 Side End Load Supports P As Req 0525 ____1 Hoist Cylinder Q As Req 9202 0073 Hoist Cyl Pin Rod End 1 per cylinder R As Req 2101 0357 Cotter Pin 3 16 2 per cylinder S As Req 0523 0028 Yoke includes jam nut 1 per cylinder T As Req 2101 ...

Page 42: ...r serial number platform size and lip size when e mailing calling or faxing orders Hydraulic Side Shift PARTS TOLERANCES UNLESS OTHERWISE NOTED FRACTIONAL 1 32 DECIMAL 00 01 000 005 ANGULAR 1 DRAWN BY C D MGM S Y S T L o a d i n g This print is the property of Systems Inc and represents a of use and or manufacture and or sale Possession of this p such permission to be granted only by written autho...

Page 43: ...1 1 4 12 One Per 9461 0003 Cam Roller F 4 2101 0161 Washer Lock 1 1 4 One Per 9461 0003 Cam Roller G 1 2751 0035 J Box Fiber Glass 3 x 5 Includes Cover H 1 9516 ____1 Carriage Assembly J 4 0521 0128 Fitting Grease Zerk 1 4 Straight K 4 0521 0129 Fitting Grease Zerk 3 16 65 L 4 0521 0073 Fitting Grease Zerk 3 16 Straight Torque Specifications 1 7 8 or 2 Roller 65 75 ft lbs 3 Roller 170 ft lbs Carri...

Page 44: ...Delta D 1 8581 0010 Valve Cartridge 2 Way N C Poppet Delta E 1 8581 0105 Valve Cartridge Relief F 2 9301 0111 Fitting 6 ORB X 8 JIC G 3 9301 0113 Fitting 90 Deg 6 ORB X 6 JIC H 3 8581 0004 Coil 115V Includes 1 2 UNF Jam Nut J 1 4301 0003 Cable Assy 24 Lg Two Coil K 1 4305 0306 Cable Assy 24 Lg One Coil M 1 8581 0139 Valve Orifice Check Lip Flow Control N 1 8581 0188 Valve Cartridge Check Poppet Ve...

Page 45: ...G 3 9301 0113 Fitting 90 Deg 6 ORB X 6 JIC H 3 8581 0004 Coil 115V Includes 1 2 UNF Jam Nut J 1 4301 0003 Cable Assy 24 Lg Two Coil K 1 4305 0306 Cable Assy 24 Lg One Coil M 1 8581 0139 Orifice Check Lip Flow Control N 1 8581 0188 Valve Cartridge Check Poppet P 1 9301 0145 Fitting Elbow 90 Deg 8 JIC x 8 JIC Q 1 9301 0115 Fitting Elbow 90 Deg 6 ORB x 8 JIC C J F Q R Return To Tank J E D J2 valve Lo...

Page 46: ...veler Side Shift Diverter Complete A 1 8581 0005 Valve Cartridge 3 Way B 1 9301 0113 Fitting 90 Deg 6 ORB X 6 JIC C 1 9301 0115 Fitting 90 Deg 6 ORB X 8 JIC D 1 9301 0116 Fitting 90 Deg 8 ORB X 8 JIC PARTS Side Shift Diverter Valve Block B D C A To Side Shift Valve To Leveler Manifold Pressure From Pump ...

Page 47: ...alve RCR Side Shift Complete A 1 8581 0011 Valve Cartridge 4 Way B 3 9301 0113 Fitting 90 Deg 6 ORB X 6 JIC C 1 9301 0115 Fitting 90 Deg 6 ORB X 8 JIC PARTS Side Shift Directional Valve Block C B B B A Pressure From Diverter Valve Return To Tank To Blind End of Cylinder To Rod End of Cylinder ...

Page 48: ...ted PPAC VS Hydraulic Components C D E P M Q K G H Q F B J N A C E F Solenoid Valve LP Lip Cylinder RV System Relief Valve HB Bore End of Hoist Cyl HR Rod End of Hoist Cyl FRV Platform Relief Valve J2 Solenoid Valve J1 Solenoid Valve P Pump Pressure R Return ...

Page 49: ... 11 includes jam nut M 1 8585 0103 Valve Assy VS RR RV Float See Page 53 N 1 9394 0049 PPAC MTG WLDT VS Remote W Valve P 1 9395 0351 PPAC REM WALL 2GPM 2 1 GAL 1PH 115 230V 1 5HP 9395 0352 PPAC REM WALL 2GPM 2 1 GAL 1PH 115 230V 1 5HP WASHDOWN 9395 0353 PPAC REM WALL 2GPM 2 1 GAL 1PH 208V 1 5HP 9395 0354 PPAC REM WALL 2GPM 2 1 GAL 1PH 208V 1 5HP WASHDOWN 9395 0355 PPAC REM WALL 2GPM 2 1 GAL 3PH 46...

Page 50: ...48 4111 0044 June 2021 2021 Systems LLC Remote Mount Valve Block w Side Shift Assembly PARTS N K U S V Z C B R Q H G X P C D T A E F J W M Y H Q Q Q Q N W Sol F 21 ...

Page 51: ...4 long P 1 4305 0306 Cable Assy 1 Coil 24 long Q 5 8581 0004 Coil 115VAC R 1 8583 0013 Valve Leveler Side Shift Diverter S 1 8585 0014 Valve Side Shift T 1 8585 0103 Valve Assy VS RR RV Float Remote U 1 9394 0020 Powerpack Mounting Weldment Side Shift V 1 9395 ____ 1 Powerpack Complete W 2 9904 0078 3 8 Hose 35 Lg 8 JICF Swivel Both Ends X 1 9904 0090 3 8 Hose 17 1 2 Lg 8 JICF Swivel Both Ends Y 1...

Page 52: ... Assy Down Speed Flow Control Barrel Lg Hoist Cylinder Parts F B B C D E A Provide dock leveler serial number platform size lip size and type of installation when e mailing calling or faxing orders Contact Technical Services for 2002 and earlier parts Seal kits are not available for vertical hoist cylinders G File Name 1751 0138 Rev B Decal Size 4 x 2 CRUSH HAZARD DO NOT REMOVE hydraulic cylinder ...

Page 53: ... 75 B C A Provide dock leveler serial number platform size lip size and type of installation when e mailing calling or faxing orders Contact Technical Services for 2002 and earlier parts BIL DES PART NO QTY ITEM FITTING BREATHER B 0521 0028 1 1 CYL LIP SHORT 2 5 BOR 0521 0238 1 2 FITTING CON STR THRD 9301 0109 1 3 DR MA A 2 1 3 77 813 GRAY PAINT USED TO SIGNIFY NO SPRING IN CYLINDER ASSEMBLY BLACK...

Page 54: ...purposes only Contact Systems LLC Technical Services with serial number for exact breakdown Remote Mount Powerpack Assembly Leveler pressure is set by relief valve on valve block Remote mount powerpack pressure is factory set UNL FRACTI DECIMA 00 000 ANGUL MATE DRAW This print patent and not conve granted on Pressure Return W B C D E F G H M N J P Q T X Y Z AA AC AD A AB R S U V K L ...

Page 55: ... 9301 0028 Gasket Pump 1 9303 0002 Coupling Assembly H 1 9302 ____ 1 Plate Drive J 1 9904 0071 Hyd Hose 1 2 x 17 8 ORB x 8 JICF Swivel K 1 9301 0116 Fitting Elbow 90 8 ORB x 8 JIC L 1 9301 0106 Plug 8 ORB M 1 3411 ____ 2 Motor Only N 1 9301 0116 Fitting Elbow 90 8 ORB x 8 JIC 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...

Page 56: ...301 0218 Breather Cap Push In D 2 9301 0120 Fitting 45 Degree 8 ORB x 8 JIC Male E 1 3411 ____ 1 Motor Only F 4 2101 0225 Cap Screw 5 16 x 1 25 G 4 2101 0039 Nylon Lock Nut 5 16 18 UNC H 8 2101 0163 Washer Flat 5 16 J 1 9301 0226 O Ring Not Shown Seal Between Reservoir and Manifold K 1 9301 0224 Plastic Reservoir L 1 2401 0001 Grommet Reservoir plastic Powerpack Assembly Carriage Mounted w Single ...

Page 57: ...1 0044 June 2021 2021 Systems LLC Flow Control Valve PARTS Quantity Part Number Description 1 9303 0025 Flow Control Valve Down Speed Provide dock leveler serial number when e mailing calling or faxing orders ...

Page 58: ...56 4111 0044 June 2021 2021 Systems LLC This page intentionally left blank MISCELLANEOUS ...

Page 59: ...mbers 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 LLC P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 www loadingdocksystems com Dock Leveler Information Model ___________________________________ Seria...

Page 60: ...k 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 LLC covered by this warranty SYSTEMS LLC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This s...