Vestil PE Series Manuale utente

Table of Contents 10/19/2020 PE MANUAL

Vestil Manufacturing Corp.

2999 North Wayne Street, P.O. Box 507, Angola, IN 46703

Telephone: (260) 665-7586 -or-Toll Free (800) 348-0868

PE-Series Dock Levelers

Instruction Manual

Receiving Instructions

After delivery, remove the packaging from the product. Inspect the product closely to determine whether

it sustained damage during transport. If damage is discovered, record a complete description of it on the

bill of lading. If the product is undamaged, discard the packaging.

NOTE: The end-

user is solely responsible for confirming that product design, use, and maintenance

comply with laws, regulations, codes, and mandatory standards applied where the product is used.

Technical Service & Replacement Parts

For answers to questions not addressed in these instructions and to order replacement parts, labels,

and accessories, call our Technical Service and Parts Department at (260) 665-7586. The Department can

also be contacted online at https://www.vestil.com/page-parts-request.php.

Electronic Copies of Instruction Manuals

Additional copies of this instruction manual may be downloaded from https://www.vestil.com/page-

manuals.php.

TABLE OF CONTENTS

PAGE

Signal Words……………………………………………………………………………………………………….……...

Safety Instructions……..…………………………………………………………………………………………............

Exploded View & Bill of Materials……………………………………………………………………………………….

Power Unit Exploded View & Bill of Materials……………………………………………………….……………..….

Single Phase Electrical Circuit Diagram…………………………………………………………………………..……

3-Phase Electrical Circuit Diagram………………………………………………………………………………..….…

Specifications……………………………………………………………………………………………………..……….

Recommended Installation Site Characteristics……………………………………………………………………....

Installation Requirements for Docks without 6” Steel Edge……………………………………………………….…

Approach Ramp Installation for Loading Docks Lower than 50”……………………………………………….……

Installation………………………………………………………………………………………………………………….

8- 12

Method 1: Loading Dock with at Least 6” Wide Steel Edge…………………………………………..………..…

Method 2: Loading Dock with Steel Edge less than 6” Wide…….…………………………………...................

10 - 11

Method 3: Loading Dock without Steel Edge……………………………………………………………..……..…

11 - 12

Completing the Installation………………………………………………………………………………………….…...

12 - 13

The Power Unit……………………………………………………………………………………………………………

Operation………………..………………………………………………………………………….……........................

Troubleshooting…………..…………………...…………………………………………………………….…………....

Record of Normal Condition……………………………………………………………………………..………………

Inspections and Maintenance……..………………………………...…………………………………………..………

Labeling Diagram………………………………………..………………………………………………………..………

Limited Warranty………………………………………………………………………………………………….………

Table of Contents 10/19/2020 PE MANUAL

SIGNAL WORDS

This manual uses SIGNAL WORDS to indicate the likelihood that a particular action will cause

personal injuries or

property damage. Signal words also specify the level of seriousness of injury if the

product is misused in the ways

described. The following signal words are used in this manual.

Identifies a hazardous situation which, if not avoided, COULD result in DEATH or

SERIOUS INJURY.

Indicates a hazardous situation which, if not avoided, COULD result in MINOR or

MODERATE injury.

Identifies actions likely to result in product/property damage, such as operation that might

damage the product.

SAFETY INSTRUCTIONS

Vestil strives to identify foreseeable hazards associated with the use of its products. However, material

handling is dangerous and no manual can address every conceivable risk. The end-user ultimately is

responsible for exercising sound judgment at all times.

If this product is installed, used, or maintained improperly serious personal injuries or death

might result. Read and understand the entire manual before installing, using, or servicing the product.

•The manual should be stored in a location known to all persons who use the dock leveler. It should be

available to anyone needing refresh the understanding of proper use and maintenance procedures.

•DO NOT attempt to resolve any issue with the product unless you are certain that it will be safe to use

afterwards.

•DO NOT modify the product in any way. Unauthorized modifications might make the lifter unsafe to use

and automatically void the Limited Warranty (see p. 25).

•DO NOT exceed the capacity of your unit. Capacity information appears on the product in label 287. The

Labeling Diagrams on p. 24 indicates where to find label 287 on your dock leveler.

•Inspect the product according to the instructions on p. 21 & 22. Replace each part that is not in normal

condition. DO NOT use the product until it is fully restored to normal condition. ONLY use manufacturer-

approved replacement parts.

•Cycle the deck all the way up and all the way down. Listen for unusual sounds as the deck rises and

lowers. Watch the deck for unusual movement.

•DO NOT use the dock leveler unless all machine guards are in place.

•This product is NOT a personnel lift. DO NOT use it to lift or transport people.

•[Hydraulically actuated units] NEVER change the setting of the pressure relief valve.

•DO NOT use this device UNLESS all labels are in place, readable, and undamaged. See Labeling

Diagramson. p.24.

Proper use, maintenance, and storage are essential for this product to function properly.

oAlways use this product in accordance with the instructions in this manual and consistent with any training

relevant to machines, devices, etc. used in conjunction with this product.

oKeep the product clean & dry. Periodically lubricate moving parts.

oFOR HYDRAULIC UNITS: Do not use brake fluid or jack oils in the hydraulic system. If oil is needed, use

an anti-wear hydraulic oil with a viscosity grade of 150 SUS at 100°F, (ISO 32 cSt @ 40°C), or Dexron

transmission fluid.

oContact the manufacturer for SDS information

Table of Contents 10/19/2020 PE MANUAL

EXPLODED VIEW AND BILL OF MATERIALS

Power unit installs on this bracket

Power Unit Exploded View on p. 4

Item

Part no.

Description

Quantity

06-513-199

06-513-204

06-513-205

06-513-206

06-513-207

06-513-203

06-513-208

06-513-209

Weldment, deck, assembly:

PE-1572-36

PE-2066

PE-2072

PE-2566

PE-2572

PE-2572-36

PE-3066

PE-3072

2 06-514-014

06-514-015

Weldment, bumper box:

Deep: PE-1572-36; PE-2572-36

15”: PE-2066; PE-2072; PE-2566; PE-2572; PE-3066; PE-3072

3 99-021-940

99-021-931-001

Cylinder, hydraulic:

11/2” x 14”: PE-1572-36; PE-2566; PE-2572; PE-2572-36; PE-3066;

& PE-3072

1” x 14”: PE-2066; PE-2072

29-001-001

Specialty molded rubber bumper

15-146-001

Spring, extension, with full loop, 13.57lb./in.

17165

Hex cap screw, grade 5, zinc finish, 7/16”-20 x 3” Return to p. 12

37127

Nylon lock nut, grade 2, zinc finish, 7/16”-20 Return to p. 12

11311

Hex bolt, grade 2, zinc finish, 5/8”-11 x 2”

9 33016 Flat washer, low carbon, USS, zinc plated,

” 4

10 13359 Bolt, HHCS, #5, zinc plated,

”-10 x 1

” 1

Mounting

plate

Bridge

plate

Dock plate

Cylinder

mounting

bracket

Cylinder mounting bracket

Return to Page 12,

Completing the

installation

Table of Contents 10/19/2020 PE MANUAL

POWER UNIT EXPLODED VIEW AND BILL OF MATERIALS

Item

Part no.

Description

Qty.

99-160-228-001

99-160-228-002

99-160-229-003

99-160-229-004

Power unit subassembly:

a. 1PH, 115V AC, 0.75HP, 1725RPM, 0.06 displacement, 1.0GPM flow control

b. 1PH, 208-230V AC, 0.75HP, 1725RPM, 0.06 displacement, 1.0GPM flow control

c. 3PH, 208-230V AC, 2HP, 1725RPM, 0.06 displacement, 1.0GPM flow control

d. 3PH, 460V AC, 2HP, 1725RPM, 0.06 displacement, 1.0GPM flow control

1.1

99-627-015

Subassembly, manifold, lift-lower

1.1.1

99-127-015

Manifold, PE

1.1.2

99-153-011

Check valve, size 08, nose-in/side-out

1.1.3

99-153-020

Pilot-to-close check valve

1.1.4

99-153-038

Flow control, pressure compensating, 1.0GPM

1.1.5

99-116-030

Fitting, hydraulic, 06MJ-06MORB straight

1.1.6

99-153-004

Valve, pressure relief, 100 bar

1.1.7

06-031-004

Accessories, hydraulic, filter disc

1.2

99-137-007-001

99-137-007-002

99-137-015-003

99-137-015-004

a. 1PH Motor/pump, 115V AC, 1PH, 0.75HP, 1725RPM, 0.060 disp.

b. 1PH Motor/pump, 208-230V AC, 1PH, 0.75HP, 1725RPM, 0.060 disp.

c. 3PH Motor/pump, 208-230V AC, 3PH, 0.75HP, 1725RPM, 0.060 disp.

d. 3PH Motor/pump, 460V AC, 3PH,

1.2.1

99-135-003

99-135-005

a. Motor, 0.75HP, 1PH, 1725RPM, 56F, 115/208, 60Hz, 2.0SF

b. Motor, 0.75HP, 1PH, 1725RPM, 56F, 115/208-230V, 60Hz, 2.0SF

c. Motor, 2HP, 3PH, 1725RPM, 56F, 208-230V, 50/60Hz

d: Motor, 2HP, 3PH, 1725RPM, 56F, 460V, 50/60Hz

1.2.2

01-143-905-002

Pump, hydraulic gear, tang shaft, manifold mount, 0.060disp., 1.0cc/r

1.2.3

23305

SHCS, utility grade, 3/8” – 16 x 1”

1.2.4

33688

Lock washer, high collar, 3/8”

1.2.5

96056

Washer, flat, 3/8” nominal, 0.406” ID, yellow zinc SAE

1.2.6

99-034-037

Accessories, electrical, Romex 0.375”

99-144-007

O-ring; manifold, 3” outer diameter

99-116-001

Suction fitting, mini-manifold

99-145-061

Clamp, worm gear hose, 213/16” – 33/4”

99-031-033

Accessories, nipple, close pipe

99-031-029

Accessories, hydraulic, screen, inlet, 13/4”

01-023-009

Reservoir, oil

01-116-003

Breather, 1/2” Return to p. 12

99-116-033

Fitting, hydraulic, 06MJ-06MAORB 90° elbow

Return to Page 3

Return to Page 12,

Completing the

installation

COMPLETE POWER UNIT

ASSEMBLIES

Motor phase & voltage

Engineering drawing

1-Phase, 115 VAC

06-160-009-001

1-Phase, 208-230V AC

06-160-009-002

3-Phase, 208-230V AC

06-160-010-003

3-Phase, 460V AC

06-160-010-004

Table of Contents 10/19/2020 PE MANUAL

Single Phase Electrical Circuit Diagram (06-124-019 rev. D)

Turn off all sources of electrical power and lock and tag them out before beginning this

installation.

Always turn off all power sources before beginning work on this equipment.

The end-user must provide overcurrent and short circuit protection compliant with NEC guidelines and local

codes.

Return to Page 12,

Completing the

installation

Table of Contents 10/19/2020 PE MANUAL

3-Phase Electrical Circuit Diagram (06-124-020 rev. D)

The end-user must provide overcurrent and short circuit protection compliant with NEC guidelines and local

codes.

Turn off all sources of electrical power and lock and tag them out before beginning this

installation.

Always turn off all power sources before beginning work on this equipment.

Return to Page 12,

Completing the

installation

Table of Contents 10/19/2020 PE MANUAL

SPECIFICATIONS

RECOMMENDED INSTALLATION SITE CHARACTERISTICS

The optimal installation site is a loading dock where the

floor is 50 inches above the ground. If the dock is lower

than 50 inches, ramps and ramp support angles are

necessary. The dock face should include 6 inch, integral

steel channel along the top edge of the loading dock floor.

This feature allows the dock leveler and dock bumpers to

be welded directly to the steel channel. Concrete anchors

must be at least 11/2inches wide by 6 inches long with a

11/2inch perpendicular segment at both ends. Anchors

must be made from at least 1/4” steel and should be welded

to the channel in 12 inch increments. Optimal

(recommended) dock edge construction is shown in the

diagrams.

MODEL A B C D E F G H

NET

WEIGHT CAPACITY

PE-1572-36 98” 72” 67

/2” 52

/2” 1

/8” 11

/8” 26

/4” 36

/8” 650 lb. 15,000 lb.

PE-2066 98” 66” 61

/2” 46

/2” 1” 12

/2” 17

/2” 29” 490 lb. 20,000lb.

PE-2072 99” 72” 67

/2” 52

/2” 1” 12

/2” 17

/2” 29” 517 lb. 20,000 lb.

PE-2566 93” 66” 61

/2” 46

/2” 1” 12

/2” 17

/2” 29” 558 lb. 25,000 lb.

PE-2572 99” 72” 67

/2” 52

/2” 1” 12

/2” 17

/2” 29” 590 lb. 25,000 lb.

PE-2572-36 98” 72” 67

/2” 52

/2” 1

/8” 11

/8” 26

/4” 36

/8” 738 lb. 25,000lb.

PE-3066 93” 66” 61

/2” 46

/2” 1” 12

/2” 17

/2” 29

/16” 645 lb. 30,000 lb.

End view of 6in.

channel with anchors

6in. channel

Anchor

6”

11/

”

Dock floor

Dock

face

6in. wide

steel

channel

Dock floor

Dock

face

Pavement

Anchor

Steel channel flush

with dock floor and

dock face

Concrete

dock

Concrete

dock

Table of Contents 10/19/2020 PE MANUAL

Installation requirements for loading docks without 6in. steel edge:

If your loading dock lacks 6 inch steel edging, then either: 1) the edging is less than 6 inches wide; or 2) there is

no steel edge.

1) If the installation site includes integral steel channel along the dock edge, but the channel is less than 6 inches

wide, the dock leveler must be both welded and fastened to the dock face with anchor bolts. This installation is

described in Method 2 on pages 9-10.

2) A steel approach plate must first be anchored to the floor if the dock has no steel edging. The dock leveler is

then welded to the front edge of the approach plate. This installation is described in Method 3 on pages 11-12.

Approach ramp installation for loading docks lower than 50

inches (dock floor less than 48 inches above pavement):

If the dock floor is less than 50 inches above the pavement,

then a ramp might be necessary. The dock leveler is installed to be

50 inches above the pavement and a ramp provides a smooth

transition from the dock floor to the top of the leveler. The diagrams

provide an example of a dock floor 48 inches above the pavement.

INSTALLATION

Improperly installing the dock leveler decreases its

capacity and might make it unsafe to use. If the dock face does not

include integral steel channel, then an approach plate must be

installed.

Three methods of installing the dock leveler are provided in this

manual. The methods are presented in order of preference, i.e. the

unit should be installed according to Method 1, which requires an

integral steel edge at least 6 inches wide. If the loading dock has a

steel edge that is less than 6 inches wide, then use Method 2. If

the dock does not have a steel edge at all, then use Method 3. For

all 3 methods, begin the installation with steps A-D by cleaning and

preparing the site and moving the dock leveler into position.

A. Clean the installation site and the steel edge. The edge must be

free of protrusions. Remove burrs, etc. from the edge surface.

The floor surface and front face of the dock should be smooth.

B. Measure the width of the dock door (double-ended arrow). Find

and mark the center of the door opening (dashed line).

C. Move the leveler to the installation site, e.g. with a forklift boom.

In the diagram, a forklift boom is shown attached to the bridge

plate.

D. Center the dock leveler on the center of the dock doorway.

Proceed to the instructions for:

i. Method 1 if the dock has a 6in. (or wider) steel edge; OR

ii. Method 2 if the dock has steel edge less than 6in. wide; OR

iii. Method 3 if the dock does not have a steel edge.

Prepare installation site

Move leveler to

installation site

Steel

edge

Dock floor 48in.

above pavement

Ramp with 2in. rise

Mounting

bracket

View of internal structure

Gusset

2in.

Mounting brackets for

3/4” x 5” anchor bolts

Dock

face

Side view of

loading dock

Center of

dock door

Bridge

plate

Table of Contents 10/19/2020 PE MANUAL

METHOD 1:Loading dock with at least 6in. wide steel edge

E. The top of the dock leveler mounting plate should be flush with the top of

the steel edge. Tack weld the mounting plate to the edge at both ends.

F. Continuously weld the top edge of the mounting plate to the steel edge.

G. Install dock bumpers on both sides of the leveler.

i. Align the top of each bumper with the top of the steel edge/dock floor.

ii. Tack weld the bumpers to the steel edge.

iii. Continuously weld the top and both sides of both bumpers to the

steel edge.

METHOD 2:Loading dock with steel edge less than 6in. wide

E. The top of the dock leveler mounting plate should be flush with the top of

the steel edge. Tack weld the mounting plate to the edge at both ends.

F. Continuously weld the mounting plate to the steel edge.

G. Install four (4) 3/4” x 5” lag bolts to fasten the (dock leveler) mounting

plate to the dock face.

H. Install dock bumpers on both sides of the leveler.

i. Align the top of each bumper with the dock floor.

ii. Tack weld the bumpers to the steel edge.

iii. Continuously weld the top of both bumpers.

iv. Continuously weld the sides of each bumper.

v. Install a 3/4” x 5” lag bolt through the outside and inside flanges of

both bumpers.

Dock face with 6in.

wide steel edge

6in. steel edge

Dock floor

Mounting plate

(of dock leveler)

Continuously weld the

mounting plate to the steel

edge and on both sides

Install bumpers

on both sides

of leveler flush

with steel

Continuously weld

top and both sides

of each bumper to

steel edge

Weld bumpers

to steel edge

Dock face with steel

edge less then 6in. wide

Additional diagrams

on following page

Table of Contents 10/19/2020 PE MANUAL

METHOD 2 (continued): Loading dock with steel edge less than 6in. wide

Mounting plate

(of dock leveler)

Continuously weld the

mounting plate to the steel

edge and on both sides

Dock floor

Steel edge less

than 6in. wide

Mounting

plate

” x 5”

lag bolt

Weld bumper flange

to steel edge and

mounting plate

Dock face

Weld

bumper to

mounting

plate (top

and

flanges)

Fasten leveler to

dock face with 3/4” x

5” lag bolts (arrows)

Dock face

Dock floor

Finished installation

Bumper assembly

” x 5”

lag bolt

Bumper flange

with 2 holes for

3/4” x 5” anchor

bolts

Rubber

bumper

Bumper

box

Fasten bumper

box to dock face

through (circled)

lower bolt hole

in both flanges.

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