Vestil PE Series User manual

Table of Contents 10/19/2020 PE MANUAL
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 1 of 17
Vestil Manufacturing Corp.
2999 North Wayne Street, P.O. Box 507, Angola, IN 46703
Telephone: [phone] -or-Toll Free [phone]
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 [phone]. 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……………………………………………………………………………………………………….……...
2
Safety Instructions……..…………………………………………………………………………………………............
2
Exploded View & Bill of Materials……………………………………………………………………………………….
3
Power Unit Exploded View & Bill of Materials……………………………………………………….……………..….
4
Single Phase Electrical Circuit Diagram…………………………………………………………………………..……
5
3-Phase Electrical Circuit Diagram………………………………………………………………………………..….…
6
Specifications……………………………………………………………………………………………………..……….
7
Recommended Installation Site Characteristics……………………………………………………………………....
7
Installation Requirements for Docks without 6” Steel Edge……………………………………………………….…
8
Approach Ramp Installation for Loading Docks Lower than 50”……………………………………………….……
8
Installation………………………………………………………………………………………………………………….
8- 12
Method 1: Loading Dock with at Least 6” Wide Steel Edge…………………………………………..………..…
9
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……………………………………………………………………………………………………………
13
Operation………………..………………………………………………………………………….……........................
14
Troubleshooting…………..…………………...…………………………………………………………….…………....
14
Record of Normal Condition……………………………………………………………………………..………………
14
Inspections and Maintenance……..………………………………...…………………………………………..………
15
Labeling Diagram………………………………………..………………………………………………………..………
16
Limited Warranty………………………………………………………………………………………………….………
17

Table of Contents 10/19/2020 PE MANUAL
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 2 of 17
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
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 3 of 17
EXPLODED VIEW AND BILL OF MATERIALS
Power unit installs on this bracket
Power Unit Exploded View on p. 4
Item
Part no.
Description
Quantity
1
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
1
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
2
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
1
4
29-001-001
Specialty molded rubber bumper
2
5
15-146-001
Spring, extension, with full loop, 13.57lb./in.
2
6
17165
Hex cap screw, grade 5, zinc finish, 7/16”-20 x 3” Return to p. 12
2
7
37127
Nylon lock nut, grade 2, zinc finish, 7/16”-20 Return to p. 12
2
8
11311
Hex bolt, grade 2, zinc finish, 5/8”-11 x 2”
4
9 33016 Flat washer, low carbon, USS, zinc plated,
5
/
8
” 4
10 13359 Bolt, HHCS, #5, zinc plated,
3
/
4
”-10 x 1
1
/
2
” 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
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 4 of 17
POWER UNIT EXPLODED VIEW AND BILL OF MATERIALS
Item
Part no.
Description
Qty.
1
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
1
1
1.1
99-627-015
Subassembly, manifold, lift-lower
1
1.1.1
99-127-015
Manifold, PE
1
1.1.2
99-153-011
Check valve, size 08, nose-in/side-out
1
1.1.3
99-153-020
Pilot-to-close check valve
1
1.1.4
99-153-038
Flow control, pressure compensating, 1.0GPM
1
1.1.5
99-116-030
Fitting, hydraulic, 06MJ-06MORB straight
1
1.1.6
99-153-004
Valve, pressure relief, 100 bar
1
1.1.7
06-031-004
Accessories, hydraulic, filter disc
1
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
1
1
1
1.2.1
99-135-003
99-135-003
99-135-005
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
1
1
1
1.2.2
01-143-905-002
Pump, hydraulic gear, tang shaft, manifold mount, 0.060disp., 1.0cc/r
1
1.2.3
23305
SHCS, utility grade, 3/8” – 16 x 1”
2
1.2.4
33688
Lock washer, high collar, 3/8”
2
1.2.5
96056
Washer, flat, 3/8” nominal, 0.406” ID, yellow zinc SAE
2
1.2.6
99-034-037
Accessories, electrical, Romex 0.375”
1
2
99-144-007
O-ring; manifold, 3” outer diameter
1
3
99-116-001
Suction fitting, mini-manifold
1
4
99-145-061
Clamp, worm gear hose, 213/16” – 33/4”
1
5
99-031-033
Accessories, nipple, close pipe
1
6
99-031-029
Accessories, hydraulic, screen, inlet, 13/4”
1
7
01-023-009
Reservoir, oil
1
8
01-116-003
Breather, 1/2” Return to p. 12
1
9
99-116-033
Fitting, hydraulic, 06MJ-06MAORB 90° elbow
1
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
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 5 of 17
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
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 6 of 17
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
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 7 of 17
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
1
/2” 52
1
/2” 1
1
/8” 11
7
/8” 26
3
/4” 36
5
/8” 650 lb. 15,000 lb.
PE-2066 98” 66” 61
1
/2” 46
1
/2” 1” 12
1
/2” 17
1
/2” 29” 490 lb. 20,000lb.
PE-2072 99” 72” 67
1
/2” 52
1
/2” 1” 12
1
/2” 17
1
/2” 29” 517 lb. 20,000 lb.
PE-2566 93” 66” 61
1
/2” 46
1
/2” 1” 12
1
/2” 17
1
/2” 29” 558 lb. 25,000 lb.
PE-2572 99” 72” 67
1
/2” 52
1
/2” 1” 12
1
/2” 17
1
/2” 29” 590 lb. 25,000 lb.
PE-2572-36 98” 72” 67
1
/2” 52
1
/2” 1
1
/8” 11
7
/8” 26
3
/4” 36
5
/8” 738 lb. 25,000lb.
PE-3066 93” 66” 61
1
/2” 46
1
/2” 1” 12
1
/2” 17
1
/2” 29
13
/16” 645 lb. 30,000 lb.
End view of 6in.
channel with anchors
6in. channel
Anchor
6”
11/
2
”
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
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 8 of 17
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
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 9 of 17
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
E
6in. steel edge
Dock floor
Mounting plate
(of dock leveler)
Continuously weld the
mounting plate to the steel
edge and on both sides
F
G
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
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 10 of 17
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
E
F
G
Mounting
plate
3/
4
” x 5”
lag bolt
H
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
3/
4
” 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.

Table of Contents 10/19/2020 PE MANUAL
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 11 of 17
METHOD 3:Loading dock without steel edge
E. Make sure that the dock floor and dock face are smooth. Grind/sand surface features on the concrete along the
dock edge. Sand a 6in. region 4.5ft. on each side of the center of the dock door. The areas to sand on the dock
floor and dock face are cross-hatched.
F. Your installation might require an approach plate to provide a smooth transition from the dock floor to the dock
leveler. For example, loading docks where palletized goods are slid across the floor and into a trailer, an approach
plate is necessary. If your installation requires an approach plate, the lip of the plate must be recessed in a groove
in the dock floor. Measure the length of the plate. Find the center of the door opening and mark the floor. Mark the
floor the length of the approach plate plus ~1in. parallel to the dock edge 12 inches from the face of the dock. Cut a
3/8in. deep x 2in. wide groove along the mark. [NOTE: The inside edge of the groove will be 10in. from the dock
edge.]
G. One edge of the approach plate is formed with a slight downward bend. Set this edge of the plate in the groove.
Adjust plate position so that the opposite edge is flush with the dock face. Then, anchor the plate to the floor with
six (6) 3/4in. x 5in. lag bolts. Do not tighten the bolts at this time.
H. Tack-weld the mounting plate of the leveler to the approach plate at both ends. The tops of the mounting plate and
approach plate should be flush and level. Continuously weld the mounting plate to the edge of the approach plate.
I. The mounting plate includes 4 bolt holes. Drill holes into the dock face at all 4 locations for 3/4in. x 5in. anchor
bolts. Install the bolts but do not tighten them completely at this time.
J. Install a dock bumper on each side of the leveler. Begin by welding the top edge of each bumper box to the edge
of the approach plate. Then, drill 4 holes (2 in each flange; see Bumper assembly on p. 10) for 3/4in. x 5in. anchor
bolts. Install the bolts and 3/4in. flat washers.
K. Tighten the bolts installed through the mounting plate (4) and bumpers (4 each; 8 in total). Then, tighten the bolts
in the approach plate (6 in total). Weld the bolts in the approach plate to the plate; then grind and round them off.
E
4.5ft.
6in.
10in.
F
Center of
dock door
Approach plate
Formed
edge
G
Install 3/
4
in. x 5in. lag
bolts
(arrows)
Groove cut in
doc
k floor
Formed edge
in groove
Length

Table of Contents 10/19/2020 PE MANUAL
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 12 of 17
Completing the installation: Diagrams appear on the next page (13).
NOTE: Numbers in parentheses correspond to part numbers in the bills of materials for the exploded views on
pages 3 (dock leveler)& 4 (power unit).
After the leveler is attached to the loading dock, the hydraulic and electrical control systems must be assembled.
1. Attach the top of the cylinder rod to the cylinder brackets with the bolt (17165) and lock nut (37127) in the bracket.
2. The hydraulic fluid reservoir ships with a shipping plug. Remove the shipping plug from the reservoir and install the
breather vent (01-116-013).
3. Mount the control box where it is close to the leveler and protected from the elements (i.e. indoor wall).
4. Install electrical wiring to connect the control box to the motor. Using 1/2” electrical conduit to protect the wiring is
recommended and might be required by law, regulation, or local code or ordinance. The conduit should follow a
path that runs below the nearer (to the motor) bumper box and up to the control box. Refer to the appropriate
electrical circuit diagram (single phase on p. 5; 3-phase on p. 6) to complete the wiring. Then, connect the control
box to electrical service.
5. Lubricate all hinges by applying grease at each of the grease zerks. Reapply grease at least every 3 months or
more regularly if the leveler is under heavy use (more than 10 cycles per day).
METHOD 3 (continued): Loading dock without steel edge
Continuously weld
mounting plate to edge
of approach plate
H
Weld top of bumper box to edge of approach
plate. Weld inside flange to mounting plate.
Fasten both
flanges to
dock face
with 3/4” x 5”
anchor bolts
(4 in total)
Tighten bolts (6 in total) in
approach plate. Weld bolts to
plate, grind and round off.
J & K
I
Install 3/
4
in. flat washers and 3/
4
in.
x 5in. anchor bolts through all 4
bolt holes in mounting plate

Table of Contents 10/19/2020 PE MANUAL
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 13 of 17
THE POWER UNIT
PE-series dock levelers use an electric-hydraulic power unit to deploy an articulated (hinged) dock plate. All
hydraulic components are rated for 3,000 psi working pressure. Power is provided by an electric motor which is
directly coupled to a pump. Pressing and holding the RAISE button on the control box activates the motor. The motor
shaft turns and rotates the pump. The pump pressurizes fluid (oil) and circulates it through the hydraulic circuit. A
manifold houses all valves in the circuit and is fastened onto the pump. A hose provides a passage for oil to flow from
the manifold to the cylinder. As the cylinder fills with pressurized fluid, a cylinder rod extends. The cylinder rod is
connected to the underside of the bridge plate. As the cylinder rod extends, it lifts the dock plate and extends the
bridge plate. When the bridge plate is fully extended, release the RAISE button. The cylinder rod retracts into the
cylinder which causes the bridge plate to descend. The bridge plate eventually contacts the floor of a parked
trailer/vehicle and bridges the gap between the loading dock and the trailer/vehicle.
The following descriptions further explain the functions of
noteworthy components of the power unit:
A. Electric motor: A/C motor operates on either single-
phase or 3-phase AC, depending on the motor ordered.
A variety of motor voltages is available.
B. Pump:The pump shaft is coupled directly to the motor
shaft. Motor shaft rotation turns the pump.
C. Manifold: the following numbers correspond to
(ballooned/circled) item numbers in the hydraulic circuit
diagram:
1. Manifold (99-127-015-DIAG): lift/return circuit
2. Pilot operated check valve (99-153-020-DIAG; nose
in, side out; size 08): when pilot pressure achieved
at 3, a ball prevents flow between 1 and 2.
Completing the installation (continued from p. 12)
Cylinder
2. Remove shipping
plug; install breather
vent
3. Attach control box to
inside wall adjacent to
dock door.
5. Apply grease
to hinges through
grease zerks
4. Run wire and
conduit from motor to
control box
Hydraulic circuit diagram (99-627-015-DIAG):

Table of Contents 10/19/2020 PE MANUAL
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 14 of 17
3. Relief valve (99-153-006-DIAG; 210bar; size 08): At pressures greater than 1,500 psi, the valve opens and
allows fluid to flow back into the reservoir.
4. Check valve (99-153-011-DIAG; size 08): prevents fluid backflow into the pump.
5. Flow control valve (99-153-038; PC; 7/16-20; 2gpm): regulates the lowering rate of the leveler.
6. Plug (6408-H-06-DIAG; socket head; with o-ring): stops oil from flowing out of the circuit.
D. Hydraulic cylinder: A displacement-style cylinder that raises and lowers the dock plate and bridge plate.
E. Hydraulic fluid: The system uses HO150 hydraulic fluid. Any anti-wear hydraulic oil with a viscosity grade of 150
SUS at 100°F (ISO 32 at 40°C), such as: AW 32 or a non-synthetic transmission fluid is acceptable.
OPERATION
Once the vehicle/trailer is in position at the dock, i.e. resting against the dock bumpers with wheels properly
chocked, press the RAISE button on the control box. Pressing the button activates the power unit. The motor rotates
which spins the hydraulic gear pump. Oil is drawn from the reservoir and flows into the pump. The pump pushes
pressurized oil through the manifold, through the hose, and into the cylinder. As oil accumulates in the cylinder, the
cylinder rod extends. The extending cylinder rod presses on the underside of the bridge plate. The bridge plate
pivots upwards. Both the bridge plate and the dock plate elevate. When the plates are completely elevated (pressing
the button does not cause them to rise any further), release the control button. The plates descend until the bridge
plate rests on the trailer.
To return the leveler to home position, simply drive away from the dock. Be certain that nobody is in the vicinity of
the leveler because it swiftly falls once the bridge plate slides off of the trailer/vehicle.
TROUBLESHOOTING
Contact the Technical Service department for assistance with issues not covered in this guide. Contact
information is provided on the cover page of this manual.
Issue
Cause
Solution
I press the control button
but the motor does not run
and the leveler does not
respond.
1. Transformer fuse blown or tripped
circuit breaker
2. No supply voltage
3. Bad control transformer
4. Malfunctioning motor relay coil
5. Malfunctioning control button
6. Thermal-overload switch tripped
1. Replace fuse or reset circuit
breaker.
2. Test voltage with meter, Check
fuses, breakers, and overloads.
3. Check for 24VAC; replace if bad.
4. Test with meter; replace if bad.
5. Test with meter; replace if bad.
6. Wait for motor to cool.
When I press the control
button, I see the motor turn,
but leveler does not rise.
1. Motor rotation is wrong
2. Pumps failing to pressurize
hydraulic system
3. Load applied to the leveler. The
leveler will only lift its own weight.
1. Confirm that motor turns clockwise
2. Contact Technical Service.
3. Unload the leveler.
While control button
pressed, motor hums and/or
pump squeals but deck
does not rise or rises very
slowly.
1. Excessive voltage drop to motor
because power cord wire size too
small, wire length too long, or incoming
voltage too low.
2. Motor running slowly, is hot, or (3-
phase only) lost one phase.
4. Pressure relief valve opening at full
system pressure.
5. Check valve failing to close
6. Load applied to deck.
1. Check power installation. Check
incoming voltage with voltmeter while
motor running.
2. Check voltage on all legs; check
fuses; repair as necessary.
4. Check for frame damage or binding
at the hinges. Check for overload
condition.
5. Remove valve and inspect.
6. Remove load from deck.

Table of Contents 10/19/2020 PE MANUAL
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 15 of 17
RECORD OF NORMAL CONDITION
When the unit is first installed, make a detailed record of its condition. Include observations about all features:
hinges, the power unit (cylinder, pump, hoses, etc.), welds, the frame (particularly the mounting plate and cylinder
mounting brackets), dock plate, bridge plate, control box, and bumper assemblies. Thoroughly photograph the unit in
both the raised and home positions. Photograph all labels applied to the leveler and control box. Add the
photographs to the record. Describe where each label is located. Press the control button until the leveler is fully
extended/raised; then release the button and watch the leveler return to the home position. Write a detailed
description of the cycle and/or make a video recording of the leveler in operation. This record establishes “normal
condition”. During future inspections, compare your observations to the record to determine if the unit is in normal
condition. See Inspections & Maintenance.
INSPECTIONS AND MAINTENANCE
Before beginning maintenance, secure the leveler in the extended position. For example, use at least 2 props or
attach a locking plate clamp to the bridge plate and lift it with an overhead lifting device like a hoist or forklift boom. It
is strongly recommended that more than one method of securing the leveler be applied each time it is serviced to
provide redundancy if one method fails.
(A) Inspect the unit at least once per week for the following:
1.) Frayed wires and loose conduit fittings. Repair or replace wiring/conduit as necessary.
2.) Damage and deformation of the structural members, cylinder brackets, etc.
3.) Run the leveler through a complete cycle. Listen for unusual noises. Watch the dock plate and bridge plate
for binding or unusual movement. Grease the hinges if the plates are noisy as they move but are otherwise
in normal condition.
(B) Inspect the following at least once per month:
1.) Oil leaks – check the hose, cylinder, fittings, etc. for oil leaks. Also check the oil level in the reservoir. Oil should
be 1” to 1½” below the fill hole in the reservoir. If you need to add oil, or if the oil needs to be replaced, only use
anti-wear hydraulic oil with a viscosity grade of 150 SUS at 100°F, (ISO 32 at 40°C), for example AW 32 or HO
150 hydraulic oil or a non-synthetic transmission fluid. Synthetic transmission fluid can be used, but the system
must first be flushed with the synthetic fluid before the reservoir is filled.
2.) Hydraulic hose and electrical wiring – check the hose and electrical wires for damage. Replace the hose if it is
leaking, bulging, or cracking.
3.) Hinge and cylinder pivot points – check for excessive wear at all pivot points. Apply grease to all hinges
through the grease zerks. Examine both cylinder mounting brackets for damage.
4.) Welds – check all welds for cracks and signs of metal fatigue, especially around hinges and cylinder mounting
brackets.
5.) Hardware – examine each anchor bolt and the concrete around it. Tighten any bolt that is loose. The leveler
must be rigidly anchored to the dock at all times. The frame should not move (e.g. rock or wobble) while the
leveler operates. Make sure that the bolt holes in the mounting plate are not elongating, cracking, etc. Also
inspect the cylinder mounting bolts (part no. 17165 in Exploded View on p. 3).
6.) Labels – confirm that each label is in place and in good condition. Refer to the Labeling Diagram on p. 16.
7.) Leveler surfaces - clean the surfaces of the leveler, underneath and around the power unit. Remove
corrosion/rust and apply touchup paint to all areas where the finish is damaged.
(C) Yearly Maintenance
1.) Thoroughly grease the hinges and both cylinder pivot points. See Exploded View on p. 3.
2.) The oil should be changed if it darkens, becomes gritty, or has a milky appearance (indicating the presence
of water). Replace the original oil with anti-wear hydraulic oil, viscosity grade 150 SUS at 100°F, (ISO 32
at 40°C). Examples of replacement oils include AW 32 or HO 150 hydraulic oil or a non-synthetic
transmission fluid. Synthetic transmission fluid can be used only if the system is flushed with the synthetic
fluid before the reservoir is filled.

Table of Contents 10/19/2020 PE MANUAL
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 16 of 17
LABELING DIAGRAM
Each unit should be labeled as shown in the diagram. However, label content and locations are
subject to change so your product might not be labeled exactly as shown. Compare the diagram below to
your Record of Normal Condition. If there are any differences between actual labeling and this diagram,
adapt the diagram to reflect actual labeling. Replace all labels that are damaged, missing, or not easily
readable (e.g. faded). To order replacement labels or to inquire whether your unit is properly labeled,
contact the technical service and parts department online at http://www.vestilmfg.com/parts_info.htm or
by calling [phone] and asking for the Parts Department.
D: Label 287 (Applied to outside surface of foot guard)
C: Label 362 (Applied to control box)
A: Label 206 (Not shown; Applied to control box)
B: Label 584 (Applied above control button)
A
B
C
D

Table of Contents 10/19/2020 PE MANUAL
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 17 of 17
LIMITED WARRANTY
Vestil Manufacturing Corporation (“Vestil”) warrants this product to be free of defects in material and workmanship
during the warranty period. Our warranty obligation is to provide a replacement for a defective, original part covered
by the warranty after we receive a proper request from the Warrantee (you) for warranty service.
Who may request service?
Only a warrantee may request service. You are a warrantee if you purchased the product from Vestil or from an
authorized distributor AND Vestil has been fully paid.
Definition of “original part”?
An original part is a part used to make the product as shipped to the Warrantee.
What is a “proper request”?
A request for warranty service is proper if Vestil receives: 1) a photocopy of the Customer Invoice that displays the
shipping date; AND 2) a written request for warranty service including your name and phone number. Send requests
by one of the following methods:
US Mail Fax Email
Vestil Manufacturing Corporation [phone] [e-mail]
2999 North Wayne Street, PO Box 507 Phone Enter “Warranty service request”
Angola, IN 46703 [phone] in subject field.
In the written request, list the parts believed to be defective and include the address where replacements should be
delivered. After Vestil receives your request for warranty service, an authorized representative will contact you to
determine whether your claim is covered by the warranty. Before providing warranty service, Vestil will require you to
send the entire product, or just the defective part (or parts), to its facility in Angola, IN.
What is covered under the warranty?
The warranty covers defects in the following original, dynamic parts: motors, hydraulic pumps, motor controllers,
and cylinders. It also covers defects in original parts that wear under normal usage conditions (“wearing parts”), such
as bearings, hoses, wheels, seals, brushes, and batteries.
How long is the warranty period?
The warranty period for original dynamic components is 1 year. For wearing parts, the warranty period is 90 days.
Both warranty periods begin on the date Vestil ships the product to the Warrantee. If the product was purchased from
an authorized distributor, the periods begin when the distributor ships the product. Vestil may, at its sole discretion,
extend a warranty period for products shipped from authorized distributors by up to 30 days to account for shipping
time.
If a defective part is covered by the warranty, what will Vestil do to correct the problem?
Vestil will provide an appropriate replacement for any covered part. An authorized representative of Vestil will
contact you to discuss your claim.
What is not covered by the warranty?
The Warrantee (you) is responsible for paying labor costs and freight costs to return the product to Vestil for
warranty service.
Events that automatically void this Limited Warranty.
•Misuse;
•Negligent assembly, installation, operation or repair;
•Installation/use in corrosive environments;
•Inadequate or improper maintenance;
•Damage sustained during shipping;
•Collisions or other accidents that damage the product;
•Unauthorized modifications: Do not modify the product IN ANY WAY without first receiving written authorization
from Vestil.
Do any other warranties apply to the product?
Vestil Manufacturing Corp. makes no other express warranties. All implied warranties are disclaimed to the extent
allowed by law. Any implied warranty not disclaimed is limited in scope to the terms of this Limited Warranty. Vestil
makes no warranty or representation that this product complies with any state or local design, performance, or safety
code or standard. Noncompliance with any such code or standard is not a defect in material or workmanship.