Vestil RR Series User manual

Table of Contents 11/5/2018 EH MANUAL
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 1 of 25
Vestil Manufacturing Corp.
2999 North Wayne Street, P.O. Box 507, Angola, IN 46703
Telephone: [phone] -or-Toll Free [phone]
RR-Series & EH-Series Dock Levelers
Instruction Manual
RR Series (Mechanical)
EH Series (Electric-Hydraulic)
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.
Replacement Parts and Technical Assistance:
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 http://www.vestilmfg.com/parts_info.htm.
TABLE OF CONTENTS
Signal Words………………………………………………………………………………………………………….……………. 2
Hazards of Improper Use…………………………………………………………………………………………...…………….. 2
EH-65, EH-66, EH-68 and EH-610 Exploded View & Bill of Materials………………………………………………………..3
EH-75, EH-76, EH-78 and EH-710 Exploded View & Bill of Materials………………………………………………………..4
Power Unit Exploded View and Bill of Materials [EH-65; EH-66; & EH-68]…………………………………………………..5
Power Unit Exploded View and Bill of Materials [EH-610; EH-75; EH-76; EH-78; & EH-710]……………………………..6
Manifold Exploded View and Bill of Materials [EH-65; EH-66; & EH-68]……………………………………………………..7
Manifold Exploded View and Bill of Materials [EH-610; EH-75; EH-76; EH-78; & EH-710]……………………………….. 7
Electrical Circuit Diagram, 115V AC, 1-Phase [EH Dock Levelers]..……………………………………..…………………..8
Electrical Circuit Diagram, 208-230V AC, 1-Phase [EH Dock Levelers]……...………………………………………………9
Electrical Circuit Diagram, 3-Phase AC [EH Dock Levelers]………………………………………………………………….10
Electrical System Operation [EH Dock Levelers]..……………………………………………………………...……………..11
Hydraulic Circuit Sequence of Operation [EH Dock Levelers]………………………………………………………………..11
Adjusting Hydraulic Settings [EH Dock Levelers]……………………………………………………………………..............12
RR-65, RR-66, RR-68, and RR-610 Exploded View and Bill of Materials…………………………….………………. 13 - 14
RR-75, RR-76, RR-78, and RR-710 Exploded View and Bill of Materials…………………………………………….. 15 - 16
Installation…………………………………………………………………………………………………………………………. 17
Operation: EH Series………………..…………………………………………………………………………………....17, 18, 19
Operation: RR Series…………………………………………………………………………………………………………….. 19
Troubleshooting: EH-Series…………………...…………………………………………………………………………...........20
Inspections and Maintenance: EH-Series………………………………...…………………………………………………….21
Inspections and Maintenance, RR-Series………………………………………………………………………………...........22
Adjusting Spring Tension: RR-Series……………………………………………………………………………………………23
Labeling Diagrams: RR-Series and EH-Series………..……………………………………………………………………….24
Limited Warranty…………………………………………………………………………………………………………………..25

Table of Contents 11/5/2018 EH MANUAL
Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 2 of 25
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.
Hazards of Improper Use:
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 used or maintained improperly serious personal injuries or death might result.
ALWAYS use the product properly.
•Failure to read and understand the entire manual before assembling, using or servicing the product
constitutes misuse.
•Read the manual to refresh your understanding of proper use and maintenance procedures whenever
necessary.
•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

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EH-65, EH-66, EH-68 and EH-610 Exploded View and Bill of Materials
Item
Part no.
Description
Qty.
Item
Part no.
Description
Qty.
1
Frame Weldment
1 10
06-014-013
Maintenance Prop
EH-65 1
06-514-001 EH-65
06-514-003 EH-66 06-014-013 EH-66
06-514-005 EH-68 06-014-011 EH-68
06-514-007 EH-610 06-014-015 EH-610
2
Deck Weldment
1
11
99-134-003 Tag, Model no., capacity, serial no.
1
06-513-020 EH-65
12
06-024-015
Guard, side skirt
EH-65
2
06-513-023 EH-66 06-024-015 EH-66
06-513-026 EH-68 06-024-013 EH-68
06-513-029 EH-610 06-024-016 EH-610
3
99-021-933-
001
Cylinder, hydraulic, 2” x 8” piston style with
clevis mounts
1 13 11107 Hex bolt, gr. A, zinc finish, 3/8”-16 x 11/4” 4
4
06-521-001
06-521-002
Assembly, cylinder, hydraulic:
EH-65; EH-66; and EH-68: 2” x 18”
EH-610: 2
1
/2” x 18”
1 14 33008 Flat washer, low carbon, USS, zinc plated, 3/8” 4
5
47-112-001 Pin, clevis, 1” x 3
1
/4”
5
15
37024 Nylon insert lock nut, gr. 2, zinc finish,
3
/8”-16
2
6
06-112-014 Pin, clevis, 1” x 2
1
/2”
1
16
51441 Star pin anchor,
3
/16” x
3
/16”
2
7 65132
Extended prong cotter pin, zinc finish, 3/
16
” x
3
1
/2”
6 *17 29-001-251 Bumper, laminated dock, 4.5” x 10.25” x 10” 2
8
11211 Bolt, HHCS,
1
/2”-13UNCx2”, zinc plated
1
*Not shown in diagram
9
36109 Hex nut, gr. A, plain finish,
1
/2”-13
1
Power unit installs on this bracket.
Maintenance prop socket
Power Unit Exploded View on p. 5
EH-610 Power Unit Exploded View on p. 6

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EH-75, EH-76, EH-78 and EH-710 Exploded View & Bill of Materials:
Item
Part no.
Description
Qty.
1
06-514-002
Weldment, frame
EH-75
1
06-514-004 EH-76
06-514-006 EH-78
06-514-008 EH-710
2
06-513-120
Weldment, deck
EH-75
1
06-513-123 EH-76
06-513-126 EH-78
06-513-129 EH-710
3
06-521-001
06-521-002
Assembly, cylinder, hydraulic:
EH-75; EH-76; and EH-78: 2” x 18”
EH-710: 2
1
/2” x 18”
1
4
99-021-933-
001
Cylinder, hydraulic, 2” x 8” piston style with
clevis mounts
1
5
47-112-001 Pin, clevis, 1” x 31/4”
5
6
06-024-015
Guard, side skirt
EH-75
2
06-024-015 EH-76
06-024-013 EH-78
06-024-016 EH-710
Item
Part no.
Description
Qty.
7 65132
Extended prong cotter pin, zinc finish, 3/
16
”
x 3
1
/2”
6
8
06-014-013
Maintenance prop
EH-75
1
06-014-013 EH-76
06-014-011 EH-78
06-014-015 EH-710
9
11211 Bolt, HHCS,
1
/2”-13UNCx2”, zinc plated
1
10
36109 Hex nut, gr. A, plain finish,
1
/2”-13
1
11
11107 Hex bolt, gr. A, zinc finish,
3
/8”-16 x 1
1
/4”
4
12 33008
Flat washer, low carbon, USS, zinc plated,
3
/8”
4
13 37024
Nylon insert lock nut, gr. 2, zinc finish, 3/
8
”-
16
2
14
99-134-003 Tag: model no. capacity, serial no.
1
15
06-112-014 Pin, clevis, 1” x 2
1
/2”
1
16
51441 Star pin anchor,
3
/16” x
3
/16”
2
*17
29-001-251 Bumper, laminated dock, 4.5”x10.25”x10”
2
* Not shown in diagram
Power Unit Exploded View on p. 6
Power unit installs on this bracket.

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Power Unit Exploded View and Bill of Materials
EH-65, EH-66, & EH-68
Item
Part no.
Description
Qty.
1 06-627-003 Subassembly, Manifold, Lift-Lower, Double Acting LIP (detail view on p. 7) 1
2
99-137-033-003
99-137-033-004
99-137-013-002
99-137-008-001
99-137-008-002
Motor-and-Pump subassembly:
208-230V AC, 3-phase, 2HP, 3450rpm, 0.180 displacement
460V AC, 3-phase, 2HP, 3450rpm, 0.180 displacement
208-230V AC, 1-phase, 2HP, 3450rpm, 0.122 displacement
115V AC, 1-phase, 0.75HP, 1725rpm, 0.073 displacement
208-230V AC, 1-phase, 0.75HP, 1725rpm, 0.073 displacement
1
1
1
1
1
3
99-116-001
Suction fitting, mini-manifold
1
4 33687 Lock washer, high collar,
5
/
16
” 4
5
23255
5/16”-18 x 1” socket head cap screw
4
6 06-023-003 Hydraulic tank 1
7 99-145-061 Clamp, worm gear hose, 2
13
/
16
” – 3
3
/
4
” 1
8 99-144-007 O-ring, manifold, 3” outer diameter 1
9
99-031-029
Accessories, hydraulic
1
10
01-116-003
Breather, 1/2” NPT
1
11
99-144-009
O-ring, manifold, 3/4” outer diameter
1
12
99-144-008
O-ring, manifold, 1/2” outer diameter
1
13
99-031-033
Accessories, nipple, close pipe
1
Return to Page 3

Table of Contents 11/5/2018 EH MANUAL
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Power Unit Exploded View and Bill of Materials
EH-610, EH-75, EH-76, EH-78, & EH-710
Item
Part no.
Description
Qty.
1
06-627-004
Subassembly, Manifold, Lift-Lower, Double Acting LIP (detail view on p. 7)
1
2
99-137-033-003
99-137-033-004
99-137-013-002
99-137-008-001
99-137-008-002
Motor-and-Pump subassembly:
208-230V AC, 3-phase, 2HP, 3450rpm, 0.180 displacement
460V AC, 3-phase, 2HP, 3450rpm, 0.180 displacement
208-230V AC, 1-phase, 2HP, 3450rpm, 0.122 displacement
115V AC, 1-phase, 0.75HP, 1725rpm, 0.073 displacement
208-230V AC, 1-phase, 0.75HP, 1725rpm, 0.073 displacement
1
1
1
1
1
3
99-116-001
Suction fitting, mini-manifold
1
4
33687
Lock washer, high collar, 5/16”
4
5
23255
5/16”-18 x 1” socket head cap screw
4
6
06-023-003
Hydraulic tank
1
7
99-145-061
Clamp, worm gear hose, 213/16” – 33/4”
1
8
99-144-007
O-ring, manifold, 3” outer diameter
1
9 99-031-029 Accessories, hydraulic 1
10 01-116-003 Breather,
1
/
2
” NPT 1
11 99-144-009 O-ring, manifold,
3
/
4
” outer diameter 1
12
99-144-008
O-ring, manifold, 1/2” outer diameter
1
13 99-031-033 Accessories, nipple, close pipe 1
Return to Page 4

Table of Contents 11/5/2018 EH MANUAL
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Manifold Exploded View (06-627-003):
EH-65; EH-66; & EH-68
Manifold Exploded View (06-627-004):
EH-610; EH-75; EH-76; EH-78, & EH-710
Item
Part no.
Description
Qty.
1 06-127-005 Manifold, hydraulic 1
2 99-153-020 Pilot-to-close check valve 1
3 99-153-004
Valve pressure relief, 100
bar
1
4 99-153-005
Valve, pressure relief, 33
bar
1
5 99-153-011
Check valve, size 08, nose
inside-out
1
6 99-153-054
Cartridge valve, sequence,
3-way, adjustable
1
7 99-153-055
Cartridge valve, sequence,
2-way with pilot
1
Item
Part no.
Description
Qty.
1
06-127-005
Manifold, hydraulic
1
2
99-153-020
Pilot-to-close check valve
1
3 99-153-004
Valve pressure relief, 100
bar
2
4 99-153-011
Check valve, size 08, nose
inside-out
1
5 99-153-054
Cartridge valve, sequence,
3-way, adjustable
1
6 99-153-055
Cartridge valve, sequence,
2-way with pilot
1
Return to Power Unit Exploded View on Page 5
Return to Power Unit Exploded View on Page 6

Table of Contents 11/5/2018 EH MANUAL
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EH Dock Leveler Electrical Circuit Diagram, 115VAC, 1-phase (06-124-029 rev. B)
Turn off all sources of electrical power and lock and tag them out before beginning this
installation. 2in. conduit is recommended for this installation to allow adequate room for auxiliary equipment that
might be added in the future, such as dock locks and lights.
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.

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EH Dock Leveler Electrical Circuit Diagram, 208-230VAC, 1-phase
(06-124-030 rev. A)
Turn off all sources of electrical power and lock and tag them out before beginning this
installation. 2in. conduit is recommended for this installation to allow adequate room for auxiliary equipment that
might be added in the future, such as dock locks and lights.
Always turn off all power sources before servicing this equipment.
The end-user must provide overcurrent and short circuit protection compliant with NEC guidelines and local
codes.

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EH Dock Leveler Electrical Circuit Diagram, 208, 230, & 460VAC, 3-phase
(06-124-031 rev. A)
Turn off all sources of electrical power and lock and tag them out before beginning this
installation. 2in. conduit is recommended for this installation to allow adequate room for auxiliary equipment that
might be added in the future, such as dock locks and lights.
Always turn off all power sources before servicing this equipment.
The end-user must provide overcurrent and short circuit protection compliant with NEC guidelines and local
codes
.

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Electrical system operation, EH Series
The electric circuit consists of a push-and-hold motor start circuit with thermal protection. The timer circuit
activates and runs the motor for approximately 10 seconds. The timer is actuated by either a limit switch in
automatic mode, or by pressing the RESET button in manual mode.
Hydraulic Circuit Sequence of Operation, EH Series [Numbers in Parentheses () Correspond to Numbers in
the Diagram Above]
EH-series dock levelers are hydraulically powered through a sequence of steps. The pressure required to raise
the deck varies with deck size.However, the pressure always remains below the pressure setting of the lip
sequence valve (6). The sequence valve is factory set to 700 PSI, unless the deck’s weight requires a different
setting, and should not be changed.
Pressing the “RAISE” button activates the pump. Oil pressure increases until it equals the cracking pressure of
the outlet check valve (3). The pressure closes valve (4), a pilot-to-close check valve with a 3:1 ratio. When the pilot
pressure exceeds one third of the inlet pressure, the valve closes.As pressure builds in the deck cylinder, the deck
rises and the lip rotates outward. When the pressure exceeds 40 PSI, the lip’s dump valve, (5), closes. The dump
valve is a normally open “pilot-to-close” directional valve.
As the lip rotates outward, oil from the cap end of the lip cylinder (12) is forced across the lip relief valve (2B).
The pressure setting of the lip relief valve divides oil flow between the deck cylinder (11) and the lip cylinder (12),
and controls the lip’s movement. If the pressure is too low, the lip will not fully extend.If pressure is too high, the lip
will retract too slowly and fail to return to its stowed position. The lip should completely rotate outward when the
deck rises approximately 18 inches.
After the deck cylinder fully extends, hydraulic pressure continues to increase until the lip sequence valve (6)
shifts. When the valve shifts, there is pressure on both sides of the lip cylinder. Because there is more pressure
applied to the cap end of the cylinder than to the rod end, the lip cylinder retracts.
Releasing the RAISE button deactivates the pump and the hydraulic pressure declines. When the pump output
pressure drops below one third of the lift pressure, the pilot-to-close check valve (4) opens and the deck begins to
descend. A pressure-compensated flow control valve (9) controls the deck’s rate of descent. Pressure continues to
decrease after the deck returns to its fully lowered position. When the pressure drops below 40 PSI, the lip dump
valve (5) opens which allows the lip to return to its stowed position.
The hydraulic system includes a safety device, called a velocity fuse, which prevents the deck from collapsing if
system pressure suddenly drops (for example, if the flow control valve fails or a hose is punctured). The fuse is
integrated into the cylinder. When the fuse closes oil cannot flow back to the reservoir.
Figure 4: Hydraulic circuit

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Table of Contents 11/5/2018 EH MANUAL
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RR-65, RR-66, RR-68 and RR-610 Exploded View (Bill of Materials on Following
Page)
Deck shock assembly (attached to underside of item 2)
Used on RR-66, RR-68, RR-610, RR-76, RR-78, & RR-710

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Item Part no. Description Qty. Item Part no. Description Qty.
1
Base frame weldment
1 18 07-146-006 Spring, lip retainer 1
07-514-002
RR-65
07-514-003
RR-66
07-514-004
RR-68
07-514-005
RR-610
2
Deck assembly
1 19 65132 Extended prong cotter pin, zinc finish, 3/16” x
31/2” 4
06-513-020
RR-65
06-513-021
RR-66
06-513-022
RR-68
06-513-023
RR-610
3
07-518-006
Weldment, standard trunnion
1
20
07-112-019
Clevis pin, 3/4” x 23/4”
1
4
07-042-001
D-comp ratchet
1
21
99-117-005
2” diameter x 1/4” steel ring
1
5
07-527-014
Subassembly, chain roller bearing
1
22
06-014-011
Frame, mechanical prop
1
6 07-646-001
Spring, subassembly, 800 cam
RR-65
RR-66
RR-68 & RR-610
6
8
10
23 07-145-018 D-comp limit chain 1
7
07-646-003
Subassembly, spring chain
1
24
99-145-050
Specialty hardware, S-hook
1
8
07-016-029
Counterbalance arm
1
25
36109
Hex nut, gr. A, plain finish, 1/2”-13
2
9
07-145-007
Screw, threaded rod
RR-65
6 26
06-024-015
Guard, side skirt
RR-65
2
07-145-007
RR-66
06-024-015
RR-66
07-145-011
RR-68
06-024-013
RR-68
07-145-012
RR-610
06-024-016
RR-610
10
33016
Flat washer, low carbon, USS, zinc plated, 5/
8
”
12
27
11107
Hex bolt, gr. A, zinc finish, 3/
8
”-16x11/
4
”
4
11
01-145-011
Specialty hardware, eyelet
1
28
33008
Flat washer, low carbon, USS, zinc plated, 3/
8
”
4
12
5546062
Grease zerk, 3/
16
”, straight, drive-in
2
29
99-145-013
Cold shut
3
13
47-112-001
Clevis pin, 1” x 31/
4
”
4
30
99-134-003
Data tag (model, capacity, serial no.)
1
14
28-112-031
3/
4
” x 41/
2
” clevis pin
1
31
51441
Star pin anchor, 3/
16
” x 3/
16
”
2
15 65080 Extended prong cotter pin, zinc finish, 1/8” x 2” 2 32
99-145-113
Specialty hardware, chain, trunnion chain
RR-75
1
99-145-114
RR-76
99-145-115
RR-78
99-145-116
RR-710
16 11119 Hex bolt, gr. A, zinc finish, 3/8”-16 x 4” 1 *33
07-145-014
Specialty hardware, pull chain
RR-75
1
07-145-015
RR-76
07-145-016
RR-78
07-145-017
RR-710
17
37024
Nylon insert lock nut, gr. 2, zinc finish, 3/8”-16
3
*34
29-001-251
Laminated dock bumper, 41/2” x 101/4” x 10”
2
* Not shown in diagram
Item
Part no.
Description
Qty.
36
07-016-065 Bracket, angle, lip rod
1
37
07-026-001 Shaft, lip adjusting rod
1
38
07-016-001 Bracket, shock absorber, formed
2
39
07-016-036 Bracket, lip adjust6ing rod, formed
2
40
07-146-007 Spring, plunger
1
41
33011 Flat washer, USS, plain finish,
1
/2”
4
42
23-112-024 Pin, clevis,
1
/2” x 6”
1
43
07-146-011 Spring/shock absorber
2
44
36219 1” – 8 plain finish hex jam nut
1
45
65080 Extended prong cotter pin, zinc finish,
1
/8” x 2 “
3
46
28-112-040 Clevis pin, 1/2” x 2”
2
47
33446 10Ga machine bushing, 1” x 18ga.
1
RR-65, RR-66, RR-68 and RR-610 Bill of Materials

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RR-75, RR-76, RR-78 and RR-710 Exploded View (Bill of Materials On Following
Page)
Deck shock assembly (attached to underside of item 2)
Used on RR-66, RR-68, RR-610, RR-76, RR-78, & RR-710

Table of Contents 11/5/2018 EH MANUAL
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Item Part no. Description Qty. Item Part no. Description Qty.
1
Base frame weldment
1 18 07-146-006 Spring, lip retainer 1
07-514-006
RR-75
07-514-007 RR-76
07-514-008
RR-78
07-514-009 RR-710
2
Deck assembly
1 19 65132 Extended prong cotter pin, zinc finish, 3/16” x
31/2” 4
06-513-040 RR-75
06-513-041
RR-76
06-513-042 RR-78
06-513-043
RR-710
3
07-518-006 Weldment, standard trunnion
1
20
07-112-019 Clevis pin,
3
/4” x 2
3
/4”
1
4
07-042-001
D-comp ratchet
1
21
99-117-005
2” diameter x 1/
4
” steel ring
1
5
07-527-014 Subassembly, chain roller bearing
1
22
06-014-011 Frame, mechanical prop
1
6
07-646-001
Spring, subassembly, 800 cam
10
23
07-145-018
D-comp limit chain
1
7
07-646-003 Subassembly, spring chain
1
24
99-145-050 Specialty hardware, S-hook
1
8
07-016-029
Counterbalance arm
1
25
36109
Hex nut, gr. A, plain finish, 1/
2
”-13
2
9
07-145-007
Screw, threaded rod
RR-75
10 26
06-024-015
Guard, side skirt
RR-75
2
07-145-007
RR-76
06-024-015
RR-76
07-145-011
RR-78
06-024-013
RR-78
07-145-012 RR-710 06-024-016 RR-710
10
33016 Flat washer, low carbon, USS, zinc plated,
5
/8”
20
27
11107 Hex bolt, gr. A, zinc finish,
3
/8”-16x1
1
/4”
4
11
01-145-011
Specialty hardware, eyelet
1
28
33008
Flat washer, low carbon, USS, zinc plated, 3/
8
”
4
12
5546062
Grease zerk, 3/16”, straight, drive-in
2
29
99-145-013
Cold shut
3
13
47-112-001 Clevis pin, 1” x 3
1
/4”
4
30
99-134-003 Data tag (model, capacity, serial no.)
1
14
28-112-031
3
/4” x 4
1
/2” clevis pin
1
31
51441 Star pin anchor,
3
/16” x
3
/16”
2
15 65080 Extended prong cotter pin, zinc finish, 1/8” x 2” 2 32
99-145-113
Specialty hardware, chain, trunnion chain
RR-75
1
RR-76
RR-78
R-710
16 11119 Hex bolt, gr. A, zinc finish, 3/8”-16 x 4” 1 *33
07-145-014
Specialty hardware, pull chain
RR-75
1
RR-76
RR-78
RR-710
17 37024
Nylon insert lock nut, gr. 2, zinc finish, 3/
8
”-16
RR-75
3 *34 29-001-251 Laminated dock bumper, 41/2” x 101/4” x 10” 2
RR-76, RR-78, & RR-710
5
* Not shown in diagram
Item
Part no.
Description
Qty.
36
07-016-065 Bracket, angle, lip rod
1
37
07-026-001 Shaft, lip adjusting rod
1
38
07-016-001 Bracket, shock absorber, formed
2
39
07-016-036 Bracket, lip adjust6ing rod, formed
2
40
07-146-007 Spring, plunger
1
41
33011 Flat washer, USS, plain finish,
1
/2”
4
42
23-112-024 Pin, clevis,
1
/2” x 6”
1
43
07-146-011 Spring/shock absorber
2
44
36219 1” – 8 plain finish hex jam nut
1
45
65080 Extended prong cotter pin, zinc finish,
1
/8” x 2 “
3
46
28-112-040 Clevis pin, 1/2” x 2”
2
47
33446 10Ga machine bushing, 1” x 18ga.
1
RR-75, RR-76, RR-78 and RR-710 Bill of Materials

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Table of Contents Copyright 2018 Vestil Manufacturing Corp. Page 17 of 25
Installation
Never work under a dock leveler unless the maintenance prop is installed in its socket.
The Dock Leveler must be level to function properly.
Do not modify the dock leveler to fit in a pit.
1. Measure the pit’s dimensions.
2. Using steel shims, position shims under the
frame to prevent frame distortions and flex so
the Dock Leveler’s final, resting position meets
the following:
•The Dock Leveler should be level.
•The Dock Leveler should be against the
rear pit curb angle.
•The platform should be centered from side
to side within the pit.
•The Dock Leveler’s rear channel must be
flush with the rear curb angle.
Do not allow the Dock Leveler
to be above the pit’s rear curb
angle.
3. With the shims in position, skip weld the rear
hinge channel to the rear curb angel, 4 inches
every 8 inches.
4. Grind welds smooth.
Operation, EH Series
The Dock Leveler has an electric motor directly
coupled to a gear-type hydraulic pump to
pressurize the hydraulic system. Hydraulic
pressure allows the cylinders to lift the platform
and extend the lip. The hydraulic control
components are housed within a hydraulic
manifold, bolted directly onto the gear pump. All
hydraulic components are rated for 3,000 psi
working pressure.
Notable power unit parts include:
1. Electric motor: The A/C motor operates on either single-phase or 3-phase AC, depending on the motor
ordered.
2. Gear pump: The pump shaft is coupled directly to the electric motor shaft.
3. Pressure relief valve: At pressures greater than 1,500 psi, fluid flows back into the reservoir.
4. Lip relief valve: The adjustable valve controls the Lip’s retract rate after the platform has risen.
5. Check valve: It prevents fluid backflow through the pump.
6. Pilot-operated check valve: This valve is closed while the leveler rises and it opens when the pilot pressure
drops to less than 1/3 of the inlet pressure, causing the deck to descend.
NOTE:
Pit bottom
should slope
¼ in. The
rear wall pit
depth should
be 24¾in.

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7. Pilot-to-close, two-position valve: Normally open, this valve closes when the pilot pressure exceeds 40 psi.
It holds the lip in the extended position until either the platform or the lip is physically supported.
8. Pilot-operated sequence valve: When system pressure reaches ~700 psi, the valve shifts to extend the lip.
9. Pressure-compensated flow control valve: Located in the deck cylinder’s port, it regulates the deck’s lowering rate.
10. Hydraulic cylinders:
a. Deck cylinder - A displacement-style cylinder with a bleeder valve located at the top end raises and
lowers the deck. The bleeder valve allows air to be removed from the hydraulic system.
b. Lip cylinder - A double-acting cylinder extends and retracts the Lip.
11. Safety velocity fuse: Located in the deck cylinder’s hose port, it closes quickly in the event of a catastrophic
hose failure to prevent the deck from collapsing. The deck remains elevated until pressure is reapplied to
the cylinder.
12. 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.
Pressing the RAISE button activates the dock leveler. The motor turns and spins the hydraulic gear pump. Oil is
drawn from the reservoir through the suction filter and into the pump. The pump forces pressurized oil through the
hydraulic manifold to the deck cylinder. Pressure first acts on the deck cylinder causing it to extend, and then,
causes the lip cylinder to extend. When the RAISE button is released, the lip remains extended and the deck
descends at a rate determined by the pressure-compensated flow control valve. The lip eventually rests on the back
end of the trailer. If the deck descends and contacts the supporting frame, a limit switch is engaged. When in
“AUTO” mode, the limit switch causes the leveler to reset itself to the resting/cross-traffic position by turning on the
motor for approximately 3 seconds. This brief period is long enough to raise the deck and retract the lip. If the unit
is in “MANUAL” mode, engaging the limit switch only causes the lip to drop.
Issues & Solutions:additional solutions are found under Inspections and Maintenance.
Before beginning work to resolve either of the issues identified below, unload the dock leveler and apply the
maintenance prop. To install the prop, press and hold the RAISE button. Continue to hold the button after the deck
reaches its maximum elevation. A second person should install the free end of the maintenance prop into the socket
on the underside of the deck. Release the RAISE button to allow the maintenance prop to seat firmly in the socket.
1. If the deck does not rise while the pump runs, remove the pilot-to-close check valve. Inspect and clean the
valve in the following manner:
a) Locate the pilot-to-close check valve, which is identified with the number “4” on the hydraulic manifold, and
remove it from the manifold.
b) Inspect the valve for contaminants. Also inspect the o-rings and back-up washers for cuts, tears, or other damage.
c) Immerse the valve in mineral spirits or kerosene. Use a thin tool, like a small screwdriver or a small hex wrench,
to push the check ball in several times from the bottom end of the valve. The ball should move freely. If it sticks
in, the valve might be defective. Replace the valve if the ball still does not move freely after cleaning. Blow the
valve off with compressed air, while simultaneously pushing the check ball in-and-out.
d) Inspect the bottom of the valve cavity in the manifold (the chamber in the manifold that houses the valve) for
debris. Clean the valve cavity as needed.
e) Reinstall the valve. Tighten the valve in the manifold to approximately 20 lb-ft of torque.
2. If the platform lowers extremely slowly, or not at all, the velocity fuse of the deck cylinder might be closing.
This is typically caused by air in the cylinder. To correct the problem, bleed air from the hydraulic system:
a) Hold a rag over the bleeder valve of the deck cylinder. The valve looks like a grease zirk. Use a ¼ in.
wrench to turn the valve about 1/2 turn. Jog the motor by quickly pressing and releasing the RAISE button.
Oil and air will sputter from the valve. Continue this process until air no longer escapes from the valve; then
close the valve.
Modes of Operation, EH Series
The leveler can be operated in either of two modes—automatic or manual. Before using the leveler, confirm normal
operation by running the leveler through a complete cycle:
1) Automatic mode: Press and hold the “RAISE” button on the remote control box. The deck will rise to its maximum
elevation and then the lip will extend. When the lip fully extends, release the “RAISE” button. The deck should

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lower smoothly until the lip rests on the truck bed. The deck will descend to the fully lowered configuration when the
truck pulls away from the dock leaving the lip unsupported. The power unit will restart and raise the deck to
maximum elevation; the lip will lower; the power unit will shut off; and the deck will settle in to its stored position flush
with the surrounding surface.
DO NOT operate the dock leveler in automatic mode if the truck bed is below the level of the dock.
2) Manual mode: Use the leveler in this mode if a truck bed is below dock level. In manual mode, the dock leveler
functions nearly identically to automatic mode. However, the power unit does not automatically start to return the
deck to the stored position when the leveler reaches the lower limit. Instead, after a truck leaves the deck descends
to its fully lowered position and the lip drops to avoid being damaged by the next truck.
“RESET” button: press the button to automatically return the leveler to the stored position while in manual mode.
3) To put the leveler into stored configuration, from either manual or automatic mode, while a truck occupies the
loading dock:
a) Press and hold the “RAISE” button until the deck reaches its maximum elevation;
b) Release the button;
c) The leveler will return to its stored position.
4) (Optional) Lip control: “LIP” button on the remote control extends the lip. First, press the “RAISE” button to
elevate the deck sufficiently that the lip will not contact the back of the truck as it extends; then press the “LIP” button
to extend the lip. Release the “RAISE” and “LIP” buttons and the lip will settle on the bed of the truck. If the RAISE
button is released but you continue to hold the LIP button, the leveler will maintain its position. Release the LIP
button to allow the lip to settle on the truck bed.
5) Emergency stop button: Pressing this button cuts all power to the unit. If the emergency stop button is
pressed at any time during the cycle of operation, the leveler will return to its stored position. Pull out the
emergency stop button to reset the switch and restore power.
Operation, RR Series
Do not leave any cargo or equipment on the Dock Leveler deck at any time.
Before Use
1. When the truck is against the Dock Lever’s bumpers, chock the truck’s wheels on both sides.
2. Verify the truck’s cargo area has ample room to accept the Dock Leveler lip. The lip will require about twelve
inches (12”) beyond the bumper for the standard sixteen inch (16”) lip.
3. If the cargo area is not sufficiently clear, clear the area.
4. Verify the lip is in the vertical position and securely behind the lip keepers.
Verify the people and equipment are clear of the leveler. The deck will rise and the lip will
automatically extend into the trailer.
5. If the deck is below dock height, release the pull and raise the deck a few inches above the dock floor.
6. Walk on the deck to lower it until the entire lip is setting on top of the trailer’s floor.
7. For Models with the ES Option: If the trailer floor is below the dock’s floor, the Emergency Stop’s safety legs
need to be retracted. Pull the ES ring, the rear-most ring on the Dock Leveler, to retract the safety legs and
completely lower the lip onto the trailer’s floor. Release the ES ring.
8. Load / unload the cargo.
After use
If the truck departs before the dock leveler is retracted, the lip will fall to the down position. The
lip might not be in the keepers.
1. Pull the recessed handle, releasing the deck, until the lip clears the truck.
2. After the deck completely retracts, walk on the deck until it returns to floor height.
3. Verify the lip is behind the keepers.
4. The trailer’s overhead door and/or the building may now be closed and the wheel chocks removed.

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Troubleshooting, EH Series
The following information is provided to diagnose and correct issues with EH-series dock levelers.
Issue
Cause
Solution
Motor does not run and
deck does not rise
1. Emergency stop button activated
(pressed)
2. Transformer fuse blown or tripped
circuit breaker
3. No supply voltage
4. Bad control transformer
5. Malfunctioning motor relay coil
6. Malfunctioning RAISE push button
7. Thermal-overload switch tripped
1. Pull up emergency stop button.
2. Replace fuse or reset circuit
breaker.
3. Test voltage with meter, Check
fuses, breakers, and overloads.
4. Check for 24VAC; replace if bad.
5. Test with meter; replace if bad.
6. Test with meter; replace if bad.
7. Wait for motor to cool.
Motor runs, but deck does
not rise and don’t hear
motor running
1. Motor rotation is wrong
2. Pumps failing to pressurize
hydraulic system
3. Load on the deck (leveler will only
lift its own weight)
1. Confirm that motor turns clockwise
opposite the shaft end.
2. Contact the factory.
3. Unload the deck.
Motor hums 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 lost
one phase (3-phase motors)
4. Pressure relief valve opening at full
system pressure.
5. Pilot-to-close check valve failing to
close
6. Load applied to deck
1. Check power installation. Check
incoming voltage while motor running.
2. Check voltage on all legs; check
fuses; repair as necessary.
4. Check for frame damage or binding
at the deck hinge, etc. Check for
platform overload condition.
5. Remove valve and inspect.
6. Remove load from deck.
Deck does not automatically
return to stored position
when truck leaves dock
1. Auto/Manual switch in manual
position
2. Defective limit switch (deck fails to
engage the below dock limit switch, or
switch malfunctioning
3. Defective timer, or timer period set
too short
4. Bad (AUTO/Manual) selector switch
contact block
1. Move switch to “auto” position
2. Change auto/manual switch to
Manual mode and press RESET
button.
3. Check the timer setting. Test for
timer output and replace if bad.
4. Test with meter; replace if bad.
Deck does not lower
1. Velocity fuse, item 10, in deck
cylinder is locked.
2. Pressure-compensated flow control
valve stuck.
1. Press and release RAISE button to
unlock fuse. If problem persists, check
for air in oil.
2. Replace valve.
Lip retracts too quickly
causing rough action
Lip relief valve, item #2B, pressure
setting too low
Turn adjustment on valve clockwise
(quarter turn or less)
Lip does not retract
Lip relief valve, item #2B, pressure
setting too high
Turn adjustment on valve
counterclockwise (quarter turn or less)
Lip retracts before
contacting truck bed
1. Lip relief valve, item #2B, pressure
setting too low
2. Faulty lip cylinder, item #12,
3. Faulty power unit
1. Turn adjustment on valve clockwise
(quarter turn or less)
2. Repair or replace
3. Repair or replace
Lip does not extend when
deck reaches top position
1. Defective lip cylinder
2. Faulty power unit
1. Repair or replace
2. Repair or replace