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Ramp (SDG) Installation

Congratulations! You have purchased a new Steel Yard Ramp for your company. Like any piece of equipment or machinery, this Steel Yard Ramp will help you tremendously, but it also needs to be operated and maintained properly to achieve maximum benefits. Here are some important tips and tricks to get the most out of your new Steel Yard Ramp while also maintaining maximum safety for your workers.

Steel Yard Ramp Dos and Don’ts

Do traverse the ramp with the forks towards the dock or the elevated end.

Do not:

• Exceed 5 mph when driving on the ramp.
• Exceed the rated capacity of the ramp.
• Travel on the ramp unless it is securely connected to the dock or the carrier floor. Make sure there is 4” of overlap onto the doc or carrier floor.
• Use the ramp without safety chains.
• Use the ramp when people, equipment, or material are in front of the ramp or the lip.
• Use the ramp if it looks damaged – tell your supervisor immediately if it looks like the ramp has sustained damage.
• Keep going if you have questions. It is much better to stop and take the time to ask your supervisor.
• Attempt to lift or lower the ramp lip in any way that is not described in our manual.
• Make sure all body parts are kept clear of the ramp at all times.

Your Responsibilities as Steel Yard Ramp Owner

Copperloy does our best to manufacture the best possible yard ramps, and we ensure their strength and safety when we are ready to deliver them. From the point the yard ramp reaches your plant, it is up to you to make sure the ramp continues to perform at capacity.

• It is up to you to make sure all of your employees are trained adequately. While our Steel Yard Ramps are amazing tools, there is danger in any dock loading/unloading situation. The more knowledgeable your employees are, the safer everyone will be.

• Make sure everything is labeled correctly and that manuals are easily accessible to all personnel.

• We create a maintenance schedule for our Steel Yard Ramps just like car manufacturers create maintenance schedules for their vehicles. The closer you follow that schedule, the more performance you will get out of the yard ramp.

• Do not try to save money or time by continuing to use a damaged Steel Yard Ramp. In the end, you will only be creating a potentially unsafe or disruptive situation. It is much better to take a pause and get your yard ramp back into working order.

• Along similar lines, do not get creative with how you use the yard ramp. Modifications are not advisable, especially if you are trying to create a work-around where a problem exists.

• Copperloy sets specific standards for the vertical lifting range and the vertical lifting range. Make sure as the owner that these standards are not exceeded.

• Talk to us about what your plans are for your Steel Yard Ramp before purchasing. In particular, let us know the applications you are planning for your yard ramp, the types of equipment that will be traveling on the yard ramp, and more. We will be able to customize a solution for you so that your workers and all loads being picked up or delivered will remain safe.

How to Unload a Flatbed Trailer

There are six easy steps involved in safely unloading a flatbed trailer. You can see more detail about the six steps along with drawings and diagrams in our full manual.

Step 1: Wait for the carrier to come to a complete stop. Once the brakes are set you can remove the hold down straps and release the ramp chains.

Step 2: Now position the lift trucks on both sides of the ramp, spreading the forks as widely as you can. The truck must have sufficient capacity to lift the ramp at a distance near the fork end. You can look at the shippers B/L to see what the actual weight of your ramp is.

Step 3: Slowly move the lift trucks forward. Be careful that not more than 9” of the fork tip is engaging with the ramp side girder.

Step 4: Take your time and lift the ramp until it has cleared all supports as well as the carrier.

Step 5: The carrier can now pull forward and get completely clear of the ramp. Once this has happened the ramp can slowly be moved to the ground.

Step 6: Verify your hydraulic system is working. Refer to our full manual for details. Be careful about this step. Some ramps have a plug in the breather location on the pump. If this plug does not get changed out, the hydraulic system can be damaged by back pressure. The pressure in the tank can even harm personnel.

How to Unload a Box Trailer

Unloading a box trailer is quite different from unloading a flatbed trailer. Do not make assumptions about the proper steps. Check our full manual for details!

Step 1: Remove all of the straps and verify the pump is in the open position.

Step 2: Now it’s time to insert the positioning sleeve into the ramp and attach the fork truck to that position sleeve. Please reference our manual for full instructions on how to do this.

Step 3: Using the fork truck, raise the ramp until it is high enough to clear the container floor. Once you have accomplished that it’s time to slowly back the ramp out until the wheels of the yard ramp are even with the back of the truck. Make sure the driver backs out in an entirely straight line while doing this. Before beginning this process, make sure the numbers are right for the fork truck to be able to lift the yard ramp safely. Missing this vital step can result in damage to the load or injury to personnel.

Step 4: Now that the ramp is backed out the wheels should be blocked in place.

Step 5: When you are sure the fork truck is attached securely to the positioning sleeve, raise the ramp until the side rails are parallel to the ground. If you have two fork trucks available go ahead and skip to step 7. If you have three fork trucks available take a look at the next step.

Step 6: While one fork truck is holding the positioning sleeve, the other two should be on each side of the ramp, centered to the ramp and under the side rails. Make adjustments until the ramp can be lifted with the weight centered on the fork trucks. Keep lifting the ramp until the wheels are clear of the truck floor, and then move ahead to step 11.

Step 7: If you only have two fork trucks, you need to pay attention to this step. First you need to block up the back side of the ramp where the fork truck and the positioning sleeve are connected. Again, you need to make sure that whatever you use to block up the ramp is strong enough to actually handle the ramp’s full weight. Before removing the fork truck verify that the blocking is secure and steady. This is for everyone’s safety as well as for the safety of the load.

Step 8: Now you can remove the fork truck from the positioning sleeve.

Step 9: With the fork truck disconnected from the positioning sleeve, you now have two fork trucks available. They can be positioned at the center of the ramp under the side rails. Keep adjusting the ramp until it is centered on the fork trucks. The ramp should be lifted until the wheels clear the truck floor.

Step 10: The blocking can now be removed.

Step 11: Now everyone is caught up to the same step regardless of how many fork trucks you have available. The truck should pull forward slowly until the ramp clears the truck. Then the ramp can be slowly lowered to the ground. Take special note of the pump reservoir. For moving purposes, this reservoir is covered with a plug, but in order to prevent leakage, this must be covered with a vent cap when in use. Be careful when you take this step and be sure to reference our full manual. Please note that if you do not take this very important step back pressure can build in the tank which can damage the ramp or cause injuries to workers.

Step 12: Verify that the hydraulic system is working properly. Please reference the OPERATION section of our full manual for instructions on how to do this safely and correctly. If you see any issues please contact us immediately. In order to fully test the hydraulic system we recommend you raise and lower the ramp a few times so that all of the air is squeezed out of the hydraulic system.

Step 13: Phew. It’s finally time to use your new Steel Yard Ramp. Make sure you inspect it one more time before beginning usage. Remember, if it is damaged, please contact us immediately. Do not use a damaged steel yard ramp.

Installing the Dock to Ground Ramp

Our full manual is an extremely important reference when installing a dock to ground ramp. Make sure you reference the manual and be sure you understand it fully before installing or operating. Please contact your supervisor or us with any questions you have. We are going to summarize the four steps you need to take to complete this process, but it is important to use the manual because the additional drawings and diagrams will assist in the job.

Step 1: Make sure the site is fully prepared before you install the ramp. This may entail pouring concrete for a footer or apron depending on your local codes and conditions. Needless to say, you want to make sure the concrete has 100% cured before installing the ramp.

Step 2: Install the Safety Chain Brackets:

Our manual illustrates how to locate the safety chain brackets. You can use the bracket to locate the mounting hole locations. You will use the ½” diameter anchor bolts (not included) to secure the safety chain brackets to the dock wall. Please note, all anchor bolt lengths need to suit local codes and conditions. This will be determined by the type and depth of the concrete. If the anchor bolts are not the correct size, the safety chain brackets can fail, which will cause disastrous results.

Step 3: Placing Ramp:

Now it’s time to place the ramp. Make sure you square up the ramp on the doc’s surface and keep the bumper plates as close to the dock face as you can. This will help prevent the ramp from moving while in operation. Please reference our full manual for illustrations of what this setup is supposed to look like.

Step 4: Attach the Safety Chains

You will see that we have supplied 9/16” bolts, washers, and nuts. These are used for attaching the ramp. The other end of the chain that is not attached to the ramp will slide through the burnout in the chain bracket that is shaped like a plus sign. While you are holding the bracket against the wall, you want to adjust the chain so it has as little slack as possible. The tighter the chain, the more likely you will be to have your ramp pull away from the face of the doc.

Operating the Mobile Ramp

Please make sure our full manual is fully accessible to everyone who will be working with your steel yard ramp. This is just a summary, but there is much more detailed information in our manual.

Step 1: Elevate

When you are ready to elevate your ramp, you first need to be sure you close the pump release valve by turning your lever clockwise. You should not need to force this valve. If you are having trouble moving it please contact a supervisor. The pump is on the side of the ramp. Use caution. Overturning can damage the valve seat. Now you take the pump handle from its storage bracket and place it into the opening on the pump. You’ll need to raise and lower this handle to get the pump started. It may take a few minutes until you are feeling the full pressure in the handle. Be very careful to remember to pick up the handle and not leave it in the pumping position. Personnel can get injured or loads can get damaged if this step is forgotten.

Step 2: Position

Move the ramp until the lip apron is completely covering the carrier floor and until the stop plates are flush against the carrier door sill. Always position the ramp to the trailer – do NOT try to back the trailers up against the ramp. Slowly open the pump release valve by turning counter clockwise. As you do this the ramp will slowly settle onto the carrier floor.

Please make sure the release valve is left in the open position as you get ready to use your Mobile Container Ramp. If you do not serious injuries or damage can occur.

Our ramps are manufactured so that the underside and the hydraulics can float freely and nothing of weight is laid upon the running gear. The ramp is like a span bridge and it is only supported at the ends. Our manual section on the positioning sleeve offers more detail on this topic.

Step 3: Secure

You will see this word a lot in any of our operation manuals. Securing a steel yard ramp or a mobile container ramp is one of the most important facets of installation and operation. To secure your mobile ramp, loop the two safety chains we supply around the carrier frame and lock them into place with grab hooks. Try to allow as little slack as possible. Please note: if the chains are missing or damaged or if you can’t for some reason connect the chains securely, do not use the ramp. If you are feeling like the ramp is not 100% secure with the chains in use, feel free to chock the carrier wheels and/or use support jacks under the trailer. As always, follow OSHA requirements in this process. Whatever you do, remember the most important thing is to make sure the ramp and the carrier do not separate during operation.

If you are going to be using the ramp at a loading dock or another fixed platform, make sure that platform has hook or eye devices that are totally secured so that they can hold the container ramp chains.

Step 4: Operation

Again, we want to reiterate how important it is to make sure the pump release vale is OPEN before operation begins. That is always step 1, even though we are talking about step 4.

Now approach the ramp in low gear and maintain an even rate of climbing speed. Please see our full manual for detailed diagrams and illustrations. Always be sure the fork truck is pointed with the forks toward the carrier end, and when ascending or descending, the truck should be in the lowest gear. Make sure the fork truck driver understands this before beginning operation.

As always, be sure to follow all lift truck safety and operation standards of ASME/ANSI B56.1-1993 and any new addenda. Once the fork truck is moving on the ramp do not stop, start, or change speeds. This can cause damage or serious injuries.

Step 5: Loading/Unloading Completion

When loading or unloading is complete, the first step is to make sure the lift trick is off and completely clear from the ramp. All safety chains can be unhooked once the truck is off, and the ramp can be disconnected from the carrier. Now close the pump release valve by turning it clockwise. Remember, you should not need to exert a lot of strength to do this. If it Is not working easily ask your supervisor for assistance. Overturning can cause damage or injury.

Slide the pump handle into the pump handle adapter and pump a few times to get the ramp a few inches above the carrier floor. Once this is done the carrier can pull away or, using the positioning sleeve, it can move the ramp to the next location. Once the ramp starts moving, or once the carrier pulls away, it is essential all personnel and objects are moved out of the way.
Please reference or full manual for more detailed information on the positioning sleeve and the towbar. Remember, this manual should be easily accessible to all personnel!

Make sure you do not let the carrier pull away with the ramp just falling to the ground. Although a steel yard ramp is a sturdy piece of equipment, this kind of activity is a great way to damage the ramp or cause injury to workers.

Step 6: Lowering the Ramp

We want to reiterate again when raising or lowering your yard ramp or mobile ramp, all personnel and objects should be well clear of the area. To lower the ramp, slowly open the release valve by turning the knob counter clockwise. Leave the valve in this open position.

When you are not using your ramp, it should be stored in the lower position so as to avoid injury the next time it is needed. When the ramp is in the lowered position, do not take shortcuts by trying to raise it with your hands. All body parts should always be clear of the space between the ground and the ramp or towbar.

Step 7: Towing (Towbar)

Copperloy makes available an optional towbar accessory. Our manual fully details how to connect this towbar to the ramp.

Step 8: Positioning Sleeve

We highly encourage you to reference the full manual so that you can see all diagrams and illustrations, which help illustrate the points here.

When positioning the ramp, never exceed 2 mph. If you try to travel at higher speeds the positioning sleeve could be damaged, which can cause many other serious problems. Whenever the ramp is supported by the positioning sleeve all hands, feet, or any other body parts should be well clear. Before starting the process of using the positioning sleeve, make sure it is not damaged in any way. A positioning sleeve will be supplied with all of our steel framer amps.

Please make sure your team understands the difference between the towbar and the positioning sleeve. The positioning sleeve is only for positioning and traveling for very short distances. The positioning sleeve should not be rotated past 90º from the center.

Believe it or not, our positioning sleeves can be used for up to several hundred yards. Talk to us before you purchase your yard ramp so we can ensure everything we provide will meet your application needs.

Maintenance

The better you do at maintaining your yard ramp, the better it will work for you, and the longer it will last. Our full manual outlines detailed instructions for how to properly maintain your Copperloy steel yard ramp. Here are some highlights.

Blocking

Most of the maintenance a ramp needs will be on the underside. For everyone’s safety, make sure the ramp is securely blocked before anyone situates to work on the ramp. For maintenance work, the support should be placed under the lip apron end. For these purposes load bearing structures like loading docks are best. Avoid using lumber or steel members. The locking chains we supply should also be used to hold the ramp secure through maintenance. As always make sure all objects are clear. Be especially cautious around the hydraulic system.

Along with securing the ramp 100%, make sure the hydraulic system is open and all the pressure has been relieved. Do this before breaking any connections or removing any hoses. Otherwise damage or injury can occur.

Maintenance Checklist

The following items should be seen to regularly.

Hydraulic Hand Pump/Reservoir

We fill up the hydraulic system and fill the vent with a plug for shipping. As has been mentioned before, it is very important to replace this plug with the vent cap before you start using the ramp.

Filling Tank

There are a few different steps involved in filling the tank. First, make sure the ramp is in the fully lowered position. Next, remove the vent cap from the pump reservoir. Our full manual offers more detail on how to complete this process. Be sure you clean away any dirt or grime so that the fluid in the reservoir has no chance to get contaminated. Contamination in the hydraulic system is one of the leading causes of malfunction in a mobile yard ramp.

Once the tank is cleaned up, use a funnel to fill the tank through that vent cap hole area. The oil should be up to a half inch to an inch from the top. You should use a hydraulic oil 46 weight or something very comparable. Make sure what you are using IS hydraulic oil. Any other kind fo oil will void your warranty. We use Citgo AW-46 when we first fill the filling tank before shipping.

Make sure you do not allow the ramp to raise at all when you are working on the hydraulic system.

Line Bleeding

It is important to make sure there is no excess air in your hydraulic system. Normally, just lowering and raising the ramp a few times is enough to work out any extra air bubbles, but if you still feel like there is too much air in the system, you will need to bleed the system of entrapped air. It sounds scary, but it’s just a few simple steps.

First, make sure the pump is at its fully lowered position. Then, loosen the hos e fitting at the cylinder. Make sure the release valve is CLOSED. Slowly operate the pump until the oil flows without any sign of air bubbles. Now remember to tighten the hose fitting and add more oil so your tank is back to the proper level of fullness.

Removing the Hydraulic Cylinder

Before removing your hydraulic cylinder, you will need to elevate the lip end of the ramp and reference our blocking instructions outlined in the full manual. First and foremost, if the ramp is not in the lowest position, use the release valve to lower it onto the support. Once the ramp is fully blocked and secure, disconnect the hose from the cylinder. You can also release the cylinder retainer pins and spacers at this time.

Now it’s time to put in your new cylinder. First, pull out the rod. If you have trouble with this step, the thing to do is to make sure the hydraulic port is open and clear. If you are still having difficulties it is time to ask your supervisor for help. Place the cylinder in position, and although it should be obvious, make sure the top is at the top. You can now put back the pins and spacers. Replace the hydraulic line but do not tighten the fitting just yet. First, with the release valve still in that open position, use the fork truck to raise the lip end of the ramp so it is clear of the support. Remove the support out of the way so you can now lower the ramp to it slowest possible position. Reference the previous section on how to bleed the hydraulic system to make sure you aren’t trapping any extra air in the system, tighten the hose fittings, and add the oil till you are at the optimum oil levels.

Removing the Hydraulic Pump

Once again, the ramp needs to be completely lowered before you start this process. Once the ramp is positioned properly, disconnect the hose from the pump. You’ll see four hex nuts at the back of the pump reservoir – remove those, and you will be removing the pump from the side of the ramp. To replace the pump just retighten the four hex nuts and make sure the pump is securely connected to the side of the ramp. Bleed the hydraulic lines and add oil as needed.

Replacing the Grating

Be very careful not to damage the crossmember during this process, because a damaged crossmember means the structural integrity of the ramp is compromised. Our full manual offers more detailed descriptions along with diagrams and illustrations.

You should not need to remove the entire piece of grating. We have manufactured the grating so smaller lengths can be replaced. Make sure you cut the grating at the center of the crossmember, and always keep both ends of the grating supported by the crossmember. Be sure to clean all areas by grinding flush and then inspect to make sure there is no damage.

If you need to install new grating, start by cutting grating to fit the area you need to replace. Don’t leave more than ¼” clearance on both ends. Place the grating over the crossmembers and make sure the spacing is right. Now weld two-inch-long welds every other crossmember six times, and make sure the welds are evenly spaced from side to side. Weld the ends as well. The welding should be done from the grating to the top of the crossmember, all the while making sure the grating is kept flat against the crossmember. Once everything is welded into place, touch up all the areas with rust proofing and you are done!

Removing the Wheels

Please reference the full manual to see detailed instructions on how to perform this task. Before reassembling the wheels, make sure any rust is cleaned away with emery cloth so that any new bearings won’t get damaged.

Whenever you are getting ready to work on the wheel or axel assembly, regardless of the specific part, the ramp should be in the lowest possible position, the release valve must be open, and the ramp should be lifted so that the wheels are slightly off the ground. Please reference our full manual for more detailed instructions and diagrams.

Steel Container Ramp Frame

The steel frame’s enamel finish should be inspected every year. If you find any rust, you need to try to wire brush it away, prime paint, and then add a top coat of paint that is also rust-inhibiting. No matter how well you take care of your steel yard ramp, it will start to rust eventually. With just a little touch-up it will remain fully functional for many years to come.