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Poweramp EH Manual Sept2013

1. U U UU UU UU UU LLULLU 12 Install Control Panel and Wiring 18 Put New Leveler Into Service J J J 19 Operation Operating Instructions J J J J T J J 20 Ramp Loading Unloading Instructions 21 Loading Unloading Instructions 22 Maintenance Service Dock Leveler Safely T 23 Periodic Maintenancoes U 24 Adjustments Valve Adjustment Procedure J J J J J 27 Adjust Auto Return To Dock 30 Troubleshooting MORO UNS SOO CN LIL T 33 Parts CONOIS c 37 Frame and 38 Hydraulic 2 40 Power Pack Assembly 42 Operation Instruction cc 46 2 47 Miscellaneous El cirical AM P 48 Customer Information J J J rere nnn 49
2. POWERAMP EH SERIES Dock Leveler Owner s User s Manual POWERAMP Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0004 Copyright 2013 Sept 2013 Table of Contents Page Safety Recognize Safety Information J 1 General Operational Safety Precautions 1 Operational Safety Precautions T J J 2 Maintenance Safety Precautions 4 ALCL Decal 5 Owner s User s Responsibilities J T J J 6 Introduction General Information U uu 7 Dock Leveler Stock Specifications 7 Component Identification J pa Run 8 liii fee e 8 Installation Placard InsirucGlions 9 Prepare u asua 10 Prepare Dock Leveler 11 Install Dock Leveler
3. Raise platform fully and engage the maintenance prop in the service position Allow platform to rest on the prop so the lip will fully fold until it contacts the lip stops 2 Turn OFF all electrical power to the dock leveler Attach safety lockout and Tag Out devices 4111 0004 Sept 2013 IMPORTANT Anytime proximity switch and target are adjusted always check for interference between target and switch before operating the leveler Damage to switch will occur if the target contacts the switch The maximum torque for proximity switch lock nuts is 10 N m 7 lb ft Damage to switch will occur if maximum torque is exceeded A 1 4 in 6 4 mm C 1 in 25 4 mm Approximate Approximate B Target D Lock Nuts E Proximity Switch NOTE Distances A and C are typical factory settings Use these dimensions only as a starting point when adjusting the proximity switch and target especially if switch and or target have been replaced When dimensions A and C are obtained the proximity switch and target may need finer adjustments to get the ARTD to operate satisfactorily 3 Loosen lock nuts D Adjust proximity switch E to obtain distance A Tighten lock nuts 4 Bend target B as needed to obtain distance C Recheck distance A and readjust if necessary NOTE At least two people may be required to manually move the lip 5 After adjusting proximity switch and target slowly move the lip up
4. uuu E Back Cover Recognize Safety Information Safety Alert Symbol The Safety Alert Symbol identifies important safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury or death Follow the instructions in the safety message The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury IMPORTANT The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 0004 Sept 2013 SAFETY General Operational Safety Precautions Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or guard is removed or disconnected Never remove DANGER WARNING or CAUTION signs or Decal s on the equipment unless replacing them Ca hy oe LLG Do not start the equipment until all unauthorized personnel in the area have been warned and hav
5. G pulled tight across the pit opening directly over the shim locations 3 Verify that each shim stack is at the correct height by measuring distance K top of shim stack L to dock floor Distance K must equal the dock leveler height A 4111 0004 Sept 2013 INSTALLATION 4 For all EH models put a 1 4 in 6 6 mm thick shim at locations C and D NOTE A 1 4 in 6 6 mm thick shim at locations C and D is used only as a starting point The final shim stack height will be determined after dock leveler is lowered into the pit The dock leveler is heavy Use chains and a lifting device with the appropriate lifting capacity and reach Failure to do so may result in damage to dock leveler and or serious personal injury or death 5 Using an appropriate lifting device connected to the lifting brackets lower dock leveler into the pit so rear hinge frame angle H is tight against rear pit curb angle F across full width of the leveler frame 6 Allow rear of dock leveler to rest on the rear shims while keeping the front of the dock leveler level with the dock floor 7 For all EH models add shims at front shim locations C and D so front of dock leveler will stay level with dock floor when leveler is resting fully on shims INSTALLATION G 3 8 in 6 in 152 mm 9 5 mm A Front of Dock Pit B Dock Leveler Frame C Side Pit Curb Angle D Gap 3 4 in 19 mm Minim
6. 12 4111 0004 Sept 2013 NOTE Poweramp dock leveler s are designed with a nominal 1 2 in 12 7 mm shimming distance to allow for pit inconsistencies 1 Determine height of shim stack L for each shim location B by performing the following a Measure leveler frame height distance A b Measure dock floor to pit floor distance J at each shim location B Write down the dimensions obtained at each location c Subtract distance A from distance J to obtain the shim height Repeat for each shim location IMPORTANT The minimum size of the shim that contacts the leveler frame i e the top shim of each shim stack must be at least 4 1 2 x 4 1 2 in 114 3 x 114 3 mm to support the full width of the frame rail and to provide a shelf for a fillet weld Use the thickest shim stock possible for stability and weld penetration purposes DO NOT use multiple layers of 1 8 in 3 18 mm or thinner shim stock 2 Using the results obtained in step 1 create the individual shim stacks on the pit floor at locations B Build each shim stack L using the pyramid method N preferred or stepped method P with the top shim having a minimum size of 4 1 2 x 4 1 2 in 114 3 x 114 3 mm and each successive lower shim being larger so the shims can be welded together using a fillet weld DO NOT use offset method Q or straight method R NOTE To assist in obtaining an accurate measurement of distance K use a string
7. 2013 Weather Seal Brush Style Part Number 0195 0018 0195 0021 0195 0024 0195 0027 0192 0097 0192 0098 0195 0036 0195 0039 0195 0044 0192 Quantity AH As Hequired Description 6 Brush and Track 1 1 2 in 8 Brush and Track 1 1 2 in 10 Brush and Track 1 1 2 in 12 Brush and Track 1 1 2 in 6 Rubber Seal and Track 1 in 8 Rubber Seal and Track 1 in 10 Rubber Seal and Track 1 in 12 Rubber Seal and Track 1 in Rear Brush Weather Seal fits all Foam Rear Seal Hinge Br Br PARTS NOTE Brush or track can be purchased separately as replacement parts Contact factory for part numbers Kits are for existing dock leveler without weather seal Provide dock leveler serial number and size of platform when calling or faxing orders Provide width of weatherstrip when replacing existing seals 4111 0004 Sept 2013 47 Electrical CUSTOMER SUPPLIED 208 V 1 PHASE 60 HZ FROM DISCONNECT SWITCH amp OVERCURRENT DEVICE BY OTHERS SELECT DISCONNECT SWITCH amp OVERCURRENT DEVICE PER THE NEC LOCATE A FUSED DISCONNECT SWITCH NEXT TO THE ENCLOSED STARTER DUAL ELEMENT TIME DELAY FUSES MUST BE USED FOR BRANCH CIRCUIT PROTECTION SEE TABLES 1 2 AND 3 L1 L2 GRD Jumper wire to be installed by others Jumper wire to be ENCLOSED STARTER installed by others BY POWERAMP INSTALLED BY OTHERS GROUNDING TERMINALS OVERHEAD DOOR DOOR CONTACT DOOR CON
8. 6 9 8 7 9 8 7 2nd Design 1Phase 3 2 1 3 2 1 Hoke PPAC Motor T1 T2 T3 T1 T2 T3 115 Volt 1 PH 220 Volt 1 PH 1 L1 P1 L1 T2 T4 T5 L2 T4 T5 L2 P2 T3 T8 P2 T2 T3 T8 42 4111 0004 Sept 2013 PARTS Hoke KTI Power Pack Components Quantity Part Number Desn 1 8581 0133 2 Way Normally 1 8581 0128 Valve Sequence S1 Silver Tip x 1 1 9391 001 Breather Hoke PowerPack o i O 1 Provide dock leveler serial number and type of installation when calling or faxing orders Provide dock leveler serial number voltage and phase when calling or faxing orders 4111 0004 Sept 2013 43 PARTS Monarch Power Pack Assembly Valve Block Valve location varies by production date Monarch PPAC Motor 115 Volt 1 PH 230 Volt 1 PH 6 5 4 9 8 7 I 3 2 1 T1 T2 T3 Notes Low Voltage connect as shown High Voltage Move lead J to Term 3 move Lead 2 to Term 4 44 208 230 Volt 3 PH 460 Volt 3 PH 6 5 4 9 8 7 3 2 1 T1 T2 T3 4111 0004 Sept 2013 PARTS Monarch Power Pack Components tem Quantity number _ Valve Sequence S1 Red Tip Valve Sequence S2 Silver Tip B D EN 4111 0004 Sept 2013 45 PARTS Operating Instruction A DANGER e Read and follow all instructions warnings and ma
9. Component Identification A Lip E Powerpack Motor Pump Reservoir H Maintenance Prop Lock Out L Control Box B Main Frame F Platform Cylinder J Maintenance Prop M Raise Button C Platform G Clean Sweep Removable Section K Toe Guards 2 used N ARTD Switch option D Lip Cylinder THEORY The EH dock leveler uses hydraulic logic and When the platform rises to the highest point of one button operation for ease of use travel left in the platform cylinder a sequence in the Powerpack directs fluid flow to the lip cylinder The dock leveler can be operated remotely using the extending the lip RAISE button M on the control panel With the lip fully extended the raise button may be Platform C is raised by pushing and holding the released allowing the leveler to float down on to the RAISE button M This activates an electric motor truck for loading or unloading E which in turn drives a hydraulic pump The hydraulic pump forces oil into the platform cylinder s See Operating Instructions for a complete operation F causing the platform to rise Releasing the guide RAISE button allows the platform to lower 8 4111 0004 Sept 2013 INSTALLATION Piacard installation Instructions e Owner is responsible for the installation and placement of product placards e Make sure placard is in plain view of dock leveler operations e Suggested placement of placard is near control box
10. Inc product in the amount equal to the original purchase price of the warranted product F O B point of manufacture discounted on a ten year straight line basis by the number of years of use prior to replacement Hydraulic Warranty For a period of three 3 years from date of shipment this warranty specifically applies to the hydraulic pump and motor all hydraulic cylinders hydraulic pressure lines and fittings and fluid logic control assembly only
11. Lip Lifter and Lip Cylinder Pin D Platform Cylinder Trunnion F Lip Cylinder to Platform Frame Pin To ensure normal operation of the dock leveler use only aircraft hydraulic fluid designed to meet Before performing any maintenance under the or exceed military specification MIL L 5606 It is dock leveler lock the electrical power source in recommended that the following hydraulic fluids be OFF position and lock the maintenance prop in the used service position using an approved locking device See Service Dock Leveler Safely in this section e ULTRA VIS HVI 15 Aero Shell Fluid 4 or Fluid 41 Failure to follow these instructions may result in e Mobile Aero HFA Mil HS606A or Aero HF serious personal injury or death Texaco Aircraft Hydraulic Oil 15 or 5606 e Exxon Univis J13 These fluid brands can be mixed together Mixing IMPORTANT with fluids that do not meet or exceed MIL H 5606 G Use of fluids that do not have equivalent may damage the equipment and WILL void warranty specifications to those in the following list will result Use of hydraulic fluids with equivalent specifications in abnormal operation of the dock leveler and to those listed here are acceptable voiding of warranty 24 4111 0004 Sept 2013 Regular maintenance must be performed on a weekly and quarterly schedule Weekly Maintenance Operate the dock leveler through the complete operating cycle to maintain lubrication NOTE To thoroughly inspect
12. equipped with ARTD OPERATION Operating Instructions Stay clear of dock leveler when transport vehicle is entering or leaving dock area in 305 mm wees acc lle mie ee Lis in 305 mm The EH hydraulic dock leveler is designed to compensate for a maximum 12 in 305 mm of height difference between the loading dock and the transport vehicles bed DO NOT use the dock leveler if the transport vehicles bed is more than 12 in 305 mm higher or lower than the dock floor DO NOT move or use the dock leveler if anyone is under or in front of leveler Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Failure to follow these instructions may result in severe personal injury or death Only trained personnel should operate the dock leveler Service height may vary with design specifications DO NOT overload the dock leveler DO NOT use a broken or damaged dock leveler Make sure proper service and maintenance procedures have been performed on leveler before using DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave equipment or material unattended Transport vehicles wheels must be chocked unless on the dock leveler the vehicle restraint is used Never remove the wheel chocks until loading unloading is finished and transport driver has been given permission to leave Failure to follow these instructions may result
13. the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 26 NOTE All Poweramp EH leveler s are factory tested and should not require additional adjustments in the field Consult the factory if minor adjustments do not result in proper operation Whenever valve adjustments are made note the number of turns made to allow an undesirable adjustment result to be reversed CAUTION Do not adjust relief valve RV1 this valve is preset has a security lock to prevent adjustment 4111 0004 Sept 2013 ADJUSTMENTS Valve Adjustment Procedure Hoke KTI A S2 Valve B RV1 Valve C S1 Valve E NV1 Valve D 2W NO Spool Valve Coil F Breather Tube Fitting G To Hoist Cylinder H To Lip Cylinder Note Not pictured on the bottom of the valve body are the RV2 and PO Check Valves S1 Sequence Valve 1 NV1 Need Valve 1 Controls the Platform Cylinder When the leveler has r
14. 04 Sept 2013 39 PARTS Hydraulic Components by qD 12 Sept 2013 4111 0004 PARTS Hydraulic Components 9391 0045 0045 PPAC Monarch 1 25HP 1PH 115 230V pal 1 PPAC Monarch 1 25HP 3PH 208 230 460 575V B 1 0521 0159 Cylinder Platform in mm Barrel Length D 1 05220156 Yoke Roll Pin 1 4 x 1 5 Long Clevis Pin 3 4 x 2 Plated Cotter Pin 1 8 Diameter x 1 Long Clip Hairpin 5 8 Diameter Pin Lip Cylinder Mounting 3 4 x 4 38 Long Cotter Pin 1 4 x 2 Long Pin Hoist Cylinder Mounting 1 25 x 7 5 Long Tube Vent 3 8 OD x 1 16 Wall O 1 9301 0111 Fitting 6 ORB Male x 8 JIC Male 9904 0128 Hose Lip Cylinder 6 Leveler 9904 0129 0129 Hose Lip Cylinder 8 Leveler 5020130 0130 Hose Lip Cylinder 10 Leveler OBE OFT Velocy Fuse Ago 88 Male Sraignr Teed ORB To FIC Ml R 1 990 0128 Hose Platform Cylinder Cotter Pin 1 4 x 2 Long Pin Hoist Cylinder Mounting 1 25 x 5 5 Long 1 Provide length and diameter of hose when calling or faxing orders 2 Provide length of lip cylinder when calling or faxing orders 3 Provide dock leveler serial number voltage and phase when calling or faxing orders 4111 0004 Sept 2013 41 PARTS Hoke KTI Power Pack Assembly Hoke PPAC Motor 115 Volt 1 PH 220 Volt 1 PH 1 2 2 3 208 230 Volt 3 PH 460 Volt 3 PH Ti T2 Ti T2 654 4 5
15. 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0004 Sept 2013 Dock Leveler Information Model Serial No Systems Inc Job No Original Owner Information Name Address Installer Information Name Address Date of Installation 49 STANDARD PRODUCT WARRANTY SYSTEMS INC warrants that its products will be free from defects in design materials and workmanship for a period of one 1 year from the date of shipment All claims for breach of this warranty must be made within 30 days after the defect is or can with reasonable care be detected In no event shall any claim be made more than 30 days after this warranty has expired In order to be entitled to the benefits of this warranty the product must have been properly installed maintained and operated in accordance with all manufacturers recommendations and or specified design parameters and not otherwise have been subject to abuse misuse misapplication acts of nature overloading unauthorized repair or modification application in a corrosive environment or lack of maintenance Periodic lubrication adjustment and inspection in accordance with all manufacturers recommendations are the sole responsibility of the Owner User In the event of a defect as determined by SYSTEMS INC covered by this warranty SYSTEMS INC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportat
16. Controls the Lip Cylinder This valve should be set RV1 Main Relief Valve to allow a smooth quiet shift Turning S2 counter Sets system pressure clockwise causes the lip to extend If the lip does not extend turn S2 counter clockwise out small increments until lip begins to extend Once the lip is extended allow the powerpack to operate in pressure relief then allow the leveler to return below dock Raise the leveler and continue to adjust the S2 valve to allow a smooth quiet shift When adjusted properly the lip should stay extended until below dock Lip extension cycle should not take more than a few seconds 28 4111 0004 Sept 2013 NOTES This page intentionally left blank 4111 0004 Sept 2013 29 ADJUSTMENTS Adjust Auto Return To Dock ARTD A Cable E Target B Proximity Switch F Lip Hinge Tube C Bracket G Platform Lip D Lock Nuts H Indicator Light EH leveler s are equipped with the optional Auto Return To Dock ARTD if leveler not interlocked with a truck restraint The ARTD allows the platform to automatically return to the cross traffic stored position after the truck departs The ARTD uses a proximity switch B located under the platform and a piece of angled steel called the target E that is attached to the lip hinge tube F The proximity switch provides a six second delay after the platform has lowered to the full below dock position after which the platform will retu
17. If an excessive transition exists between the dock floor and leveler and or lip does not contact both lip keepers evenly contact Poweramp Technical Services for further instructions 3 Install the dock bumpers as required 4 Turn the main electrical power ON Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or death may result 5 Raise the leveler platform fully by pushing and holding the RAISE button NOTE The platform of a properly operating dock leveler will automatically stop rising when it reaches its maximum full raised height at which point the lip extends When the lip is fully extended the powerpack will go in to by pass If the lip does not extend or extend fully see Platform Rises to Full Height But Lip Does Not Fully Extend in the Troubleshooting section 6 Release the RAISE button to lower the platform As long as there is no vehicle present at the dock the platform will lower to the full below dock position as the lip folds NOTE Ifa Transport Vehicle is present the platform will lower until the lip rests on the Transport Vehicles bed See Operating Instructions in Operation section 4111 0004 Sept 2013 INSTALLATION 7 When the platform lowers to the full below dock position push and hold the RAISE button until the platform rises just enough to clear the lip keepers then release the RAISE button to allow the platform to lower to
18. TACT IF USED DOOR CONTACT BY OTHERS CONTACT TO BE OPEN WHEN DOOR IS NOT FULLY RAISED CONTACT TO BE CLOSED WHEN DOOR IS FULLY RAISED IF DOOR CONTACT NOT USED WIRE FROM TERMINAL L1 TO TERMINAL 95 ON THE STARTER J BOX AT REAR OF PIT WALL BY OTHERS FLEX CONDUIT W WIRES BY POWERAMP DOCK LEVELER BY POWERAMP INSTALLED BY OTHERS Note 1 Phase control box show jumper will be the same for 3 phase control box s 48 4111 0004 Sept 2013 Customer Information MISCELLANEOUS NOTE Refer to illustration for left right orientation of dock leveler The model serial number decal A is located on the right platform joist near the front lip of dock leveler When you receive your EH dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keeping of the numbers in the event the model serial number decal A becomes lost or damaged Also write down Systems Inc s job number the company that installed the dock leveler and the Original owner s name This will all help to identify the specific dock leveler if more information is required When ordering use part numbers and description to help identify the item ordered Do not use item numbers These are only for locating the position of the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER For service call or contact Systems Inc P O Box 309 Germantown WI
19. approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Always post safety warnings and barricade the Unless the dock leveler is equipped with a tethered work area at dock level and ground level to prevent remote two people are required to engage the unauthorized use of the dock leveler before maintenance prop one person to operate the unit maintenance Is complete Failure to do this may the other person to engage the maintenance prop result in serious personal injury or death Failure to follow these instructions may result in serious personal injury or death Before performing the detailed troubleshooting procedures check the following items first Check all fuses inside the control panel s Replace Make sure the correct voltages are present at the any blown fuse s with a fuse of equal specification proper locations inside the control panel s Platform does not rise Motor overload device Reset overload relay three phase or replace Motor does not energize tripped or fuse blown fuse s single phase Determine cause of overload NOTE When replacing fuse s the new fuse must have the same specification as the old fuse Motor starter three Check voltage at starter or relay coil phase or motor relay single phase not e f voltage is present and starter or relay does not energizing energize replace star
20. attached to electrical conduit by using nylon tie If there is no control box present mount placard on wall to the immediate left of leveler at eye level SSNS NET SNS ST ER SSS SOY MESE SS 2 pum NS y TRG FP ERE ws Nylon Tie lt WZ SSS ylon Tie lt NN SSS Z SS 4111 0004 Sept 2013 INSTALLATION A Distance Pit Width B Distance Dock Floor to Pit C Distance Pit Length D Distance Pit Corner to Corner Top Front and Rear Floor All Four Corners Both Sides of Pit Bottom and Both Sides Before lowering the dock leveler into the pit the following must be performed Post safety warnings and barricade the work area at dock level and ground level to prevent 1 Remove all debris from the pit and sweep the pit unauthorized use of the dock leveler before clean installation has been completed 2 Check the entire dock leveler pit for proper Failure to follow the installation instructions can construction according to approved certified pit result in damage to dock leveler the facilities and drawings Make sure pit is square by making the or serious personal injury or death following measurements Measure pit width distance A at both front and rear of pit Measure dock floor to pit floor distance B at all four corners Measure pit length distance C at both sides Measure corner to corner cris cross distance D at both sides Take measu
21. by hand while observing the target and proximity switch The target MUST NOT contact the switch otherwise damage to switch will occur Readjust switch and or target if necessary then recheck for interference 4111 0004 Sept 2013 ADJUSTMENTS Turn ON electrical power to the dock leveler Disengage the maintenance prop Turn the ARTD switch on control panel to the ON position Raise the platform until the lip is fully extended then allow the platform to drift to the below dock position After approximately 6 seconds the platform must return to the cross traffic position 10 Adjust the proximity switch and target as necessary Make small adjustments then operate the dock leveler to check results Do this until satisfied with the ARTD operation Use the following illustrations to assist in fine tuning and or diagnosing the ARTD operation Cross Traffic Position Lip Keeper NOTE The platform lip is fully folded when the platform is at the cross traffic stored position lip engaged with keepers or when platform is resting on the maintenance prop Whenever the platform lip is at the cross traffic position the following conditions will exist for a normally operating ARTD Target not in the sensing area of proximity switch Proximity switch OFF open no signal sent to control panel Proximity switch indicator light is OFF Platform stays at this position unless the operator acti
22. ce and information identifying the maximum uncontrolled drop encountered when sudden removal of support while in the working range of the equipment It is recommended that when the transportation vehicle is positioned correctly in the dock opening and in contact with both bumpers there shall be a minimum of 4 00 inches 100mm overlap of the leveling device and the transportation vehicle at all times during the loading and unloading process The Owner User must review all name plates placards decals instructions and posted warnings and place the same in view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for any replacements Manufacturers recommended periodic maintenance and inspection procedures in effect at the date of shipment shall be followed at all times Written documentation of maintenance replacement parts or damage should be retained In the event of damage notification to the manufacturer is required Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main support while under load such as what might occur when a transport vehicle pulls out from under the leveling device shall be removed from service inspected by a manufacturer s authorized representative and repaired or replaced as needed before being placed back in service Any modifications or alterations of loading dock equipment shall only be done with prior written approval fr
23. ce if necessary Defective motor centrifugal Replace motor switch Defective motor capacitor Replace motor The auto return proximity Adjust proximity switch and target as necessary switch not sensing target See Adjust Auto Return To Dock ARTD in the correctly Adjustment section Defective proximity switch Replace switch Broken wire Loose or Repair or replace wires and connections as corroded wire connections necessary 4111 0004 Sept 2013 TROUBLESHOOTING Platform does not Heavy object s on platform Remove object s from platform rise Pump operates in pressure relief mode Dock leveler binds Pressure relief set too low NOTE For safety reasons the dock leveler is designed to lift only the platform s own weight Check for visible obstructions that could cause binding Remove obstructions If no obstructions found call Poweramp Technical Services See inside back cover for phone number and address Increase pressure relief See Adjust Main Pressure Relief in the Adjustment section NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure reliet The full load amp value can be found on the inside cover of the control panel Platform rises slowly Low hydraulic fluid Add fluid as needed See Periodic Maintenance in the Maintenance section Contaminat
24. ce prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 4111 0004 Sept 2013 Whenever maintenance is to be performed under the dock leveler platform support the platform with maintenance prop E Position the maintenance prop behind front header plate while staying clear of the lip The lip will fold down after the platform has rested on the maintenance prop Lock the maintenance prop in the service upright position using an OSHA approved lockout device C and Tag Out device D Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout device B and Tag Out device A Only the person servicing the equipment should have the capability to remove the lockout devices The Tag Out devices must inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to OSHA regulation 1910 147 Refer to OSHA regulation 1910 146 23 MAINTENANCE Periodic Maintenance A Lip Hinge Area C Platform Hinge Area E Platform Cylinder to Platform Pin B
25. de dock leveler serial number voltage phase and options when calling or faxing controller orders 4111 0004 Sept 2013 37 PARTS Frame and Platform T JE gt oN 7 7 APTT 2 30 4111 0004 Sept 2013 PARTS Frame and Platform Part Number BesHpio B 1 7828 2 Platform Welded Assembly o Z C 1 95155 PinlipHnge OO DKIT 9179 Toe Guards Sliding 6 Includes Both Sides DKIT 9180 DKIT 9180 Toe Guards Sliding 8 Includes Both Sides DKIT 9181 Toe Guards Sliding 10 Includes Both Sides E 1 920 4 FameEH J F 6 211004 CotrPin 1 4x2in Q AR 210 001 Cap Screw 5 16 18 UNCx1in R 1 J 17510010 Decal Model Serial D HEEL E EN TERES Lip Keeper 16 Inch Lip 20 Inch Pit 0984 Lip Keeper 18 Inch Lip 20 Inch Pit ee 0985 Lip Keeper 20 Inch Lip 20 Inch Pit Se 0986 Lip Keeper 16 Inch Lip 24 Inch Pit 0987 Lip Keeper 16 Inch Lip 24 Inch Pit 8432 0988 0988 Lip Keeper 16 Inch Lip 24 Inch Pit AR As Required 1 Provide dock leveler serial number platform size and lip size when calling or faxing orders 2 Provide length and width of inspection plate opening when calling or faxing orders For left right orientation of dock leveler see inside back cover of this manual 4111 00
26. e moved outside the operating zone Remove any tools or foreign objects from the operating zone before starting Keep the operating zone free of obstacles that could cause a person to trip or fall SAFETY Operational Safety Precautions Learn the safe way to operate this equipment Read and understand the manufacturer s instructions If you have any questions ask your supervisor wor Stay clear of dock leveling device when transport vehicle is entering or leaving area Do not move or use the dock leveling device if anyone is under or in front of it Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts eS Chock restrain all transport vehicles Never remove the wheel chocks until loading or unloading is finished and driver has been given permission to drive away INT Tee Do not use a broken or damage dock leveling device Make sure proper service and maintenance procedures have been performed before using _ or Make sure lip overlaps onto the transport vehicles trailer at least 4 in 102 mm Keep a safe distance from both side edges 4111 0004 Sept 2013 SAFETY 2 wer Do not use dock leveling device if transport vehicle is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock levelin
27. eached the top of its travel allow the leveler to float down Fluid should flow through the NV1 valve If you hear the motor spinning backwards or Leveler and or Lip may dropping prematurely adjust S1 clockwise in small increments testing each time until the motor is not spinning backwards or Leveler and or Lip may drop correctly S2 Sequence Valve 2 Controls the Lip Cylinder This valve should be set to allow a smooth quiet shift Turning S2 counter clockwise causes the lip to extend If the lip does not extend turn S2 counter clockwise out small increments until lip begins to extend Once the lip is extended allow the powerpack to operate in pressure relief then allow the leveler to return below dock Raise the leveler and continue to adjust the S2 valve to allow a smooth quiet shift When adjusted properly the lip should stay extended until below dock Lip extension cycle should not take more than a few seconds 4111 0004 Sept 2013 Controls the Down speed of the ramp cylinder Increase Down speed by turning NV1 counter clockwise Decrease Down speed by turning NV1 clockwise RV2 Relief Valve 2 Allows the lip to collapse below dock protects the lip if it is backed in to Set the RV2 valve by backing out adjustment screw as far as it goes Return leveler to keepers and begin to raise it Halfway up allow the leveler to return for a second then raise leveler The lip should not extend If lip extends turn S2 va
28. ed hydraulic system Damaged or restricted hydraulic hose s Pressure relief set too low Pump motor loads down Pressure relief set too high when platform reaches the full raised position 4111 0004 Sept 2013 Clean and inspect valves Flush contaminated oil from hydraulic system Fill system with new oil See Periodic Maintenance in the Maintenance section Replace damaged hose s Remove restriction Increase pressure relief See Valve Adjustment section NOTE The pressure relief valve RV1 must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Decrease pressure relief See Adjust Main Pressure Relief in the Adjustment section NOTE The pressure relief valve RV1 must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel 35 TROUBLESHOOTING Platform does not rise to Low hydraulic fluid Add fluid as needed See Periodic Maintenance in full height the Maintenance section Lip does not stay S1 Sequence Valve requires See Valve Adjustment Procedure Section extended when leveler adjustment 1 8 increments lowers clockwise at a ti
29. ep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death IMPORTANT DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground welding equipment to the dock leveler frame NEVER to the platform Failure to follow these instructions may damage the motor hoist cylinder wiring and or control panel NOTE The illustration on the previous page shows a typical weld pattern The weld pattern will vary slightly depending on size of dock leveler 4111 0004 Sept 2013 INSTALLATION IMPORTANT DO NOT weld continuously along the full length of the rear hinge frame angle This can put unnecessary stress on the leveler components causing the leveler to malfunction and shorten the life soan of the affected components 11 With the rear hinge frame angle F tight against the rear pit curb angle G weld the rear hinge frame angle F to the rear pit curb angle G using a 3 8 in 9 5 mm flare bevel skip weld each weld being 6 in 152 mm long Start at each end with a 6 in 152 mm long weld Space all the other welds out evenly leaving approximately 6 in 152 mm space between each weld 12 Weld front of dock leveler frame B to shims located unde
30. eveler platform to the cross traffic stored position by performing one of the following Turn the ARTD switch A to the ON position if equipped After approximately six seconds the platform will automatically rise to the cross traffic position OR e Push the Raise button B until the lip clears the lip keepers Release Raise button leveler will return to the stored or cross traffic position 11 Remove chocks from Transport Vehicles wheels or release the restraint if used 12 Indicate to the driver that the Transport Vehicle may leave the dock 4111 0004 Sept 2013 Service Dock Leveler Safely MAINTENANCE Side View A Maintenance Prop B Tag Out Tag C 2 Styles of Out Device When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenan
31. fting bracket hardware Over tightening can damage the weather seal if equipped NOTE Overall width of platform and lifting brackets A must be kept to a minimum to prevent interference between the lifting brackets and the pit walls as the dock leveler is lowered into the pit 2 Make sure the mounting hardware of lifting brackets A is snug The brackets should pivot relatively freely on the mounting cap screw DO NOT over tighten 3 Attach lifting chains to lifting brackets A and to a lifting device i e hoist or fork truck having the appropriate lifting capacity and reach 4 Remove wood blocks that are attached to the leveler frame before putting the dock leveler into the pit INSTALLATION Install Dock Leveler Shim Stacking Methods Q 2 N P B See page 16 for Hoist cylinder shimming 9 H A Distance Leveler Frame G String Height H Rear Hinge Frame Angle B Shim Locations Under J Distance Dock Floor to T 1 Rear Vertical Supports Pit Floor ANT TO C Shim Location Under K Distance Top of Shim Maintenance Prop Stack to Dock Floor re aes Same as D L Shim Stack ice ae D Shim Locations Under M Dock Leveler Frame D K d i b Lip Keepers N Pyramid Preferred uS M E Dock Floor P Stepped Acceptable NONI F Rear Pit Curb Angle Q Offset Not Acceptable NL R Straight Not Acceptable 2 ld 4
32. g any maintenance under the dock leveler lock the electrical power source in OFF position and lock the maintenance prop in the service position using an approved locking device See Service Dock Leveler Safely in this section Failure to follow these instructions may result in serious personal injury or death Check reservoir fluid level Q 1 Put the dock leveler platform at the full above dock position 2 Turn OFF all electrical power to the leveler 4 Remove breather cap P 5 Measure fluid level The fluid level should be approximately 2 in 50 8 mm N from top of reservoir M with platform at the below dock position 6 Add hydraulic fluid if necessary Use only recommended fluid 7 Install breather cap and inspection plate 8 Turn ON electrical power to the leveler 9 Return the platform to the cross traffic position 25 ADJUSTMENTS Valve Adjustment Procedure When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of
33. g device 4111 0004 Sept 2013 3 SAFETY Maintenance Safety Precautions Hydraulic and electrical power must be OFF when servicing the equipment For maximum protection use an OSHA approved locking device to lock out all power sources Only the person servicing the equipment should have the key to unlock the device Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete The maintenance prop must be in the upright service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the device ALWAYS disconnect electrical power source and ground wire before welding on dock leveler DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground to the dock leveler frame Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before p
34. in personal injury and or damage to equipment The dock leveler operating instructions are Make sure platform lip rests on the transport divided into the two methods of loading and vehicles bed with at least 4 in 102 mm of overlap unloading Maintain a safe distance from side edges of leveler For ramp loading and unloading see Ramp during the loading unloading process Loading Unloading Instructions on page 21 Failure to follow these instructions may result in e For end loading and unloading see End serious personal injury or death Loading Unloading Instructions on page 22 20 4111 0004 Sept 2013 OPERATION Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 24 For ramp loading or unloading the EH dock leveler can be operated by using the RAISE button on the control panel a 1 Check to make sure the transport vehicle is 5 Proceed with loading or unloading the transport positioned squarely against dock bumpers vehicle 2 Instruct driver to remain at the dock until the 6 If end loading is necessary see End Loading loading or unloading process has been completed Unloading Instructions on page 20 3 Chock the transport vehicles wheels or use the truck restraint if available A RAISE Button B ARTD Switch 7 When loading or unloading is finished raise the platform by pushi
35. intenance schedules in the manual and on placards e Operation and servicing of dock leveler is restricted to trained personnel Always chock transport vehicle wheels or engage vehicle restraint and set parking brakes before operating dock leveler or beginning to load or unload Before activating dock leveler ensure lip avoids contact with transport vehicle sides and cargo If lip does not lower to transport vehicle bed reposition transport vehicle Ensure the transport vehicle floor supports extended lip or the leveler frame lip Keepers or below dock endload supports supports the ramp before driving on ramp Stay clear of hinges and front and sides of moving dock leveler Never use hands or equipment to move the ramp or lip Never use damaged or malfunctioning dock leveler Report problems immediately to supervisor Always store dock leveler and remove people material and equipment from ramp before vehicle leaves the dock DO NOT ENTER PIT unless dock leveler is securely supported by the maintenance prop Disconnect power and follow proper lockout tagout procedures for the dock leveler before entering the dock leveler pit or doing any repair or inspection under the dock leveler FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR OTHER SERIOUS INJURY OPERATING INSTRUCTIONS POWERED DOCK LEVELERS NORMAL OPERATION Raise the platform by depressing and holding the RAISE button 2 Hold the RAISE button unti
36. ion This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS SUBSIDIARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUDING THIRD PARTIES FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERRUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY EH SERIES LEVELER In addition to the Standard Product Warranty provided with all Poweramp Products Systems Inc guarantees materials components and workmanship to be free of defects for the following extended periods e Structural Warranty For a period of ten 10 years from the date of shipment product will carry a prorated structural warranty This warranty specifically applies to the deck section lip section frame rear hinge assembly and front hinge assembly only This warranty covers structural repairs to or replacement of dock leveler in Systems Inc sole discretion and expense including reasonable labor materials freight and travel If Systems Inc determines replacement is necessary it will provide the original purchaser with a credit toward the purchase of the new replacement Systems
37. l the lip is fully extended then release the RAISE button The platform will lower until lip is resting on the transport vehicle STORING LEVELER 1 Depress the RAISE button until the lip is completely folded When the lip is folded release the RAISE button The platform will lower returning to the cross traffic position BELOW DOCK ENDLOADING e HYDRAULIC ONLY Depress and hold the RAISE button until the leveler is fully raised As the lip starts to extend release the RAISE button The leveler will lower to the below dock position provided the lip extension allows the lip to clearthe lip keepers AIR POWERED ONLY Depress and hold the RAISE button until the leveler is 12 above dock level Pull the below dock level chain until the leveler passes the below dock position HYDRAULIC WITH INFINITE LIP CONTROL If equipped raise the platform by depressing and holding the RAISE button When the lip is just above the lip keepers simultaneously depress and hold the RAISE Poweramp 1 262 255 1510 or 1 800 643 5424 button and the LIP OUT button until lip has MORE Call for additional placards or manuals or with questions extended beyond the lip keepers Release regarding proper use maintenance and repair of dock leveler both buttons wwwDockSystemsInc com Loading Dock Equipment NOTE If equipped depressing E STOP button will stop platform from lowering 1751 0874 Operating Instruction 46 4111 0004 Sept
38. lve clockwise 1 4 turn and repeat until lip does not extend PO CHK Pilot Operated Check Valve Keeps Lip from collapsing until it is below dock This valve is not adjustable If lip malfunctions cleaning or replacement may be required RV1 Main Relief Valve Sets system pressure 2W 2 Way Normally Open Spool Valve Optional If present can extend lip with Lip Out option or it can be used as an emergency stop if power is not running 27 ADJUSTMENTS Valve Adjustment Procedure Monarch Bucher Valve location varies by production date A S2 Valve C S1 Valve E NV1 Valve G To Hoist Cylinder B RV1 Valve D Not Used F Breather Tube Fitting H To Lip Cylinder S1 Sequence Valve 1 NV1 Need Valve 1 Controls the Platform Cylinder When the leveler has Controls the Down speed of the ramp cylinder reached the top of its travel allow the leveler to float Increase Down speed by turning NV1 counter down Fluid should flow through the NV1 valve If you clockwise Decrease Down speed by turning hear the motor spinning backwards or Leveler and or NV1 clockwise Lip may dropping prematurely adjust 1 clockwise in small increments testing each time until the motor is PO CHK Pilot Operated Check Valve not spinning backwards or Leveler and or Lip may drop Keeps Lip from collapsing until it is below dock This correctly valve is not adjustable If lip malfunctions cleaning or replacement may be required S2 Sequence Valve 2
39. me Platform DOES rise to Low hydraulic fluid Add fluid as needed See Periodic Maintenance in full height but lip DOES the Maintenance section NOT extend or extend fully S2 Sequence Valve 2 See Valve Adjustment Procedure Section requires adjustment 1 8 increments at a time Lip does not extend S2 Sequence Valve 2 See Valve Adjustment Procedure Section requires adjustment 1 8 increments at a time Lip extends almost S2 Sequence Valve 2 See Valve Adjustment Procedure Section immediately when the requires adjustment RAISE button is pushed Platform rises after lip is fully extended Platform locks into Platform lowering speed is See Valve Adjustment Procedure Section safety as platform too fast NV1 Needle Valve lowers Lip drops to 1 requires adjustment vertical position Velocity fuse failed Replace Velocity Fuse Incorrect fluid NOTE Extreme cold weather OH incorrect fluid may cause platform to lock Adjustment is same If adjustments and velocity fuse replacement fail to correct problem fluid replacement may be required 36 4111 0004 Sept 2013 PARTS Controls Standard Control Box Optional Control Box w lt Quantity Part Number Description A 0961 0085 Proximity Switch with Harness ARTD Feature Only 1 Button Controller C 1 9511 0004 J Box Standard 4 x 4 in Metal Box 9512 0429 J Box Cold Weather 5 x 5 in Plastic Box Provi
40. movable Frame Section D Maintenance Prop Two people are required to engage the maintenance prop one person to operate the lifting device the other person to engage the maintenance prop DO NOT use the maintenance prop to support the raised platform until the maintenance prop has been properly shimmed and welded The shims must be welded to each other the leveler frame and to the front pit curb steel Failure to do this may result in serious personal injury or death c Raise maintenance prop D to the service upright position and lock prop in this position using an OSHA approved locking device d Proceed to step 18 4111 0004 Sept 2013 INSTALLATION Make sure the platform is properly supported in the raised position before entering the pit to finish weld the shims Failure to do this may result in serious personal injury or death 18 All model leveler s Install shims at locations B 20 When all welding has been completed paint all using the pyramid or stepped shimming method the welds and shims Both platform cylinder trunnions must be solidly shimmed the entire length of the trunnion Make NOTE EH models are shipped with a front frame sure the trunnions are level from side to side as section C installed This temporary frame well as from front to back holds the leveler frame at the correct dimensions until the leveler is permanently 19 Finish weld all frame and cylinder trunnion shims anch
41. ng and holding RAISE button A RAISE Button Hold the RAISE button until the lip folds enough 4 Extend the platform lip onto transport vehicle as to clear the transport vehicles bed then release follows the RAISE button The lip will fold and the platform will return to the cross traffic position a Raise the platform by pushing and holding RAISE button 8 Remove chocks from transport vehicle wheels or release the truck restraint if used b Hold the RAISE button until the lip is fully extended then release the RAISE button The 9 Indicate to driver that the transport vehicle may platform will lower until the lip is resting on the leave the dock Transport Vehicle bed c Make sure that the lip is fully extended and supported on the transport vehicle along the entire width of the platform with at least 4 in 102 mm of lip contacting the transport vehicle bed 4111 0004 Sept 2013 21 OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE If ramp loading is required see Ramp Loading Unloading Instructions on page 19 End loading or unloading can be done with the dock at the cross traffic position or below dock position depending on the height of the Transport Vehicles bed 1 Check to make sure transport vehicle is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the t
42. no equipment material or people are on the dock leveler e Return the dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or serious injury labels or owner users decal placed in same position on both sides 1751 0329 x2 decal placed in same position on both sides 1751 0330 x2 decal placed in same position on both sides ADANGER CRUSH HAZARD 1 75 1 0 1 3 8 DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance prop Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury 1751 0729 ADANGER CRUSH HAZARD Do not work under dock leveler unless this maintenance prop has been secured in the upright position See owner s user s manual for proper procedures Failure to comply will result in death or serious injury 1751 0729 DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch 1 7 1 7 1 and insert through the maintenance prop housing Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury 4 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 1 75 1 072 6 safely supported by maintenance prop Place barriers on driveway and dock floor to indicate service work being performed Refer to owner s user s manual for pr
43. om the manufacturer and the same shall be at least as safe as the original equipment was prior to the modification and shall also satisfy all safety requirements of the manufacturer for the particular application of the leveling device When industrial moving devices are being used in the loading or unloading of product from the transportation vehicle this vehicle shall have the brakes and wheel chocks applied appropriately or all other positive restraining device shall be fully utilized It is recommended that trailers with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize trailer bed drop Loading dock safety equipment should never be used outside of its intended use vertical working range or capacity Please consult the manufacturer if you have any questions as to the use vertical working range or capacity of the equipment Only properly trained and authorized personnel should operate the equipment When selecting loading dock safety equipment it is important to consider not only present requirements but also future plans and any possible adverse conditions environmental factors or usage 4111 0004 Sept 2013 General Information Congratulations on your choice of a Poweramp dock leveler This manual covers the EH series hydraulic dock leveler Designed by Poweramp to be a marvel of simplicity and efficiency your dock leveler when properly installed will pr
44. oper maintenance procedures Failure to comply will result in death or serious injury 1751 0726 OWNER S USER S RESPONSIBILITIES 10 The owner user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle The owner user should therefore train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer s recommendations and industry standards Effective operator training should also focus on the owner s user s company policies and operating conditions Maintaining updating and re training all operators on safe working habits and operation of the equipment regardless of previous experience should be done on a regular basis and should include an understanding and familiarity with all functions of the equipment Owner s user s shall actively maintain update and retrain all operators on safe working habits and operations of the equipment The manufacturer shall provide to the initial purchaser all necessary information regarding Safety Information Operation Installation and Safety Precautions Recommended Initial and Periodic Inspections Procedures Planned Maintenance Schedule Product Specifications Troubleshooting Guide Parts Break Down Warranty Information and Manufacturers Contact Information as well as tables to identify the grade slope for all variations of length or configuration of the dock leveling devi
45. ored into place Only then should it be using a fillet weld removed e Adjust shim height as needed Remember There are four cap screws and nuts that each upright rear frame member must be fasten the T frame to the rest of the leveler solidly shimmed between the floor of the leveler frame Tack welds may also be used pit and the bottom of the frame section 21 For all EH models remove the Clean Sweep Weld all shims within each shim stack to each frame section C by grinding the tack welds that other then weld the shim stack to the leveler hold it in place during transport Paint after frame Weld the front leveler frame shim stacks to the front pit curb steel Shim Stacking Methods N P Q 2 For left right orientation of dock leveler see inside back cover of this manual 4111 0004 Sept 2013 17 INSTALLATION Install Control Panel and Wiring cs SSS PBR 4 DANGER AW Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer to NFPA 70E for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death DO NOT make any final electrical connections until A Disconnect Panel provided by others all welding has been completed Failure to do this B Distance 48 in 14 630 mm may result in serio
46. ovide many years of trouble free performance with an absolute minimum of maintenance Its revolutionary hydraulic system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended The EH series dock leveler comes equipped with an electrical control panel which allows pushbutton operation of the dock leveler functions Each EH dock leveler unit and control panel has been factory prewired and tested to ensure satisfactory operation To illustrate which connections are to be made in the field at installation electrical drawings are included with each order or by contacting Poweramp Technical Services Once again thank you and congratulations on your purchase of a Poweramp hydraulic dock leveler 4111 0004 Sept 2013 INTRODUCTION Dock Leveler Stock Specifications EH dock leveler s are available in the following sizes weight capacities and options Width EH 6 ft 1828 8 mm 6 1 2 ft 1981 2 mm ft 2133 6 mm Length 6 ft 1828 8 mm 8 ft 2438 mm 10 ft 3048 mm 12 ft 3658 mm Capacity CIR 25 000 Ib 11 340 kg 30 000 Ib 13 608 kg 35 000 Ib 15 876 kg 40 000 Ib 18 144 kg 45 000 Ib 20 412 kg 50 000 Ib 22 680 kg 60 000 Ib 27 216 kg CIR Comparative Industry Rating Call Poweramp to discuss available voltages phases and options to meet your specific needs INTRODUCTION
47. r the keepers then weld the shims to the front pit curb steel 13 With leveler welded into place remove the shipping bands from around lip and leveler frame If the platform is raised using an external lifting device or the hydraulic system is opened to atmosphere air will enter into the hydraulic system Whenever this happens always cycle the leveler at least 4 times using the leveler s own hydraulic power system before allowing the leveler to be put into service This is to make sure all air is purged from the hydraulic cylinders Failure to do this may result in serious personal injury or death INSTALLATION A Platform Joists B Shim Locations Under Platform Cylinder Trunnions C Removable Clean Sweep Frame Section 14 Using an external lifting device i e crane or fork truck attached to the platform lifting brackets slowly raise the platform Check for binding as platform is being raised 15 If binding occurs lower the platform Reposition leveler and or add or remove shims as necessary Slowly raise platform again If platform still binds contact Poweramp Technical Services for further instructions 16 All EH models a Install shims under maintenance prop D where prop attaches to leveler frame Make sure prop is solidly shimmed b Using the appropriate lifting device attached to the platform lifting lugs slowly raise the dock to the fully open position 16 C Clean Sweep Re
48. ransport vehicles wheels or use the vehicle restraint if available eX End Loading Unloading Platform at Cross Traffic Position 4 f transport vehicles bed is at or above dock floor level leave leveler at the cross traffic position and proceed with loading or unloading End Loading Unloading Platform at Below Dock Position 5 If transport vehicles bed is below the dock floor level and the dock is equipped with the optional lip out button perform steps 6 12 Whenever end loading or unloading with the platform in the below dock position make sure the ARTD switch is in the OFF position DO NOT turn the ARTD switch to the ON position until end loading or unloading is finished 22 A ARTD Switch 6 Turn the ARTD switch A on the control panel to the OFF position if equipped 7 Push the Raise button B to the platform just enough to clear the lip keepers 8 When the platform lip clears the lip keepers push the Lip Out button C just long enough to clear the lip keepers Release Lip Out button The platform will drift down to the full below dock position 9 Proceed with loading or unloading NOTE When end unloading is finished and access to the rest of the Transport Vehicles is still required the platform lip will need to be extended See Ramp Loading Unloading Instructions on page 19 for further instructions 10 When the loading or unloading is finished return the dock l
49. rements at dock IMPORTANT floor level and at pit floor level DO NOT remove the shipping bands around the If any measurement is off by more than 1 8 in dock leveler lip until instructed to do so 3 18 mm contact Poweramp Technical Services before proceeding 3 Make sure the field junction box for the dock leveler E is at the correct location per pit diagrams 10 4111 0004 Sept 2013 Prepare Dock Leveler A Lifting Bracket 2 used B Shipping Bands Poweramp dock leveler s are designed with installation in mind Each unit is shipped with lifting brackets A fastened to the platform side joists The dock leveler is heavy Use a lifting device and chains with the appropriate lifting capacity and reach Always use the lifting brackets provided with the unit whenever lowering or lifting a dock leveler into or out of a pit Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death 4111 0004 Sept 2013 INSTALLATION IMPORTANT DO NOT remove the shipping bands B around the platform lip and leveler frame at this time The shipping bands are needed to hold the leveler together during the installation process 1 Remove any control panel and bumpers that may be banded to the frame of the dock leveler DO NOT remove the shipping bands B around the platform lip and leveler frame at this time IMPORTANT DO NOT over tighten the li
50. rn to the cross traffic position The switch also contains an indicator light H that can be used for diagnosing and adjusting the switch NOTE Some proximity switches have an indicator light at the back of the housing and some have the light at the side of the housing 30 Adjust the ARTD as Follows 1 When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death
51. roceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death ALWAYS stand clear of dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death DANGER Arc Flash Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer to NFPA 70E for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death 4111 0004 Sept 2013 Safety Decal s Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily leg ible If any are missing or require replacement please call 1 800 643 5424 for replacements 4111 0004 Sept 2013 SAFETY DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar 1 75 1 0727 Do not force maintenance prop forward of bar to support lip Refer to owner s user s manual for proper use Failure to comply will result in death or serious injury 1751 0730 x2 SAFETY INFORMATION Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always Ensure that
52. ter or relay If voltage is not present check all components in series with the starter or relay coil 4111 0004 Sept 2013 33 TROUBLESHOOTING Three phase units only Platform does not rise Motor hums but does not run Three phase units only Platform does not rise Motor runs in reverse Single phase units only Platform does not rise Motor energizes but does not run Dock leveler equipped with ARTD Platform does not automatically return to the cross traffic position or operates abnormally 34 No voltage is present on Check for blown fuses at branch circuit disconnect one line Replace fuse Determine cause of blown fuse NOTE A motor that is Check motor starter as follows missing voltage on line Disconnect wires at load side of starter is said to be single phased Ep ergize the starter 3 Measure line to line voltage at line side of starter 4 Measure line to line voltage at load side of starter 5 Line side and load side voltages should be approximately the same Replace starter if voltage values are considerably different from one another Check all wiring to motor for high resistance or no connection Phase reversed Reverse any two legs at the branch circuit disconnect Line voltage too low Check wiring to motor for high resistance Check for loose or corroded connections Check if gauge of wires to motor are of correct size and specification for load requirement Repla
53. the cross traffic stored position lip engages lip keepers NOTE For dock leveler s equipped with the Auto Return To Dock ARTD the platform will automatically return to the cross traffic position if the ARTD is enabled When the platform is at the full below dock position there is a six second delay before the platform will automatically rise to the cross traffic position 8 Perform steps 5 7 at least four times to purge any air that may be in the hydraulic system and to ensure proper operation Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop 9 Raise the platform fully Hold the platform at this position using the RAISE button and move the maintenance prop to the service upright position Release the RAISE button to allow the platform to lower until it is resting on the maintenance prop 10 Secure the maintenance prop with the maintenance prop lock out 10 With the maintenance prop supporting the platform remove the lifting brackets and Clean Sweep frame section in between lip keepers if you haven t already done so 10 Release the maintenance prop by unlocking the lock out 12 Push and hold the RAISE button until the maintenance prop drops to its stored position Release the RAISE button and allow the platform to lower fully 13 Perform step 7 if not
54. the platform hinge area put the platform in the full below dock position Inspect the platform hinge and the lip hinge areas The hinge areas must be kept free of dirt and debris Build up of foreign material in the hinge areas will cause abnormal operation Quarterly Maintenance IMPORTANT Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler Lubricate the following areas with light weight machine oil A Lip hinge area unless equipped with grease fittings apply oil to the top of the entire length of lip hinge when platform is at the full below dock position and lip is folded C Platform hinge area apply oil to top of all platform hinges when platform is at the full below dock position E Platform cylinder to platform frame pin F Lip cylinder to platform frame pin G Lip lifter and lift cylinder pin Lubricate the following areas with white lithium grease B Valve lever pivot and top of logic block spool valve D All platform cylinder trunnions NOTE Apply grease to lip hinge grease fittings if equipped 4111 0004 Sept 2013 MAINTENANCE M Reservoir N 2 in 51 mm From Top of Reservoir IMPORTANT A low fluid level or the use of hydraulic fluids not equivalent to the fluid types recommended will cause abnormal operation of the leveler and WILL void warranty P Breather Cap Q Fluid Level Before performin
55. um 8 With rear hinge frame angle F tight against rear pit curb angle G perform check the following Pry between the platform and rear hinge frame angle at locations E to make sure rear edge of platform is parallel to the rear hinge frame angle F e Gap D must exist equally along both sides of leveler so weather seal if equipped will not bind during dock leveler operation 14 E Pry Locations F Rear Hinge Frame INNA G Rear Pit Curb Angle H Flare Bevel Weld Typical Angle To Fit Spacing 9 If gap D cannot be obtained equally at both sides of leveler grind or add material at the rear edge of rear hinge frame angle F as needed 10 Allow the dock leveler to rest fully on the shim stacks Check that a smooth and level transition exists between the dock floor and the dock leveler platform Add or remove shims as necessary until a smooth transition is obtained 11 If leveler cannot be squared and or made level as instructed in steps 8 10 contact Poweramp Technical Services 4111 0004 Sept 2013 DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always ke
56. us personal injury or death 1 Mount the push button control panel B so bottom of control panel to dock floor distance C is 48 in The electrical power must be OFF prior to electrical 1219 2 mm installation For maximum protection use an OSHA approved locking device to lock out all power 2 Install electrical disconnect panel A if not already sources Only the person installing the equipment installed should have the key to unlock the power source 3 Install and connect the control wiring Failure to follow these instructions may result in serious personal injury or death 4 Connect the dock leveler power cable to the field wires in the pit junction box Refer to the electrical drawings supplied with the dock leveler 5 After all electrical connections in the pit have been made disengage the maintenance prop and lower the platform using the external lifting device connected to the platform lifting brackets All electrical work including the installation of the disconnect panel control panel and final connections to the pit junction box must be performed by a certified electrician and conform to all local and applicable national codes 18 4111 0004 Sept 2013 Put New Dock Leveler Into Service 1 Disconnect the external lifting device and chains from the lifting brackets 2 Check that the leveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly
57. vates the leveler 31 ADJUSTMENTS Full Below Dock Position Lip Keeper Whenever the platform lip is at the full below dock position the following conditions will exist for a normally operating ARTD Proximity switch senses target Proximity switch ON closed signal sent to the control panel Proximity switch indicator light is ON Platform will automatically rise after approximately a six second delay then returns to the cross traffic position 32 Lip Fully Extended Position Whenever the platform lip is at the fully extended position the following conditions will exist for a normally operating ARTD Target not in the sensing area of proximity switch Proximity switch OFF open no signal sent to the control panel Proximity switch indicator light is OFF If the platform lip is resting on the truck bed the platform will stay at this position unless the operator activates the leveler 4111 0004 Sept 2013 TROUBLESHOOTING Troubleshooting When service under the dock leveler is required Always stand clear of the dock leveler lip when always lock all electrical disconnects in the OFF working in front of the dock leveler position after raising the platform and engaging the maintenance prop Failure to do this may result in The maintenance prop MUST be in the service serious personal injury or death position when working under the dock leveler For maximum protection use an OSHA

Poweramp EH Manual Sept2013

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