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Poweramp EH Series Owner & User Manual

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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: 262.257.7399 • www.docksystemsinc.com • techservices@docksystemsinc.com
Printed in U.S.A.
Manual No. 4111-0004
Sept 2010
Copyright
2003
©
Rev "B" February 2011

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Summary of Contents for Poweramp EH Series

  • Page 1 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: 262.257.7399 • www.docksystemsinc.com • techservices@docksystemsinc.com Printed in U.S.A. Manual No. 4111-0004 Sept 2010 Copyright 2003 ©...

  • Page 2: Table Of Contents

    Table of Contents Page Safety Recognize Safety Information ....... 1 General Operational Safety Precautions .

  • Page 3: Safety

    SAFETY Recognize Safety Information General Operational Safety Precautions 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 Read and understand the operating instructions and the instructions in the safety message.

  • Page 4: Operational Safety Precautions

    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. Stay clear of dock leveling device when freight Chock/restrain all freight carriers. Never remove carrier is entering or leaving area.
  • Page 5 SAFETY Do not use dock leveling device if freight carrier 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 leveling device.

  • Page 6: Maintenance Safety Precautions

    SAFETY Maintenance Safety Precautions 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.

  • Page 7: Safety Decal's

    SAFETY 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. DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar.

  • Page 8: Owner's User's Responsibilities

    OWNER’S/USER’S RESPONSIBILITIES 1. 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.

  • Page 9: Introduction

    Call Poweramp to discuss available voltages, phases and options to meet your specific needs. 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.

  • Page 10: Component Identification

    INTRODUCTION Component Identification A — Lip E — Powerpack (Motor/Pump/Reservoir) H —Maintenance Prop L —Control Box B — Lip Prop F — Platform Cylinder Lock-Out M —Raise Button C —Platform G— Main Frame J— Maintenance Prop N—ARTD Switch (option) D — Lip Cylinder H—...
  • Page 11 This page intentionally left blank 4111-0004 —November 2003 Rev “B” February 2011...

  • Page 12: Installation

    If any measurement is off by more than 1/8 in. DO NOT remove the shipping bands around the (3.18 mm), contact Poweramp Technical Services dock leveler lip until instructed to do so. before proceeding.

  • Page 13: Prepare Dock Leveler

    A— Lifting Bracket (2 used) B — Shipping Bands Poweramp dock leveler's are designed with NOTE: Overall width of platform and lifting brackets installation in mind. Each unit is shipped with lifting (A) must be kept to a minimum to prevent brackets (A) fastened to the platform side joists.

  • Page 14: Install Dock Leveler

    INSTALLATION Install Dock Leveler Shim Stacking Methods See page 16 for Hoist cylinder shimming A— Distance (Leveler Frame G— String Height) H— Rear Hinge Frame Angle B— Shim Locations (Under J— Distance (Dock Floor-to-Pit Rear Vertical Supports) Floor) C— Shim Location (Under K—...
  • Page 15 INSTALLATION NOTE: Poweramp dock leveler's are designed with a 4. For all EH models, put a 1/4 in. (6.6 mm) thick nominal 1/2 in. (12.7 mm) shimming distance shim at locations (C and D) . to allow for pit inconsistencies.
  • Page 16 (if equipped) will not bind during dock leveler operation. 11. If leveler cannot be squared and/or made level as instructed in steps 8 — 10, contact Poweramp Technical Services. 4111-0004 —November 2003 Rev “B” February 2011...
  • Page 17 INSTALLATION IMPORTANT DO NOT grind or weld if hydraulic fluid DO NOT weld continuously along the full length of or other flammable liquid is present on the surface the rear hinge frame angle. This can put to be ground or welded. unnecessary stress on the leveler components, causing the leveler to malfunction and shorten the DO NOT grind or weld if uncontained hydraulic...
  • Page 18 Slowly raise platform again. If platform still binds, contact Poweramp Technical Services for further instructions. DO NOT use the maintenance prop to support the raised platform until the maintenance prop has 16.
  • Page 19 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.

  • Page 20: Install Control Panel And Wiring

    INSTALLATION Install Control Panel and Wiring The electrical power must be OFF prior to electrical installation. For maximum protection, use an OSHA approved locking device to lock out all power sources. Only the person installing the equipment should have the key to unlock the power source. Failure to follow these instructions may result in serious personal injury or death.

  • Page 21: Put New Leveler Into Service

    NOTE: For dock leveler's equipped with the Auto floor and leveler and/or lip does not contact both Return To Dock (ARTD), the platform will lip keepers evenly, contact Poweramp Technical automatically return to the cross-traffic Services for further instructions. position if the ARTD is enabled. When the platform is at the full below-dock position, 3.

  • Page 22: Operation

    OPERATION Operating Instructions Stay clear of dock leveler when freight carrier is 12 in. (305 mm) entering or leaving dock area. DO NOT move or use the dock leveler if anyone is under or in front of leveler. 12 in. (305 mm) Keep hands and feet clear of pinch points.

  • Page 23: Ramp Loading/Unloading Instructions

    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. 1.

  • Page 24: End Loading/Unloading Instructions

    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 truck/trailer bed.

  • Page 25: Maintenance

    MAINTENANCE Service Dock Leveler Safely Side View A— Lip Maintenance Prop B —Tag Out Device C — Lock Out Device E.—3 Styles of Lock When service under the dock leveler is required, Always post safety warnings and barricade the always lock all electrical disconnects in the OFF work area at dock level and ground level to prevent position after raising the platform and engaging the unauthorized use of the dock leveler before...

  • Page 26: Periodic Maintenance

    MAINTENANCE Periodic Maintenance A— Lip Hinge Area C— Platform Hinge Area E— Platform Cylinder-to-Platform Pin B— 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 or Before performing any maintenance under the exceed military specification MIL-L-5606.
  • Page 27 MAINTENANCE 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 the platform hinge area, put the platform in the full below-dock position.

  • Page 28: Adjustments

    ADJUSTMENTS Valve Adjustment Procedure NOTE: All Poweramp EH leveler's are factory tested and should not require additional adjustments in the field. Consult the factory if When service under the dock leveler is required, minor adjustments do not result in proper always lock all electrical disconnects in the OFF operation.

  • Page 29: Valve Adjustment Procedure

    ADJUSTMENTS Valve Adjustment Procedure Hoke / KTI A—S2 Valve C—S1 Valve E— NV1 Valve G—To Hoist Cylinder B— RV1 Valve D— 2W NO Spool Valve/Coil F— Breather Tube/Fitting 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.
  • Page 30 ADJUSTMENTS Valve Adjustment Procedure Monarch 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.
  • Page 31 This page intentionally left blank 4111-0004 —November 2003 Rev “B” February 2011...

  • Page 32: Adjust Auto Return To Dock (Artd)

    ADJUSTMENTS Adjust Auto Return To Dock (ARTD) Adjust the ARTD as Follows: 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.
  • Page 33 ADJUSTMENTS IMPORTANT 6. Turn ON electrical power to the dock leveler. Anytime proximity switch and target are adjusted, 7. Disengage the maintenance prop. always check for interference between target and switch before operating the leveler. Damage to 8. Turn the ARTD switch (on control panel) switch will occur if the target contacts the switch.
  • Page 34 ADJUSTMENTS Full Below-Dock Position Lip Fully Extended Position Lip Keeper 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. Whenever the platform lip is at the full below-dock •...

  • Page 35: Troubleshooting

    TROUBLESHOOTING Troubleshooting Always stand clear of the dock leveler lip when When service under the dock leveler is working in front of the dock leveler. required, always lock all electrical disconnects in the OFF position after raising the platform and The maintenance prop MUST be in the service engaging the maintenance prop.
  • Page 36 TROUBLESHOOTING Symptom Possible Cause Solution Three-phase units only: No voltage is present on Check for blown fuses at branch circuit disconnect. Platform does not rise. one line. Replace fuse. Determine cause of blown fuse. Motor hums, but does not run. NOTE: A motor that is Check motor starter as follows: missing voltage on one line...
  • Page 37 Dock leveler binds. 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. Pressure relief set too low. Increase pressure relief. See Adjust Main Pressure Relief in the Adjustment section.
  • Page 38 TROUBLESHOOTING Symptom Possible Cause Solution 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”...

  • Page 39: Parts

    PARTS Controls Optional Control Box Standard Control Box Item Quantity Part Number Description 0961-0085 Proximity Switch with Harness (ARTD Feature Only) Push Button Controller 9511-0004 J-Box, Standard (4 x 4 in. Metal Box) 9512-0429 J-Box, Cold Weather (5 x 5 in. Plastic Box) * Provide dock leveler serial number, voltage, phase, and options when calling or faxing controller orders 4111-0004 —November 2003 Rev “B”...

  • Page 40: Frame And Platform

    PARTS Frame and Platform 4111-0004 —November 2003 Rev “B” February 2011...
  • Page 41 PARTS Frame and Platform Item Quantity Part Number Description 0595-____ Lip, Welded Assembly 7823-____ Platform, Welded Assembly 9515-____ Pin, Lip Hinge 9202-____ Toe Guard Welded Assembly, Left 0015-____ Frame, EH 2101-0047 Cotter Pin, 1/4 x 2 in. 9202-0002 Rear Hinge Pin 2101-0039 Nylon Lock Nut, 5/16-18 UNC 9222-0382...

  • Page 42: Hydraulic Components

    PARTS Hydraulic Components 4111-0004 —November 2003 Rev “B” February 2011...
  • Page 43 PARTS Hydraulic Components Item Quantity Part Number Description 9391-0017 PPAC, Hoke H8, 1.5HP, 1PH, 115/230V, 1.97GPM 9391-0018 PPAC, Hoke H8, 1.5HP, 3PH, 208/230/460/575V, 1.97GPM 9391-0045 PPAC, Monarch, 1.25HP, 1PH, 115/230V, 9391-0046 PPAC, Monarch, 1.25HP, 3PH, 208/230/460/575V, 0521-0159 Cylinder, Platform, in. ( mm) Barrel Length 0525-0085 Lip Cylinder, in.

  • Page 44: Power Pack Assembly

    PARTS Hoke / KTI Power Pack Assembly Hoke PPAC Motor 115 Volt 1 PH 220 Volt 1 PH 208/230 Volt 3 PH 460 Volt 3 PH 4 5 6 6 5 4 T1 T2 T1 T2 9 8 7 9 8 7 3 2 1 3 2 1 T1 T2 T3...
  • Page 45 PARTS Hoke / KTI Power Pack Components Item Quantity Part Number Description Motor, Hoke H8, 1.5HP, 1726 RPM, 1PH, 115/230V Motor, Hoke H8, 1.5HP, 1726 RPM, 3PH, 208/230/460/575V 8581-0134 Coil & Nut for 8581-0133 Valve 8581-0133 Valve, 2 Way Normally Open 9301-0109 Fitting, #6 SAE to #6 JIC 8581-0130...
  • Page 46 PARTS Monarch Power Pack Assembly Motor Pump Valve Block Monarch PPAC Motor 115 Volt 1 PH 230 Volt 1 PH 460 Volt 3 PH 208/230 Volt 3 PH 6 5 4 6 5 4 9 8 7 9 8 7 3 2 1 3 2 1 T1 T2 T3...
  • Page 47 PARTS Monarch Power Pack Components Item Quantity Part Number Description 9301-0109 Fitting, #6 SAE to #6 JIC 8581-0128 Valve, Sequence, S1 (Red Tip) 8581-0136 Valve, Sequence, S2 (Silver Tip) 8581-0151 Needle valve, Down Speed 8581-0150 Valve, Pilot Operated Check 9301-0232 Strainer, Suction 9301-0233 Reservoir,Plastic...

  • Page 48: Weather Seal, Rubber Style

    PARTS Weather Seal, Rubber Style Item Quantity Part Number Description 0192-____* Foam Seal, Rear Hinge AR = As Required NOTE: 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 —November 2003 Rev “B”...

  • Page 49: Weather Seal, Brush Style

    PARTS Weather Seal, Brush Style Item Quantity Part Number Description 0195-0018 6’ Brush and Track, 1-1/2 in 0195-0021 8’ Brush and Track, 1-1/2 in 0195-0024 10’ Brush and Track, 1-1/2 in 0195-0027 12’ Brush and Track. 1-1/2 in 0192-0097 6’ Rubber Seal and Track, 1 in 0192-0098 8’...

  • Page 50: Electrical Diagram

    Electrical Jumper wire to be Jumper wire to be installed by others. installed by others. Note: 1 Phase control box show jumper will be the same for 3 phase control box’s. 4111-0004 —November 2003 Rev “B” February 2011...

  • Page 51: Miscellaneous

    MISCELLANEOUS Customer Information NOTE: Refer to illustration for left/right orientation of Dock Leveler Information dock leveler. Model ___________________________________ The model/serial number decal (A) is located on the right platform joist near the front (lip) Serial No. ________________________________ of dock leveler. Systems, Inc., Job No.

  • Page 52: Warranty

    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: • Structural Warranty – For a period of ten (10) years from the date of shipment, product will carry a prorated structural warranty.

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