Poweramp LHP Series Owner & User Manual Download Page 2

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Table of Contents

Page

Precautions

Recognize Precautionary Information ................................................ 1

General Operational Precautions ........................................................ 1

Operational Precautions ...................................................................... 2

Safety Decals ......................................................................................... 4

Placard ................................................................................................... 5

Owner’s/User’s Responsibilities ......................................................... 6

Introduction

General Information .............................................................................. 8

Component Identification ..................................................................... 9

Installation

Installation Precautions ...................................................................... 10

Prepare Pit ............................................................................................ 12

Prepare Dock Leveler .......................................................................... 13

Install Dock Leveler ............................................................................. 14

Install Control Panel and Wiring ........................................................ 20

Put New Dock Leveler Into Service .................................................... 24

Operation

Operational Precautions ..................................................................... 25

Operating Instructions ........................................................................ 26

Optional Equipment ............................................................................. 27

Maintenance

Maintenance Precautions .................................................................... 28

Periodic Maintenance .......................................................................... 30

Adjustments

Adjust Main Pressure Relief ............................................................... 32

Adjust Lip Function ............................................................................. 33

Troubleshooting

Troubleshooting ................................................................................... 34

Parts

Danfoss Control Box ........................................................................... 38

Optional Electrical Parts (Control Box) ............................................. 39

Lip and Platform Parts ........................................................................ 40

Hydraulic Components ........................................................................ 42

Weather Seals ...................................................................................... 44

Toe Guards ........................................................................................... 46

Miscellaneous

Customer Information ......................................................................... 49

Warranty ................................................................................ Back Cover

Summary of Contents for LHP Series

Page 1: ...2018 Systems LLC All Rights Reserved Manual No 4111 0012 Sept 2018 Poweramp Division of Systems LLC W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www poweramp com techservices poweramp com Owner s User s Manual ...

Page 2: ...ock Leveler 14 Install Control Panel and Wiring 20 Put New Dock Leveler Into Service 24 Operation Operational Precautions 25 Operating Instructions 26 Optional Equipment 27 Maintenance Maintenance Precautions 28 Periodic Maintenance 30 Adjustments Adjust Main Pressure Relief 32 Adjust Lip Function 33 Troubleshooting Troubleshooting 34 Parts Danfoss Control Box 38 Optional Electrical Parts Control ...

Page 3: ...re known to the State of California to cause cancer or birth defects or other reproductive harm For more information go to www P65Warnings ca gov Safety Alert Symbol The Safety Alert Symbol is a graphic representation intended to convey a safety message without the use of words When you see this symbol be alert to the possibility of death or serious injury Follow the instructions in the safety mes...

Page 4: ...nt of it Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Chock restrain all transport vehicles Never remove the wheel chocks or release the restraining device until loading or unloading is finished and transport driver has been given permission to drive away Do not use a broken or damaged dock leveling device or restraining device Make sure proper se...

Page 5: ...autions 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 leveling device ...

Page 6: ...ards warning labels or owner s user s manuals File Name 1751 0730 Rev B Decal Size 9 12 x 3 25 MAINTENANCE SERVICE 7 Stay clear of hinges and front and sides of moving dock leveler 8 N e v e r u s e d a m a g e d o r malfunctioning dock leveler Report problems immediately to supervisor 1 Read and follow all instructions w a r n in g s a n d m a i n t e n a n c e schedules in the owner s user s man...

Page 7: ...UCTIONS WILL RESULT IN DEATH OR OTHER SERIOUS INJURY POWERED DOCK LEVELERS NORMAL OPERATION 1 Raise the platform by depressing and holding the RAISE button 2 Hold the RAISE button until 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 l...

Page 8: ...he interface between the loading dock and the transport 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 operating conditions and the manufacturer s specific ...

Page 9: ...roduct warranty the dock safety equipment must have been properly installed maintained and operated in accordance with all manufacturer s 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 lubricatio...

Page 10: ...t the control panel will allow for operation of both units in the same control panel Each LHP series dock leveler unit has been factory 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 Systems LLC Technical Services LHP dock levelers are available in the following si...

Page 11: ...latform Cylinder G Main Frame H Lip Keepers J Full Range Toe Guards K Control Box Component Identification Inspect package and all components Report any missing or damaged items immediately and note on the shipping Bill Of Lading BOL Control box appearance may vary depending on options Figure 4 INTRODUCTION K A D B C F E G J H ...

Page 12: ...ilure to follow these instructions may damage the motor hydraulics wiring and or control panel Installation Precautions DO NOT remove the shipping bands around the dock leveler lip until instructed to do so Only trained installation professionals with the proper equipment should install this product It is recommended and good safety practice to use an additional means to support the dock platform ...

Page 13: ...11 4111 0012 Sept 2018 2018 Systems LLC This page intentionally left blank INSTALLATION ...

Page 14: ...asure dock floor to pit floor distance B at all four corners Measure pit length distance C at both sides Measure corner to corner diagonal distance D at both sides Take measurements at dock floor level and at pit floor level If any measurement is off by more than 1 8 in 3 18 mm contact Systems LLC Technical Services before proceeding 3 Make sure the field junction box for the dock leveler is at th...

Page 15: ...e sure the mounting hardware of lifting brackets A is snug The brackets should pivot without binding on the mounting cap screw 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 5 Proceed to Install Doc...

Page 16: ...aintenance Prop D Shim Locations Under Lip Keepers E Dock Floor F Rear Pit Curb Angle G String H Rear Hinge Frame Angle J Shims Location Under Hoist Cylinder K Distance Dock Floor to Pit Floor L Distance Top of Shim Stack to Dock Floor M Shim Stack N Dock Leveler Frame P Lip Keeper Shim as required Figure 9 Install Dock Leveler P L F M H N G E K Figure 8 Figure 7 ...

Page 17: ...him that contacts the leveler frame i e the top shim of each shim stack must be at least 4 1 2 x 4 1 2 114 3 mm 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 Note A 1 4 6 6 mm thick shim at locations C ...

Page 18: ...ame angle F Gap D must exist equally along both sides of leveler so weather seal if equipped will not bind during dock leveler operation 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...

Page 19: ...rk truck attached to the platform lifting brackets slowly raise the platform Check for binding as platform is being raised 16 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 Systems LLC Technical Services for further instructions Install Dock Leveler continued If the platform is raised using...

Page 20: ...side to side as well as from front to back 19 Finish weld all shims using a fillet weld Weld all shims within each shim stack to each other then weld the shim stack to the leveler frame Weld the front leveler frame shim stacks to the front pit curb steel 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 ...

Page 21: ... Leveler continued LH models are shipped with a front frame section C installed This temporary frame holds the leveler frame at the correct dimensions until the leveler is permanently anchored into place Only then should it be removed There are four cap screws and nuts that fasten the T frame to the rest of the leveler frame Tack welds may also be used Offset w Load Over Center Acceptable Stepped ...

Page 22: ...Always ground welding equipment to the dock leveler frame NEVER to the platform Failure to follow these instructions may damage the motor hydraulics wiring and or control panel Make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes All electrical work including the installation of the disconnect panel control panel and final...

Page 23: ...s Control Panel Wiring 3 Phase Jumper wire A1 to L2 Jumper wire A1 to L2 Jumper wire L1 to 95 Jumper wire L1 to 95 Note All Danfoss control boxes require jumper wires shown to be added for push button to function INSTALLATION Voltage Motor FLA 208V 3 7A 230V 3 8A 460V 1 9A Voltage Motor FLA 115V 13 8A 208V 6 9A 230V 6 9A ...

Page 24: ...ler and or vehicle restraint operations Suggested placement of placard is near control box attached to electrical conduit by using nylon cable tie If there is no control box present mount placard on wall to the immediate left of leveler at eye level A B C D A Control Box B Placard C Nylon Cable Tie D Conduit Placard Installation Instructions Control Box Conduit Nylon Tie Placard Owner Users are re...

Page 25: ...23 4111 0012 Sept 2018 2018 Systems LLC INSTALLATION This page intentionally left blank ...

Page 26: ... RAISE button to allow the platform to lower to the cross traffic stored position lip engages lip keepers Put New Dock Leveler Into Service Note For dock levelers 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 w...

Page 27: ...tions Stay clear of dock leveler and vehicle restraint when transport vehicle is entering or leaving dock area DO NOT move or use the dock leveler or restraint 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 12 in 305 mm 12 in 305 mm The LHP hydraulic dock leveler is designed to compensate for a maximum 12 in...

Page 28: ...g on the 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 See Figure 16 5 Proceed with loading or unloading the transport vehicle Operating Instructions Figure 16 6 When loading or unloading is finished raise the platform by pressing an...

Page 29: ...to clear the lip keepers then release the RAISE button 6 Allow the platform to drift down to the full below dock position 7 Proceed with loading or unloading see Figure 19 Operating Instructions continued Figure 18 Figure 19 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 Ins...

Page 30: ...inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to OSHA regulations 1910 146 Confined Space and 1910 147 Lockout Tagout 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 Unless the dock leveler is equipped with a tethered remote two peo...

Page 31: ...29 4111 0012 Sept 2018 2018 Systems LLC MAINTENANCE This page intentionally left blank ...

Page 32: ... brands can be mixed together Use of hydraulic fluids with equivalent specifications to those listed here are acceptable 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 Inspect the platform hinge and the lip hinge areas The hinge areas must be...

Page 33: ...orm is at the full below dock position Lubricate the following areas with white lithium grease C Platform cylinder pins D Lip cylinder pins Note Apply grease to lip hinge grease fittings if equipped Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler E Reservoir G Fluid Level F Breather Cap Check reservoir fluid level G see Figure 24 1 Put the dock leveler p...

Page 34: ... leveler 8 Remove lock out tag out devices 9 Disengage the maintenance prop 10 Cycle leveler and verify pressure relief setting 11 Repeat steps 1 10 as necessary 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 Always post safety warnings and barricade the work area at dock level ...

Page 35: ...tory If the lip will not fully retract when the platform returns to the stored position turn sequence valve counterclockwise in 1 4 turn increments 6 Tighten the jam nut 7 Turn ON electrical power to the dock leveler 8 Remove lock out tag out devices 9 Disengage the maintenance prop 10 Cycle leveler and verify lip operation 11 Repeat steps 1 10 as necessary A Sequence Valve B Pressure Relief Valve...

Page 36: ...two legs at the branch circuit disconnect 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 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 A hard hat or other appl...

Page 37: ... not run 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 Replace if necessary Faulty motor centrifugal switch Replace motor Faulty motor capacitor Replace motor Platform does not rise Pump operates in pressure relief mode Heavy object s on platform Remo...

Page 38: ... 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 Pump motor loads down when platform reaches the full raised position Pressure relief set too high Decrease pressure relief See page 32 for instruction Note The pressure relief valv...

Page 39: ... instructions Lip extends almost immediately when the RAISE button is depressed Sequence Valve requires adjustment Adjust valve as necessary See page 33 for adjustment instructions Platform locks into safety as platform lowers Lip drops to vertical position Faulty velocity fuse Replace velocity fuse Incorrect or aged hydraulic fluid Replace hydraulic fluid see pages 30 31 for proper fluid level an...

Page 40: ...1 Phase Danfoss Control Box MTR 3627A 7141 0269 230v 1 Phase Danfoss Control Box MTR 3627C 7141 0270 230v 3 Phase Danfoss Control Box MTR 3627E 7141 0271 460v 3 Phase Danfoss Control Box MTR 3627F Provide dock leveler serial number voltage phase and options when e mailing calling or faxing controller orders PARTS ...

Page 41: ...18 Systems LLC PARTS Part Number Description Control Box w Optional Equipment Provide dock leveler serial number voltage phase and options when e mailing calling or faxing controller orders Optional Electrical Parts Control Box ...

Page 42: ...40 4111 0012 Sept 2018 2018 Systems LLC PARTS B A D C Lip and Platform Parts ...

Page 43: ...T WIDTH 16 DLIP 1274 DLIP 1280 DLIP 1283 18 DLIP 1275 DLIP 1281 DLIP 1284 20 DLIP 1276 DLIP 1282 DLIP 1285 COMPONENTS B 2 DPLA 2101 6 0 FOOT LIP SHAFT DPLA 2102 6 5 FOOT LIP SHAFT DPLA 2103 7 0 FOOT LIP SHAFT C 2 8432 0983 16 LIP KEEPER 8432 0984 18 LIP KEEPER 8432 0985 20 LIP KEEPER 8432 0986 16 LIP KEEPER 24 PIT MODELS 8432 0987 18 LIP KEEPER 24 PIT MODELS 8432 0988 20 LIP KEEPER 24 PIT MODELS D...

Page 44: ...42 4111 0012 Sept 2018 2018 Systems LLC PARTS Hydraulic Components A B C D E F G G G G H J K K L L L L M M N N P ...

Page 45: ...e 3 GPM G 4 DOTH 2739 90 Deg Swivel 3 8M x 1 4F H 1 DOTH 2854 Powerpack 115 230v 1ph 60Hz DOTH 2855 Powerpack 230 460v 3ph 60Hz DOTH 2856 Powerpack 110 220v 1ph 50Hz DOTH 2857 Powerpack 208 380v 3ph 50Hz J 1 DFRA 1205 Pivot Pin 1 OD x 9 1 8 K 2 DOTH 2205 Washer 1 3 4 OD x 1 1 8 ID x 1 8 L 4 DOTH 2382 Pin Cotter 1 4 x 2 M 2 DOTH 2815 Pin Hitch Clip N 2 DOTH 2816 Pin Clevis 1 x 3 P 1 DPLA 0389 Pin M...

Page 46: ...des Item Quantity Part Number Description B 1 0192 0098 Brush Refill 1 1 2 in 82 Lg C 1 0192 0085 Rubber Refill 1 1 2 in 82 Lg D 1 0192 0146 Replacement Channel Item Quantity Part Number Description E 1 0195 0044 Rear Brush Weather Seal Universal F 1 0195 0046 Rear Foam Seal Self Adhesive Pre Cut 6 Wide Levelers 0195 0047 Rear Foam Seal Self Adhesive Pre Cut 6 5 Wide Levelers 0195 0048 Rear Foam S...

Page 47: ...45 4111 0012 Sept 2018 2018 Systems LLC PARTS This page intentionally left blank ...

Page 48: ... Sliding 10 Includes Both Sides B 1 0011 0052 Toe Guard Middle 6 Foot 0011 0054 Toe Guard Middle 8 Foot 0011 0056 Toe Guard Middle 10 Foot C 1 0011 0051 Toe Guard Lower 6 Foot 0011 0053 Toe Guard Lower 8 Foot 0011 0055 Toe Guard Lower 10 Foot D 2 DOTH 2043 Cap Screw E 6 DOTH 2207 Washer F 2 DOTH 2131 Lock Nut G 2 0011 0010 Platform Mounting Tab A G Provide dock leveler serial number and size of pl...

Page 49: ...47 4111 0012 Sept 2018 2018 Systems LLC PARTS This page intentionally left blank ...

Page 50: ...48 4111 0012 Sept 2018 2018 Systems LLC This page intentionally left blank MISCELLANEOUS ...

Page 51: ... 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 LLC P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 www loadingdocksystems com Dock Leveler Information Model ___________________________________ Serial No ________________________________ ...

Page 52: ... 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 LLC covered by this warranty SYSTEMS LLC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This sh...

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