SYSTEMS Poweramp EH Series Owner'S Manual Download

Page: 47 / 62

4111-0004 — Apr. 2021

Symptom

Possible Cause

Solution

Platform does not rise to

full height.

Low hydraulic fluid.

Add fluid, see pages 30-31 for proper fluid level and

type.

Lip does not stay

extended when leveler

lowers.

S1 Sequence Valve requires

adjustment.

Adjust valve as necessary. See pages 32-35 for

adjustment instructions.

Platform DOES rise to

full height, but lip DOES

NOT extend or extend

fully.

Low hydraulic fluid.

Add fluid, see pages 30-31 for proper fluid level and

type.

S2 Sequence Valve 2

requires adjustment.

Adjust valve as necessary. See pages 32-35 for

adjustment instructions.

Lip does not extend.

S2 Sequence Valve 2

requires adjustment.

Adjust valve as necessary. See pages 32-35 for

adjustment instructions.

Lip extends almost

immediately when the

RAISE button is Pressed.

Platform rises after lip is

fully extended.

S2 Sequence Valve 2

requires adjustment.

Adjust valve as necessary. See pages 32-35 for

adjustment instructions.

Platform locks into

“safety” as platform

lowers. Lip drops to

vertical position.

Platform lowering speed is

too fast; NV1 Needle Valve

1 requires adjustment

Adjust valve as necessary. See pages 32-35 for

adjustment instructions.

Faulty velocity fuse.

Replace velocity fuse.

Incorrect or aged hydraulic

fluid.

Replace hydraulic fluid, see pages 30-31 for proper

fluid level and type.

Technical Service at 800-643-5424 or [email protected]

If additional troubleshooting assistance is required, contact Systems, LLC

Technical Services with equipment serial number or customer order number (CO#).

TROUBLESHOOTING

Summary of Contents for Poweramp EH Series

Page 1: ...2021 Systems LLC All Rights Reserved Manual No 4111 0004 Apr 2021 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: ...ational Precautions 24 Ramp Loading Unloading Instructions 26 End Loading Unloading Instructions 27 Optional Equipment 28 Maintenance Maintenance Precautions 29 Periodic Maintenance 30 Adjustments Valve Adjustments Monarch Bucher Powerpacks 32 Valve Adjustments Hoke KTI Powerpacks 34 Valve Adjustments Bucher 60K or 10 Levelers 36 Adjust Auto Return To Dock ARTD 38 Adjust Leveler Stored Switch 41 T...

Page 3: ...e 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 mess...

Page 4: ... 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 service and mai...

Page 5: ...t 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 PRECAUTIONS ...

Page 6: ...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 manual 2 Maintenance Se...

Page 7: ...LT IN DEATH OR OTHER SERIOUS INJURY DANGER POWERED DOCK LEVELERS NORMAL OPERATION 1 Raise the platform by Pressing 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 Press the RAISE button until the lip is completely folded When the lip is folded r...

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: ...oduct 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 lubrication...

Page 10: ...nits in the same control panel Each EH series dock leveler unit and control panel has been factory pre wired 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 Systems LLC Technical Services EH series dock levelers are available in the following sizes and weight ca...

Page 11: ...G Clean Sweep Removable Section H Maintenance Prop Lock Out J Maintenance Prop K Toe Guards 2 used L Lip Keepers 2 used M Control Box Inspect package and all components Report any missing or damaged items immediately and note on the shipping Bill Of Lading BOL Figure 4 INTRODUCTION M Control box appearance may vary depending on options A B C D E F G H J K L L K ...

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 INSTALLATION 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 d...

Page 13: ...11 4111 0004 Apr 2021 2021 Systems LLC INSTALLATION This page intentionally left blank ...

Page 14: ...sure 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 the...

Page 15: ...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 Dock Leveler on Page 14 DO NOT over tighten the lifting bracket hardware Over tightening can damage the weather seal if equipped DO NOT remove the ...

Page 16: ...ons 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 L F M H N G E K Figure 8 UN FRACT DECIM 00 000 ANGUL MATE DRAW c This print patent an not conve granted o C D A B J Figure 7 Inst...

Page 17: ...of the shim that contacts the leveler frame i e the top shim of each shim stack must be at least 4 x 4 101 6 mm x 101 6 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 location C i...

Page 18: ...y 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 floor and the dock leveler platfor...

Page 19: ...k 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 INSTALLATION If the platform is ...

Page 20: ...appropriate shimming method see Figure 13 Both platform cylinder trunnions must be solidly shimmed the entire length of the trunnion Make sure the trunnions are level from 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 t...

Page 21: ...nchored into place Only then should it be removed 21 Remove the Clean Sweep frame section C by grinding the tack welds that hold it in place during transport Paint after 22 Install the dock bumpers as required 23 Proceed to Install Control Panel and Wiring on Page 20 Install Dock Leveler continued INSTALLATION Figure 13 Offset w Load Over Center Acceptable Stepped Acceptable Pyramid Preferred Shim...

Page 22: ...ntrol wiring to the field wires in the dock equipment junction boxes Refer to the electrical diagrams supplied with the dock equipment Note When installing electrical controls in a temperature controlled environment the installer must determine an appropriate means to isolate prevent thermal and vapor transfer through electrical conduit where conduit routing crosses temperature zones Systems LLC i...

Page 23: ... k E Danfoss Control Panel Wiring 1 Phase Danfoss Control Panel Wiring 3 Phase INSTALLATION 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 ...

Page 24: ...ls online www Loadin gDockSyste ms com WARNING CANCER AND REPRODUC TIVE HARM www P65Wa rnings ca gov OP E R AT I N G INSTRUCTIONS Read and follow all instructions warnings and maintenance schedules in the manual and on placards Operation and servicing of dock leveler is restricted to authorized personnel Always chock transport vehicle wheels or engage vehicle restraint and set parking brakes befor...

Page 25: ...release the 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...

Page 26: ...al Precautions 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 EH hydraulic dock leveler is designed to compensate for a maxim...

Page 27: ...25 4111 0004 Apr 2021 2021 Systems LLC OPERATION This page intentionally left blank ...

Page 28: ...utton until the lip is fully extended then release the RAISE button The platform will lower until the lip is resting 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...

Page 29: ... 5 5 Raise the platform by pressing and holding the RAISE button until the lip extends just enough to clear the lip keepers then release the RAISE button 6 Allow the platform to drift down to the full below dock position Operating Instructions continued Figure 18 7 Proceed with loading or unloading see Figure 19 Note When end unloading is finished and access to the rest of the transport vehicles i...

Page 30: ... EMERGENCY STOP button outward 4 Continue operating dock equipment as needed Auto Return To Dock ARTD Note For dock levelers equipped with optional Auto Return To Dock ARTD the dock leveler can self store if a transport vehicle departs the loading dock before the platform is stored To enable Auto Return To Dock turn the ARTD switch to the ON position If end loading or unloading is required turn th...

Page 31: ...hould 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 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 maintenan...

Page 32: ...astrol Brayco Micronic 756 These fluid brands can be mixed together Use of hydraulic fluids with equivalent specifications to those listed here are acceptable Use of fluids that do not have equivalent specifications to those in the preceding list will result in abnormal operation of the dock leveler and voiding of warranty Figure 23 A B C D E F Weekly Maintenance Operate the dock leveler through t...

Page 33: ...ricate the following areas with white lithium grease see Figure 23 D All platform cylinder trunnions Note Apply grease to lip hinge grease fittings if equipped Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler Check reservoir fluid level C see Figure 24 1 Raise platform fully and engage the maintenance prop in the service position Allow platform to rest on...

Page 34: ...LC A S1 Valve B S2 Valve C RV1 Valve D NV1 Valve E Breather Cap F To Hoist Cylinder G To Lip Cylinder ADJUSTMENTS Valve Adjustments Monarch Bucher Powerpacks 9 2010 present A B C D E F G Valve location varies by production date Figure 25 ...

Page 35: ...HK Pilot Operated Check Valve not shown Keeps Lip from collapsing until it is below dock This valve is not adjustable If lip malfunctions cleaning or replacement may be required All Poweramp EH dock levelers are factory tested and should not require additional adjustments in the field Consult Systems LLC Technical Services if minor adjustments do not result in proper operation Whenever valve adjus...

Page 36: ...Valve D 2W NO Spool Valve E NV1 Valve 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 ADJUSTMENTS Valve Adjustments Hoke KTI Powerpacks pre 9 2010 B C D E F G H A Figure 26 ...

Page 37: ... adjust unless specifically instructed by Systems LLC Technical Services Optional 2W Normally Open Spool Valve D If present allows operation of Lip Out and Emergency Stop functions when solenoid coil is energized NV1 Needle Valve 1 E 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 not ...

Page 38: ...36 4111 0004 Apr 2021 2021 Systems LLC ADJUSTMENTS Valve Adjustments Bucher Powerpacks 60K or 10 Levelers A Needle Valve B Sequence Valve C RV1 Valve Figure 27 A B C ...

Page 39: ... small increments until lip begins to extend If the lip extends too early before platform reaches full height turn the sequence valve clockwise in small increments until correct performance is achieved Tighten jam nut after adjustment RV1 Main Relief Valve C Sets system pressure This valve has a security lock to prevent adjustment Do not adjust unless specifically instructed by Systems LLC Technic...

Page 40: ...switch provides a six second delay after the platform has lowered to the full below dock position after which the platform will return 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 A...

Page 41: ...ly extended then allow the platform to drift to the below dock position After approximately 6 seconds the platform should 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 Note Use the illustrations on page 40 to assist in fine tuning and o...

Page 42: ...nal sent to the control panel Proximity switch indicator light is OFF If the platform lip is resting on the transport vehicle bed the platform will stay at this position unless the operator activates the leveler Cross Traffic Lip Fully Folded Position Note The platform lip is fully folded when the platform is at the cross traffic position stored with lip engaged with keepers or when platform is re...

Page 43: ... behind the header Then lockout tag out the equipment 2 When the sensor and target are positioned correctly the target should be parallel to the face of the sensor with a gap of 1 4 when the lip is in the stored position See Figure 33 3 To adjust the sensor loosen the nuts C around the sensor body to move the sensor and achieve the correct gap 4 Verify that the target will not contact the sensor f...

Page 44: ...rvice 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 applicable head protection should always be worn when...

Page 45: ...nnection Three phase units only Platform does not rise Motor runs in reverse Phase reversed Reverse any two legs at the branch circuit disconnect Single phase units only Platform does not rise Motor energizes but does 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 ...

Page 46: ... and type Contaminated hydraulic system Clean and inspect valves Flush contaminated oil from hydraulic system Fill system with new oil See page 31 Damage or blocked hydraulic hose s and or valve s Replace damaged hose s Check and remove blockage from hose s and or valve s Pressure relief set too low Increase pressure relief Contact Systems LLC Technical Services for instruction Note The pressure r...

Page 47: ... necessary See pages 32 35 for adjustment instructions Lip extends almost immediately when the RAISE button is Pressed Platform rises after lip is fully extended S2 Sequence Valve 2 requires adjustment Adjust valve as necessary See pages 32 35 for adjustment instructions Platform locks into safety as platform lowers Lip drops to vertical position Platform lowering speed is too fast NV1 Needle Valv...

Page 48: ...1 Phase Danfoss Control Box MTR 3627B 7141 0269 230v 1 Phase Danfoss Control Box MTR 3627C 7141 0310 208v 3 Phase Danfoss Control Box MTR 3627D 7141 0270 230v 3 Phase Danfoss Control Box MTR 3627E 7141 0271 460v 3 Phase Danfoss Control Box MTR 3627F PARTS Provide dock leveler serial number voltage phase and options when e mailing calling or faxing controller orders ...

Page 49: ...h Harness ARTD Feature Only B 1 Control Box w Optional Equipment C 1 9511 0004 J Box Standard 4 x 4 in Metal Box 2751 0042 J Box Cold Weather 5 x 5 in Plastic Box Provide dock leveler serial number voltage phase and options when e mailing calling or faxing controller orders Optional Electrical Parts PARTS C B A ...

Page 50: ...48 4111 0004 Apr 2021 2021 Systems LLC Frame and Platform PARTS Detail A Detail A A B C D E F G H J J K L M N P ...

Page 51: ... 0047 Cotter Pin 1 4 x 2 in G 3 9202 0002 Rear Hinge Pin H AR 2101 0039 Nylon Lock Nut 5 16 18 UNC J AR 2101 0163 Washer 5 16 in Flat K AR 2101 0011 Cap Screw 5 16 18 UNC x 1 in L 2 2101 0046 Cotter Pin 1 4 x 1 1 4 in M 1 9225 ____1 Maintenance Prop Rod N 1 9201 0006 Prop Pin and Clip P 2 8432 ____1 Lip Keeper Frame and Platform AR As Required 1 Provide dock leveler serial number platform size and...

Page 52: ...NG NO DATE KRV 4 12 2018 S Y S T E M S I N C L o a d i n g D o c k E q u i p m e n t P O W E R A M P M C G U I R E D L M This print is the property of Systems Inc and represents a proprietary article in which Systems Inc retains any and all patent and other rights including exclusive rights of use and or manufacture and or sale Possession of this print does not convey any permission to reproduce p...

Page 53: ...9 0060 Tube Vent 3 8 OD x 1 16 Wall N 2 0521 0007 Elbow 90 1 4 NPT Male x 1 4 Tube P 1 9301 0111 Fitting 6 ORB Male x 8 JIC Male Q 1 9904 0128 Hose Lip Cylinder 6 Leveler 9904 0129 Hose Lip Cylinder 8 Leveler 9904 0130 Hose Lip Cylinder 10 Leveler R 1 8581 0127 Velocity Fuse 4GPM 8 Male Straight Thread ORB to 8 JIC Male S 1 9904 0128 Hose Platform Cylinder T 2 2101 0047 Cotter Pin 1 4 x 2 Long U 1...

Page 54: ...52 4111 0004 Apr 2021 2021 Systems LLC Monarch Bucher Powerpack Assembly 9 2010 present PARTS Pump Motor I F H G B C A A D E K J Valve Block Valve location varies by production date ...

Page 55: ...educer Pipe 3 4 NPTM to 1 4 NPTF Monarch Bucher Powerpack Components PARTS 1 Provide dock leveler serial number and type of installation when e mailing calling or faxing orders 2 Provide dock leveler serial number voltage and phase when e mailing calling or faxing orders Monarch Three Phase Wiring 208 230 Volt 6 5 4 T1 T2 T3 9 8 7 3 2 1 460 Volt 6 5 4 9 8 7 3 2 1 T1 T2 T3 Current Monarch Single Ph...

Page 56: ...54 4111 0004 Apr 2021 2021 Systems LLC Hoke KTI Powerpack Assembly pre 9 2010 PARTS A D E I G F B J C H ...

Page 57: ...to 1 4 NPTF H 1 9391 0032 O Ring Powerpack I 1 9391 0031 Breather Hoke Powerpack J 1 9391 0030 Reservoir 4 Quart Hoke H8 PARTS 1 Provide dock leveler serial number and type of installation when e mailing calling or faxing orders 2 Provide dock leveler serial number voltage and phase when e mailing calling or faxing orders 208 230 Volt 460 Volt 6 5 4 3 2 1 T1 T2 T3 9 8 7 4 5 6 T1 T2 T3 3 2 1 9 8 7 ...

Page 58: ... 4 CARTRIDGE VALVE 2 WAY N O SPOOL 8581 0116 1 5 TOLERANCES UNLESS OTHERWISE NOTED FRACTIONAL 1 32 DECIMAL 00 01 000 005 ANGULAR 1 MATERIAL DRAWN BY CHECKED BY DRAWING NO DATE KRV 8 23 201 8583 0072 EH ESTOP LIPOUT VALVE ASSEMBLY P O W E R A M P M C G U I R E D L M L o a d i n g D o c k E q u i p m e n t This print is the property of Systems Inc and represents a proprietary article in which System...

Page 59: ...es 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 Se...

Page 60: ...oth Sides B 2 0011 0052 Toe Guard Middle 6 Foot 0011 0054 Toe Guard Middle 8 Foot 0011 0056 Toe Guard Middle 10 Foot C 2 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 Screw HHCS 3 8 16 x 1 25 E 6 2101 0060 Washer Flat 3 8 F 2 2101 0040 Locknut Nylon Insert 3 8 16 G 2 0011 0010 Platform Mounting Tab A G Provide dock leveler serial ...

Page 61: ...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 ________________________________ S...

Page 62: ...OT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS LLC 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 S...

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