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4111-0004 — Apr. 2021

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

This manual provides current information on the

EH-series dock leveler. Due to ongoing product

improvement, some parts may have changed, along

with operation and troubleshooting methods. This

manual describes these changes where applicable.

The EH-series dock leveler comes equipped with

an electrical control panel, which allows push button

operation of the dock leveler functions. When

combining a EH-series dock leveler with a Poweramp

hydraulic vehicle restraint, the control panel will allow

for operation of both units 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 capacities:

Width

6 ft (1829 mm)

6-1/2 ft (1981 mm)

7 ft (2134 mm)

Length

6 ft (1829 mm)

8 ft (2438 mm)

10 ft (3048 mm)

Capacity (CIR*)

25,000 lb (11 340 kg)

30,000 lb (13 608 kg)

35,000 lb (15 876 kg)

40,000 lb (18 144 kg)

45,000 lb (20 412 kg)

50,000 lb (22 680 kg)

60,000 lb (27 216 kg)

* CIR (Comparative Industry Rating)

Call Systems, LLC to discuss available voltages,

phases and options to meet your specific needs.

General Information

Figure 3

INTRODUCTION

Содержание Poweramp EH Series

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

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

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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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