Poweramp EH Series User manual

POWERAMP • Division of Systems, Inc. • W194 N11481 McCormick Drive • ermantown, WI 53022
800.643.5424 • fax: [phone] • www.docksystemsinc.com • [email protected]
EH SERIES
Dock Leveler
Owner’s/User’s Manual
Printed in U.S.A.
Copyright ©2003
Manual No. 4111-0004
Sept 2010
Rev “B” February 2011

Page
Safety
Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 1
Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Decal's . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Owner’s User’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introduction
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dock eveler Stock Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation
Prepare Pit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Prepare Dock eveler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Install Dock eveler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install Control Panel and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Put New eveler Into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operation
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ramp oading/Unloading Instructions . . . . . . . . . . . . . . . . . . . . 21
End oading/Unloading Instructions . . . . . . . . . . . . . . . . . . . . . 22
Maintenance
Service Dock eveler Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Adjustments
Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Adjust Auto Return To Dock (ARTD) . . . . . . . . . . . . . . . . . . . . . . . . 30
Troubleshooting
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Parts
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Frame and Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Power Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Weather Seal, Rubber Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Weather Seal, Brush Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Miscellaneous
Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Customer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Table of Contents
4111-0004 —November 2003
Rev “B” February 2011

1
SAFETY
4111-0004 —November 2003
Rev “B” February 2011
Recognize Safety Information
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 DAN ER, WARNIN , or CAUTION
signs or Decal's on the equipment unless replacing
them.
General Operational Safety
Precautions
Do not start the equipment until all unauthorized
personnel in the area have been warned and have
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.
The use of the word DAN ER signifies the
presence of an extreme hazard or unsafe practice
which will most likely result in severe injury or
death.
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 WARNIN signifies the
presence of a serious hazard or unsafe practice
which may result in serious injury or death.
IMPORTANT
The use of the word IMPORTANT is to draw
attention to a procedure that needs to be followed
to prevent machine damage.
The use of the word CAUTION signifies possible
hazard or unsafe practice which could result in
personal injury.
Op
era
tin
g
Zo
ne
O
peratin
g Zon
e

2
SAFETY
4111-0004 —November 2003
Rev “B” February 2011
earn the safe way to operate this equipment. Read and understand the
manufacturer's instructions. If you have any questions, ask your supervisor.
Operational Safety Precautions
Stay clear of dock leveling device when freight
carrier 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.
Chock/restrain all freight carriers. Never remove
the wheel chocks until loading or unloading is
finished and truck driver has been given
permission to drive away.
Do not use a broken or damage dock leveling
device. Make sure proper service and
maintenance procedures have been performed
before using.
Make sure lip overlaps onto trailer at least 4 in.
(102 mm).
Keep a safe distance from both side edges.

3
SAFETY
4111-0004 —November 2003
Rev “B” February 2011
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.

4
SAFETY
4111-0004 —November 2003
Rev “B” February 2011
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.
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.
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 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 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.
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.
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.

5
SAFETY
4111-0004 —November 2003
Rev “B” February 2011
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.
CCCCa
6666<<<<66667777((((00006666,,,,1111&&&&
1751-0727
1751-0138
CRUSH HAZARD
Maintenance prop must
support leveler behind bar.
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.
DANGER
1751-0727
DANGER
!
CRUSH HAZARD
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.
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.
DANGER
1751-0729
CRUSH HAZARD
Rotate prop to maintenance
position. Open the pin latch
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.
DANGER
1751-0731
CRUSH HAZARD
DO NOT ENTER PIT unless dock leveler is
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 proper maintenance
procedures. Failure to comply will result in death
or serious injury.
DANGER
1751-0726
1751-0729
1751-0731
1751-0726
Unsupported dock leveler
ramps can lower unexpectedly.
Before allowing vehicle to leave
the dock always:
Ensure that no equipment,
material or people are on the
dock leveler.
Return the dock leveler to its
stored position at dock level.
Failure to follow posted instructions will result in death or serious injury.
SAFETY INFORMATION
Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.
Operation
1. Read and follow all instructions and
warnings in the owner’s/user’s
manual.
2. Use of dock leveler restricted to
trained operators
3. Always chock trailer wheels or
engage truck restraint before
operating dock leveler or beginning to
load or unload.
4. Never use hands or equipment to
move the ramp or lip
5. Before activating dock leveler:
 Ensure trailer is backed in against
bumpers.
 Remove any end loads if required.
 Check trailer alignment to avoid lip
interference. If lip does not lower to
trailer bed, reposition vehicle.
6. Ensure that truck bed supports
extended lip or the leveler frame
supports the ramp before driving on
ramp.
7. Stay clear of hinges and front and
sides of moving dock leveler.
8. Never use damaged or
malfunctioning dock leveler. Report
problems immediately to supervisor.
Maintenance/Service
1. Read and follow all instructions,
warnings and maintenance schedules
in the owner’s/user’s manual.
2. Maintenance/Service of dock leveler
restricted to trained personnel.
3. Place barriers on the driveway and on
dock floor to indicate service work is
being performed.
4. DO NOT ENTER PIT unless dock
leveler is securely supported by
maintenance prop.
5. If electrically powered turn off and use
OSHA lockout/tagout procedures.
DANGER
D




FORK THIS SIDE
FORK
HERE
1751-0730 (x2)
(decal placed in same position on both sides)
(decal placed in same position on both sides)
(decal placed in same position on both sides)
1751-0329 (x2)
1751-0330 (x2)

64111-0004 —November 2003
Rev “B” February 2011
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. Before
operation of the equipment, all operators shall read, understand and be familiar with all
functions of equipment as described in the owner’s/user’s manual.
2. The manufacturer shall provide to the initial purchaser all necessary information with
regards to: Safety Information, Operation, Installation and Safety Precautions,
Recommended Initial and Periodic Inspections Procedures, Planned Maintenance
Schedule, Product Specifications, Troubleshooting uide, Parts Break Down, Warranty
Information and Manufacturers Contact Information. The owner/ user shall be responsible
to verify that this information is available and received as well as proper instructions,
training and familiarity of the equipment for all operators has been completed. Owner’s/
User’s shall actively maintain, update and re train all operators on safe working habits and
operations of the equipment.
3. It is recommended 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.
4. Name plates, placards, Decal's, instructions and posted warnings shall not be obscured
from the view of the operator or maintenance personnel for whom such warnings are
intended for. Contact manufacturer for any replacements.
5. Manufacturer’s 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 requested.
6. Any modifications or alterations of loading dock equipment shall only be done with prior
written approval from the original equipment manufacturer.
7. 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.
8. Loading dock safety equipment should never be used outside of its intended use, range,
or capacity. Please consult the manufacturer if you have any questions as to the use,
range or capacity of the equipment.
9. When selecting loading dock safety equipment, it is important to consider not only present
requirements but also future plans and any possible adverse conditions, environments or
use.

7
4111-0004 —November 2003
Rev “B” February 2011
INTRODUCTION
General Information
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)
7 ft (2133.6 mm)
ength
6 ft (1828.8 mm)
8 ft (2438 mm)
10 ft (3048 mm)
12 ft (3658 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 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.
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.
Dock eveler Stock Specifications
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 provide 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.

84111-0004 —November 2003
Rev “B” February 2011
Component Identification
A — ip
B — ip Prop
C —Platform
D — ip Cylinder
E — Powerpack (Motor/Pump/Reservoir)
F — Platform Cylinder
G— Main Frame
H— Clean Sweep Removable Section
H —Maintenance Prop
ock-Out
J— Maintenance Prop
K —Toe Guards (2 used)
—Control Box
M —Raise Button
N—ARTD Switch (option)
The EH dock leveler uses hydraulic logic and
one-button operation for ease of use.
The dock leveler can be operated remotely using the
RAISE button (M) on the control panel .
Platform (C) is raised by pushing and holding the
RAISE button (M). This activates an electric motor
(E) which, in turn, drives a hydraulic pump. The
hydraulic pump forces oil into the platform cylinder(s)
(F), causing the platform to rise. Releasing the
RAISE button allows the platform to lower.
When the platform rises to the highest point of
travel left in the platform cylinder, valving in the
Powerpack directs fluid flow to the lip cylinder,
extending the lip.
With the lip fully extended, the raise button may be
released, allowing the leveler to float down on to the
truck for loading or unloading.
*See Operating Instructions for a complete operation
guide.
THEORY
INTRODUCTION
H
N
M
F
K
A
C
B
D
G
E
I
J
H

9
4111-0004 —November 2003
Rev “B” February 2011
This page intentionally left blank

10 4111-0004 —November 2003
Rev “B” February 2011
INSTA ATION
Prepare Pit
Before lowering the dock leveler into the pit, the
following must be performed:
1. Remove all debris from the pit and sweep the pit
clean.
2. Check the entire dock leveler pit for proper
construction according to approved/certified pit
drawings. Make sure pit is square by making the
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 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 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.
A—Distance (Pit Width)
(Front and Rear)
B— Distance (Dock Floor-to-Pit
Floor) (All Four Corners)
C— Distance (Pit ength)
(Both Sides of Pit)
D— Distance (Pit Corner-to-Corner)
(Top, Bottom, and Both Sides)
IMPORTANT
DO NOT remove the shipping bands around the
dock leveler lip until instructed to do so.
Post safety warnings and barricade the work area
at dock level and ground level to prevent
unauthorized use of the dock leveler before
installation has been completed.
Failure to follow the installation instructions can
result in damage to dock leveler, the facilities,
and/or serious personal injury or death.
Only trained installation professionals with the
proper equipment should install this product.
B
A
D
C

11
4111-0004 —November 2003
Rev “B” February 2011
INSTA ATION
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.
Poweramp dock leveler's are designed with
installation in mind. Each unit is shipped with lifting
brackets (A) fastened to the platform side joists.
Prepare Dock eveler
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.
A— ifting Bracket (2 used) B — Shipping Bands
IMPORTANT
DO NOT over tighten the lifting bracket hardware.
Over tightening can damage the weather seal, if
equipped.
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.
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.
A
B

12 4111-0004 —November 2003
Rev “B” February 2011
INSTA ATION
A
A— Distance ( eveler Frame
Height)
B— Shim ocations (Under
Rear Vertical Supports)
C— Shim ocation (Under
Maintenance Prop)
*Same as (D)
D— Shim ocations (Under
ip Keepers)
E— Dock Floor
F— Rear Pit Curb Angle
G— String
H— Rear Hinge Frame Angle
J— Distance (Dock Floor-to-Pit
Floor)
K— Distance (Top of Shim
Stack-to-Dock Floor)
— Shim Stack
M— Dock eveler Frame
N — Pyramid (Preferred)
P— Stepped (Acceptable)
Q— Offset (Not Acceptable)
R — Straight (Not Acceptable)
Install Dock eveler
See page 16 for Hoist cylinder shimming
N
P
Q
R
Shim
Stacking Methods
F
EG
H
M
K
J
B
C
D
A

13
4111-0004 —November 2003
Rev “B” February 2011
INSTA ATION
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.
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.
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.
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
(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).
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.
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.

14 4111-0004 —November 2003
Rev “B” February 2011
INSTA ATION
A— Front of Dock Pit
B— Dock eveler Frame
C— Side Pit Curb Angle
D— Gap [3/4 in. (19 mm)
Minimum]
E— Pry ocations
F— Rear Hinge Frame Angle
G— Rear Pit Curb Angle
H— Flare Bevel Weld, Typical
(To Fit Spacing)
8. With rear hinge frame angle (F) tight against rear
pit curb angle ( ), 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).
• ap (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 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.
6 in.
(152 mm)
3/8 in.
(9.5 mm)
GH
AB
E
C
F
C
DD

15
4111-0004 —November 2003
Rev “B” February 2011
INSTA ATION
11. With the rear hinge frame angle (F) tight against
the rear pit curb angle ( ), weld the rear hinge
frame angle (F) to the rear pit curb angle ( )
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 under 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.
NOTE: The illustration on the previous page shows a
typical weld pattern. The weld pattern will
vary slightly depending on size of dock
leveler.
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 span of the affected components.
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.
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 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.
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.

16 4111-0004 —November 2003
Rev “B” February 2011
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.
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.
A— Platform Joists
B— Shim ocations (Under Platform Cylinder Trunnions)
C— Removable “Clean Sweep” Frame Section
C—Clean Sweep Removable Frame Section
D— Maintenance Prop
E— ip Prop
INSTA ATION
Two people are required to engage the
maintenance prop: one person to operate the lifting
device, the other person to engage the
maintenance prop.
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.
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.
B
D
A
C
E

17
4111-0004 —November 2003
Rev “B” February 2011
18. All model leveler's: Install shims at locations (B)
using the pyramid or stepped shimming method.
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 frame and cylinder trunnion shims
using a fillet weld.
• Adjust shim height as needed. Remember,
each upright rear frame member must be
solidly shimmed between the floor of the leveler
pit and the bottom of the frame section.
• 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.
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.
INSTA ATION
* For left/right orientation of dock leveler, see inside back cover of
this manual.
20. When all welding has been completed, paint all
the welds and shims.
NOTE: EH 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.
21. For all EH models, remove the Clean Sweep
frame section (C) by grinding the tack welds that
hold it in place during transport. Paint after.
N
P
Q
R
Shim
Stacking Methods

18 4111-0004 —November 2003
Rev “B” February 2011
INSTA ATION
1. Mount the pushbutton control panel (B) so bottom
of control panel-to-dock floor distance (C) is 48 in.
(1219.2 mm).
2. Install electrical disconnect panel (A) if not already
installed.
3. Install and connect the control wiring.
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.
Install Control Panel and Wiring
A— Disconnect Panel
B— Control Panel
(provided by others)
C— Distance, 48 in. (14 630 mm)
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.
DO NOT make any final electrical connections until
all welding has been completed. Failure to do this
may result in serious personal injury or death.
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.
B
A
C