SYSTEMS Poweramp EH Series User manual
EH Series
Dock Leveler
Printed in U.S.A.
©2021 Systems, LLC - All Rights Reserved
Manual No. 4111-0004
Apr. 2021
Poweramp • Division of Systems, LLC • W194 N11481 McCormick Drive • Germantown, WI 53022
Owner’s/User’s Manual
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
Placard Installation Instructions ........................................................ 22
Put New Dock Leveler Into Service.................................................... 23
Operation
Operational 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
Troubleshooting
Troubleshooting................................................................................... 42
Parts
Danfoss Control Box ........................................................................... 46
Optional Electrical Parts ..................................................................... 47
Frame and Platform ............................................................................. 48
Hydraulic Components........................................................................ 50
Powerpack Assembly .......................................................................... 52
Valve Block - Emergency Stop/Lip Out ............................................. 56
Weather Seal ........................................................................................ 57
Toe Guards ........................................................................................... 58
Miscellaneous
Customer Information ......................................................................... 59
Warranty................................................................................ Back Cover
1
4111-0004 — Apr. 2021
©2021 Systems, LLC
Do not start the equipment until all unauthorized
personnel in the area have been warned and have
moved outside the operating zone (see Figure 1).
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.
Read and understand the Owner’s/User’s Manual 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 DANGER, WARNING, or CAUTION
signs, Placards or Decals on the equipment unless
replacing them.
General Operational Precautions
O
p
e
r
a
t
i
n
g
Z
o
n
e
O
p
e
r
a
t
i
n
g
Z
o
n
e
Figure 1
Recognize Precautionary Information
PRECAUTIONS
WARNING: This product can expose you to chemicals including lead, which are 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 message panel.
The use of the word DANGER signifies the
presence of an extreme hazard or unsafe practice
which will most likely result in death or severe
injury.
The use of the word WARNING signifies the
presence of a serious hazard or unsafe practice
which could result in death or serious injury.
The use of the word CAUTION signifies possible
hazard or unsafe practice which could result in
minor or moderate injury.
The use of the word NOTICE indicates information
considered important, but not hazard-related, to
prevent machine or property damage.
Indicates a type of safety sign, or separate panel on
a safety sign, where safety-related instructions or
procedures are described.
24111-0004 — Apr. 2021
©2021 Systems, LLC
Operational Precautions
Learn the safe way to operate this equipment. Read and understand the
manufacturer’s instructions. If you have any questions, ask your supervisor.
Stay clear of dock leveling device when transport
vehicle 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 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 maintenance procedures have been
performed before using.
Make sure lip overlaps onto transport vehicle bed
at least 4 in. (102 mm).
Keep a safe distance from both side edges.
PRECAUTIONS
3
4111-0004 — Apr. 2021
©2021 Systems, LLC
Operational Precautions
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.
PRECAUTIONS
44111-0004 — Apr. 2021
©2021 Systems, LLC
Safety Decals
1.28"
2.43"
Control Box Size:
Decal Size: 2.75 x 1.25
File Name: 1751-0735
PROUDLY
MADEIN USA
SYSTEMS, INC.
GERMANTOWN, WI
MALVERN, AR
1751-0735
2
File Name: 1751-0330 REV C
Decal Size: 5.375 x 1.75
FORK
HERE
1751-0330 Rev C
File Name: 1751-0330 REV C
Decal Size: 5.375 x 1.75
FORK
HERE
1751-0330 Rev C
1751-0330
3
3
6
8
8
1751-0726 Rev B
File Name: 1751-0726 Rev B
Decal Size: 5.92 x 2.36
CRUSH HAZARD
DO NOT ENTER PIT unless dock leveler is
securely supported by maintenance prop. Place
barriers on driveway and dock floor to indicate
service work being performed. Failure to comply
will result in death or serious injury. Refer to
owner‘s/user‘s manual for proper maintenance
procedures.
1751-0726
5
File Name: 1751-0329 Rev A
Decal Size: 13 x 2
DO NOT
FORK THIS SIDE
1751-0329 Rev A
File Name: 1751-0329 Rev A
Decal Size: 13 x 2
DO NOT
FORK THIS SIDE
1751-0329 Rev A
1751-0329
1
1
Unsupported dock leveler
ramps can lower unexpectedly.
Before allowing vehicle to leave
the dock always:
•
•
Ensure no equipment,
material or people are on
dock leveler.
Return dock leveler to its
stored position at dock level.
Failure to follow posted instructions will result in death or serious injury.
Call 262.255.1510 for replacement placards, 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 i n g s a n d m a i n t e n a n c e
sche dules in the ow ner ‘s/us er‘s
manual.
2. Maintenance/Service of dock leveler
restricted to trained personnel.
3. Place barriers on the driveway and
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.
OPERATION
1. Read and follow all instructions and
warnings in owner’s/user’s manual.
2. Use of dock leveler restricted to
trained operators
3. Always c hoc k trai ler wh eel s or
en gag e tr u ck r e st ra i nt b e fo re
operating dock leveler or beginning to
load or unload.
4. Never use hands or equipment to
move 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 truck bed supports extended
lip or leveler frame supports the ramp
before driving on ramp.
•
•
•
1751-0730 Rev B
Unsupported dock leveler
ramps can lower unexpectedly.
Before allowing vehicle to leave
the dock always:
•
•
Ensure no equipment,
material or people are on
dock leveler.
Return dock leveler to its
stored position at dock level.
Failure to follow posted instructions will result in death or serious injury.
Call 262.255.1510 for replacement placards, 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 i n g s a n d m a i n t e n a n c e
sche dules in the ow ner ‘s/us er‘s
manual.
2. Maintenance/Service of dock leveler
restricted to trained personnel.
3. Place barriers on the driveway and
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.
OPERATION
1. Read and follow all instructions and
warnings in owner’s/user’s manual.
2. Use of dock leveler restricted to
trained operators
3. Always c hoc k trai ler wh eel s or
en gag e tr u ck r e st ra i nt b e fo re
operating dock leveler or beginning to
load or unload.
4. Never use hands or equipment to
move 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 truck bed supports extended
lip or leveler frame supports the ramp
before driving on ramp.
•
•
•
1751-0730 Rev B
1751-0730
4
4
Decal Size: 8.72 x 1.02
Material: Ritrama 3-1190 (3.5 mil thick) calendered vinyl
02 hi-tack permanent acrylic adhesive
Ritrama 3-7146 (1.0 mil thick) clear polyester laminate
File Name: 1751-0729 Rev A
CRUSH HAZARD
Do not work under dock leveler unless this maintenance prop has been secured in the
upright position. Failure to comply will result in death or serious injury. See owner’s/user’s
manual for proper procedures 1751-0729 Rev A
1751-0729
7
4
Left Platform Side
6
Right Platform Side
1751-0640
9
2
1751-0138
10
10
11
3
1
5
9
File Name: 1751-0727 Rev B
Decal Size: 5.06 x 2.40
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. 1751-0727 Rev B
2.40"
5.05"
Decal Size: 5.05 x 2.40
File Name: 1751-0731 Rev A
CRUSH HAZARD
Open the pin latch and insert
through the maintenance
prop housing and prop
completely. Close the pin latch
to secure prop. Use every
time dock leveler is serviced.
Failure to comply will result
in death or serious injury.
1751-0731 Rev A
1751-0731
11
Right Platform Side
48
17
www. .comDockSystemsInc
1.800.643.5424
Decal Size:6x2
File Name: 1751.0651
1751-0651
Decal Placement
for H Series
1751-0727
Serial Tag
9
File Name: 1751-0138 Rev B
Decal Size: 4 x 2
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. 1751-0138 Rev B
www.DockSystemsInc.com 1.800.643.5424
HP SERIES
TM
Decal Size:6x2.4
File Name: 1751.0640
www. .comDockSystemsInc
1.800.643.5424
Decal Size:6x2
File Name: 1751.0651
Two positions one on top of each fork pocket.
Figure 2
PRECAUTIONS
5
4111-0004 — Apr. 2021
©2021 Systems, LLC
PRECAUTIONS
1751-0874
OPERATING
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 before operating dock leveler or beginning
to load or unload.
• Before activating dock leveler, check to make sure the transport
vehicle is positioned squarely against dock bumpers. Ensure lip will
avoid contact with transport vehicle frame, sides and cargo during
dock leveler activation. If contact is likely or observed, reposition
transport vehicle.
• Ensure the transport vehicle oor supports extended lip or the
leveler frame (lip keepers or below dock endload supports) supports
the ramp before driving on ramp.
• Stay clear of hinges and front and sides of moving dock leveler.
• Never use hands or equipment to move the ramp or lip.
• Never use damaged or malfunctioning dock leveler. Report problems
immediately to supervisor.
• Always store dock leveler and remove people, material, and
equipment from ramp before vehicle leaves the dock.
• DO NOT ENTER PIT unless dock leveler is securely supported
and proper lockout/tagout procedures have been completed. See
“Maintenance Precautions” in Owner’s/User’s Manual.
FAILURE TO FOLLOW THESE INSTRUCTIONS WILL RESULT
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,
release the RAISE button. The platform will
lower returning to the cross-trafc position.
BELOW DOCK ENDLOADING
• (AIR POWERED ONLY) Press and hold
the RAISE button until the leveler is 12”
above dock level. Pull the below dock level
chain until the leveler lowers the full below
dock position.
• (HYDRAULIC ONLY)
Press and hold
the RAISE button until the leveler is fully
raised. As the lip starts to extend, release
the RAISE button. The leveler will lower
to the below dock position provided the
lip extension allows the lip to clear the lip
keepers.
•
(HYDRAULIC WITH INFINITE LIP
CONTROL) If equipped, raise the platform
by Pressing and holding the RAISE button.
When the lip is just above the lip keepers,
simultaneously Press and hold the RAISE
button and the LIP OUT button until lip has
extended beyond the lip keepers. Release
both buttons.
NOTE: If equipped, Pressing E-STOP button will stop platform from lowering.
1.800.643.5424
Call for additional placards, or manuals, or with questions
regarding proper use, maintenance, and repair of dock leveler.
1751-0874 Rev D
Scan to view our owner’s/user’s manuals online.
www.LoadingDockSystems.com
WARNING: CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov
Placard
64111-0004 — Apr. 2021
©2021 Systems, LLC
1) The manufacturer shall provide to the initial
purchaser and make the following information
readily available to the owners/users and their
agents, all necessary information regarding
Safety Information, Operation, Installation and
Safety Precautions, Recommended Initial and
Periodic Inspections Procedures, Planned
Maintenance Schedule, Product Specifications,
Troubleshooting Guide, Parts Break Down,
Warranty Information, and Manufacturers
Contact Information, as well as tables to identify
the grade(slope) for all variations of length or
configuration of the dock leveling device and
information identifying the maximum uncontrolled
drop encountered when sudden removal of
support while in the working range of the
equipment.
2) When selecting loading dock safety equipment,
it is important to consider not only present
requirements but also future plans and any
possible adverse conditions, environmental
factors or usage. The owners/users shall provide
application information to the manufacturer
to receive recommendations on appropriate
equipment specifications and capacity.
3) The owner/user must see all nameplates,
placards, decals, instructions and posted
warnings are in place and legible and 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.
4) Dock leveling devices may become hazardous
if the manufacturer’s instructions regarding
modifications or adjustments are not followed.
Modifications or alterations of dock leveling
devices shall only be made with prior written
approval from the original manufacturer. These
changes shall be in conformance with all
applicable provisions of the MH30.1 standard
and shall also satisfy all safety recommendations
of the original equipment manufacturer of the
particular application.
5) The owner/user should recognize the inherent
dangers of the 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
instructions provided with the dock leveling
device. Maintaining, updating and retraining all
operators on safe working habits and operation of
the equipment, regardless of previous experience,
should be done on a regular basis and should
include an understanding and familiarity with all
functions of the equipment. Owners/users shall
actively maintain, update and retrain all operators
on safe working habits and operations of the
equipment.
6) An operator training program should consist of,
but not necessarily be limited to, the following:
a) Select the operator carefully. Consider the
physical qualifications, job attitude and aptitude.
b) Assure that the operator reads and fully
understands the complete manufacturer’s owners/
users manual.
c) Emphasize the impact of proper operation
upon the operator, other personnel, material
being handled, and equipment. Cite all rules and
why they are formulated.
d) Describe the basic fundamentals of the dock
leveling device and components design as related
to safety, e.g., mechanical limitation, stability,
functionality, etc.
e) Introduce the equipment. Show the control
locations and demonstrate its functions.
Explain how they work when used properly and
maintained as well as problems when they are
used improperly.
f) Assure that the operator understands the
capacity rating, nameplate data, placards and all
precautionary information appearing on the dock
leveling device.
g) Supervise operator practice of equipment.
h) Develop and administer written and practical
performance tests. Evaluate progress during and
at completion of the course.
i) Administer periodic refresher courses. These
may be condensed versions of the primary course
and include on-the-job operator evaluation.
OWNER’S/USER’S RESPONSIBILITIES
7
4111-0004 — Apr. 2021
©2021 Systems, LLC
7) Loading dock safety equipment should never
be used outside of its vertical working range, or
outside the manufacturer’s rated capacity. It shall
also be compatible with the loading equipment
and other conditions related to dock activity.
Please consult the manufacturer if you have any
questions as to the use, vertical working range or
capacity of the equipment. Only properly trained
and authorized personnel should operate the
equipment.
8) It is recommended that the transport vehicle
is positioned as close as practical to the dock
leveling device and in contact with both bumpers.
When an industrial vehicle is driven on or off a
transport vehicle during loading and unloading
operations, the transport vehicle parking brakes
shall be applied and wheel chocks or a restraining
device that provides equal or better protection of
wheel chocks shall be engaged. Also, whenever
possible, air-ride suspension systems should have
the air exhausted prior to performing said loading
and unloading operations.
9) When goods are transferred between the loading
dock and a trailer resting on its support legs/
landing gear instead of a tractor fifth wheel
or converter dolly, it is recommended that an
adequate stabilizing device or devices shall be
utilized at the front of the trailer.
10) In order to be entitled to the benefits of the
standard product 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, adjustment and inspection
in accordance with all manufacturers’
recommendations are the sole responsibility of the
owner/user.
11) Manufacturer’s recommended maintenance and
inspection of all dock leveling devices shall be
performed in conformance with the following
practices: A planned maintenance schedule
program must be followed, only trained and
authorized personnel shall be permitted to
maintain, repair, adjust and inspect dock leveling
devices, and only the use of original equipment
manufacturer parts, manuals, maintenance
instructions, labels, decals and placards or
their equivalent. Written documentation of
maintenance, replacement parts or damage
should be kept. In the event of damage,
notification to the manufacturer is required.
12) Loading dock devices that are structurally
damaged or have experienced a sudden loss of
support while under load, such as might occur
when a transport vehicle is pulled out from under
the dock leveling device, shall be removed from
service, inspected by a manufacturer’s authorized
representative, and repaired or replaced as
needed or recommended by the manufacturer
before being placed back in service.
OWNER’S/USER’S RESPONSIBILITIES
84111-0004 — Apr. 2021
©2021 Systems, LLC
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
9
4111-0004 — Apr. 2021
©2021 Systems, LLC
Component Identification
A — Lip
B — Main Frame
C — Platform
D — Lip Cylinder
E — Powerpack (Motor/Pump/Reservoir)
F — Platform Cylinder
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.
TOLERANCES
(UNLESS OTHERWISE NOTED)
FRACTIONAL: ``1/32"
DECIMAL:
.00 = ``.01"
.000 = ``.005"
ANGULAR: ``1~~
DRAWN BY CHECKED BY
DRAWING NO.
DATE
KRV 3/12/2018
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 i s the property of Sys tems, Inc. and repres ents a proprietary art icle in which Systems , Inc. retains any and all pa tent and other right s, including exclus ive rights
of use and/ormanufacture and/or sale. Possession of this print does not convey any permission to reproduce,print or manufacture the article or articles sh own therein,
such permiss ion to be granted only by written au thorization signed by an offi cer or other authorized agen t of Systems,Inc . thereof.
MATERIAL STOCK NO.
EH FINAL ASSEMBLY
A
B
C
D
E
F
G
H
J
K
L
L
K
10 4111-0004 — Apr. 2021
©2021 Systems, LLC
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.
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, 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 dock platform
and lip anytime when physically working in front of
or under the dock leveler. This additional means
may include, but is not limited to a boom truck, fork
truck, stabilizing bar or equivalent.
Always post safety warnings and barricade the
work area at dock level and ground level to prevent
unauthorized use of the dock leveler before
installation is complete.
A hard hat or other applicable head protection
should always be worn when working under or
around a dock leveler.
Always stand clear of platform lip when working in
front of the dock leveler.
11
4111-0004 — Apr. 2021
©2021 Systems, LLC
INSTALLATION
This page intentionally left blank.
12 4111-0004 — Apr. 2021
©2021 Systems, LLC
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 (see Figure 5):
• 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 (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 correct location per pit diagrams.
A—Pit Width
(Front and Rear)
B— Dock Floor-to-Pit Floor
(All Four Corners)
C— Pit Length
(Both Sides of Pit)
D— Pit Corner-to-Corner
(Top, Bottom, and Both Sides)
CL
14”
10”
D
C
B
A
CL
Figure 5
INSTALLATION
13
4111-0004 — Apr. 2021
©2021 Systems, LLC
A— Lifting Bracket (2 used) B — Shipping Bands
Poweramp dock levelers are shipped with lifting
brackets (A) fastened to the platform side joists,
and shipping bands (B) around the platform lip and
leveler frame (see Figure 6).
1. Remove any bumpers and/or control panels that
may be banded to the frame of the dock leveler.
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
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 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 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.
Figure 6
Prepare Dock Leveler
INSTALLATION
TOLERANCES
(UNLESS OTHERWISE NOTED)
FRACTIONAL:
1/32"
DECIMAL:
.00 =
.01"
.000 =
.005"
ANGULAR:
1
DRAWN BY CHECKED BY
DRAWING NO.
DATE
coreyhafemeister 1/28/2020
S Y S T E M S
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 propertyof Systems, LLC and represents a proprietary article in whichSystems, LLC retains any and all patent and other rights,including exclusive rights
of use and/or manufactureand/or sale. Possession of this print does not convey any permissionto reproduce, print or manufacture the article or articlesshown therein,
such permission to begranted only by written authorization signed by an officeror other authorized agent of Systems, LLC thereof.
MATERIAL STOCK NO.
PR20 7835-20 Views
REV A - ECN 18-066
A
B
14 4111-0004 — Apr. 2021
©2021 Systems, LLC
INSTALLATION
Figure 9
DETAIL A
SCALE 1 / 4
A
TOLERANCES
(UNLESS OTHERWISE NOTED)
FRACTIONAL: 1/32"
DECIMAL:
.00 = .01"
.000 = .005"
ANGULAR: 1
DRAWN BY CHECKED BY
DRAWING NO.
DATE
BDK 7/18/2018
S Y S T E M S
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 ofSystems, LLC and represents a proprietary article in whichSystems, LLC retains any and all patent and other rights, includingexclusive rights
of use and/or manufactureand/or sale. Possession of this print does not convey any permissionto reproduce, print or manufacture the article or articlesshown therein,
such permission to be grantedonly by written authorization signed by an officer or otherauthorized agent of Systems, LLC thereof.
MATERIAL STOCK NO.
SHIMMING LAYOUT
REV A - ECN 18-066
GOOD BAD
P
A— Distance (Leveler Frame
Height)
B— Shim Locations (Under
Rear Vertical Supports)
C— Shim Location (Under
Maintenance 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)
L
F
M
H
N
G
E
K
Figure 8
TOLERANCES
(UNLESS OTHERWISE NOTED)
FRACTIONAL:
1/32"
DECIMAL:
.00 =
.01"
.000 =
.005"
ANGULAR:
1
MATERIAL
DRAWN BY CHECKED BY
DRAWING NO.
DATE
coreyhafemeister 4/6/2021
VH7835-20
Shim view
P O W E R A M P
M C G U I R E
D L M
S Y S T E M S
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, LLC and represents a proprietary article in which Systems, LLC 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, print or manufacture the article or articles shown therein, such permission to be
granted only by written authorization signed by an officer or other authorized agent of Systems, LLC thereof.
STOCK NO.
REV A - ECN 18-066
C
D
A
B
J
Figure 7
Install Dock Leveler
15
4111-0004 — Apr. 2021
©2021 Systems, LLC
Note: Poweramp dock levelers are designed with a
nominal 1/2” (12.7 mm) shimming distance to allow
for pit inconsistencies.
1. Determine height of shim stack (M) for each shim
location (B) by performing the following:
a. Measure leveler frame height distance (A).
b. Measure dock floor-to-pit floor distance
(K) at each shim location (B). Write down the
dimensions obtained at each location.
c. Subtract distance (A) from distance (K) to
obtain the shim height. Repeat for each shim
location.
2. Using the results obtained in step 1, create the
individual shim stacks on the pit floor at location (B).
Build each shim stack (M) with the top shim having
a minimum size of 4” x 4” (101.6 mm x 101.6 mm)
and each successive lower shim being larger so the
shims can be welded together using a fillet weld. If
using offset method, make sure load is over center of
shim stack, NOT over the edge. DO NOT use straight
method. See Figure 10.
Note: To assist in obtaining an accurate
measurement of distance (L), 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 (L) [top of shim stack (M) to
dock floor]. Distance (L) must equal the dock leveler
height (A).
4. Put a 1/4” (6.6 mm) thick shim underneath each
lip keeper (C).
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” 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) is
used only as a starting point. The final shim stack
height will be determined after dock leveler is lowered
into the pit.
5. Using an appropriate lifting device connected to
the lifting brackets, lower dock leveler into the pit so
rear hinge frame angle (G) is tight against rear pit
curb angle (E) 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. Add shims at front shim locations (C) so front
of dock leveler will stay level with dock floor when
leveler is resting fully on shims.
Note: Hoist cylinder and maintenance prop will be
shimmed later in the install process.
Install Dock Leveler (continued)
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.
INSTALLATION
Oset w/Load Over Center
(Acceptable)
Stepped
(Acceptable)
Pyramid
(Preferred)
Shim Stacking Methods
Oset w/Load Over Edge
(Not Acceptable)
Straight
(Not Acceptable)
Figure 10
16 4111-0004 — Apr. 2021
©2021 Systems, LLC
A— Front of Dock Pit
B— Dock Leveler Frame
C— Side Pit Curb Angle
D— Gap [3/4 in. (19 mm)
Minimum]
E— Pry Locations
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 (G), 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).
• 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 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 Systems, LLC
Technical Services.
Install Dock Leveler (continued)
INSTALLATION
TOLERANCES
(UNLESS OTHERWISE NOTED)
FRACTIONAL: ``1/32"
DECIMAL:
.00 = ``.01"
.000 = ``.005"
ANGULAR: ``1~~
DRAWN BY CHECKED BY
DRAWING NO.
DATE
NMW 3/12/2018
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 pri nt is the property of S ystems, Inc. and r epresents a propri etary article in whi ch Systems, Inc. re tains any and all pa tent and other ri ghts, including e xclusive rights
of use and/ormanufacture and/or sale. Possession of this print does not convey any permission to reproduce,print or manufacture the article or articles sh own therein,
such permiss ion to be granted only by written au thorization signed by an offi cer or other authorized agen t of Systems,Inc . thereof.
MATERIAL STOCK NO.
EH MANUAL PAGE
16
3/8 in. 6 in.
GH
AB
C
F
C
D
6 in.
(152 mm)
3/8 in.
(9.5 mm)
D
E
Figure 11
17
4111-0004 — Apr. 2021
©2021 Systems, LLC
12. With the rear hinge frame angle (F) tight against
the rear pit curb angle (G), weld the rear hinge frame
angle (F) to the rear pit curb angle (G) 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.
Note: Figure 11 shows a typical weld pattern. The
weld pattern will vary slightly depending on size of
dock leveler.
13. Weld front of dock leveler frame (B) to shims
located under the keepers, then weld the shims to
the front pit curb steel.
14. With leveler welded into place, remove the
shipping bands from around lip and leveler frame.
15. 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.
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 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.
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
lifespan of the affected components.
18 4111-0004 — Apr. 2021
©2021 Systems, LLC
17. Shim and weld the maintenance prop (Figure 12):
a. Install shims under maintenance prop (D)
where prop attaches to leveler frame (E). Make
sure prop is solidly shimmed.
b. Raise maintenance prop (D) to the service
(upright) position and lock prop in this position
using an OSHA approved locking device.
A — Platform Joists
B — Shim Location (Under Platform Cylinder Trunnions)
C — Removable “Clean Sweep” Frame Section
D — Maintenance Prop
E — Shim Location (Under Maintenance Prop)
Install Dock Leveler (continued)
18. Install shims at locations (Band E) using an
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 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 welded to each other, and also to the
leveler frame.
Make sure the platform is properly supported in the
raised position before entering the pit to finish weld
the shims.
INSTALLATION
TOLERANCES
(UNLESS OTHERWISE NOTED)
FRACTIONAL: ``1/32"
DECIMAL:
.00 = ``.01"
.000 = ``.005"
ANGULAR: ``1~~
DRAWN BY CHECKED BY
DRAWING NO.
DATE
KRV 3/12/2018
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 i s the property of Sys tems, Inc. and repres ents a proprietary art icle in which Systems , Inc. retains any and all pa tent and other right s, including exclus ive rights
of use and/ormanufacture and/or sale. Possession of this print does not conveyany permissionto reproduce, printor manufacture the article or articl ess hown therein,
such permiss ion to be granted only by written au thorization signed by an offi cer or other authorized agen tof Sy stems,Inc. thereof.
MATERIAL STOCK NO.
EH FINAL ASSEMBLY
PAGE 18
A
B
C
D
E
Figure 12
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