r n a “EHP” & “HP” Hydraulic Dock Levelers*Before doing any electrical work, make certain...

SM

Rugged. Dependable. PIONEER.

“EHP” & “HP” Hydraulic Dock Levelers

Owners Manual

P.O. Box 338 • Spring Hill, Tennessee 37174 • 1-800-251-3382 • fax: 931-486-0316 • www.pioneerleveler.com

warranty

a FULL FIVE yEar warranty is standard on Pioneer “HP” series levelers, to include all structural members. a one year warranty covers the motor/pump assembly, cylinders and miscellaneous parts.

a FULL twO yEar warranty is standard on Pioneer “EHP” series levelers, to include all structural members. a one year warranty covers the motor/pump assembly, cylinders and miscellaneous parts.

Pioneer accepts full responsibility for the cost of materials, labor and freight for any warranty claim during the warranty period, which begins at date of shipment. Pioneer reserves the right to either repair or replace any defective parts. a claim for breach of warranty will be honored if the product has been properly installed, maintained and operated within its rated capacity, and not damaged by abuse.

PIOnEEr ManUFaCtUrInG, InC. SHaLL nOt BE LIaBLE FOr LOSS OF USE OF any EQUIPMEnt Or InCIDEntaLDaMaGES.

PIOnEEr EXPrESSLy DISCLaIMS any anD aLL IMPLIED warrantIES.

all PIOnEEr products meet or exceed Federal Occupational Safety and Health act Standards, Commercial Standards 202-56, and american Society of Mechanical Engineers Specifications anSI MH14. 1-84.

Pioneer Loading Dock Equipment – “EHP” & “HP” Series Hydraulic Dock Levelers

Warranty Phone: 1-866-228-6195

WARNING

DO NOT install, operate or service product unless you have read and understand the Safety Procedures,

Warnings, Installation and Operating instructions contained in this manual. Failure to do so could result in serious

injury and/or death.

Safety P

roced

ures

WA

RN

ING

: Read

and und

erstand all safety p

ractices and o

perating

instructions

Befo

re installing, o

perating

or servicing

the do

ck leveler. Failure to fo

llow

thesafety p

ractices and o

perating

instructions m

ay result in pro

perty d

amag

e, serio

us bo

dily injury and

/or d

eath.

If you d

o no

t understand

the safety pro

cedures o

r the instructions, ask yo

ur sup

ervisor to

explain the safety p

roced

ures and/o

r teach you ho

w to

use the d

ock leveler.

CA

UTIO

N: The installer and

/or operator M

US

T be very fam

iliar with the op

eration, function and

various parts of the P

ION

EE

R P

it Leveler PR

IOR

to installation and

/or operation. If this is not the case, it is IM

PE

RATIV

E that the installer and

/or opertor

read, and

fully understand

, the entire contents of this manual. B

e certain to read

and

understand

all warning

and cautio

n statements co

ntained in this m

anual prio

r to

any installation, o

peratio

n or servicing

of this unit.

1Donotop

eratethisequip

mentw

hileundertheinfluenceofd

rugsoralcohol.

2Donotstand

inthedrivew

aybetw

eenthedocklevelerand

atruckbackingorp

ulling

aw

ay.

3Besurethetruckw

heelsarechocked,orthetruckisheld

inplaceb

yarestraining

device,b

eforeattemptingtoload

orunloadthetruck.

4Donotusethed

ocklevelerifitlooksbrokenord

oesnotseemtow

orkright.Tellyour

sup

ervisor imm

ediately.

5 D

o not operate the leveler w

ith equip

ment, m

aterial or peop

le on the platform

and/or

lip

or in front of the leveler.

6 B

e certain that equip

ment, m

aterial or peop

le are not on the dock leveler b

efore

allowingatrucktop

ullout.

7Keep

clearofthedocklevelerw

henitismoving.N

ever placeyourhand

s,arms,feet,

orlegsinthepositionw

hereamovingd

ockleveleroramovingload

couldcause

injury. If in d

oub

t, do

not d

o it!

8Ifthed

ocklevelerisnotworkingp

roperly,usingtheop

erationinstructionsinthismanual,

do

not use the d

ock leveler. C

ontact your authorized P

ION

EE

R rep

resentative.

9 N

ever attemp

t to work und

er the dock leveler, for service or rep

air, without p

roper

placem

entofsafetybracing.

10Dam

agetothedockleveler,p

ersonalinjuryordeathcanresultfrom

abuseand

/ornegligent

use of this equip

ment.

11 If you have any q

uestions, or if a malfunction occurs w

hich is not understood

, ask

your supervisor to contact your authorized

PIO

NE

ER

representative for assistance

PRIORtoattem

ptinganycorrectivem

easures.

THIS IS THE SAFETY ALERT SYMBOL. IT IS USED TO ALERT YOU TO POTENTIAL PERSONAL INJURY HAZARDS. OBEY ALL SAFETY MESSAGES THAT FOLLOW THIS SYMBOL TO AVOID POSSIBLE INJURY AND/OR DEATH.

INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY AND/OR DEATH.

KEEP THIS MANUAL AND ALL SAFETY PROCEDURES IN A SECURE LOCATION WITH EASY ACCESS.

WARNING! READ AND UNDERSTAND THIS ENTIRE MANUAL PRIOR TO OPERATING.

WARNING! A DOCK LEVELER CAN BE A POTENTIAL THREAT TO PERSONS AND PROPERTY, IF NOT USED PROPERLY. SAFE OPERATION IS THE RESPONSIBILITY OF THE OPERATOR.

WARNING! DO NOT ENTER THE AREA IN FRONT OF OR BELOW THE DOCK LEVELER. SERIOUS PERSONAL INJURY AND/OR DEATH MAY RESULT.

WARNING! DO NOT ATTEMPT TO INSTALL, MAKE REPAIRS OR ADJUSTMENTS. ONLY A TRAINED AND AUTHORIZED SERVICE TECHNICIAN SHOULD PERFORM REPAIRS OR ADJUSTMENTS. ONLY A QUALIFIED CONTRACTOR/SUB-CONTRACTOR SHOULD PERFORMTHE INSTALLATION PROCESS. CONTACT YOUR LOCAL PIONEER DEALER FOR ASSISTANCE.

WARNING

section 1 installation instructions eHP & HP series

WARNING**Before doing any electrical work, make certain the power is disconnected and properly tagged or locked out.

**All electrical work must be done by a qualified technician and must meet all applicable codes.

**If it is necessary to make troubleshooting checks inside the control panel with the power on, USE EXTREME CAUTION.

**Do Not place fingers or uninsulated tools inside the control box. Touching wires or other parts inside the control box could cause electrical shock, serious injury and/or death.

10/08 Pioneer Loading Dock Equipment – “EHP” & “HP” Series Hydraulic Dock Levelers 1-1


SECTIon 1 installation instructions receiving and Handling

section 1 installation instructions installation

Caution: Before you start to install the leveler, use proper safety signs and barriers to separate the work area from the remainder of the dock.

RECEIVING: Checkforpossibledamageormissingpartsimmediatelyuponreceiptof unit. Note any damage or possible damage on receiving papers.

Prepareanyclaimsagainstcarrierifnecessary.

NotifyPIONEERofanydamageormissingparts.

HANDLING: Movelevelerintopositionbyusing:

•chainslinginsertedintosideplateholes.(SeeFigureA)or

•forklift,insertedinfrontbaseangle(SeeFigureA)(HPonly)

NOTE: Control box, two bumpers, and weather seals, if applicable, are

strapped under leveler. Handle with care to avoid damage to these components.

INSTALLATION: (Consistsof3phases) Pitpreparation

Leveler Preparation

Leveler Installation

(FigureA)

eHP & HP series

eHP & HP series

Before installing the dock leveler, read and follow the safety procedures and the operating instructions. Failure to follow the safety procedures could result in serious injury and/or death.

Never allow anyone to stand on or near dock leveler when it is being lifted or placed into the pit. Failure to follow this warning can allow the dock leveler to fall, tip, or swing into people, resulting in serious injury and/or death.

WARNING

WARNING


VARIABLE DIMENSIONSMODEL SIZE “A” “B” “C” “D”

6’W X 6’L 74” 63” 19 1/2” 20”6’W X 8’L 74” 87” 19 1/2” 20”6’-6"W X 6’L 80” 63” 19 1/2” 20”6’-6"W X 8’L 80” 87” 19 1/2” 20”7'W X 6’L 85” 63” 19 1/2” 20”7’W X 8’L 85” 87” 19 1/2” 20”6’W X 10’L 74” 111” 23 1/2” 24”6’-6"W X 10’L 80” 111” 23 1/2” 24”7’W X 10’L 85” 111” 23 1/2” 24”

section 1 installation instructions pit preparation

pIt pREpARAtION AND ELECtRICAL INStALLAtION:

Figure C

Figure B

1. Examine pit. Pit walls should be square and plumb. Clean all debris from pit. The floor at the rear and both sides should be level.

2. Measure pit dimensions. (See Figure B for accurate dimensions.)

Verify that pit walls are:

•Square

•Plumb

Place shims in general locations on pit floor before lowering leveler into place in pit.

[Pit depth at shim locations (minus 19” or minus 23” on 10 ft. units) equals shims thickness.]

NOTE: Shims are to be placed directly under rear frame uprights, under base of cylinder, under base frame support struts, and under lip keepers, See Figure B, page 1-3 & Figure D, page 1-5.

3. Install control box on wall near pit. (See Figure C)

4. Install wire leads for motor and proximity sensors per wiring diagram. (See Troubleshooting section, pages 4-1 - 4-9.)

Wire must be installed through conduit. (Conduit to be supplied by customer.) Additional wire leads may be used to supply temporary power to leveler from control box. Wires for motor must be long enough to reach mid section of leveler while in front of opening. this extra may be cut back and discarded after installation. (It is not necessary to hook up proximity sensors (HP only) for this test.)

eHp & Hp series

1” EMBEDDED CONDuIT rEquIrED FOr ElECTrIC WIrINg

Before welding the rear frame, cover the rearweather seal with a piece of sheet metal to pre-vent setting fire to the weather seals. Failureto do so may result in property damage.


section 1 installation instructions receiving and Handling

1. Position leveler directly in front of pit.

2. Cutrestrainingbandonlip.

3. Connecttemporarywireleadstoproperwiregroupingatmotor.

NOTE: Unit may fail to operate correctly at this point if temporary power does not supply adequate voltage. DO NOT make adjust-ments to leveler. Provide proper voltage before attempting to oper-ate leveler. (See Electrical Page 3-1)

eHP & HP series

CAUTION

LEVELER PREPARATION

Fully support the lip, while working under the leveler. The lipplate could fall causing serious injury and/or death.

Inadequate lifting equipment or practices can cause a load to fall unexpectedly. Make sure the lifting equipment is in good condition. Never allow anyone to stand on or near the dock leveler when it is lifted or placed into the pit. Stand clear of the dock leveler when it is placed into the pit. Failure to follow this warning can allow the dock leveler to fall, tip, or swing into people, causing serious injury and/or death.

WARNINGWARNING

Route power cord clear of edges and resting surfaces so that it is not damaged during lifting and placement.

SHIM UNDERLEFT & RIGHTLIP KEEPER

SHIM UNDERMAIN CYLINDER

FIGURE D

SHIM UNDEREACH UPRIGHT

FIGURE E

4. Check motor operation.

5. Check fluid level in hydraulic reservoir. Check all hydraulic hose

connectionsandfittings.

If unit does not raise when motor activates, rotation may be wrong. Recheck connections per wiring diagram to correct rotation.NOTE: Do not attempt to adjust valves until contacting an autho-rized Pioneer Dealer or the factory.

Withlevelerinraisedpositionandmaintenancestrutengagedreservoirshould be half full. If necessary, fill to correct level, using Dextron IItransmission fluid or aircraft hydraulic fluid

SHIM UNDERLEFT & RIGHTLIP KEEPER

SHIM UNDERMAIN CYLINDER

FIGURE D

SHIM UNDEREACH UPRIGHT

FIGURE E


section 1 installation instructions receiving and Handling

eHP & HP series

LEVELER PREPARATION

NOTE: Protect WeatherSeals During Welding.

section 1 installation instructions leveler installation


TOP VIEW

1/4" FILLET WELD

PICTORIAL VIEW

1/4"WELD

SIDE VIEW

1/4"

FRONT VIEW

1/4"FILLET WELD

20" Lip Keeper Installation Instructions

Twoseparate lip keeperanglesareprovidedwitheveryunitthathasa20"lip.Theseanglesaretackwelded to the leveler base frame just behind the lip.

Break each one loose and set the leveler into the pit per the installation instructions in the owner's manual.

Prior to angle installationor shimmingmake surethat the unit is snug against the embedded curbangleatthebackofthepit.

Placethelipkeepersunderthefrontbaseangleoneithersideoftheunitwiththetopoftheanglepro-trudingoutpastthebase1/4" inthefrontandontheleftforthelefthandkeeperandontherightfortherighthandkeeper.Thiswillfacilitatewelding.

Fullyweldthekeeperangletothebaseangle.

Proceedwithshimmingpertheowner'smanual.

eHP & HP series

1.Placelevelerintopitopening.

2.Recheckshimpackstoensurelevelerisatproperheight,flushwith floor level, front and rear.



Allow one inch (1'') equal clearance between leveler sides and pitwalls.Rear frameangleof levelershouldbe tightagainstand flushwithrearcurbangleforproperwelding.

Shimsmustbeplacedproperlyundereachrearframeupright,undercylinderandfront lipkeepers. (SeeFIgureD,page1-5forcloseupviewandFigureB,page1-3forshimlocations.)

Skipweldrearof levelertocurbangle(weldcenterfirst,thenends)andfrontshimstolevelerandcurbangle.(SeeFigureE,Page1-5.)Protect rear weather seals from weld splatter if applicable.

eHP & HP series

LEVELER INSTALLATION:

CAUTION

Keep fingers, hands, and head away from the lip when it is released. Fingers, hands, or head could be struck by or caught between the lip and other pars of the dock leveler causing serious injury and/or death.

WARNING

DO NOT work under the dock leveler, ramp, or lip unless the main-tenance strut is in place.

WARNING

Welding with the dock leveler's power connected can damage elec-trical components. If the dock leveler has previously been electri-cally connected, turn off power to control box and unplug all dock leveler electrical cords from receptacles in the rear pit wall before welding. Ground welder to dock leveler. Failure to do so can result in product damage.

Be certain that the rear hinge assembly is held tightly against the rear pit curb angle before welding.

Improper installation of anchoring devices or installation into aged or unsound concrete could result in serious injury and/or death.

WARNING

CAUTIONIf front and rear pit curb angles are not parallel DO NOT attempt to shim dock leveler supports to match pit angles. The front supports and rear frame angle must be parallel for proper operation of the dock leveler. Add or subtract shims as required.

LEVELER INSTALLATION:

3.Bringdecksectionoflevelertofullyraisedposition.

4. Place maintenance strut securely under deck.

5. Weld all shims securely in place.

6. Connect permanent power source to control box on wall.

7. Make permanent electrical hook up to motor.

(HPOnly)8. Connecttwo(2)proximityswitchesthroughconduittowallmounted

controlbox.(Seeelectricaldiagram,page11.)



usetemporarypower,orliftslowlywithforkliftunderlipedge

(HPOnly) Removestrutfromhangerbracketunderrighthandcenterofdeck,rotate down to vertical position, and place in cup on frame.

EHP-Maintenancestrutistapedtothebaseframeforshipping.Remove the tape, place the bottom of strut into the cup on the base frame and the top into the cup welded to the bottom side of the lip.

Leveler should now be ready to operate

eHP & HP series

Hydraulic pressure must be maintained on the ramp to hold it in the raised position until the maintenance strut is in place. DO NOT WORK UNDER THE DOCKLEVELER RAMP OR LIP UNLESS MAINTENANCE STRUT IS SECURED.

WARNING

Keephands,fingersandheadawayfromthelipwhentheraisebuttonisreleased.Thelipanddocklevelerarefreetomovedownwardwhenhydraulic pressure is removed from cylinders.

WARNING

ABOVE DOCK USE:

9. Close control box and activate leveler until lip fully extends.

10. Store maintenance strut.

HP Series11. Allowlevelertocompletecycle,descendingtostoredposition.

HP Series11.A Operate leveler through each of its complete cycles to check

forproperoperation. (Seepages2-1 through2-6,NormalandBelowDockOperation.)

EHP Series12. Allow leveler to descend to below dock position.

EHP Series12.A Raise leveler to stored position

13. Recheckallhydraulichoseconnectionsandfittings.

14. Install bumpers on dock face.

15. Complete weld at rear of leveler.

Be sure selector switch on control box is set to Normal mode.

Two person operation. One person holds pressure on OPERATE button while a second person stores the maintenance strut. Do not hold pres-sure on OPERATE button for more than 10 seconds.

Release OPERATE button. Leveler will drift down to below dock, auto-matically restart, rise several inches above dockwhile lip is closing,then turn off and store in home position.

Cycles include ABOVE DOCK cycle, and BELOW DOCK cycle.

Release OPERATE button. Leveler will drift down to below dock. Push OPERATE button and raise leveler above dock until lip closes. Release OPERATE button and leveler will store in home position with lip in keepers. Makesureallfittingsaresnugandnoleaksarepresent.

Securelyboltbumperstodockfaceasclosetopitopeningaspossible.Bumpers should be flush with dock floor or 48” off ground. Raisedbumpers should be supported to floor from behind.

Weld shall cover approximately 50%of the length of the rear angle.Ensureweldsareplaceddirectlybehindframeuprights:(4eachon6’widemodels, 6 eachon7’widemodels) andat endsof angle. (SeeFigureE,page1-5)(Protectweathersealsduringwelding).



CAUTION: Contact your PIONEER representative or the factory if a malfunction occurs which is not understood. DO NOT attempt to correct situation without proper information and understanding, as this may damage components and void the warranty.

eHP & HP series

(HPOnly)


section 1 installation instructions normal oPerating ProcedureeHP & HP series

ALWAYS secure the vehicle with a vehicle restraint and wheel chocks before operating the dock leveler. * DO NOT operate leveler with anyone standing on or in front of leveler. * DO NOT lift the leveler by hand. * ALWAYS keep fingers, hands, feet, and head clear of all moving parts.

WARNING

If the lip does not fall to the stored position, the dock levelerrequires maintenance or adjustment. Notify you supervisor.DO NOT use dock leveler until it has been repaired. Failureto do so could result in serious injury and/or death.

WARNING

ALWAYS be certain that the truck wheels are chocked, and that thetruck is locked in place by a truck restraining device and the brakes set before loading or unloading. Visually inspect vehicle restraint to make sure it is properly engaged. Trucks pulling away unexpectedly can cause uncontrolled drop of the dock leveler, which can result in serious injury and/or death.

WARNING

If the lip does not fully extend, do not lift by hand. Restore lev-eler to dock level and try again. If lip still does not fully extend, the dock leveler requires maintenance or adjustment. Notify your supervisor. DO NOT use the leveler until it has been repaired. Failure to do so could result in serious injury and/or death.

WARNING

Visually check that the lip is supported by the truck bed or the ramp is supported by both front lip keepers before driving or walk-ing on the ramp.

ALWAYS return the dock leveler to its dock level (stored) positionbefore allowing the truck to leave the dock. If the truck pulls awaybefore the dock leveler is stored, the lip will fall to its pendantposition and may not be supported by the lip keepers. In addition,failure to properly store the dock leveler may leave the leveler in aposition below the level of the dock floor. These conditions may result in unexpected drop of personnel or material handlingequipment and result in serious injury and/or death.

WARNING

10/08 Pioneer Loading Dock Equipment – “HP” Series Hydraulic Dock Levelers 2-3

RECYCLE PROCEDURE WITH TRUCK AT DOCK:

1. Press and hold the OPERATE button.

2. Release the Operate button.

Hold the button until the platform partially raises and lip is fully with-drawn from truck.

Leveler will descend to stored, cross traffic position.

section 2 oPerating instructions normal recYcle Procedure

LIP EXTENDED ONTO TRUCK FOR UNLOADING BELOW DOCK:

1. Turn selector switch to Normal mode.

2. Press and hold the Operate button.

3. Release the Operate button (and optional Lip Out button.)

4. Turn the selector switch from Normal to Below Dock mode while levelerisdescending.

Wait until the platform raises and the lip fully extends.

With optional Lip Out button, simply allow leveler to rise above floor of truck, then also press Lip Out button. Deck will stop and lip will extend.

Levelerwillsettletotruckflooraslowas12”belowdocktoserviceverylowtruckswithoutrecycling.

section 2 oPerating instructions below dock oPeration

HP series

HP series

ALWAYS secure the truck with a vehicle restraint or wheel chocks before operating the dock leveler. DO NOT operate dock leveler with anyone standing on or in front of leveler. DO NOT drive on dock leveler or lip until it is fully extended and supported by the truck bed. ALWAYS keep hands and feet clear of all moving parts. ALWAYS store the leveler to its safe dock level position after servicing the truck.

WARNING


RETURN LEVELER TO STORED POSITION FROM BELOW DOCK:

1. Turn selector mode to Normal mode.

RECyCLEPROCEDuREFROMBELOWDOCK:

1. Turn selector switch to Normal mode.

Leveler will automatically return to stored, cross traffic position.

Do not push Operate button.

(unitdoesnotrecyclefromthis(dead)positionwhentruckdeparts.) If hit while extended, the lip will yield to impact.

Leveler will now return to its stored, cross traffic position automati-cally, before or after truck departs.

section 2 oPerating instructions below dock recYcle Procedure (continued)

AUTOMATIC SAFETY STOP

To restore the leveler to normal operation:

If lip of leveler should become unsupported while a load of 1,000 poundsorgreater ison theplatform, thehydraulicsystemautomati-callylockstheplatforminposition,supportingtheload.

1. Remove the load.

2. Press and release the Operate button. Leveler should drift down-ward and recycle.

section 2 oPerating instructions automatic safetY stoP

HP series

HP series

ALWAYS secure the truck with a vehicle restraint or wheel chocks before operating the dock leveler. DO NOT operate dock leveler with anyone standing on or in front of leveler. DO NOT drive on dock leveler or lip until it is fully extended and supported by the truck bed. ALWAYS keep hands and feet clear of all moving parts. ALWAYS store the leveler to its safe dock level position after servicing the truck.

WARNING

10/08 Pioneer Loading Dock Equipment – “EHP” Series Hydraulic Dock Levelers 2-6

RECYCLE PROCEDURE WITH TRUCK AT DOCK:



Holdthebuttonuntil theplatformreachesmaximumheightandlipfully retracts.

Leveler will descend to stored, cross traffic position.

section 2 oPerating instructions

LIP EXTENDED FOR UNLOADING BELOW DOCK:



Waituntiltheplatformraisesandthelipbeginstoextend.

Leveler will settle between dock floor and truck.

section 2 oPerating instructions below dock oPeration

eHP series

eHP series

AUTOMATIC SAFETY STOP

To restore the leveler to normal operation:

If lip of leveler should become unsupported while a load of 1,000 poundsorgreater ison theplatform, thehydraulicsystemautomati-callylockstheplatforminposition,supportingtheload.

1. Remove the load.

2. Press the Operate button until lip fully retracts. Immediately upon fullretractionreleaseoperatebuttonpriortolipre-extension.

section 2 oPerating instructions automatic safetY stoPeHP series

Caution: ALWAYS SECURE LEVELER WITH LIP IN KEEPERS TO INSURE SAFE CROSS TRAFFIC USE.


HyDRAuLICFLuIDCONTENT

ELECTRICAL Motor: (Both)

Control Panel: (HPSeries)

Proximity Sensor Controls: (HPSeriesOnly)

Control Box: (EHPSeries)

OptionalControlBox(EHPSeries) (requiredfor3phaseor230volt1phase):

Levelers are shipped filled with Dextron II automatic transmission fluid. (Optionalaircrafthydraulicfluidavailableforcoldclimates.)

1 HP, 15 minute duty cycle

Wall mounted metal box (12” x 10” x 5 1/4”), Meets N.E.M.A. 12,hingedcoverforeasyaccess.

AutomaticRecycleFunction,BelowDockLipControl,2eachModel3010A-A312ACI

Wallmountedrotarybox(115volt/singlephaseonly)standard.MeetsN.E.M.A. 12. Circuit protection provided by others.

Wall mounted polymer box, with exterior reset button. Meets N.E.M.A. 12.

section 3 major comPonents

MOTOR AMP DRAW POWER (amperage) VOLTAGE(AC) PHASE (RuNNING) REquIREMENT

115 1 15.0 30

230 1 7.2 20

208-220-240 3 3.6 10

440-460-480 3 1.8 10

1 HP, 1 ph motor draws 25 amps to start motor.

To avoid voltage drop, Pioneer recommends #10 wire onshortrunsand#8wireonlongruns.

Consult code requirements.

caution: a motor can burn out for anY of tHe following reasons:1. Hookuptoincorrectlinevoltage.2. Singlephasingofpolyphasemotorcausedbyablownfuseorlossofonelegofelectricalsupply.3. Lowvoltagetomotorduetoinsufficientlinecapacity.Thisisthemostcommonwith110V,1phoperation.

eHP & HP series

section 3 major comPonents


eHP series

eHP series control box

from owners protected power source

to motor leads

This equipment is shippedfrom the factory fully test-ed and operative.

The majority of operatingproblems are caused by IMPROPER VOLTAGE oruNNECESSARy ADJuST-MENT By uNquALIFIEDPERSONNEL!

To comply with warranty,contact your local Pioneerrepresentative or call thefactory direct if you areexperiencingdifficultywiththe levelerduring thewar-ranty period. DO NOT RISKVOIDING THE WARRANTYBY TAMPERING WITH THEEQUIPMENT.

THIS STATEMENT IS VALID FOR BOTH EHP AND HP UNITS.

CAUTION:

Always place mainte-nance strut and discon-nect power before climb-ing under or placing hands under leveler

10/08 Pioneer Loading Dock Equipment – "EHP" & “HP” Series Hydraulic Dock Levelers 3-8

Co

ntrol Valve Functio

n & A

djustm

ent

Levelers are shipp

ed o

nly after thoro

ugh testing

and ad

justment and

are ready fo

r installatio

n. Co

ntrol valve ad

justments are no

t norm

ally required

and valves sho

uld

not b

e adjusted

except to

alleviate defi

nite malfunctio

ns.

1) Seq

uence Valve contro

ls the timing

of lip

out-sw

ing. R

emo

ve cap and

turn ad-

justing screw

"out" (co

unterclockw

ise) to cause o

ut-swing

to b

egin so

oner. Turning

screw

"in" (clockw

ise) will d

elay the beg

inning o

f lip o

ut-swing

.

2) Seco

ndary R

elief Valve contro

ls "hold

-out" o

f lip. Turning

screw "o

ut" (counter-

clockw

ise) will d

ecrease lip "ho

ld-o

ut". Ho

wever, turning

screw to

o far o

ut will cause

lip to

sag. If lip

"sags", screw

must b

e turned "in" a little at a tim

e until the lip re-

mains extend

ed. Turning

screw "in" to

o far w

ill excessively increase lip "ho

ld-o

ut" p

ressure and w

ill defeat the ab

ility of lip

to yield

under im

pact.

3) Shuttle Valve co

ntrols the lo

wering

speed

of the m

ain platfo

rm. Turning

screw "in"

(clockw

ise), will d

ecrease rate of d

escent. Turning screw

"out" (co

unter-clockw

ise), w

ill increase rate of d

escent. This valve sho

uld no

t require ad

justing in the fi

eld.

4) Prim

ary Relief Valve reg

ulates pum

p p

ressure. Turning ad

justing screw

"in" (clock-

wise) increases p

ump

pressure. Turning

screw "o

ut" (counter-clo

ckwise) w

ill de-

crease pressure. T

his valve should

not req

uire adjusting

in the field

. Co

ntact factory

befo

re attemp

ting to

make p

ressure adjustm

ent .

Mo

tor P

ump

Ad

justment

To lip cylind

erTo m

ain cylinder

Breather cap

with d

ipstick

3)ShuttleValvecontrols

ramplow

eringspeed

Oil reservoir

4)Prim

aryReliefValve

controls pum

p p

ressure(Donotad

just)

2)Second

aryReliefValve

controls lip retraction

and lip

"hold out"

1)Seq

uenceValvecontrolstim

ingoflipoutsw

ing

FluidSpecification

Label


section 4 troublesHooting

SYMPTOM:

RAMPWILLNOTRAISEFROMSTOREDPOSITION:

MotornotrunninginNormalmodewhenOperate button is pressed.

PROBABLE CAUSE:

1. Incorrect or disconnected electrical hook-up.

2. Blown fuses or open circuit breaker.

3. Lossoflinevoltage.

4. Open overload relays on motor starter in control panel.

(EHPSeriesonoptionalcontrolboxonly)

5. Burned motor.

CORRECTION:

1. Reviewwiringdiagramandcheckconnections.

2. Replace bad fuses.

Reset circuit breakers.

Determine and correct other elec-trical problems.

3. Check lines and repair if necessary.

4. Allow to cool.

Push“RESET”buttonlocatedincontrol box.

5. Determinecauseofburn-out.

Correct problem.

Replacemotor.(Contactfactory.)

eHP & HP series

Readandfollowthesafetyproceduresinthismanualbeforedoinganyserviceorrepairtothedockleveler.ALWAySSECuRELEVELERWITHMAINTENANCESTRuTBEFORECLIMBINGINTOTHEDOCKLEVELERPITORDOINGANyMAINTENANCEORREPAIRuNDERTHEDOCKLEVELER.Failuretodosocouldresultinseriousinjuryand/ordeath.

WARNING



SYMPTOM:

RAMP WILL NOT RAISE OR LIP WILL NOT ExTENDFuLLy:

Motorrunningorhumminginnormalmode

(1phmotor)

(1phmotor) (3phmotor) (3phmotor)

(1phor3phmotor)

(1phor3phmotor)

(1phor3phmotor)

RAMP WILL NOT AUTOMATICALLy RETuRNFROMBELOWDOCK: (HPSeriesonly)

PROBABLE CAUSE:

1. Voltagedrop,probablyduetoinsuf-ficient line capacity, resulting inblown fuses, tripped circuit break-ers or motor hum.

2. Wrongrotation.

2. Wrongrotation.

3. Motorsingle-phasing.

4. Load on ramp.

5. Low fluid.

6. Motor or pump physically dam-aged.

1. unitisnotdesignedtoautomati-cally return when selector is in Below Dock mode.

CORRECTION:

1. Test voltage at motor starter withmotor running. Test for amperagedrain. (Low voltage/high amperageindicates inadequate feed line for distance of run.) Replace feed linewith adequate wire size.

2. Seewiringinstructionsonmotor2. Reverse T1 and T3 at terminal strip.

(SeeFigureH,page3-4)

3. Check for bad fuse or loss of power in one line due to loose connections or tripped breakers or overloads.

4. Remove the load. Ramp is not designed to lift more than its ownweight.

5. Refill if needed. Check fittings andhosesandtightenifloose.

6. Replace.

1. Return switch to Normal position. Unit will now automatically recycle and store at floor level.

eHP & HP series

SYMPTOM:

RAMPWILLNOTLOWERAFTERBEINGFuLLyRAISED:

RAMP ExPERIENCES LONG DELAy BEFORERAISING:

RAMP WILL NOT AUTOMATICALLy RETuRNFROMBELOWDOCK:

PROBABLE CAUSE:

1. Physical obstruction.

2. Safetystopinhydraulicfittingshaslocked up.

1. Air in hydraulic system.

1. unitisnotdesignedtoautomati-cally return to stored position.

CORRECTION:

1. Checkandremove.(Alwaysusemaintenancestrutforsafety.)

2. Push and release the Operate button to unlock and allow the unit to descend. If symptom persists, consult factory.

1. Consult factory.

1. Press Operate button and raise lev-eler until lip fully retracts. Release Operate button and leveler will store in home position.


section 4 troublesHootingeHP series

10/08 Pioneer Loading Dock Equipment – “EHP” & "HP" Series Hydraulic Dock Levelers 4-6

Contact your PIONEER representative or the factory if a malfunction occurs which is not understood. DO NOT attempt to correct the situation without proper information and understanding as this may damage components and void the warranty.

CAUTION:

section 4 troublesHootingeHP series

BEFORE SERVICING THE DOCK LEVELER, READ AND FOLLOW ALL SAFETY PROCEDURES IN THIS MANUAL. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY AND/OR DEATH.

WARNING

BEFORE SERVICING THE DOCK LEVELER, ALWAYS POSITION TRAFFIC CONES OR A BARRICADE BEHIND THE DOCK LEVELER. ALSO POSITION CONES OR BARRICADES IN FRONT OF THE LEVELER TO WARN AGAINST VEHICLE TRAFFIC. * ALWAYS NOTIFY A FOREMAN OR SUPERVISOR THAT YOU ARE WORKING UNDER THE EQUIPMENT.

* ALWAYS MAKE SURE THAT THE MAINTENANCE STRUT IS IN POSITION BEFORE WORKING UNDER THE LEVELER.

* ALWAYS MAKE SURE THAT THE OVERHEAD DOOR IS SECURELY HELD IN THE RAISED POSITION.

WARNING

SERVICE AND MAINTENANCEPioneer recommends periodic inspection and servicing of the “HP” AND OR THE "EHP" Hydraulic dock leveler to assure proper operation and maximum life span of the dock leveler. Units should be inspected a minimum of every six months and, if needed, (See “OPERATING INSTRUCTIONS, page 2-2) adjusted and lubricated. Adjustment of Hydraulic valves are con-sidered normal maintenance and are not covered under warranty. Contact your local Pioneer dealer to secure a complete maintenance plan.



1

3

4

5

678

2

ITEM DESCRIPTION

1

2

3

4

5

6

7

8

DeckCylinderwithVelocityFuse

Pins&ClevisKeys,DeckCylinder

Motor&PumpAssembly1HP/1PH

Motor&PumpAssembly1HP/3PH(OPT.)

HydraulicHose(PumptoDeckCylinder)

Hose Assembly, Pump to Lip Cylinder

Hose Assembly, Deck Cylinder to Lip Cylinder

Lip Cylinder

Pins&ClevisKeys,LipCylinder

eHP series

EHP Series Hydraulic System



HP Series Hydraulic System

FIGURE J

HP series

ITEM DESCRIPTION

4

5

6

7

8

9

10

14

DeckCyc.W/HarnessPins&ClevisKeys

Pins&Keys,DeckCylinder

LipCylinderW/Pins&ClevisKeys

Pins&Keys,LipCylinder

HoseAssembly,DeckCylindertoLipCylinder28”

HoseAssembly,PumptoDeckCylinder31”

HoseAssembly,PumptoLipCylinder40”

Motor&PumpAssembly

Warra

nty P

roced

ure

The in

form

atio

n o

n th

e W

arra

nty C

laim

Request F

orm

must b

e p

rovid

ed w

ith a

ll w

arra

nty c

laim

s.

When a call is received

with a w

arranty pro

blem

a Custo

mer S

ervice numb

er (CS

F ####) w

ill be issued

for that p

rob

lem o

nly and canno

t be used

again w

ithout p

rior ap

pro

val. T

his numb

er must b

e on all invo

ices subm

itted fo

r paym

ent and o

n all corresp

ond

ence.

Befo

re and after p

ictures of all the w

ork p

erform

ed m

ust be sup

plied

with each claim

. If yo

u take dig

ital pictures, e-m

ail them to

warranty@

pio

neerleveler.com

. If you use a fi

lm

camera fo

rward

the film

to P

ioneer Lo

ading

Do

ck Eq

uipm

ent, PO

Bo

x 338 Sp

ring H

ill, TN

37174, A

ttn: Warranty D

ept.

No

claim w

ill be co

nsidered

for p

rocessing

witho

ut the required

inform

ation.

Pio

neer’s Warranty P

olicy fo

r paym

ent is a credit that w

ill be ap

plied

to yo

ur account fo

r p

ayment. A

cop

y of the cred

it mem

o w

ill be sent to

your b

illing ad

dress. If a check p

ay-m

ent is required

, the request m

ust be in w

riting. T

he request then has to

be ap

pro

ved b

y P

ioneer’s acco

unts payab

le dep

artment.

Repla

cem

ent P

art u

nder W

arra

nty

Any rep

lacement p

arts will b

e invoiced

at the time o

f shipm

ent. Cred

it will b

e given w

hen the d

amag

ed p

arts are returned to

Pio

neer. Any excep

tions w

ill be d

etermined

by P

io-

neer. At P

ioneer’s d

iscretion, rep

lacement p

arts will b

e shipp

ed either U

PS

gro

und o

r O

TR

truck. Any o

ther requested

metho

d o

f shipm

ent will b

e charged

to the d

ealer. (i.e. U

PS

next day-Fed

-Ex., etc.)

All returned

parts w

ill be issued

a Return A

uthorizatio

n Num

ber (R

GA

####). A fo

rm w

ill b

e faxed w

ith the RG

A num

ber. A

signed

cop

y is to b

e faxed to

1-931-486-0316 and re-

turned w

ith the parts. T

he Return A

uthorizatio

n is go

od

for 30 d

ays. The R

GA

# must b

e listed

on all returns, using

the RG

A Fo

rm as a p

acking list.

No

credits w

ill be issued

witho

ut prio

r pro

per autho

rization.

A co

py o

f the credit m

emo

will b

e sent to yo

ur billing

add

ress. The cred

it will b

e given

against the invo

ice issued fo

r the replacem

ent parts. C

redits w

ill be lim

ited to

repair

parts, lab

or, and

shipp

ing fees d

irectly related to

warranty failures. N

o C

redit w

ill be

given o

n non-P

ioneer p

arts.

Any q

uestions reg

arding

Warranty o

r Return A

uthorizatio

n should

be d

irected to

Cus-

tom

er Service at w

arranty@p

ioneerleveler.co

m o

r 1-866-728-6195.

8/29/2008

SM

SMW

arranty claim request form

The Fo

llow

ing Info

rmatio

n Must B

e Sup

plied

To P

rocess A

ny Claim

Dealer N

ame: *_____________________________________________

Co

ntact Perso

n: * ___________________________________________

Pio

neer Invoice N

umb

er : __________ Date O

f Purchase: _______

End

User N

ame A

nd ad

dress:

Nam

e: ___________________________________________________

Ad

dress: __________________________________________________

City: _________________________ S

tate: ______ Zip

: __________

Pro

duct: __________________________________________________

Mo

del N

umb

er: *________________ Serial N

umb

er: *____________

Custo

mer C

om

plaint: * _____________________________________________________________________

____________________________________________________________________________________________

___________________________________________________________________________________________

Sco

pe o

f Service P

erform

ed: * ______________________________________________________________

____________________________________________________________________________________________

____________________________________________________________________________________________

_______________________________________________

Estim

ated R

epair: H

ours: *______________ $ *__________________

If multip

le repairs list ho

urs and $ fo

r each item.

Pio

neer requires an invo

ice for all claim

s requiring

a paym

ent.

*Befo

re And

After P

ictures Must B

e Sup

plied

With A

ll Wo

rk Perfo

rmed

Purchase a d

ispo

sable cam

era and send

it to P

ioneer alo

ng w

ith the receipt.

*Req

uired to

pro

cess all warranty claim

s.8/28/2008

warranty

a FULL FIVE yEar warranty is standard on Pioneer “HP” series levelers, to include all structural members. a one year warranty covers the motor/pump assembly, cylinders and miscellaneous parts.

a FULL twO yEar warranty is standard on Pioneer “EHP” series levelers, to include all structural members. a one year warranty covers the motor/pump assembly, cylinders and miscellaneous parts.

Pioneer accepts full responsibility for the cost of materials, labor and freight for any warranty claim during the warranty period, which begins at date of shipment. Pioneer reserves the right to either repair or replace any defective parts. a claim for breach of warranty will be honored if the product has been properly installed, maintained and operated within its rated capacity, and not damaged by abuse.

PIOnEEr ManUFaCtUrInG, InC. SHaLL nOt BE LIaBLE FOr LOSS OF USE OF any EQUIPMEnt Or InCIDEntaLDaMaGES.

PIOnEEr EXPrESSLy DISCLaIMS any anD aLL IMPLIED warrantIES.

all PIOnEEr products meet or exceed Federal Occupational Safety and Health act Standards, Commercial Standards 202-56, and american Society of Mechanical Engineers Specifications anSI MH14. 1-84.

Pioneer Loading Dock Equipment – “EHP” & “HP” Series Hydraulic Dock Levelers

Warranty Phone: 1-866-228-6195

r n a “EHP” & “HP” Hydraulic Dock Levelers*Before doing any electrical work, make certain...

Documents

Transcript of r n a “EHP” & “HP” Hydraulic Dock Levelers*Before doing any electrical work, make certain...