Poweramp HM Manual June2010
Contents
1. June 2010 M Hold Down Mechanism N Safety Leg 2 used P Lip Spring OPERATION 7 5 NE 1 y Wage SED S L Platform Maintenance Prop Q Shock Absorber R Safety Leg Linkage S Safety Leg Retract Pull Ring T Lift Arm U Lift Springs The ratchet pawl disengages only when the platform release ring F is pulled AND held Spring tension from pawl spring J causes the ratchet pawl to engage the ratchet bar when the release ring is let go When the platform rises to approximately 2 3 inches b1 76 mm from its full raised height the snubber spring P and a chain pulls the lip link D forward This in conjunction with the lip assist spring E causes the lip linkage to push the lip out and up The lip assist spring also helps control the amount of time required for the lip to fully fold To lower the platform the operator walks out onto the platform The platform will lower until the extended lip rests on the truck bed If the lip did not fully extend or there is no truck at the dock the platform will lower until one of the following conditions occur e Lip is resting on lip keepers cross traffic position e Lip did not fully fold causing the platform to rest on safety legs below dock position e Lip did not fully fold and safety legs are retracted causing the platform to rest on the safety stops full below dock position The hold2. av D Prop Pin amp Clip Whenever maintenance is to be performed under the dock leveler platform support the platform with the platform maintenance prop B Put the platform maintenance prop in the service upright position so that the prop is cradled in the u bracket C Lock the platform maintenance prop in this position by inserting the prop pin and clip D or attaching an OSHA approved lockout device and tagout device supplied by others Only the person servicing the equipment should have the capability to remove the lockout device The tagout device must inform that repairs are in process and clearly state who is responsible for the lockout condition If maintenance requires that the lip be in the extended position raise the lip by hand and support the lip with the lip maintenance prop A NOTE Make sure to disengage the lip maintenance prop and allow the lip to fold fully before disengaging the platform maintenance prop Refer to OSHA regulation 1910 147 21 MAINTENANCE Periodic Maintenance q E E 5 70 S 0 T ENSS ena he 2 SS on j Se gt ook VEX SS J e M c 479 TE GE M 7 4 EU A Lip Hinge Grease Fittings D Platform Hinge Area G Lift Arm Pivot K Lip Lift Assist Pin B Lip Maintenance Prop Pivot E Lift Arm Roller Bushing H Hold Down Pivot Pu
3. 6 6 mm thick shim at locations C is used only as a starting point The final shim stack height will be determined after the dock leveler is lowered into the pit 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 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 13 INSTALLATION am P 777 Vm 3 8 in 6 in 9 5 mm A Front of Dock Pit B Dock Leveler Frame C Side Pit Curb Angle D Gap 3 4 in 19 mm Minimum 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 e 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 can
4. A Division of Systems Inc HM Series PON Dock Leveler Owner s User s Manual POWERAMP Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 257 7349 www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0007 Copyright 2003 June 2010 Table of Contents Page Safety Recognize Safety Information 1 General Operational Safety Precautions 1 Operational Safety Precautions 2 Maintenance Safety Precautions 4 Safety Decals 5 Owner s User s Responsibilities 6 Introduction General Information 7 Dock Leveler Stock Specifications 7 Component Identification 8 Installation Prepare Gcr 9 Prepare Dock Leveler 10 Install Dock Leveler 12 Operation THEO ccc LD CC O d 17 Operating Instructions 18 Loading Unloading Instructions 19 End Loading Unloading Instructions 20 Maintenance Service Dock Leveler Safely 21 Periodic Maintenance
5. 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 4 4111 0007 June 2010 SAFETY Safety Decals 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 DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar 1 75 1 0727 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 0730 x2 A DANGER Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always e Ensure that no equipment material or people are on the dock leveler e Return the dock leveler to its stored position at dock level osi Failure to follow posted instructions will result in death or serious injury Cal 262 255 1510 for replacement placards waming labels or ownersjuser s manuals decal placed in same position on both sides 1751 0329 x2 i 7 decal placed in same position on both sides 0 Q OM DO Q SSS 00 O M ANY MD SEEN C 1751 0330 2 23 decal placed in same position on both si
6. be done with the dock at the cross traffic position or below dock position depending on the height of the truck trailer bed Check to make sure truck trailer is positioned squarely against dock bumpers Instruct driver to remain at the dock until the loading or unloading process has been completed Chock the truck trailer wheels or use truck restraint if present Uo Tete End Loading Unloading Platform at Cross Traffic Position 4 If truck trailer bed is at or above dock floor level leave leveler at the cross traffic position and proceed with loading or unloading When finished perform steps 9 and 10 If truck trailer bed is below the dock floor level perform steps 5 10 5 Pull and hold the platform release ring A until the platform is at the fully raised position 20 Slowly walk the platform down allowing enough time for the lip to fold Just before the platform reaches the cross traffic position pull and hold the safety leg retract pull ring B located in a recess at front of the platform The platform will continue lowering to the full below dock position End Loading Unloading Platform at Below Dock Position 7 Proceed with loading or unloading NOTE When end unloading is finished and additional access to the truck trailer requires that the platform lip be extended see Hamp Loading Unloading Instructions on page 19 for further instructions 8 When lo
7. down ratchet assembly will keep the platform at the desired position until the platform release ring is pulled again 17 OPERATION Operating Instructions Stay clear of dock leveler when freight carrier is 12 in 805 mm entering or leaving dock area y DO NOT raise or lower the dock leveler if anyone is under or in front of leveler a 12 in 305 mm Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts The HM series mechanical dock leveler is designed Failure to follow these instructions may result in to compensate for 12 in 305 of height severe personal injury or death difference between the loading dock and the truck bed DO NOT use the dock leveler if the truck trailer bed is more than 12 in 305 mm higher or lower than the dock floor DO NOT activate the dock leveler until the DO NOT overload the dock leveler truck trailer is positioned squarely against the bumpers and the truck wheels are chocked DO NOT operate any equipment while under the influence of alcohol or drugs Never remove the wheel chocks until loading and unloading is finished and truck driver has been DO NOT leave store equipment or material given permission to leave unattended on the dock leveler DO NOT use the dock leveler if the freight carrier is Failure to follow these instructions may result in too high or too low personal injury and or damage to equipment NEVER use a fork truck
8. location 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 2 Using the results obtained in step 1 create the individual shim stacks on the pit floor at locations Build each shim stack using the pyramid method M preferred or stepped method N with the top shim having a minimum size of 4 1 2 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 P or straight method Q NOTE To assist in obtaining an accurate measurement of distance J use a string F 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 J top of shim stack K to dock floor Distance J must equal the dock leveler height A 4111 0007 June 2010 INSTALLATION 4 Put a 1 4 in 6 6 mm thick shim at locations C under lip keepers maintenance prop and safety legs Make sure shims are larger than frame angle iron so pyramid or stepped stacking method can be used NOTE A 1 4 in
9. obstructions that could cause binding Check weather seal if equipped If no obstructions found call Poweramp Technical Services See inside back cover for phone number and address Insufficient main spring Increase tension on main springs See Adjust Lift tension Arm Spring and Lip Assist Spring Tension in the Adjustments section Damaged or worn Clean and inspect hold down mechanism hold down mechanism 4111 0007 June 2010 27 TROUBLESHOOTING Platform rises to full Lip assist chain Connect or replace chain height but lip does not disconnected or broken fully extend Insufficient main spring Increase tension on main lift springs See Adjust Lift tension Arm Spring and Lip Assist Spring Tension in the Adjustments section Insufficient lip assist force j Increase lip assist spring tension See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section Platform does not lower Excessive main spring Reduce main spring tension See Adjust Lift Arm when operator walks out tension opring and Lip Assist Spring Tension in the onto the platform Adjustments section Damaged or worn Clean and inspect hold down mechanism hold down mechanism Lip folds too fast during Insufficient lip assist force Increase lip assist spring tension See Adjust Lift normal walk down Arm Spring and Lip Assist Spring Tension in the Adjustments section Disconnected worn or Inspec
10. or any other material handling equipment to lower the dock leveler IMPORTANT DO NOT drive any equipment onto the dock leveler When activating the leveler always pull AND hold until platform lip is resting on the truck trailer with the platform release ring until the platform is at the at least 4 in 102 of overlap full raised position Releasing the ring while the platform is still rising may result in damage to the Always maintain a safe distance from side edges of equipment leveler during the loading and unloading process NEVER attempt to walk on an unsupported lip The dock leveler operation instructions are NEVER allow untrained personnel to operate the divided into the two methods of loading and dock leveler unloading NEVER attempt to lift any part of the leveler by e For ramp loading and unloading see Ramp hand Loading Unloading Instructions on page 19 Failure to follow these instructions may result in e For end loading and unloading see End serious personal injury or death Loading Unloading Instructions on page 20 18 4111 0007 June 2010 Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 20 1 Check to make sure truck trailer is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the truck
11. 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 22 23 24 16 Install shims under lift arm at locations using the pyramid shimming method The lift arm pivot must be solidly shimmed the entire length of the lift arm pivot Make sure the lift arm pivot is level from side to side Finish weld all shims using a fillet weld e Weld all shims within each shim stack to each other then weld the shim stack to the leveler frame e Weld the front leveler frame shim stacks to the front pit curb steel if not done previously When all welding has been completed remove all slag then paint all the welds and shims 25 26 27 28 29 30 31 32 Remove the lifting brackets from the platform side joists Disengage the platform maintenance prop Slowly walk out onto the platform to lower the platform until it is at the cross traffic stored position Check operation of dock leveler by cycling the leveler at least four times e When the platform is at full height lip will be fully extended e Lip will begin to drop after full height is reached taking approximately 12 seconds to fully fold Check below dock position by walking platform down before lip folds completely Lip will be over lip keepers e Platform safety legs will be resting on frame Check full below dock posi
12. provide many years of trouble free performance with an absolute minimum of maintenance To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended Once again thank you and congratulations on your purchase of a Poweramp mechanical dock leveler 4111 0007 June 2010 INTRODUCTION Dock Leveler Stock Specifications HM Series dock levelers are available in the following sizes weight capacities and options Width 6 ft 1828 8 mm 6 1 2 ft 1981 2 mm 7 ft 2133 6 mm Length 5 ft 6 ft 8 ft 10 ft 1424 mm 1828 8 mm 2438 mm 3048 mm PR Capacity CIR 30 000 Ib 13 608 kg 35 000 Ib 15 876 kg 40 000 Ib 18 144 kg 45 000 Ib 20 412 kg 50 000 Ib 22 680 kg CIR Comparative Industry Rating Call Poweramp for your specific needs INTRODUCTION Component Identification SS cus ee 7 d 4 P 6 0 gt H M N ol E Ts A M SA NN 2 0 B e g 3 A Lip F Platform Release Ring L Platform Maintenance Prop R Safety Leg Linkage B Lip Maintenance Prop G Ratchet Pawl M Hold Down Mechanism S Safety Leg Release Ring C Platform H Ratchet Bar N Safety Leg 2 used T Lift Arm Assembly D Lip Link J Pawl Spring P Lip Snubber Spring U Lift Main Spring E Lip Assist Spring
13. to unlock the maintenance prop Failure to follow these instructions may result in Always stand clear of the dock leveler lip when serious personal injury or death working in front of the dock leveler Failure to do this may result in serious personal injury or death 24 4111 0007 June 2010 NOTE Adjusting the tension of lift springs D usually requires that the lip assist spring C also be adjusted If the platform does not rise fully and or lip does not extend fully the lift spring tension may be set too low If the platform cannot be walked down or is difficult to walk down the lift spring tension may be set too high If the platform does not rise fully on its own it may be necessary to use an external lifting device Use a lifting device with the appropriate lifting capacity to safely raise the platform Make sure to engage and lock the platform maintenance prop after raising the platform Failure to do this may result in serious personal injury or death IMPORTANT When using an external lifting device to raise the platform make sure hold down mechanism F is disengaged Pull and hold platform release ring during the lifting process to avoid shearing the ratchet pawl and ratchet bar teeth 1 Raise the platform and engage the platform maintenance prop Lock the maintenance prop in the service position using an appropriate locking device 2 Adjust tension of lift springs D as follows NOT
14. trailer wheels or use truck restraint if present 4 Raise the platform by pulling and holding the platform release ring A 5 Hold the release ring until the platform is at the fully raised position and lip is fully extended 6 Walk out onto the platform The platform will lower until the lip rests on the truck trailer bed 4111 0007 June 2010 OPERATION 7 Make sure that the lip is fully extended and supported on the truck trailer along the entire width of the platform with at least 4 in 102 mm of lip contacting the truck bed Tere 8 Proceed with loading or unloading NOTE If end loading is necessary see End Loading Unloading Instructions on page 20 9 When the loading or unloading process has been completed return platform to cross traffic stored position as follows a Raise the platform to the full raised position by pulling and holding the platform release ring A b Lower platform by slowly walking out onto the platform allowing time for the lip to fully fold and clear the truck trailer Continue walking out on platform until platform lowers to the cross traffic position lip engages in the lip keepers 10 Remove chocks from truck trailer wheels or release truck restraint if used 11 Indicate to driver that truck may leave the dock 19 OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE End loading or unloading can
15. 20 Extrusion For Brush 8 DOTH 2820 Extrusion For Brush 10 DKIT 9178 Full Range Toe Guard Assembly 5 4 DKIT 91 79 Full Range Toe Guard Assembly 6 DKIT 9180 Full Range Toe Guard Assembly 8 DKIT 9181 Full Range Toe Guard Assembly 10 34 4111 0007 June 2010 PARTS Toe Guard Weather Seal Optional c 9 jud B i 3 a 3 TOS co DW og 0 C SEG cgo S F gt Cave 200Z00 oo gt O0 O O H i ca O 02 0 0 Bo oO x O qw OR Q xo co lt a Biiiiiio P 2 oo0ooooo O 000 00 C gt jud S IN QN sim 5 5 lt 35 June 2010 4111 0007 NOTES This page intentionally left blank 36 4111 0007 June 2010 MISCELLANEOUS Customer Information NOTE Refer to illustration for left right orientation of dock leveler The model serial number decal A is located on the right platform joist near the front lip of dock leveler Serial No Poweramp Job No When you receive your HM series dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keeping of Original Owner Information the numbers in the event the model serial number decal A bec
16. 22 Adjustments Adjust Lift Arm Spring and Lip Assist Spring Tension 24 Adjust Lip Stop RC uu 26 Troubleshooting Troubleshooting A CL 27 Parts Hold Down Mechanism 29 Frame Components 30 Platform Components 32 Toe Guard Weather Seal Optional 35 Miscellaneous Customer Information 37 Warranty PRE Back Cover 4111 0007 June 2010 Recognize Safety Information 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 DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury IMPORTANT The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 0007 June 2010 SAFETY General Operational Safety Prec
17. 4 5 Ratchet Bar AD 1 DOTH 2222 Washer 1 DRFA 1205 Pin AH As Required 1 Provide dock leveler serial number platform size lip size and pit depth when calling or faxing orders 4111 0007 June 2010 31 PARTS Platform Components 4111 0007 June 2010 32 Platform Components PARTS Item Quantity Part Number Description A 1 DLPA 1 Platform Welded Assembly B 1 DOTH 1721 Decal Warning C 2424 Fitting Grease D 1 DOTH 2075 Cap Screw Lip Stop E 2 DOTH 2160 Nut Hex 5 8 11 F 1 DOTH 2131 Nut Nylon Lock G 2 DOTH 2214 Washer H 1 DOTH 2547 Spring Lip Maintenance Prop J 1 DOTP 2006 Prop Lip Maintenance K 1 DOTH 2062 Cap Screw L 1 DLIP 1 Lip Welded Assembly 2 DPLA 2101 Pin Lip Hinge 6 ft wide M 2 DLPA 2102 Pin Lip Hinge 6 5 ft wide 2 DLPA 2103 Pin Lip Hinge 7 ft wide N 2 DOTH 2380 Pin Cotter Shock Absorber Assembly P 1 DOTH 2582 Shock Absorber Q 2 DOTH 2374 Pin Cotter R 2 DOTH 2210 Washer S 2 DOTH 2351 Bolt Clevis T 2 DOTH 2163 Nut Nylon Lock 1 DKIT 6465 Single Shock Absorber Assembly Includes Items Safety Legs Assembly U 1 DOTH 2423 Ring Chain V 1 DOTH 2412 Chain Safety Leg X 2 DOTH 2432 Spring Snap 3 16 in Y 1 DOTH 6231 Leg Left Safety Assembly with Spring Z 1 DPLA 2122 Pull Bar Rod Assembly Safety Leg AA 1 DOTH 2356 Pin Clevis AB 1 DOTP 6647 R
18. E Use 1 2 turn increments when adjusting lift spring bolt E Check platform operation after each adjustment Repeat until proper operation is obtained To increase lift spring tension turn lift spring bolt E clockwise To decrease lift spring tension turn lift spring bolt E counterclockwise 4111 0007 June 2010 ADJUSTMENTS 3 After lift spring adjustment is completed check operation of the lip e f the lip folds before the platform can be walked down tension of lip assist spring C may be set too low e f the lip does not fold fully or takes too long to fold tension of lip assist spring C may be set too high 4 Adjust lip assist spring tension as follows NOTE Use two turn increments when adjusting lip assist spring C Check lip operation after each adjustment Repeat until proper operation is obtained a Loosen jam nut A b To increase spring tension turn nut B clockwise To decrease spring tension turn nut B counterclockwise d Tighten jam nut 5 Recheck operation of platform and lip Readjust lift spring tension and lip assist spring tension until proper operation is obtained 29 ADJUSTMENTS Adjust Lip Stop Bolt Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand c
19. Frame Q Lip Shock Absorber Assembly 8 4111 0007 June 2010 INSTALLATION A Distance Pit Width B Distance Dock Floor to Pit C Distance Pit Length D Distance Pit Corner to Corner Front and Rear Floor Four Corners Both Sides of Pit Top Bottom and Both Sides Before lowering the dock leveler into the pit the following must be performed Post safety warnings and barricade the work area at dock level and ground level to prevent 1 Remove all debris from the pit and sweep the pit unauthorized use of the dock leveler before clean installation has been completed 2 Check the entire dock leveler pit for proper Failure to follow the installation instructions can construction according to approved certified pit result in damage to dock leveler the facilities drawings Make sure pit is square by making the and or serious personal injury or death 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 criss cross distance D at both sides Take measurements IMPORTANT at dock floor level and at pit floor level DO NOT remove the shipping bands around the If any measurement is off by more than 1 8 in dock leveler lip until instructed to do so 3 18 mm contact Poweramp Technical Services before proceeding 4111 0007 Ju
20. M Make sure lip overlaps onto trailer at least 4 in 102 mm Keep a safe distance from both side edges 4111 0007 June 2010 SAFETY 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 4111 0007 June 2010 3 SAFETY Maintenance Safety Precautions 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 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 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 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 The maintenance prop must be in the upright service position when working under the dock leveler
21. ading or unloading is finished raise the platform to the full raised position by pulling and holding the platform release ring Slowly walk the platform down allowing enough time for the lip to fold The platform will lower to the cross traffic position lip engages in the lip keepers Remove chocks from truck trailer wheels or release truck restraint if used 10 Indicate to the driver that the truck may leave the dock 4111 0007 June 2010 MAINTENANCE Service Dock Leveler Safely 707 9 LS Ty TT Dey 25 Lip Maintenance Prop B Platform Maintenance Prop Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death The platform maintenance prop MUST be in the 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 maintenance prop Failure to follow these instructions may result in serious personal injury or death 4111 0007 June 2010 C U Bracket p II dota T
22. autions Head 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 DANGER WARNING or CAUTION signs or decals on the equipment unless replacing them DO NOT activate the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone Hemove 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 SAFETY Operational Safety Precautions Learn the safe way to operate this equipment Read and understand the manufacturer s instructions If you have any questions ask your supervisor ee _ otay 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 9 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 EN Tee Do not use a broken damaged dock leveling device Make sure proper service and maintenance procedures have been performed before using T
23. des Za ADANGER CRUSH HAZARD Do not remove main springs until leveler is safely supported by maintenance prop Main springs contain stored energy Be sure springs are fully unloaded and ends are loose before removal Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury ADANGER 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 1751 0788 DANGER CRUSH HAZARD Open the pin latch and insert through the maintenance 1751 0789 e 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 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 7 5 7 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 1751 0726 4111 0007 June 2010 5 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 th
24. e 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 Guide 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 decals instructions and posted warnings shall not be obscured from the view of the operator or maintenance personnel for whom such warn
25. ents PARTS Quantity Part Number Description A 1 DFRA_ Frame Welded Assembly DFRA 1 Frame Clean Sweep Welded Assembly Optional B 1 DOTH 2555 Spring Snubber C 1 DOTH 2416 Lap Link 3 16 x 1 0 in D 1 DPLA 2128 Chain Lip Assist Link E 1 DOTH 2421 Cold Shut Link 5 16 in 1 DFRA 0326 6 Foot Bolt Spring Adjuster amp Plate Spring Tensioner 1 0327 8 Foot Bolt Spring Adjuster amp Plate Spring Tensioner 1 DOTH 2222 Washer G 1 DOTP 6424 Lift Arm Short 25 1 DOTP 6423 Lift Arm Long 27 J 1 DOTH 2402 Roller Assembly Cam K AR DOTH Spring Lift L 5 DOTH 2382 Pin Cotter 1 4 x 2 in M 3 9202 0002 Pin Rear Hinge N 1 DOTH 2061 Bolt Shoulder P 4 DOTH 2432 Spring Snap 3 16 in Q 1 DOTH 2423 Ring Chain 5 1 DOTH 2131 Nut Nylon Lock T 1 DLPA 1210 Chain Release Pull U 1 DOTH 6929 Arm E Z Release 1 DOTP 6921 Chain Hold Down Release 5 ft V 1 DOTP 6922 Chain Hold Down Release 6 ft 1 DOTP 6923 Chain Hold Down Release 8 ft 1 DOTP 69241 Chain Hold Down Release 10 ft W 1 DOTP _ 1 Prop Maintenance X 2 ____1 Keeper Lip 1 DOTH 2356 Pin Clevis Z 1 DOTH 2405 Roller Hold Down Release Chain AA 1 DOTH 2375 Pin Cotter AB 1 DOTH 2563 Hold Down Assembly Complete 31 5 Ratchet Bar 1 DOTH 2564 Hold Down Assembly Complete 3
26. eriod begins upon the completion of the installation or the Sixtieth 60th day after shipment whichever is earlier All guarantee claims will be settled on a timely basis when defects are found to be from other than improper installation operating contrary to instructions or beyond rated load capacities abuse careless or negligent use or failure to maintain the unit as recommended by the owner s manual There are no guarantees either expressed or implied including any implied guarantees of merchantability or fitness for a particular purpose which shall extend beyond the guarantee periods indicated above This guarantee is valid only if the unit s is unaltered from original condition as delivered from the factory and a survey is completed by a Poweramp representative
27. hinge frame angle This can put unnecessary stress on the leveler components causing the leveler not to function correctly and shortening the lifespan of the affected components NOTE The illustration on the previous page shows a typical weld pattern The weld pattern will vary slightly depending on size of dock leveler 13 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 6 in 152 long weld Space all the other welds out evenly leaving approximately 6 in 152 mm space between each weld Alternate welding locations to distribute heat Welding sequentially from one end to the other may cause warping or distortion 4111 0007 June 2010 INSTALLATION 14 Remove shipping bands at this time Allow platform to float Add Remove shims as necessary to bring platform level flush with floor Make sure all personnel are outside of the leveler operating zone and stand clear of the platform lip before removing the shipping bands Failure to do this may result in serious personal injury or death 15 Weld front of dock leveler frame B to shims located under the keepers then weld the shims to the front pit curb steel 16 Disconnect lifting device and chains from the lifting brackets Make sure all pers
28. ings 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 6 4111 0007 June 2010 General Information Congratulations on your choice of a Poweramp dock leveler This manual covers the HM series mechanical dock leveler Designed by Poweramp to be a marvel of simplicity and efficiency your dock leveler when properly installed will
29. lear of the dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death The platform maintenance prop MUST be in the 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 maintenance prop Failure to follow these instructions may result in serious personal injury or death Check that lip E is fully resting on the lip keepers D and at the lowest part of the keeper cradle If lip is not resting properly in keepers perform the following adjustment 1 Fully raise platform Manually raise the lip and engage lip maintenance prop not shown 2 Loosen jam nut B 3 Adjust stop bolt C as necessary e Turn stop bolt in clockwise to allow lip to fold closer to platform A e Turn stop bolt out counterclockwise to hold lip further away from platform A 26 A Platform D Lip Keeper B Jam Nut E Lip C Stop Bolt Tighten jam nut B Disengage lip maintenance prop Walk platform down to cross traffic stored position Check lip position in both keepers Repeat procedure if necessary 4111 0007 June 2010 TROUBLESHOOTING Troubleshooting Always post safety warnings and barricade the The platform mai
30. lley L Hold Down to Platform Pin C Lip Link Pivots F E Z Release Bellcrank Pivot J Safety Leg Linkage Pivots Always post safety warnings and barricade the The platform maintenance prop MUST be in the work area at dock level and ground level to prevent service position when working under the dock unauthorized use of the dock leveler before leveler For maximum protection use an OSHA maintenance is complete Failure to do this may approved locking device to lock the maintenance result in serious personal injury or death prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Failure to follow these instructions may result in Always stand clear of the dock leveler lip when serious personal injury or death working in front of the dock leveler Failure to do this may result in serious personal injury or death 22 4111 0007 June 2010 Regular maintenance must be performed on weekly and quarterly schedule Weekly Maintenance e Operate the dock leveler through the complete operating cycle to maintain lubrication NOTE To thoroughly inspect the platform hinge area position the platform in the full below dock position e Inspect the platform hinge and the lip hinge areas The hinge areas must be kept free of dirt and debris Build up of foreign material in the hinge areas will increase wear and cause abnormal operation IMPORTANT Failure to properly
31. lubricate the dock leveler will cause abnormal operation of the leveler DO NOT lubricate the hold down ratchet bar and pawl 4111 0007 June 2010 MAINTENANCE Quarterly Maintenance e Lubricate the following areas with light weight machine oil B Lip maintenance prop pivot C Lip link pivots F E Z release bellcrank pivot H Hold down pivot pulley J Safety leg linkage pivots L Hold down to platform pin Lubricate the following areas with white lithium grease A Lip hinge area inject grease into all the lip hinge grease fittings D Platform hinge area inject grease into all the platform hinge grease fittings E Lift arm roller bushing G Lift arm pivot K Lip assist pin 23 ADJUSTMENTS Adjust Lift Arm Spring and Lip Assist Spring Tension A Jam Nut C Lip Assist Spring E Lift Spring Bolt B Adjustment Nut D Lift Springs F Hold Down Mechanism Always post safety warnings and barricade the The platform maintenance prop MUST be in the work area at dock level and ground level to prevent service position when working under the dock unauthorized use of the dock leveler before leveler For maximum protection use an OSHA maintenance is complete Failure to do this may approved locking device to lock the maintenance result in serious personal injury or death prop in the service position Only the person servicing the equipment should have the key
32. ly 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 4111 0007 June 2010 INSTALLATION 11 INSTALLATION Install Dock Leveler GEE ES A Distance Leveler Frame Height B Shim Locations Under Rear Vertical Supports C Shim Locations Under Lip Keepers and Prop D Dock Floor E Rear Pit Curb Angle 7 F String G Rear Hinge Frame Angle H Distance Dock Floor to Pit Floor J Distance Top of Shim Stack to Dock Floor K Shim Stack L Dock Leveler Frame M Pyramid Preferred N Stepped Acceptable P Offset Not Acceptable Q Straight Not Acceptable Shim Stacking Methods 4111 0007 June 2010 NOTE Poweramp dock levelers are designed with a nominal 1 2 in 12 7 mm shimming distance to allow for pit inconsistencies 1 Determine height of shim stack K for each shim location B by performing the following a Measure leveler frame height distance A b Measure dock floor to pit floor distance H at each shim location B Write down the dimensions obtained at each location c Subtract distance A from distance H to obtain the shim height Repeat for each shim
33. ne 2010 INSTALLATION Prepare Dock Leveler A Lifting Bracket 2 used 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 the dock leveler and or serious personal injury or death 10 B Shipping Bands Poweramp dock levelers are designed with installation in mind Each unit is shipped with lifting brackets A fastened to the platform side joists 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 4111 0007 June 2010 1 Remove any bumpers that may be banded bolted to the frame of the dock leveler DO NOT remove the shipping bands B around the platform lip and leveler frame at this time IMPORTANT DO NOT over tighten the lifting bracket hardware Over tightening can damage the weather seal if equipped NOTE OvVerall 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 relative
34. not be obtained equally at both sides of leveler grind or add material at the rear edge of rear hinge frame angle F as needed 14 152 mm E Pry Locations F Rear Hinge Frame Angle H Flare Bevel Weld Typical To Fit Spacing G Rear Pit Curb Angle 10 Allow the dock leveler to rest fully on the shim stacks Make sure the leveler is in the cross traffic stored position with lip resting on lip keepers 11 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 12 If leveler cannot be squared and made level as instructed in steps 8 10 contact Poweramp Technical Services 4111 0007 June 2010 DO 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 IMPORTANT Always ground welding equipment to the dock leveler frame NEVER to the platform DO NOT weld continuously along the full length of the rear
35. ntenance prop MUST be in the work area at dock level and ground level to prevent service position when working under the dock unauthorized use of the dock leveler before leveler For maximum protection use an OSHA maintenance is complete Failure to do this may approved locking device to lock the maintenance result in serious personal injury or death prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Failure to follow these instructions may result in Always stand clear of the dock leveler lip when serious personal injury or death working in front of the dock leveler Failure to do this may result in serious personal injury or death Platform does not rise Heavy object s on platform Remove object s from platform NOTE For safety reasons the dock leveler is designed to lift only the platform s own weight Disconnected or broken Connect or replace cable release cable Dock leveler binds Check for visible obstructions that could cause binding Check weather seal if equipped If no obstructions found call Poweramp Technical Services See inside back cover for phone number and address Platform rises slowly or Heavy object s on platform Remove object s from platform does not rise to the full raised position NOTE For safety reasons the dock leveler is designed to lift only the platform s own weight Dock leveler binds Check for visible
36. od Push AC 1 DOTH 2374 Pin Cotter AD 1 DOTH 6232 Leg Right Safety Assembly with Spring AR As Required 1 Provide dock leveler serial number platform size and lip size when calling or faxing orders 4111 0007 June 2010 Continued on next page 33 PARTS Platform Components Continued from previous page Item Quantity Part Number Description Lip Assist Assembly AE 1 DPLA 2130 Rod Lip Assist Adjuster 1 1 8 in x 34 in Heavy Duty Short AF 1 DOTH 2548 Spring STD Lip Assist DOTH 2546 opring HD Lip Assist AG 1 DOTH 2061 Bolt Shoulder AH 1 DOTH 2131 Nut Nylon Lock AJ 1 DOTH 2160 Nut Nylon Lock 5 8 11 UNC AK 2 DOTH 2404 Bearing Roller AL 2 DOTH 2211 Washer 5 8 1 5 16 in OD x 11 16 in ID AM 1 DOTH 6644 Spacer 1 1 4 in OD x 3 4 in ID x 1 in AN 1 DOTH 2076 Cap Screw 5 8 11 UNC x 3 1 2 in AO 1 DPLA 2126 Link Lip With Chain AP 2 DOTH 2131 Nut Nylon Lock 3 8 16 in AQ 2 DOTH 2061 Bolt Socket Head Shoulder Toe Guard and Weatherstripping shown on following page Item Quantity Part Number Description Lip Assist Assembly DOTH 2842 Track Weatherstrip 5 A 4 DOTH 2819 Track Weatherstrip 6 DOTH 2817 Track Weatherstrip 8 DOTH 2843 Track Weatherstrip 10 DOTH 2821 Extrusion For Brush 5 C 1 DOTH 2821 Extrusion For Brush 6 DOTH 28
37. omes lost or damaged Also write down Poweramp s job number the Address company that installed the dock leveler and the original owner s name This will all help to identify the specific dock leveler if more information is required Installer Information When ordering use part numbers and description to help identify the item ordered Do not use item numbers These are only for locating the position of Address the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER For service call or contact Date of Installation Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0007 June 2010 37 POWERAMP WARRANTY HM SERIES MECHANICAL LEVELER Systems Inc guarantees the materials components and workmanship in your Poweramp HM Series dock leveler to be of the highest quality and to be free of defects in material and workmanship for a full One 1 Year Base Warranty on all components The Base Warranty includes replacement parts labor and freight Structural components carry a Ten 10 Year Pro Rated Parts Warranty Example after two years customer is responsible for 20 three years 30 etc Specifically the structural warranty includes the frame deck section lip section rear hinge and front hinge Systems Inc warrants all components to be free of defects in material and workmanship under normal use during the warranty period This base warranty p
38. onnel are outside of the leveler operating zone and clear of the platform lip before activating the leveler Failure to do this may result in serious personal injury or death IMPORTANT When activating the leveler always pull AND hold the platform release ring until the platform is at the full raised position Releasing the ring while the platform is still rising may result in damage to the equipment 17 Pull and hold the release ring located in recess at rear of platform until the platform is fully raised Check for binding as platform rises 18 Slowly walk out onto the platform to lower the platform Allow the platform to lower to the cross traffic position Check for binding as platform lowers 19 If binding occurs reposition leveler and or add or remove shims as necessary Raise and lower platform again If platform still binds contact Poweramp Technical Services for further instructions 20 Check that the leveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly 19 INSTALLATION A Safety Leg Chain Pull Ring B Platform Maintenance Prop C Shim Location Under Lift Arm Pivot D Prop Pin amp Clip 2 Pull the release ring to raise platform Engage the platform maintenance prop B in the service upright position and lock the maintenance prop at this position using an OSHA approved locking device D Engage lip maintenance prop Make sure the platform is
39. t shock absorber Connect or replace shock broken shock absorber absorber Platform does not stay Entangled release chain Hemove cause of entanglement down Dirt impacted in ratchet bar Clean and inspect ratchet bar and ratchet pawl teeth teeth DO NOT lubricate the ratchet assembly Broken or damaged ratchet Replace ratchet assembly DO NOT lubricate the assembly teeth ratchet assembly Disconnected or broken Replace hold down pivot pins hold down pivot pins Damaged or worn Clean and inspect hold down mechanism hold down mechanism Lip does not fold after Lip hinge binding because Inject grease into all of the lip hinge grease fittings truck departs of lack of lubrication See Periodic Maintenance in the Maintenance section Excessive lip assist force Decrease lip assist spring tension See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section 28 4111 0007 June 2010 Hold Down Mechanism PARTS Item Quantity Part Number Description 1 DOTH 2563 Hold Down Assembly Complete 31 5 Ratchet Bar DOTH 2564 Hold Down Assembly Complete 34 5 Ratchet Bar 1 DKIT 2575 Ratchet Bar and Pawl Assembly 31 5 Ratchet Bar DKIT 2576 Ratchet Bar and Pawl Assembly 34 5 Ratchet Bar C 1 1751 0043 Decal Warning D 1 DOTH 2559 Spring Release Arm 4111 0007 June 2010 29 PARTS Frame Components 30 4111 0007 June 2010 Frame Compon
40. tion by walking the platform down Pull and hold safety leg chain A before lip folds completely If the lip does not extend fully or lip folds too quickly see appropriate symptom in the Troubleshooting section Install the dock bumpers as required 4111 0007 June 2010 Theory RARE ERA OIA A Lip B Lip Maintenance Prop Platform D Lip Link E Lip Assist Spring F Platform Release Ring G Ratchet Pawl H Ratchet Bar J Pawl Spring Frame The HM series mechanical dock leveler uses large lift springs U to apply force to lift arm T The lift arm pushes against the underside of the platform C roling on the cam not pictured forcing the platform to rise The force of the spring tension is just enough to lift the weight of the platform IMPORTANT When activating the leveler always pull AND hold the platform release ring until the platform is at the full raised position Releasing the ring while the platform is still rising may result in damage to the equipment To actuate the dock leveler platform the operator pulls and holds the platform release ring F located in the recess at the rear of the platform This causes ratchet pawl G to disengage from ratchet bar H With the ratchet pawl disengaged spring tension from lift springs U forces the platform to rise NOTE Hatchet pawl G and bar H are part of the hold down mechanism M 4111 0007
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