Poweramp CentraAir® Manual May2015
Contents
1. 49 Warranty J J Back Cover Recognize Safety Information Safety Alert Symbol The Safety Alert Symbol identifies NOTICE 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 The use of the word NOTICE is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 0034 May 2015 SAFETY General Operational Safety Precautions 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 or Decal s on the equipment unless replacing them Tee e2. 16 Placard 17 Air Line Installation 18 Put New Leveler Into Service 22 Operation Operating Instructions J J J Q J J 24 Ramp Loading Unloading Instructions 25 Loading Unloading Instructions 26 Maintenance Service Dock Leveler Safely T 27 Periodic Maintenancoes J J 28 Adjustments Adjust Lip Latch and Lip Actuator Springs 31 32 Troubleshooting Troubleshooting T 35 Parts u 36 T 37 Air Control 221 1 2 J J 39 Below Dock COMO tic ULU Lu u uuu Lu uu 41 Pit Extension Ill l l 42 B llows and R gulalor LLULLU 43 rrameandPlhlallopi aku 44 46 Weather 47 PICS 48 Miscellaneous Customer Information
3. LIPS Table A 6 0 FOOT 20K 25 30K 35K 40K 45K 50K 1 16 0595 1500 0595 1503 0595 1506 0595 1509 0595 0512 0595 1515 1 18 0595 1501 0595 1504 0595 1507 0595 1510 0595 0513 0595 1516 1 20 0595 1502 0595 1505 0595 1508 0595 1511 0595 1514 0595 1517 6 5 FOOT 1 16 0595 1518 0595 1521 0595 1524 0595 1527 0595 1530 0595 1533 1 18 0595 1519 0595 1522 0595 1525 0595 1528 0595 1531 0595 1534 1 20 0595 1520 0595 1523 0595 1526 0595 1529 0595 1532 0595 1535 7 0 FOOT 1 16 0595 1536 0595 1539 0595 1542 0595 1545 0595 1548 0595 1551 1 18 0595 1537 0595 1540 0595 1543 0595 1546 0595 1549 0595 1552 1 20 0595 1538 0595 1541 0595 1544 0595 1547 0595 1550 0595 1553 4111 0034 May 2015 45 PARTS Lip Activation Located on Located on Lip Item Quantity Part Number Description A 1 9513 0099 Lip Assist Rod Complete 34 Lg Includes Nuts B 1 2101 0221 Washer C 1 9511 0156 Spring Lip STD 9514 0114 opring Lip HD D 1 9513 0097 Lip Latch Plate E 1 2101 0051 Bolt x 215 Lg F 2 2101 0004 Washer G 2 2101 0103 Nut 1 2 Lock Nut H 1 2101 0222 Bolt Shoulder x x 134 1 2101 0223 Nut Nylon lock J 1 9514 0091 Prop Lip Maintenance Kit includes all hardware 5775 0004 Lip Latch Assembly Includes Spring and Cable 16 long 5775 0005 Lip Latch Assembly Includes Spring an
4. 2 ex Do not start 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 we eer Stay clear of dock leveling device when transport Chock restrain all transport vehicles Never remove vehicle is entering or leaving area the wheel chocks until loading or unloading is finished and transport vehicles driver has been given permission to drive away NT ee Do not use a broken or damaged dock leveling Do not move or use the dock leveling device if device Make sure proper service and maintenance anyone is under or in front of it procedures have been performed before using _ or Keep hands and feet clear of pinch points Avoid Make sure lip overlaps onto transport vehicles bed putting any part of your body near moving parts at least 4 in 102 mm Keep a safe distance from both side edges 4111 0034 May 2015 SAFETY wer Do not use dock leveling device if transports vehicles bed is too high or too low Do not overload the dock leveling device
5. E u r m an i gt Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop and lip 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 Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death A Lip Latch Spring B Lip Actuator Spring Adjustment Adjustment 30 4111 0034 May 2015 Adjusting Lip Latch Spring Tension This adjustment is set at the factory and should not require additional adjustment Unlike mechanical levelers the lip will not immediately begin to fold as the platform returns to the stored position After the platform is fully raised and the lip extends the lip latch is designed to hold the lip in the extendeq position until the platform drifts down to the below dock position If the lip does not remain extended check proper engagement of the lip latch NOTE Use two turn incremen
6. To Air Regulator o o 0o O O O O O O O O O O O O O To Air Bellows Electric Pneumatic Controls See Page 21 To Control Panel Air Regulator To Air Bellows To Air Regulator 60000000 3 8 line Installed at Factory 3 8 line Provide By Systems 20 4111 0034 May 2015 Su111 J 10ssaJduJo2 JY y pue Joop ay uo p seq 131 qof Aq Jo yL 21 INSTALLATION usnd uojNqusnd 211329 9 5 Ajddns 8313A 31200Q 1 V amp J1u2 dO NOILVTIVLSNI SLYVd OSIIN usnd 5 314133 31304394 Ajddns ST00 90T9 usnd 2100 9019 513259J9 5 Ajddns 4111 0034 2015 INSTALLATION Install Control Panel and Wiring or Pneumatic Lines The electrical power must be OFF prior to electrical installation For maximum protection use an OSHA approved locking device to lock out power sources Only the person installin
7. 2756 0006 Push Button Controller 9 0 800 0 DLM Label B 1 1751 0801 Decal English 1 1751 0736 Decal Arc Flash 4111 0034 May 2015 37 Control Box Main Supply Pilot Supply Item Quantity Part Number Description A 2 9301 0249 3 8 Bulkhead fitting B 1 1751 0890 Decal English C 1 8581 0163 Valve Air 2 Position 3 Way Includes Knob D 2 9301 0248 3 8 Male Elbow E j 2756 0001 Push Button Controller 9 V0 800 0 E POWERAMP DECALS 2756 0003 Push Button Controller 9 V0 800 0 E DLM DECALS F 1 1751 0893 Decal Supply Pilot English Item Quantity Part Number Description A 1 9301 0241 Elbow 3 8 B 1 9301 0244 Tee 3 8 9301 0260 Tee 1 2 38 4111 0034 May 2015 To Air Bellows C VALVE BLOCK ANB D From Regulator Item Quantity Part Number Description A 1 0521 0048 Brass Reducer 1 4 to 3 8 B 1 0521 0178 Breather Muffler C 1 9301 0236 Fitting 3 8 NPT to 3 8 Tube D 1 9301 0237 Fitting 3 8 NPT to 3 8 Swivel Elbow 9301 0261 Fitting 3 8 NPT to 1 2 Swivel Elbow E A R 8581 0152 Clamp Air line not Shown F 1 8583 0069 Valve Assembly Mechanical Operation G 1 5402 0009 Lanyard Valve Operator H 1 7953 0188 Cable Assembly Includes Pull Ring and Weight 1 9512 2061 Lanyard Control Bracket J 2 2101 0008 Bolt 1 4 x 2 Long K 2 2
8. May 2015 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 When you receive your CA Series dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keeping of the numbers in the event the model serial number decal A becomes lost or damaged Also write down Systems Inc s job number the 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 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 the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER For service call or contact Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 E mail techservices 9 docksystemsinc com 4111 0034 May 2015 MISCELLANEOUS Dock Leveler Information Model Serial No Systems Inc Job No Original Owner Information Name Address Installer Information Name Address Date of Installation 49 STANDARD PRODUCT WARRANTY SYSTEMS INC warrants that its products will be free from defects in design materials and workmanship for a period o
9. NOTE Apply grease to lip hinge grease fittings if equipped Lubricate the following areas with light weight machine oil G Lip maintenance prop pivot H Lip link pivots l Safety leg linkage pivots Lubricate the following areas with white lithium grease if equipped with grease fittings J Lip hinge area inject grease into all the lip hinge grease fittings K Platform hinge area inject grease into all the platform hinge grease fittings L Lip assist pin Regulator M Check Kill frost level may be required more frequently depending on usage N Drain water may be required more frequently depending on usage and compressor size O Verify Line Pressure is at 95 psi Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler 29 ADJUSTMENTS Adjusting the Latch and Lip Actuator Spring Tension When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Y EM gr 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 Pm
10. 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 ensure lip avoids contact with transport vehicle sides and cargo If lip does not lower to transport vehicle bed reposition transport vehicle Ensure the transport vehicle floor 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 by the maintenance prop Disconnect power and follow proper lockout tagout procedures for the dock leveler before entering the dock leveler pit or doing any repair or inspection under the dock leveler FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR OTHER SERIOUS INJURY Scan to view our owner s user s POWERAMP i MCGUIRE manuals online DLM www DockSystemsinc com SYSTEMS INC 1 800 643 5424 Loading Dock Equipment Call for additional placards or manuals or with questions regarding proper use maintenance and repair of dock leveler ILOARe A OPERATING I
11. C Lip Linkage Assembly D Lip Latch Assembly E Lip Maintenance Prop Pivot F Lip Actuator Chain Spring G Lip Actuator Chain not shown I Lip Keepers 2 used THEORY The CA dock leveler uses Compressed Air with lanyard or single push button operation for ease of use The dock leveler can be operated three different ways 1 Depress RAISE button N on the control panel This activates an electric solenoid P The solenoid allows compressed air into the air bellows causing the platform to rise When RAISE button is released the platform to lower 2 Depress RAISE button S on the control panel Allows allows compressed air into the air bellows causing the platform to rise Releasing the RAISE button allows the platform to lower 3 Pull up and hold the Lanyard Q chain in the rear of the unit until platform and lip are fully extended Heleasing the chain allows the platform to lower The regulator R supplies 95 psi to the bellows J When the platform rises to with in 2 3 in 51 76 mm of its full raised height the lip spring F and lip actuator chain G causes the lip linkage assembly to push the lip out and up 8 H Lip Actuator Chain Adjustment Link L Maintenance Prop P Air Control Valve J Air Bellows K Main Frame Q Lanyard R Filter Regulator M Toe Guard 2 used Lubricator N Raise Button Electric S Raise Button Air O Safety L
12. DO NOT ENTER PIT unless dock 5 leveler is securely supported by maintenance prop Ifelectrically powered tum off and use OSHAlockout tagout procedures Failure to follow posted instructions will result in death or serious injury Call 262 255 1510 for replacement placards warning labels or owner sluser s manuals decal placed in same position on both sides 1751 0329 x2 decal placed in same position on both sides 1751033000 decal placed same position both sides 1751 0729 ADANGER 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 DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch and insert through the maintenance prop housing Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury 1751 0731 1751 0731 RevA DANGER 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 1751 0726 Rev A 4111 0034 May 2
13. PARTIES FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERRUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY CENTRAAIR SERIES LEVELER In addition to the Standard Product Warranty provided with all Poweramp Products Systems Inc guarantees materials components and workmanship to be free of defects for the following extended periods e Structural Warranty For a period of ten 10 years from the date of shipment product will carry a prorated structural warranty This warranty specifically applies to the deck section lip section frame rear hinge assembly and front hinge assembly only This warranty covers structural repairs to or replacement of dock leveler in Systems Inc sole discretion and expense including reasonable labor materials freight and travel If Systems Inc determines replacement is necessary it will provide the original purchaser with a credit toward the purchase of the new replacement Systems Inc product in the amount equal to the original purchase price of the warranted product F O B point of manufacture discounted on a ten year straight line basis by the number of years of use prior to replacement e Pneumatic Warranty For a period of four 4 years from the expiration of the Standard Product Warranty Systems will provide replacement component parts from defective lifting system This war
14. dock service position The platform will drift down to the full below dock position 9 Proceed with loading unloading NOTE When end unloading is finished and access to the rest of the transport vehicle is still required the platform lip will need to be extended See Ramp Loading Unloading Instructions on page 25 for further instructions 10 When the loading or unloading is finished return the dock leveler platform to the cross traffic stored position 11 Pull the lanyard ring B or push the RAISE button A until the lip clears the lip keepers Release lanyard ring or RAISE button leveler will return to the stored or cross traffic position 12 Remove chocks from transport vehicle wheels or release the vehicle restraint if used 13 Indicate to the driver that the transport vehicle may leave the dock 4111 0034 May 2015 Service Dock Leveler Safely p AN 2 When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop 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 The 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 m
15. from entering the control box DO NOT use compressed air to clean control box Hecommended to vacuum debris from inside 15 INSTALLATION DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death 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 wiring and or control panel Shim Stacking Methods Q 2 For left right orientation of dock leveler see inside back cover of this manual 16 DO NOT weld continuously along the full length of the rear hinge frame angle This can put unnecessary stress on the leveler components causing the leveler to malfunction and shorten the life span of the affected components NOTE The illustration on page 1
16. joists The dock leveler is heavy Use a lifting device and chains with the appropriate lifting capacity and reach Always use the lifting brackets provided with the unit whenever lowering or lifting a dock leveler into or out of a pit Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death Leveler 5 Recommended Compressor Size 7 8 3 6 1 5 HP 20 GAL 90 PSI 175 6 amp up 5HP60GAL 9100 PSI 10 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 1 Remove any control panel and bumpers that may be banded to the frame of the dock leveler DO NOT remove the shipping bands B around the platform lip and leveler frame at this time DO NOT over tighten the lifting bracket hardware Over tightening can damage the weather seal if equipped NOTE Overall width of platform and lifting brackets A must be kept to a minimum to prevent interference between the lifting brackets and the pit walls as the dock leveler is lowered into the pit 2 Make sure the mounting hardware of lifting brackets A is snug The brackets should pivot relatively freely on the mounting cap screw DO NOT over tighten 3 Attach lifting chains to lifting brackets A and to a lifting device i e hoist or fork truc
17. of platform and lip Readjust lift spring tension and lip assist spring tension until proper operation is obtained 31 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 A 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 A Platform Frame D Lip Keeper Failure to follow these instructions may result in B Jam Nut E Lip serious personal injury or death C Stop Bolt Check that lip E is fully resting on the lip keepers 4 Tighten jam nut D and at the lowest part of the keeper cradle If lip is not resting properly in keepers perform the following 5 Disengage lip maintenance prop adjustment 6 Walk platform down to cross traffic stored position 1 Fully raise platform Manually raise the lip and engage lip maintenance prop 7 Check lip position in both keepers Repeat proc
18. to dock floor 4111 0034 May 2015 INSTALLATION 4 For all CentraAir models put a 1 4 in 6 6 mm thick shim at locations C D and E NOTE A 1 4 in 6 6 mm thick shim at locations C D and E is used only as a starting point The final shim stack height will be determined after 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 1 is tight against rear pit curb angle G 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 INSTALLATION G 3 8 in 9 5 mm 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 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 lev
19. to coil to the electrical drawings supplied with the 5 Install the Placard s D in close proximity to the 9 PP control box and in plain sight 4 DANGER 6 After all electrical connections in the pit have been made raise the leveler disengage the N 20 maintenance allow the platform to lower Arc Flash and 7 Install the Placard s D in close proximity to the Equipment Required control box and in plain sight De energze equipment before working on or inside Do not open cover without appropriate PPE Refer to NFPA 70 for PPE requirements This panel may contain more than one power source Hazardous Voltage will Cause Sever Injury or Death 22 4111 0034 May 2015 Put New Dock Leveler Into Service 1 Disconnect the external lifting device and chains from the lifting brackets 2 Check that the leveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly If an excessive transition exists between the dock floor and leveler and or lip does not contact both lip Keepers evenly contact Technical Services for further instructions 3 Install the dock bumpers as required 4 Turn the main electrical power ON Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or death may result 5 Pull lanyard cable and hol
20. 015 OWNER S USER S RESPONSIBILITIES 10 The owner user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle The owner user should therefore train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer s recommendations and industry standards Effective operator training should also focus on the owner s user s company policies and operating conditions Maintaining updating and re training 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 Owner s user s shall actively maintain update and retrain all operators on safe working habits and operations of the equipment The manufacturer shall provide to the initial purchaser 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 suppor
21. 101 0143 Nut Lock 1 4 4111 0034 May 2015 39 VALVE BLOCK Item Quantity Part Number Description A 1 0521 0048 Brass Reducer 1 4 NPT to 3 8 NPT B 1 0521 0178 Breather Muffler C 1 9301 0236 Fitting 3 8 NPT to 3 8 Tube D 1 9301 0261 Fitting 1 8 NPT to 3 8 Straight E 1 9301 0237 Fitting 3 8 NPT to 3 8 Swivel Elbow F A R 8581 0152 Clamp Air line not Shown G 1 8583 0071 Valve Assemble To Air Bellows From Regulator Item Quantity Part Number Description A 1 0521 0048 Brass Reducer 1 4 NPT to 3 8 NPT B 1 0521 0178 Breather Muffler C 1 9301 0236 Fitting 3 8 NPT to 3 8 Tube D 1 9301 0237 Fitting 3 8 NPT to 3 8 Swivel Elbow 9301 0261 Fitting 3 8 NPT to 1 2 Swivel Elbow E A R 8581 0152 Clamp Air line not Shown F 1 8583 0068 Valve Assembly Electrical Operation G 1 8581 0159 Replacement Solenoid 40 4111 0034 May 2015 PARTS Below Dock Control D GXHXI Item Quantity Part Number Description A 1 9514 0108 Leg Right Safety Assembly with Spring B 1 9514 0109 Leg Left Safety Assembly with Spring D 1 DPLA 2122 Pull Bar Assembly Safety Leg E 1 DOTH 2075 Cap Screw Lip Stop 11 UNC F 1 DOTH 2356 Nut Hex 5 8 11 UNC G 1 DOTP 6647 Rod Push H 1 DOTH 2356 Pin Clevis 1 2374 J 1 7953 0131 Safety Chain ki
22. 4 shows a typical weld pattern The weld pattern will vary slightly depending on size of dock leveler 18 With the rear hinge frame angle F tight against the rear pit curb angle and flush with the 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 19 All model levelers Install shims at locations B p 11 using the pyramid or stepped shimming method Make sure the platform is level from side to side as well as from front to back and flush with dock floor 20 Weld front of dock leveler frame B to shims located under the keepers then weld the shims to the front pit curb steel 21 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 22 When all welding has been completed paint all the welds and shims Make sure the platform is properly supported in the raised position before entering the pit to finish weld the shims Failure to do this may result in serious personal injury or death 4111 0034 May 2015 PLACARD Placard installation Instructions Owner is res
23. 6 24 4111 0034 May 2015 OPERATION Operating Instructions Continued Below Dock Loading Unloading Instructions Ramp Loading Unloading Instructions NOTE If end unloading is required see End NOTE end unloading is required see End Loading Unloading Instructions on page 26 n e 7 Check to make sure transport vehicle is positioned For ramp loading or unloading the CA dock DUMPE leveler be operated by pulling the lanyarq chain or depress RAISE button on the control panel A 8 Instruct driver to remain at the dock until the loading or unloading process has been completed 9 Chock the transport vehicle wheels or use vehicle 1 Check to make sure transport vehicle is positioned Mb restraint if present squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading 10 Raise the platform by pulling lanyard ring B or or unloading process has been completed depressing the RAISE button A to fully raise the leveler and extend the lip 3 Chock the transport vehicle wheels or use the vehicle restraint if available 11 Walk out on the leveler Pull and Hold the release ring see picture below until the platform lowers onto the transport vehicle Make sure there is a minimum of 4 of lip overlapping the transport vehicle A RAISE Button mmi B LANYARD ills 4 Extend the platform lip onto transport vehicle as follo
24. A Division of Systems Inc CentraAire PATENT PENDING pu Premium Loading Dock Dock Leveler POWERAMP Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www docksystemsinc com techservices 9 docksystemsinc com Printed in U S A Manual No 4111 0034 Copyright O 2015 May 2015 Table of Contents Page Safety Recognize Safety Information J 1 General Operational Safety Precautions 1 Operational Safety Precautions T J 2 Maintenance Safety Precautions 4 DECAN E 5 Owner s User s Responsibilities J T J J 6 Introduction General Information Dock Leveler Stock Specifications 7 Dock Leveler Stock Specifications 7 Component Identification 8 TOCO 8 Installation xz Diya U 9 Prepare DOCK Leveler 10 install Dock Levelepru u cr 12 Install Control Panel and Wiring
25. 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 0034 May 2015 3 SAFETY Maintenance Safety Precautions Hydraulic and electrical power must be OFF when servicing the equipment For maximum protection use an OSHA approved locking device to lock out all power sources Only the person servicing the equipment should have the key to unlock the device 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 A maintenance prop permanently attached and hinged to the unit with means for lock out tag out requirements per OSHA 1910 147 is included with each pit style dock leveler In addition 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 not limited to a boom truck fork truck stabilizing bar or equivalent ALWAYS disconnect electrical power source and ground wire before welding on dock leveler DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground to the dock leveler frame Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death DO
26. NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death ALWAYS 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 4 DANGER AN Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De enemyze equipment before working on or Inside Do mot open cover without appropriate PPE Refer to NFPA 7DE for FPE requirements Ths panel may contain mare than ane Power SOLUCE Hazardous Voltage Will Cause Sever Injury or Death 4111 0034 May 2015 SAFETY Safety Decal s Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or require replacement please call 1 800 643 5424 for replacements 4 DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar Do not force maintenance prop forward of bar to support lip Failure to comply will result in deat
27. NSTRUCTIONS POWERED DOCK LEVELERS NORMAL OPERATION 1 Raise the platform by depressing and holding the RAISE button OQ 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 Depress 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 traffic position BELOW DOCK ENDLOADING e HYDRAULIC ONLY Depress 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 KEG lip extension allows the lip to clear the lip keepers AIR POWERED ONLY Depress and hold the RAISE button until the leveler is 12 above dock level Pull the below dock level chain until the leveler passes the below 2 e HYDRAULIC WITH INFINITE LIP CONTROL equipped raise the platform by depressing and holding the RAISE button When the lip is just above the lip keepers simultaneously depress and hold the RAISE button and the LIP OUT button until lip has extended beyond the lip keepers Release both buttons NOTE If equipped depressing E STOP button will stop platform from lowering Item Quantity Part Number Description A 1 1751 0874 Placard CA 48 4111 0034
28. age 25 End loading or unloading can be done with the dock at the cross traffic position or below dock position depending on the height of the transport vehicle bed 1 Check to make sure transport vehicle 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 transport vehicle wheels or use the vehicle restraint if available Loading Unloading Platform at Cross Traffic Position 4 f transport vehicle bed is at or above dock floor level leave leveler at the cross traffic position and proceed with loading or unloading End Loading Unloading Platform Too High Use Below Dock Position 5 f transport vehicle bed is below the dock floor level perform steps 6 12 End Loading Unloading Platform at Below Dock Position 26 6 Pull lanyard ring or push the Raise button to position the platform high enough to clear the lip keepers but not high enough to extend the lip 7 Walk out on the leveler pull and hold the safety leg retract pull ring located in the recess at the front of the platform This will cause the lip to extend away from the lip keepers and the cross traffic safety legs to fold to allow the leveler to lower to the below dock position 8 When the platform lip clears the lip keepers continue to hold the pull chain as the leveler lowers to the below
29. aintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 4111 0034 May 2015 N W 5 4 mS Sen MAINTENANCE lt 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 Whenever performing maintenance under the dock leveler platform support the platform with the maintenance prop A Position the maintenance prop behind front header plate while staying clear of the lip The Lip Prop should be used to keep the lip extended D Additional supports should be used to prevent the lip from collapsing if working under the leveler Lock the maintenance prop in the service upright position using OSHA approved lockout tag out B amp C Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout tag out device B Turn off air supply to the leveler E Only the pe
30. cies 1 Determine height of shim stack B for each shim location S by performing the following a Measure leveler frame height distance A b Measure dock floor to pit floor distance J at each shim location B Write down the dimensions obtained at each location c Subtract distance A from distance J to obtain the shim height Repeat for each shim location 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 hoist cylinder storage prop weldment 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 5 Build each shim stack B using the pyramid method M preferred or stepped method N with the top shim having a minimum size of 4 1 2 x 4 1 2 in 114 3 x 114 3 mm and each successive lower shim being larger so the shims can be welded together using a fillet weld DO NOT use offset method O or straight method P NOTE Toassistin obtaining an accurate measurement of distance A use a string H 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 A top of shim stack B
31. d Cable 21 Long L 1 2101 0220 Bolt 1 2 x 1 Lg M 5 2101 0079 Washer 12 N 1 2101 0045 Cotter Pin 1 00 LG O 1 0941 0006 Snubber Spring P 1 DPLA 2128 Chain Q 1 DOTH 2416 Lap Link 3 16 H 1 DOTH 2421 Cold Shut 5 16 S 1 DPLA 0341 Linkage Bar T 2 DOTH 2061 Bolt Shoulder U 2 DOTH 2131 Nut Lock Nut 46 4111 0034 May 2015 Weather Seal Weather Seal Kits PARTS Item Quantity Part Number Description A 1 0195 0021 Brush Kit Includes Seal and Track 1 1 2 in 82 Lg Both Sides B 1 0195 0033 Rubber Kit Includes Seal and Track 1 1 2 in 82 Lg Both Sides Individual Replacement Seals Item Quantity Part Number Description C 1 0195 0021 Brush Refill 1 1 2 in 82 Lg D 1 0195 0033 Rubber Refill 1 1 2 in 82 Lg E 1 0192 0146 Heplacement Channel y SS B Item Quantity Part Number Description F 3 0195 0044 Rear Powerseal Brush Seal 0195 0046 Foam Seal Kit 6 G 1 0195 0047 Foam Seal Kit 6 1 2 0195 0048 Foam Seal Kit 7 Provide dock leveler serial number and size of platform when calling or faxing orders Provide width of weather strip when replacing existing seals 4111 0034 May 2015 47 PLACARD ADANGER Read and instructions warnings and maintenance schedules the manual and on placards Operation and servicing of dock leveler is restricted to authorized personnel
32. d until leveler platform is fully raised OR Raise the leveler platform fully by pushing and holding the RAISE button 6 Release lanyard cable if no transport vehicle present at the dock the platform will lower to the full below dock position as the lip folds OR Helease the RAISE button to lower the platform As long as there is no transport vehicle present at the dock the platform will lower to the full below dock position as the lip folds NOTE If a transport vehicle is present the platform will lower until the lip rests on the transport vehicle bed See Operating Instructions in Operation section 4111 0034 May 2015 7 INSTALLATION When the platform lowers to the full below dock position the lip will fold Pull lanyard ring or push and hold the RAISE button until the lip rises just enough to clear the lip keepers then release the lanyard ring or RAISE button to allow the platform to lower to the cross traffic stored position lip engages lip keepers Perform steps 5 7 at least four times make sure the leveler functions properly and there is no binding Two people are required to engage the maintenance prop one person to operate the lifting device the other person to engage the maintenance prop 10 11 Raise the platform fully Hold the platform at this position by pulling the lanyard ring or RAISE button and move the maintenance prop to the service upright positi
33. e than 12 in 805 mm higher or lower than the dock floor Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts trained should the dock service height may vary with design specifications eveler DO NOT overload the dock leveler DO NOT use a broken or damaged dock leveler Make sure proper service and maintenance procedures have been performed on leveler before using DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave equipment or material unattended on Transport vehicle wheels must be chocked unless the dock leveler the vehicle restraint is used Never remove the wheel chocks until loading unloading is finished and transport vehicle driver has been given permission to leave Failure to follow these instructions may result in personal injury and or damage to equipment Make sure platform lip rests on the transport vehicle The dock leveler operating instructions are divided bed with at least 4 in 102 mm of overlap into the two methods of loading and unloading Maintain a safe distance from side edges ol leveler For ramp loading and unloading see Ramp during the loading unloading process Loading Unloading Instructions on page 25 Failure to follow these instructions may result in For end loading and unloading see End Loading serious personal injury or death Unloading Instructions on page 2
34. edure if necessary 2 Loosen jam nut B 3 Adjust stop bolt C as necessary Turn stop bolt in clockwise to allow lip to fold closer to platform frame A Turn stop bolt out counterclockwise to hold lip further away from platform frame A 3e 4111 0034 May 2015 NOTES This page intentionally left blank 4111 0034 May 2015 33 TROUBLESHOOTING When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the 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 The 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 Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to f
35. egs T Lip Assist Spring The lip assist spring S also assist pushing the lip out When the lip is fully extended the lip latch cable engages the lip latch assembly locking the lip in the extended position The dock leveler has reached its full height when the lip is fully extended To lower the platform release the lanyard Q or RAISE button N or 5 The platform will lower until the extended lip rests on the transport vehicle If the lip did not fully extend there is no transport vehicle at the dock the platform will lower until one of the following conditions occur Lip is resting in lip keepers cross traffic position Leveler went to the below dock position lip folds automatically leveler rests on the safety legs below dock position Leveler went to the below dock position with operator holding the safety leg retract cable not shown safety legs are retracted lip folds automatically causing dock to rest in the full below dock position 4111 0034 May 2015 INSTALLATION Prepare Pit A Distance Pit Width X B Distance Dock Floor to Pit Distance Pit Length D Distance Pit Corner to Corner Top Front and Rear Floor All Four Corners Both Sides of Pit 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 unauthorized use of the d
36. eler operation 14 ASS Z 6 in 152 mm 7 4 43 AMA 2 A SA A S yes Z m E Pry Locations F Rear Hinge Frame Angle G Rear Pit Curb Angle H Flare Bevel Weld Typical To Fit Spacing 9 If gap D cannot be obtained equally at both sides of leveler grind or add material at the rear edge of rear hinge frame angle F as needed 10 Allow the dock leveler to rest fully on the shim stacks Check that a smooth and level transition exists between the dock floor and the dock leveler platform Add or remove shims as necessary until a smooth transition is obtained 11 If leveler cannot be squared and or made level as instructed in steps 8 10 contact Poweramp Technical Services 4111 0034 May 2015 12 13 14 15 16 17 With the leveler square in the pit and flush with the surrounding dock remove the banding on the lip of the leveler Lift leveler with appropriate machinery Slowly raise the platform Check for binding as platform is being raised If binding occurs lower the platform Reposition leveler and or add or remove shims as necessary Slowly raise platform again If platform still binds contact Poweramp Technical Services for further instructions All CentraAir models Once leveler is flush square and does not bind a Install shims under maintenance prop D wh
37. ere prop attaches to leveler frame Make sure prop is solidly shimmed b Using appropriate machinery raise the dock to the fully open position c Raise maintenance prop to the service upright position and lock prop in this position using an OSHA approved locking device Remove air bellows from the leveler by unbolting the bellows from the frame and the deck or wrap bellows with fire proof blanket to protect from weld sparks and splatter 4111 0034 May 2015 INSTALLATION Two people are required to engage the maintenance prop one person to operate the lifting device the other person to engage the maintenance prop DO NOT use the maintenance prop to support the raised platform until the maintenance prop has been properly shimmed and welded The shims must be welded to each other the leveler frame and to the front pit curb steel Failure to do this may result in serious personal injury or death DO NOT weld before disconnecting all electrical components DO NOT weld before removing air bellows Failure to follow these instructions may result damage to these components from stray sparks and weld splatter When drilling access hole in the control box DO NOT penetrate too deep components may be damaged DO NOT turn control upside down to drill any access holes To prevent damaged to electrical components from debris cover components prior to drilling Seal all conduit entrances to prevent moisture
38. evolutionary air bellows system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended The CentraAir dock has three control options Lanyard cable electrical control or pneumatic control which allows operation of the dock leveler functions Each CentraAir leveler unit and control panel have been factory assembled and tested to ensure satisfactory operation To illustrate which connections are to be made in the field at installation electrical drawings and pneumatic hose drawings are included with each order or by contacting Poweramp Technical Services Once again thank you and congratulations on your purchase of a Poweramp CentraAir dock leveler 4111 0034 May 2015 INTRODUCTION Dock Leveler Stock Specifications CentraAir 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 6 ft 1828 8 mm 8 ft 2438 mm 10 ft 8048 mm Capacity CIR 25 000 Ib 11 340 kg 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 w lt lt T CIR Comparative Industry Rating All docks are available in 115V Controls pneumatic push button or lanyard INTRODUCTION Component Identification A Lip B Lip Assist Rod
39. f below dock is required 4111 0034 2015 Frame and Platform PARTS Item Quantity Part Number Description A 1 See Table Lip Welded Assembly B 1 9515 2 Platform Welded Assembly 9202 0050 Pin Lip Hinge 6 W C 1 9202 0051 Pin Lip Hinge 6 5 W 9202 0052 Pin Lip Hinge 7 W DKIT 9179 Toe Guard Assembly 6 Foot Both Sides and Hardware D 1 DKIT 9180 Toe Guard Assembly 8 Foot Both Sides and Hardware DKIT 9181 Toe Guard Assembly 10 Foot Both Sides and Hardware E 2 2101 0039 Nylon Lock Nut 5 16 18 UNC F 4 2101 0163 Washer 5 16 in Flat G 2 2101 0011 Cap Screw 5 16 18 UNC x 1 in H 1 8435 1 3 9202 0002 Rear Hinge Pin J 6 2101 0047 Cotter Pin 1 4 x 2 in 9224 0030 Maintenance Prop 39 K 1 9224 0031 Maintenance Prop 431 9224 0079 Maintenance Prop 4772 L 1 9201 0006 Prop Pin amp Clip M 1 1751 0010 Decal Model Serial ID N 2 2101 0046 Cotter Pin 1 4 x 114 in 8432 0983 Lip Keeper 16 Lip O 2 8432 0984 Lip Keeper 18 Lip 8432 0985 Lip Keeper 20 Lip P 1 8434 0821 Lip latch release Upgrade 1 Provide dock leveler serial number platform size and lip size when calling or faxing orders Provide length and width of inspection plate opening when calling or faxing orders For left right orientation of dock leveler see inside back cover of this manual
40. f one 1 year from the date of shipment All claims for breach of this warranty must be made within 30 days after the defect is or can with reasonable care be detected In no event shall any claim be made more than 30 days after this warranty has expired In order to be entitled to the benefits of this warranty the product must have been properly installed maintained and operated in accordance with all manufacturers 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 In the event of a defect as determined by SYSTEMS INC covered by this warranty SYSTEMS INC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS SUBSIDIARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUDING THIRD
41. g the equipment should have the key to unlock the power source TERN Failure to follow these instructions may result in serious personal injury or death Placard placement shown as reference DO NOT make any final electrical connections until all welding has been completed Failure to do this may result in serious personal injury or death All electrical work including the installation of the disconnect panel control panel and final connections to the pit junction box must be performed by a certified electrician and conform to all local and applicable national codes A Disconnect Panel Provided by others B Control Panel D Placard C Distance 48 in 14 630 mm Pneumatic Controls Mount the push button control panel B so bottom of control panel to dock floor distance C is 48 in 1219 2 mm Electric Controls Mount the push button control panel B so bottom of control panel to dock floor distance C is 48 in 1219 2 mm 2 Install pneumatic air lines to control panel 2 Install electrical disconnect panel A if not already Installed 3 Re install the air bellows and connect pneumatic atr ne 3 Installand the control wiring 4 After all pneumatic connections yi the pit have 4 He install the air bellows and connect air line been made raise the leveler disengage the maintenance prop and allow the platform to lower 5 Connect the dock leveler power cable
42. h or serious injury Refer to owner s users manual for proper use 1751 0727 Rev 1751 0727 1751 0730 x2 ADANGER SAFETY INFORMATION 1 Read and follow all instructions and sidesofmovingdockleveler warningsinowner s user smanual 8 Never use damaged Use of dock leveler restricted to malfunctioning dock leveler Report Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave dock always e Ensure no equipment material or people are on dock leveler Return dock leveler to its stored position at dock level trained operators 3 Always chock trailer wheels or engage truck restraint before operating dock leveler or beginning to load orunload Never use hands or equipment to moveramporlip Before activating dock leveler Ensure trailer is backed in against bumpers Remove any end loads ifrequired Check trailer alignment to avoid lip interference If lip does not lower to trailer bed reposition vehicle Ensure truck bed supports extended lip or leveler frame supports the ramp before driving on ramp problems immediately to supervisor MAINTENANCE SERVICE Read and follow all instructions warnings and maintenance schedules the owner sluser s manual 2 Maintenance Service of dock leveler restricted o trained personnel 3 Place barriers on the driveway and dock floor to indicate service work is being performed
43. k having the appropriate lifting capacity and reach 4 Remove wood blocks that maybe attached to the leveler frame before putting the dock leveler into the pit 5 Raise the leveler to allow the leveler sit on the maintenance prop Remove 3 plastic ties 2 Rear 1 Front before lowering into NOTICE pit Compressor pump MUST be filled with appropriate oil prior To initial start up Refer to manufactures manual for proper maintenance procedure 1751 1 4111 0034 May 2015 INSTALLATION This page intentionally left blank 4111 0034 May 2015 INSTALLATION Install Dock Leveler Shim Stacking Methods 2 2 A A Distance Leveler Frame K Dock Leveler Frame Height M Pyramid Preferred B Shim Locations Under N Stepped Acceptable Rear Vertical Supports O Offset Not Acceptable C Shim Location Under Straight Not Acceptable Lip Keepers Q Removable Frame Section D Shim Locations Under R Shim Location Bellows Maintenance Prop Mounting Plate Both E Shim Locations Under sides Lip Spring S Shim Locations F Dock Floor T Shim between lip keeper G Rear Pit Curb Angle curb angle when required H String I Rear Hinge Frame Angle J Distance Dock Floor to Pit Floor 12 4111 0034 2015 NOTE Poweramp dock levelers are designed with a nominal 1 2 in 12 7 mm shimming distance to allow for pit inconsisten
44. modification and shall also satisfy all safety requirements of the manufacturer for the particular application of the leveling device 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 It is recommended that transport vehicles with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize transport vehicle bed drop Loading dock safety equipment should never be used outside of its intended use vertical working range or capacity 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 When selecting loading dock safety equipment it is NOTICE to consider not only present requirements but also future plans and any possible adverse conditions environmental factors or usage 4111 0034 May 2015 General Information Congratulations on your choice of a Poweramp dock leveler This manual covers the CentraAir dock leveler Designed by Poweramp to be a marvel of simplicity and efficiency your dock leveler when properly installed will provide many years of trouble free performance with an absolute minimum of maintenance Its r
45. ock leveler before installation has been completed 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 Failure to follow the installation instructions can result in damage to dock leveler the facilities and or serious personal injury or death e Measure pit width distance A at both front and rear of pit e Measure dock floor to pit floor distance B at all four corners Measure pit length distance C at both sides e Measure corner to corner crisscross distance D at both sides Take measurements at dock floor level and at pit floor level DO NOT remove the shipping bands around the If any measurement is off by than 1 8 dock leveler lip until instructed to do so in 3 18 mm contact Poweramp Technical Services before proceeding When Required 3 Make sure the field junction box for the dock leveler E is at the correct location per pit diagrams 4 Make sure the conduit for the air lines E are at the correct location per the pit diagram 4111 0034 May 2015 INSTALLATION Prepare Dock Leveler Tad ix E UTR A Lifting Bracket 2 used 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
46. ollow these instructions may result in serious personal injury or death Before performing the detailed troubleshooting procedures check the following items first Check all fuses inside the control panel s Replace any blown fuse s with a fuse of equal specification Make sure the correct voltages are present at the proper locations inside the control panel s 34 4111 0034 May 2015 TROUBLESHOOTING Minimum 80 Psi required at regulator if lower check Low Air pressure air supply Check breakers if okay check voltage at control box No voltage to solenoid and solenoid Platform does not rase Lanyard Cable Adjustment Check Cable adjustment Incorrect Air Line Verify pilot and Main supply air line connections are Connections correct at control box Air bladder or connecting air Check air bladder and air line repair or replace as lines punctured Damaged or restricted air lines Minimum 80 Psi required at regulator if lower check Low Air pressure air supply Check for visible obstructions that could cause Replace damaged air line or remove restriction Platform rises slowly Dock leveler binding binding Remove obstructions no obstructions found call Poweramp Technical Services See Platform Rises Slowly See Platform Rises Slowly See Periodic Maintenance in the Maintenance Platform does not rise to section full height Minimum 80 Psi required at regulator if lo
47. on Release the lanyard ring or RAISE button to allow the platform to lower until it is resting on the maintenance prop Lockout tagout Remove lifting brackets located on each side of platform Support toe guards then remove cotter pin used in shipping and carefully release the toe guards Pull lanyard ring or push and hold the RAISE button until the maintenance prop drops to its stored position Release the lanyard ring or RAISE button and allow the platform to lower fully Check operation of toe guards When the platform lowers to the full below dock position the lip will fold Pull lanyard ring or push and hold the RAISE button until the lip rises just enough to clear the lip keepers then release the lanyard ring or RAISE button to allow the plattorm to lower to the cross traffic stored position lip engages lip keepers 23 OPERATION Operating Instructions Stay clear of dock leveler when transport vehicle is entering or leaving dock area in 305 mm DO NOT move or use the dock leveler if anyone is ee md under in front of leveler C Lie in 305 mm The CentraAir hydraulic dock leveler is designed Failure to follow these instructions may result in to compensate for a maximum 12 in 305 mm severe personal injury or death of height difference between the loading dock and the transport vehicle DO NOT use the dock leveler if the transport vehicle is mor
48. ponsible for the installation and placement of product placards Make sure placard is in plain view of dock leveler operations Suggested placement of placard is near control box attached to electrical conduit by using nylon tie If there is no control box present mount placard on wall to the immediate left of leveler at eye level qx MER OUT ontrol oe SENS RRR up gt SSN 1 SSS MESZ S 7 RSS 2 NN 4111 0034 May 2015 17 INSTALLATION Overhead Air Supply Above Door Pneumatic Supply Kit 6106 0016 See Page 21 Supply From Regulator 1 2 or larger Verify Systems Sa Sa Ss aT pe Ss a ray Valve L 17 sal bid mirzi Pilot Supply 1 d Control Box to EE u 1 2 line Provided by Others 00000000 3 8 line Installed at Factory Me 3 8 line Provide By Systems 1 2 NPT to 3 8 tube Provide by Systems z lh To Air Bellows 4111 0034 May 2015 INSTALLATION Underground Air Supply New Construction Kit 6101 0018 See Page 21 Pilot Supply Control Box to To Air Bellows Valve End run Tee NOT Required N Supply From Regulator 1 2 line Provided by Systems 00000000 3 8 line Installed at Factory m 3 8 line Provide By Systems 4111 0034 May 2015 19 INSTALLATION Lanyard Air Supply See Page 21
49. ranty specifically covers material and freight only and applies to Bellows hoses and Valves
50. rson servicing the equipment should have the capability to remove the lockout tag out devices The Tag out devices must inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to OSHA regulation 1910 146 Refer to OSHA regulation 1910 147 27 MAINTENANCE Periodic Maintenance A Lip Hinge Area C Lip Link Pivots E Lip Assist Pin D Platform Hinge Area G Safety leg linkage pivots B Lip Maintenance Prop Pivot Adjusting knob Clockwise increase PSI Counter Clockwise decrease PSi Lubricator Gentle turn clock wise a sss until it stops then turn back 1 2 turn H Recommend 95 Psi for factory setting line to dock leveler F Fill line with Kill Frost or equivalent lubricator may not be on every unit N G Drain water as needed Pk 1 r1 raises G L 4111 0034 May 2015 28 Regular maintenance must be performed on a weekly and quarterly schedule Follow all safety precautions Weekly Maintenance A Check Kill frost level may be required more frequently depending on usage B Drain water may be required more frequently depending on usage and compressor size C Verify Line Pressure is at 95 psi Operate the dock leveler through the complete operating cycle to maintain lubrication NOTE To thoroughly inspect the platform hinge area put the platform in the f
51. t K 1 4261 0004 Ring Chain L 1 7951 0019 Chain Safety leg M 1 2101 0216 Quick Link N 1 2101 0239 Chain Snap link 4111 0034 May 2015 41 PARTS Pit Extension Kit Item Quantity Part Number Description 1 1 8436 0035 4 inch Pit Extension Kit For all size levelers 42 4111 0034 May 2015 PARTS Item Quantity Part Number Description A 1 5811 0002 Air Bellows B 1 9514 0160 Top Mounting Weldment C 1 9512 2090 Pin 49 64 X 10 34 Lg D 2 2101 0045 Cotter Pin E 8 2101 0273 3 8 16 UNC x 1 Lg F 8 2101 0258 Washer 95 PSI 7 Recommend for best performance E I II Item Quantity Part Number Description A 1 8586 0008 Regulator Assembly W Lubricator Flow Left To Right SHOWN 8586 0009 Regulator Assembly W Lubricator Flow Right to Left B 1 8581 0154 Filler Regulator C 1 8581 0153 Oil Lubricator Pint 8583 0167 Oil Lubricator Quart D A R R981 0001 Kill Frost 1 Pint Parts Below not included in 8586 0008 or 8586 0009 AR R980 0001 Nylon Air Line 3 8 R984 0001 Nylon Air Line 1 2 9301 0236 Fitting Straight 3 8 9301 0258 Fitting Straight 1 2 4111 0034 May 2015 43 PARTS Frame and Platform 4 as Lip latch Release Arm Up Grade Maybe required on some levers manufactured before 4 2014 i
52. t while in the working range of the equipment It is recommended that 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 The Owner User must review all name plates placards decals instructions and posted warnings and place the same in view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for any replacements Manufacturers 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 required Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main support while under load such as what might occur when a transport vehicle pulls out from under the leveling device shall be removed from service inspected by a manufacturer s authorized representative and repaired or replaced as needed before being placed back in service Any modifications or alterations of loading dock equipment shall only be done with prior written approval from the manufacturer and the same shall be at least as safe as the original equipment was prior to the
53. ts when adjusting lip assist spring Check lip operation after each adjustment Repeat until proper operation is obtained Adjust spring tension as follows 1 Loosen jam nut A 2 Toincrease spring tension turn nut B clockwise 3 To decrease spring tension turn nut B counterclockwise 4 Tighten jam nut Hecheck operation of platform and lip Readjust lip latch spring tension and lip assist spring tension until proper operation is obtained 4111 0034 May 2015 ADJUSTMENTS Adjusting Lip Actuator Spring Tension This adjustment is set at the factory and should not require additional adjustment Unlike mechanical levelers the lip will not immediately begin to fold as the platform returns to the stored position The leveler lip remains extended as the platform drifts down to the below dock position The lip will automatically fold when the platform when the dock is resting on the safety legs in the below dock position 1 Check air bellows and hoses for possible leaks 2 If the lip does not fully extend additional spring tension may be needed NOTE Use two turn increments when adjusting lip assist spring Check lip operation after each adjustment Repeat until proper operation is obtained Adjust spring tension as follows 1 Loosen jam nut A 2 Toincrease spring tension turn nut B clockwise 3 To decrease spring tension turn nut B counterclockwise 4 Tighten jam nut Hecheck operation
54. ull below dock position 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 cause abnormal operation Inspect the area under the platform around and under the air bellows Build up of foreign material in this area may damage air bellows components causing abnormal operation J A d E 3 1 A 5 maintenance permanently attached and hinged to the unit with means for lock out tag out requirements per OSHA 1910 147 is included with each pit style dock leveler In addition 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 not limited to a boom truck fork truck stabilizing bar or equivalent 4111 0034 May 2015 MAINTENANCE Quarterly Maintenance Perform Weekly Service Items Lubricate the following areas with light weight machine oil D Lip hinge area unless equipped with grease fittings apply oil to the top of the entire length of lip hinge when platform is at the full below dock position and lip is folded E Platform hinge area apply oil to top of all platform hinges when platform is at the full below dock position F Lip lifter and lift cylinder pin
55. wer check Low Air pressure air supply Platform DOES rise to full height but lip DOES Lip actuator spring needs Inspect lip actuator chain repair or replace as NOT extend or extend additional tension needed fully See Adjustment Section Lip Latch Spring Lip extends but does Increase tension as needed to keep latch not remain extended as spring 95 engaged additional tension leveler drops Clean any debris from lip latch area e Lubricate as instructed in maintenance section 4111 0034 May 2015 35 Electrical CUSTOMER SUPPLIED 115 V 1 PHASE 60 HZ FROM BRANCH CIRCUIT DISCONNECT SWITCH N amp OVERCURRENT DEMCE BY OTHERS SELECT DISCONNECT SWITCH amp OVERCURRENT DEVICE PER THE NEC 1 2 1 1 SS RAISE 1 SE NOTE C 14 DOOR SEE C Controls 4111 0034 May 2015 36 Control Box Electrical Control DANGER Arc Flash and Shock Hazard PPE Personal Protection 6 00 Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer to 7 for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Sever Injury or Death eS ll EE 0 5 FLA Amp Draw Item Quantity Part Number Description 2756 0004 Push Button Controller 9 0 800 0 Poweramp Label
56. ws a Raise the platform by pulling lanyard ring B or Loading Unloading Completed Reset Leveler depressing and holding RAISE button A z b Pull lanyard ring B or depress the RAISE button until the lip is fully extended then release the lanyard ring or RAISE button A The platform will lower until the lip is resting on the transport vehicle bed B LANYARD Cable c Make sure that the lip is fully extended and UN supported on the transport vehicle along the entire width of the platform with at least 4 in 102 mm of lip contacting the transport vehicle 12 When loading or unloading is finished raise the platform by pulling lanyard ring B or depressing and holding RAISE button A 13 Pull lanyard ring B or hold the RAISE button A until the lip folds enough to clear the transport vehicle then release the RAISE button The lip will fold and the platform will return to the cross traffic position 5 Proceed with loading unloading the transport 14 Remove chocks from transport vehicle wheels or vehicle release the vehicle restraint if used 6 If below dock loading is necessary see steps 7 11 15 Indicate to driver that transport vehicle may leave If not proceed to step 12 the dock 4111 0034 May 2015 29 OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE If ramp loading is required see Loading Unloading Instructions on p
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