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Poweramp CentraAir Owner & User Manual

Dock leveler
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CentraAir
®
PATENT PENDING
Dock Leveler
Owner's / User's Manual
POWERAMP ® • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022
800.643.5424 • fax: 262.255.5917 • www.docksystemsinc.com • techservices@docksystemsinc.com
Printed in U.S.A.
Manual No. 4111-0034
Copyright © 2015
May 2015

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Summary of Contents for Poweramp CentraAir

  • Page 1 ® PATENT PENDING Dock Leveler Owner’s / User’s Manual POWERAMP ® • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022 800.643.5424 • fax: 262.255.5917 • www.docksystemsinc.com • techservices@docksystemsinc.com Printed in U.S.A. Manual No. 4111-0034 Copyright © 2015...

  • Page 2: Table Of Contents

    Table of Contents Page Safety Recognize Safety Information ............. 1 General Operational Safety Precautions ..........1 Operational Safety Precautions ............2 Maintenance Safety Precautions ............4 Safety Decal’s ..................5 Owner’s User’s Responsibilities ............6 Introduction General Information, Dock Leveler Stock Specifications ....7 Dock Leveler Stock Specifications .............

  • Page 3: Safety

    SAFETY Recognize Safety Information General Operational Safety Precautions 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 Read and understand the Owner’s/User’s manual and the instructions in the safety message.

  • Page 4: Operational Safety Precautions

    SAFETY Operational Safety Precautions 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. Stay clear of dock leveling device when transport Chock/restrain all transport vehicles. Never remove vehicle is entering or leaving area.
  • Page 5 SAFETY Do not use dock leveling device if transports vehicles bed 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.

  • Page 6: Maintenance Safety Precautions

    SAFETY Maintenance Safety Precautions ALWAYS disconnect electrical power source and ground wire before welding on dock leveler. DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler. Always ground to the dock leveler frame. Failure to follow these instructions may result in damage to dock leveler and/or serious personal Hydraulic and electrical power must be OFF when injury or death.

  • Page 7: Safety Decal's

    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 DANGER CRUSH HAZARD for replacements. Maintenance prop must support leveler behind bar.

  • Page 8: Owner's User's Responsibilities

    OWNER’S/USER’S RESPONSIBILITIES 1. The owner/ user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle. The owner/ user should, therefore, train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer’s recommendations and industry standards.

  • Page 9: Introduction

    INTRODUCTION General Information 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)

  • Page 10: Component Identification

    INTRODUCTION Component Identification A — Lip F — Lip Actuator Chain Spring J — Air Bellows P —Air Control Valve B — Lip Assist Rod G — Lip Actuator Chain K — Main Frame Q —Lanyard C —Lip Linkage Assembly H —...

  • Page 11: Installation

    NOTICE If any measurement is off by more than 1/8 DO NOT remove the shipping bands around the ® in. (3.18 mm), contact Poweramp Technical dock leveler lip until instructed to do so. Services before proceeding. When Required: 3.

  • Page 12: Prepare Dock Leveler

    (A) must be kept to a minimum to prevent interference between the lifting brackets and ® Poweramp dock levelers are designed with installation the pit walls as the dock leveler is lowered in mind. Each unit is shipped with lifting brackets (A) into the pit.
  • Page 13 INSTALLATION This page intentionally left blank 4111-0034 — May 2015...

  • Page 14: Install Dock Leveler

    INSTALLATION Install Dock Leveler Shim Stacking Methods 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 P — Straight (Not Acceptable) Lip Keepers) Q—...
  • Page 15 INSTALLATION 4. For all CentraAir ® models, put a 1/4 in. (6.6 mm) ® NOTE: Poweramp dock levelers are designed with a nominal 1/2 in. (12.7 mm) shimming distance thick shim at locations (C,D and E). to allow for pit inconsistencies.
  • Page 16 (if equipped) will not bind during dock leveler operation. 11. If leveler cannot be squared and/or made level as ® instructed in steps 8 — 10, contact Poweramp Technical Services. 4111-0034 —May 2015...
  • Page 17 Failure to do this may result in 16. All CentraAir ® models - Once leveler is flush, serious personal injury or death. square and does not bind: a.

  • Page 18: Install Control Panel And Wiring

    INSTALLATION NOTICE DO NOT grind or weld if hydraulic fluid or other DO NOT weld continuously along the full length of flammable liquid is present on the surface to be the rear hinge frame angle. This can put unnecessary ground or welded. stress on the leveler components, causing the leveler to malfunction and shorten the life span of DO NOT grind or weld if uncontained hydraulic fluid...

  • Page 19: Placard Installation

    PLACARD Placard Installation Instructions • Owner is responsible 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.

  • Page 20: Air Line Installation

    INSTALLATION Overhead Air Supply Above Door Pneumatic Supply Kit #6106-0016 See Page 21 Supply From Regulator 1/2 or larger Verify Systems Valve 1/2 NPT to 3/8 tube Provide by Systems Pilot Supply Control Box to To Air Bellows 1/2 line Provided by Others 3/8 line Installed at Factory 3/8 line Provide By Systems 4111-0034 —May 2015...
  • Page 21 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. Supply From Regulator 1/2 line Provided by Systems 3/8 line Installed at Factory 3/8 line Provide By Systems 4111-0034 —...
  • Page 22 INSTALLATION Lanyard Air Supply See Page 21 To Air Regulator To Air Bellows Electric/ Pneumatic Controls See Page 21 To Control Panel Air Regulator To Air Bellows To Air Regulator 3/8 line Installed at Factory 3/8 line Provide By Systems 4111-0034 —May 2015...
  • Page 23 INSTALLATION 4111-0034 — May 2015...
  • Page 24 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 Control Box approved locking device to lock out all power sources. Only the person installing the equipment should have the key to unlock the power source.

  • Page 25: Put New Leveler Into Service

    8. Perform steps 5 – 7 at least four times make sure ® lip keepers evenly, contact Poweramp Technical the leveler functions properly and there is no Services for further instructions.

  • Page 26: Operation

    Keep hands and feet clear of pinch points. Avoid putting any part of your body near moving parts. 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.

  • Page 27: Ramp Loading/Unloading Instructions

    OPERATION Operating Instructions—Continued Below Dock Loading/Unloading Instructions NOTE: If end unloading is required, see End Ramp Loading/Unloading Instructions Loading/Unloading Instructions on page 26. NOTE: If end unloading is required, see End Loading/Unloading Instructions on page 26. 7. Check to make sure transport vehicle is positioned squarely against dock bumpers.

  • Page 28: End Loading/Unloading Instructions

    OPERATION Operating Instructions—Continued End Loading/Unloading Instructions NOTE: If ramp loading is required, see Ramp Loading/Unloading Instructions on page 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 6.

  • Page 29: Maintenance

    MAINTENANCE Service Dock Leveler Safely A— Maintenance Prop B —Tag Out Device C —Lock out Device D— Lip Prop E —Valve,Air Supply When service under the dock leveler is required, Always post safety warnings and barricade the always lock all electrical disconnects in the OFF work area at dock level and ground level to prevent position after raising the platform and engaging the unauthorized use of the dock leveler before...

  • Page 30: Periodic Maintenance

    MAINTENANCE Periodic Maintenance A— Lip Hinge Area C— Lip Link Pivots E— Lip Assist Pin B— Lip Maintenance Prop Pivot D— Platform Hinge Area G— Safety leg linkage pivots Adjusting knob Clockwise increase PSI Counter Clockwise decrease PSi (H) Recommend 95 Psi Lubricator: Gentle turn clock wise until it stops then turn back 1/2 turn for factory setting.
  • Page 31 MAINTENANCE Regular maintenance must be performed on a weekly Quarterly Maintenance and quarterly schedule. Follow all safety precautions. • Perform Weekly Service Items Weekly Maintenance • Lubricate the following areas with light weight (A)— Check Kill frost level. (may be required more machine oil: frequently depending on usage) (D)—...

  • Page 32: Adjustments

    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.

  • Page 33: Adjust Lip Latch And Lip Actuator Springs

    ADJUSTMENTS Adjusting Lip Latch Spring Tension Adjusting Lip Actuator Spring Tension This adjustment is set at the factory and should not This adjustment is set at the factory and should not require additional adjustment. require additional adjustment. Unlike mechanical levelers, the lip will not immediately Unlike mechanical levelers, the lip will not immediately begin to fold as the platform returns to the stored begin to fold as the platform returns to the stored...

  • Page 34: Adjust Lip Stop

    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 clear of the dock leveler lip when working in front of the dock leveler.
  • Page 35 NOTES This page intentionally left blank 4111-0034 — May 2015...

  • Page 36: Troubleshooting

    TROUBLESHOOTING Always stand clear of the dock leveler lip when When service under the dock leveler is required, always lock all electrical disconnects in the OFF working in front of the dock leveler. position after raising the platform and engaging the The maintenance prop MUST be in the service maintenance prop.

  • Page 37: Troubleshooting

    Low Air pressure air supply. Check for visible obstructions that could cause Dock leveler binding binding. Remove obstructions. If no obstructions ® found, call Poweramp Technical Services. See Platform Rises Slowly See Platform Rises Slowly See Periodic Maintenance in the Maintenance section.

  • Page 38: Electrical

    Electrical Controls 4111-0034 —May 2015...

  • Page 39: Control Box

    Control Box Electrical Control 4.00” 6.00” 4.00” 0.5 FLA Amp Draw Item Quantity Part Number Description 2756-0004 Push Button Controller, (9-V0-800-0-E) Poweramp Label 2756-0006 Push Button Controller, (9-V0-800-0-E) DLM Label 1751-0801 Decal (English) 1751-0736 Decal, Arc Flash 4111-0034 — May 2015...
  • Page 40 3/8 Bulkhead fitting 1751-0890 Decal (English) 8581-0163 Valve,Air 2 Position 3 Way (Includes Knob) 9301-0248 3/8 Male Elbow 2756-0001 Push Button Controller, (9-V0-800-0-E) POWERAMP DECALS Push Button Controller, (9-V0-800-0-E) DLM DECALS 2756-0003 Decal, Supply / Pilot (English) 1751-0893 Item Quantity Part Number...

  • Page 41: Air Control Valves

    VALVE BLOCK From Regulator To Air Bellows Item Quantity Part Number Description 0521-0048 Brass Reducer 1/4 NPT to 3/8 NPT 0521-0178 Breather / Muffler 9301-0236 Fitting 3/8 NPT to 3/8 Tube 9301-0237 Fitting 3/8 NPT to 3/8 Swivel Elbow 9301-0261 Fitting 3/8 NPT to 1/2 Swivel Elbow 8581-0152 Clamp, Air line (not Shown)
  • Page 42 VALVE BLOCK Item Quantity Part Number Description 0521-0048 Brass Reducer 1/4 NPT to 3/8 NPT 0521-0178 Breather / Muffler 9301-0236 Fitting 3/8 NPT to 3/8 Tube 9301-0261 Fitting 1/8 NPT to 3/8 Straight 9301-0237 Fitting 3/8 NPT to 3/8 Swivel Elbow 8581-0152 Clamp, Air line (not Shown) 8583-0071...

  • Page 43: Below Dock Control

    PARTS Below Dock Control Item Quantity Part Number Description 9514-0108 Leg, Right Safety Assembly with Spring. 9514-0109 Leg, Left Safety Assembly with Spring DPLA-2122 Pull Bar Assembly, Safety Leg DOTH-2075 Cap Screw, Lip Stop -11 UNC DOTH-2356 Nut,Hex 5/8-11 UNC DOTP-6647 Rod, Push Pin, Clevis...

  • Page 44: Pit Extension Kit

    PARTS Pit Extension Kit Item Quantity Part Number Description 8436-0035 4 inch Pit Extension Kit, For all size levelers 4111-0034 —May 2015...

  • Page 45: Bellows And Regulator

    PARTS Item Quantity Part Number Description 5811-0002 Air Bellows 9514-0160 Top Mounting Weldment 9512-2090 Pin, 49/64 X 10-¾ Lg. 2101-0045 Cotter Pin 2101-0273 3/8-16 UNC x 1” Lg. 2101-0258 Washer 95 PSI Recommend for best performance Item Quantity Part Number Description 8586-0008 Regulator Assembly W/ Lubricator Flow Left To Right (SHOWN).

  • Page 46: Frame And Platform

    PARTS Frame and Platform Lip latch Release Arm Up Grade. Maybe required on some levers (manufactured before 4/2014) if below dock is required 4111-0034 —May 2015...
  • Page 47 PARTS Frame and Platform Item Quantity Part Number Description See Table A Lip, Welded Assembly 9515-____ Platform, Welded Assembly 9202-0050 Pin, Lip Hinge 6’W 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) DKIT-9180 Toe Guard Assembly 8 Foot (Both Sides and Hardware) DKIT-9181...

  • Page 48: Lip Activation

    PARTS Lip Activation Located on Deck Located on Lip K L M G Item Quantity Part Number Description 9513-0099 Lip Assist Rod Complete 34” Lg (Includes Nuts) 2101-0221 Washer 9511-0156 Spring, Lip STD 9514-0114 Spring, Lip HD 9513-0097 Lip Latch Plate 2101-0051 Bolt,½...

  • Page 49: Weather Seal

    PARTS Weather Seal Weather Seal Kits Item Quantity Part Number Description 0195-0021 Brush Kit Includes Seal and Track, 1-1/2 in. 82" Lg. (Both Sides) 0195-0033 Rubber Kit Includes Seal and Track, 1-1/2 in. 82" Lg. (Both Sides) Individual Replacement Seals Item Quantity Part Number...

  • Page 50: Placard

    PLACARD DANGER O P E R AT I N G INSTRUCTIONS POWERED DOCK LEVELERS • Read follow instructions, warnings, and NORMAL OPERATION maintenance schedules in 1. Raise the platform by depressing and the manual and on placards. holding the RAISE button. •...

  • Page 51: Miscellaneous

    MISCELLANEOUS Customer Information NOTE: Refer to illustration for left/right orientation of Dock Leveler Information dock leveler. The model/serial number decal (A) is located Model ___________________________________ on the right platform joist near the front (lip) Serial No. ________________________________ of dock leveler. Systems, Inc., Job No.

  • Page 52: Warranty

    ® ” SERIES LEVELER ENTRA ® 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: • Structural Warranty – For a period of ten (10) years from the date of shipment, product will carry a prorated structural warranty.

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