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Poweramp CentraAir Owner & User Manual

Dock leveler
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CentraAir
®
PATENT # 8,627,529
Dock Leveler
Owner's/User's Manual
Poweramp • Division of Systems, LLC • W194 N11481 McCormick Drive • Germantown, WI 53022
800.643.5424 • fax: 262.255.5917 • www.poweramp.com • techservices@poweramp.com
Printed in U.S.A.
Manual No. 4111-0034
© 2018 Systems, LLC - All Rights Reserved
Sept. 2018

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  • Page 1 ® PATENT # 8,627,529 Dock Leveler Owner’s/User’s Manual Poweramp • Division of Systems, LLC • W194 N11481 McCormick Drive • Germantown, WI 53022 800.643.5424 • fax: 262.255.5917 • www.poweramp.com • techservices@poweramp.com Printed in U.S.A. Manual No. 4111-0034 © 2018 Systems, LLC - All Rights Reserved...

  • Page 2: Table Of Contents

    Table of Contents Page Precautions Recognize Precautionary Information ..........1 General Operational Precautions ............1 Operational Precautions ..............2 Safety Decals ..................4 Placard ....................5 Owner’s/User’s Responsibilities............6 Introduction General Information ................8 Component Identification ..............9 Installation Installation Precautions ..............10 Air Supply Requirements ..............

  • Page 3: Precautions

    PRECAUTIONS Recognize Precautionary Information General Operational Precautions Safety-Alert Symbol The Safety-Alert Symbol is a graphic representation intended to convey a safety message without the use of words. When you see this symbol, be alert Read and understand the Owner’s/User’s Manual and become thoroughly familiar with the equipment and to the possibility of death or serious injury.

  • Page 4: Operational Precautions

    PRECAUTIONS Operational Precautions Learn the safe way to operate this equipment. Read and understand the manufacturer’s instructions. If you have any questions, ask your supervisor. Stay clear of dock leveling device when transport Chock/restrain all transport vehicles. Never vehicle is entering or leaving area. remove the wheel chocks or release the restraining device until loading or unloading is finished, and transport driver has been given...
  • Page 5 PRECAUTIONS Operational Precautions Do not use dock leveling device if transport vehicle is too high or too low. Do not overload the dock leveling device. Do not operate any equipment while under the influence of alcohol or drugs. Do not leave equipment or material unattended on dock leveling device.

  • Page 6: Safety Decals

    02 hi-tack permanent acrylic adhesive completely. Close the pin latch Ritrama 3-7146 (1.0 mil thick) clear polyester laminate to secure prop. Use every time dock leveler is serviced. CentraAir Failure to comply will result patent pending in death or serious injury. 1751-00817...

  • Page 7: Placard

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

  • Page 8: Owner's/User's Responsibilities

    OWNER’S/USER’S RESPONSIBILITIES 1) The manufacturer shall provide to the initial the owner’s/user’s company policies, operating purchaser and make the following information conditions and the manufacturer’s specific readily available to the owners/users and their instructions provided with the dock leveling agents, all necessary information regarding device.
  • Page 9 OWNER’S/USER’S RESPONSIBILITIES 7) Loading dock safety equipment should never instructions, labels, decals and placards or be used outside of its vertical working range, or their equivalent. Written documentation of outside the manufacturer’s rated capacity. It shall maintenance, replacement parts or damage also be compatible with the loading equipment should be kept.

  • Page 10: Introduction

    INTRODUCTION General Information Figure 3 This manual provides current information on the CentraAir Series dock levelers are available in the CentraAir®-series (CA) dock leveler. Due to ongoing following sizes, weight capacities, and options: product improvement, some parts may have changed, along with operation and troubleshooting methods.

  • Page 11: Component Identification

    INTRODUCTION Component Identification Inspect package and all components. Report any missing or damaged items immediately and note on the shipping Bill Of Lading (BOL). Optional rubber donuts shown A — Lip G — Lip Actuator Chain J — Air Bellows P —Air Control Valve B —...

  • Page 12: Installation

    INSTALLATION Installation Precautions It is recommended and good safety practice to use DO NOT connect the dock leveler electrical wiring an additional means to support the dock platform and ground connections until all welding has been and lip anytime when physically working in front of completed.

  • Page 13: Air Supply Requirements

    INSTALLATION Air Supply Requirements Compressor pump must be filled with appropriate oil prior to initial start up. Refer to the compressor manufacturer's manual for proper startup and maintenance procedures. # of Levelers Recommended Compressor 1.5HP, 20GAL, 5.2CFM @ 90PSI 5 or more 5HP, 60GAL, 14.2CFM @ 125 PSI The CA dock leveler will not function correctly with less than 80 psi available at the regulator.

  • Page 14: Prepare Pit

    INSTALLATION Prepare Pit 10” 14” Figure 5 A—Pit Width B— Dock Floor-to-Pit Floor C— Pit Length D— Pit Corner-to-Corner (Front and Rear) (All Four Corners) (Both Sides of Pit) (Top, Bottom, and Both Sides) Before lowering the dock leveler into the pit, the following must be performed: 1.
  • Page 15 Figure 6 A— Lifting Bracket (2 used) B — Shipping Bands Poweramp dock levelers are shipped with lifting 3. Attach lifting chains to lifting brackets (A) and to brackets (A) fastened to the platform side joists, a lifting device (i.e., hoist or fork truck) having the and shipping bands (B) around the platform lip and appropriate lifting capacity and reach.

  • Page 16: Install Dock Leveler

    INSTALLATION Install Dock Leveler Figure 7 Figure 9 DETAIL A SCALE 1 / 4 Figure 8 A— Distance (Leveler Frame D— Shim Locations (Under K— Distance (Dock Floor-to- M— Shim Stack Height) Lip Keepers) Pit Floor) N— Dock Leveler Frame B—...
  • Page 17 INSTALLATION Install Dock Leveler (continued) Shim Stacking Methods Note: Systems, LLC dock levelers are designed with a nominal 1/2” (12.7 mm) shimming distance to allow for pit inconsistencies. 1. Determine height of shim stack (M) for each shim location (B) by performing the following: Pyramid Stepped (Preferred)
  • Page 18 INSTALLATION 3/8 in. 6 in. (9.5 mm) (152 mm) Figure 11 A— Front of Dock Pit C— Side Pit Curb Angle E— Pry Locations G— Rear Pit Curb Angle B— Dock Leveler Frame D— Gap [3/4 in. (19 mm) F— Rear Hinge Frame H—...
  • Page 19 INSTALLATION Install Dock Leveler (continued) 12. With the leveler square in the pit and flush with the surrounding dock floor, remove the banding on the lip of the leveler. DO NOT use the maintenance prop to support the raised platform until the maintenance prop has 13.
  • Page 20 INSTALLATION Install Dock Leveler (continued) Shim Stacking Methods Make sure the platform is properly supported in the raised position before entering the pit to finish weld the shims. Pyramid Stepped (Preferred) (Acceptable) 19. Finish weld all shims using a fillet weld. •...
  • Page 21 INSTALLATION This page intentionally left blank. 4111-0034 — Sept. 2018 © 2018 Systems, LLC...

  • Page 22: Install Control Panel- Electric

    INSTALLATION Install Control Panel - Electric Where indicated, all components must be connected Make sure that the power source has been locked to a SAFETY EARTH GROUND that conforms to out and tagged according to OSHA regulations and the 1999 National Electrical Code Section 250-50 approved local electrical codes.

  • Page 23: Install Control Panel- Pneumatic

    INSTALLATION Install Control Panel - Electric (continued) Install Control Panel - Pneumatic 1. Mount the push button control panel (B) so bottom of control panel-to-dock floor distance (C) is 48 in. (1219 mm). See Figure 15. 2. Install pneumatic air lines to control panel, valve and air bellows under dock leveler as shown on pages 22-23.

  • Page 24: Air Supply

    INSTALLATION Overhead Air Supply Supply From Regulator 1/2" or larger must be verified Valve 1/2" NPT to 3/8" tube Provided by Systems Pilot Supply from Control Box Valve To Air Bellows 1/2" line Provided by Others 3/8" line Installed at Factory 3/8"...
  • Page 25 INSTALLATION Underground Air Supply Pilot Supply from Control Box 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 Provided By Systems 4111-0034 — Sept. 2018 ©...
  • Page 26 INSTALLATION Lanyard Air Supply Valve To Air Regulator To Air Bellows Electric Operator Air Supply To Control Box To Air Bellows Valve 3/8" line Installed at Factory To Air Regulator 3/8" line Provided By Systems 4111-0034 — Sept. 2018 © 2018 Systems, LLC...

  • Page 27: Placard Installation Instructions

    INSTALLATION Placard Installation Instructions Placard Installation Instructions • Owner/Users are responsible for the installation and placement of product • Owner/Users are responsible for the installation and placement of product • Owner/Users are responsible for the installation and placement of product placards.

  • Page 28: Put New Dock Leveler Into Service

    INSTALLATION Put New Dock Leveler Into Service 8. Raise the platform fully. Hold the platform at this position by pulling the lanyard ring (or pressing the RAISE button) and move the maintenance prop to the A hard hat or other applicable head protection service (upright) position.

  • Page 29: Operation

    OPERATION Operational Precautions Stay clear of dock leveler and vehicle restraint 12 in. (305 mm) when transport vehicle is entering or leaving dock area. DO NOT move or use the dock leveler or restraint if 12 in. (305 mm) anyone is under or in front of leveler. Keep hands and feet clear of pinch points.

  • Page 30: Ramp Loading/Unloading Instructions

    OPERATION Operating Instructions Ramp Loading/Unloading 7. Remove chocks from transport vehicle wheels, or release the vehicle restraint if used. 1. Before activating dock leveler, check to make sure the transport vehicle is positioned squarely against 8. Indicate to driver that the transport vehicle may dock bumpers.

  • Page 31: End Loading/Unloading Instructions

    OPERATION Operating Instructions (continued) End Loading/Unloading 1. Before activating dock leveler, check to make sure the transport vehicle is positioned squarely against dock bumpers. Ensure lip will avoid contact with transport vehicle frame, sides and cargo during dock leveler activation. If contact is likely or observed, reposition transport vehicle.

  • Page 32: Maintenance

    MAINTENANCE Maintenance Precautions Figure 23 Figure 22 Figure 21 A - Tag Out Device B - Lock Out Device C - Maintenance D - Header E - Lip Prop F - Air Shutoff 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.
  • Page 33 MAINTENANCE Maintenance Precautions When working with electrical or electronic controls, make sure that the power source has been tagged (A) and locked out (B) according to OSHA regulations * and approved local electrical codes (see Figure 21). Whenever maintenance is to be performed under the dock leveler platform, support the platform with maintenance prop (C).

  • Page 34: Periodic Maintenance

    MAINTENANCE Periodic Maintenance Figure 24 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) 95 PSI Recommended Lubricator: Gently turn clockwise until it stops, then turn back 1/2 turn...
  • Page 35 MAINTENANCE Weekly Maintenance Quarterly Maintenance • Operate the dock leveler through the complete • Complete Weekly Maintenance. operating cycle to maintain lubrication. • Inspect the following for damage/abnormal wear: Note: To thoroughly inspect the platform hinge area, • Check welds for cracks. put the platform in the full below-dock position.

  • Page 36: Adjustments

    ADJUSTMENTS Adjust Lip Latch & Lip Actuator Spring Tension 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. In addition, it is recommended and good safety practice to use an additional means to support the dock platform and lip anytime when physically...
  • Page 37 ADJUSTMENTS Adjust Lip Latch & Lip Actuator Spring Tension (continued) The lip latch and lip actuator spring tension Lip Actuator Spring Tension are set at the factory and should not require additional adjustment unless parts have been Note: Use two-turn increments when adjusting replaced.

  • Page 38: Adjust Lip Stop Bolt

    ADJUSTMENTS Adjust Lip Stop Bolt When at rest, lip (E) should be fully resting on the lip keepers (D) and at the lowest part of the lip keepers. If lip is not resting properly in the lip keepers, perform the following adjustment: 1.

  • Page 39: Adjust Lip Assist Chain And Shackle

    ADJUSTMENTS Adjust Lip Assist Chain and Shackle Figure 28 The lip assist chain and shackle are set at the factory and should not require additional adjustment unless parts have been replaced. The above dock service range of the leveler is determined by the overall length of the lip assist chain and shackle assembly.

  • Page 40: Troubleshooting

    TROUBLESHOOTING Unless the dock leveler is equipped with a tethered When service under the dock leveler is required, remote, two people are required to engage the always lock all electrical disconnects in the OFF maintenance prop: one person to operate the unit, position after raising the platform and engaging the the other person to engage the maintenance prop.
  • Page 41 TROUBLESHOOTING Symptom Possible Cause Solution Air bladder or connecting air Check air bladder and air line; repair or replace as lines punctured needed Damaged or restricted air Replace damaged air line or remove restriction lines Minimum 80 PSI required at regulator, if lower check Platform rises slowly.

  • Page 42: Parts

    Control Box Size : Decal Size: 4.75 X 2 File Name : 1751-1174 Item Quantity Part Number Description 9-V0-80E-0-B Push Button Controller, Poweramp Label 1751-0890 Decal (English) 1751-0736 Decal, Arc Flash 1751-1174 Decal, Bulk Head Fitting 9301-0249 Fitting, Bulk Head...

  • Page 43: Pneumatic Control Box

    PARTS Pneumatic Control Box Pilot Supply Main Supply Item Quantity Part Number Description 2756-0001 Push Button Controller, (9-V0-800-0-E) Poweramp Decals 9301-0249 3/8 Bulkhead fitting 1751-0892 Decal (English) 8581-0163 Valve,Air 2 Position 3 Way (Includes Knob) 9301-0248 3/8 Male Elbow 1751-0893...

  • Page 44: Electric/Pneumatic Operator Valve

    PARTS Electric/Pneumatic Operator Valve Item Quantity Part Number Description 8583-0071 Valve Assy Elec/Pneumatic 0521-0048 Brass Reducer 1/4 NPT to 3/8 NPT 0521-0178 Fitting, Breather / Muffler Speed Control 9301-0236 Fitting, 3/8 NPT to 3/8 Tube 9301-0250 Fitting 1/8 NPT to 3/8 Straight 9301-0237 Fitting 3/8 NPT to 3/8 Swivel Elbow 2101-0260...

  • Page 45: Lanyard Operator Valve

    PARTS Lanyard Operator Valve Item Quantity Part Number Description 5265-0001 Cable Assembly (Includes Pull Ring) 8103-0001 Weight Assembly 5402-0009 Lanyard Arm 2101-0116 Bolt ¼” x 2” Lg 2101-0143 Lock Nut ¼” R985-0001 ⅜ Tubing 8581-0158 Valve Operator, Mechanical 9512-2061 Lanyard Control Bracket 9301-0236 Fitting, Straight 9301-0237...
  • Page 46 PARTS Item Quantity Part Number Description 0941-0013 Spring, Lip Latch Extension 2101-0230 Ring, Split 1-3/4” OD 2101-0239 Link, Chain snap 1/4” 4111-0034 — Sept. 2018 © 2018 Systems, LLC...

  • Page 47: Air Bellows And Regulator

    PARTS Air Bellows and Regulator Item Quantity Part Number Description 5811-0002 Air Bellows 9514-0160 Top Mounting Weldment 9202-0072 Pin, Platform, Hoist, VS3/RR/CA, 49/64 Dia. x 10.75, SW85 2101-0357 Cotter Pin, 3/16 2101-0273 3/8-16 UNC x 1” Lg. 2101-0163 Washer 95 PSI Recommended for best performance Item...

  • Page 48: Frame And Platform

    PARTS Frame and Platform BILL OF MATERIAL ITEM PART NO. DESCRIPTION SIZE 8432-1006 SNUBBER MOUNT AP SERIES 8432-1212 LIP LATCH RELEASE ARM Lip Latch Release Upgrade May be required on some levelers manufactured pre- 4/2014 if full below dock operation is required. P O W E R A M P D L M N C.
  • Page 49 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 50: Lip Activation

    PARTS Lip Activation Located on Deck DPLA-0338 Complete Located on Lip Item Quantity Part Number Description DLIP-0305 Lip Assist Rod Complete 34” Lg (Includes Nuts) 2101-0221 Washer 1-3/4 9511-0156 Spring, Lip STD 9514-0114 Spring, Lip HD 2101-0222 Bolt, Shoulder x ½ x 1¾ 2101-0223 Nut, Nylon lock 9513-0091...

  • Page 51: 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 5/8-11 x 2.5 LG UNC GR5 (2101-0243) DOTH-2356 Nut,Hex 5/8-11 UNC ( 2101-0042) DOTP-6646...

  • Page 52: Weather Seals

    PARTS Weather Seals 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 53 PARTS This page intentionally left blank. 4111-0034 — Sept. 2018 © 2018 Systems, LLC...

  • Page 54: Miscellaneous

    MISCELLANEOUS This page intentionally left blank. 4111-0034 — Sept. 2018 © 2018 Systems, LLC...

  • Page 55: Customer Information

    MISCELLANEOUS Customer Information Figure 30 Figure 29 NOTE: Refer to Figure 29 for left/right orientation of dock Dock Leveler Information leveler and Figure 30 for example of decal. The LEVELER model/serial number decal is Model ___________________________________ located on the left platform joist near the front (lip) of dock leveler (A).

  • Page 56: Warranty

    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 LLC, guarantees materials, components and workmanship to be free of defects for the following extended periods: •...

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