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Poweramp CM Series Owner & User Manual

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CM-Series
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. 4111-0006
September 2010
Copyright
2003
©

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  • Page 1 CM-Series 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. 4111-0006 September 2010 Copyright 2003 ©...

  • Page 2: Table Of Contents

    Table of Contents Page Safety Recognize Safety Information ....... 1 General Operational Safety Precautions .

  • Page 3: Safety

    SAFETY Recognize Safety Information General Operational Safety Precautions Safety-Alert Symbol The Safety-Alert Symbol identifies important safety messages on equipment, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow Read and understand the operating instructions and the instructions in the safety message.

  • Page 4: Operational Safety Precautions

    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. Stay clear of dock leveling device when freight Chock/restrain all freight carriers. Never remove carrier is entering or leaving area.
  • Page 5 SAFETY Do not use dock leveling device if freight carrier is too high or too low. Do not overload the dock leveling device. Do not operate any equipment while under the influence of alcohol or drugs. Do not leave equipment or material unattended on dock leveling device.

  • Page 6: Maintenance Safety Precautions

    SAFETY Maintenance Safety Precautions DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present. Stray sparks can ignite spills or leaks near the work area.

  • Page 7: Safety Decals

    SAFETY Safety Decals Every 90 days (quarterly) inspect all safety labels and tags to ensure they are on the dock leveler and are easily leg- ible. If any are missing or require replacement, please call 1-800-643-5424 for replacements. DANGER CRUSH HAZARD Maintenance prop must 1751-0727 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

    This manual covers the CM-series mechanical dock leveler. * CIR (Comparative Industry Rating) Designed by Poweramp to be a marvel of simplicity Call Poweramp for your specific needs. and efficiency, your dock leveler, when properly installed, will provide many years of trouble-free performance with an absolute minimum of maintenance.

  • Page 10: Component Identification

    INTRODUCTION Component Identification A — Lip F — Platform Release Ring L — Platform Maintenance Prop R— Safety Leg Linkage B — Lip Maintenance Prop G — Ratchet Pawl M— Hold-Down Mechanism S — Safety Leg Release Ring C — Platform H —...

  • Page 11: Installation

    IMPORTANT IMPORTANT If any measurement is off by more than 1/8 in. DO NOT remove the shipping bands around the (3.18 mm), contact Poweramp Technical Services dock leveler lip until instructed to do so. before proceeding. 4111-0006 — Sept 2010...

  • Page 12: Prepare Dock Leveler

    Prepare Dock Leveler A— Lifting Bracket (2 used) B — Shipping Bands Poweramp dock levelers are designed with installation in mind. Each unit is shipped with lifting The dock leveler is heavy. Use a lifting device and brackets (A) fastened to the platform side joists.
  • Page 13 INSTALLATION 1. Remove any bumpers that may be banded, or bolted to the frame of the dock leveler. DO NOT remove the shipping bands (B) around the platform lip and leveler frame at this time. IMPORTANT IMPORTANT DO NOT over-tighten the lifting bracket hardware. Over-tightening can damage the weather seal, if equipped.

  • Page 14: Install Dock Leveler

    INSTALLATION Install Dock Leveler Shim Stacking Methods A— Distance (Leveler Frame F— String Height) G— Rear Hinge Frame Angle B— Shim Locations (Under H— Distance (Dock Floor-to- Rear Vertical Supports) Pit Floor) C— Shim Locations (Under J— Distance (Top of Shim Lip Keepers and Prop) Stack-to-Dock Floor) D—...
  • Page 15 INSTALLATION NOTE: Poweramp dock levelers are designed with a 4. Put a 1/4 in. (6.6 mm) thick shim at locations (C) nominal 1/2 in. (12.7 mm) shimming distance (under lip keepers/maintenance prop and safety to allow for pit inconsistencies. legs). Make sure shims are larger than frame angle iron so pyramid or stepped stacking method 1.
  • Page 16 (if equipped) will not bind during dock leveler operation. 12. If leveler cannot be squared and made level as instructed in steps 8 – 10, contact Poweramp 9. If gap (D) cannot be obtained equally at both Technical Services.
  • Page 17 If platform still binds, contact Alternate welding locations to distribute heat. Welding sequentially from one end to the other Poweramp Technical Services for further may cause warping or distortion. instructions. 20. Check that the leveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly.
  • Page 18 INSTALLATION A— Safety Leg Chain Pull Ring B— Platform Maintenance Prop C — Shim Location (Under Lift Arm Pivot) D —Prop Pin & Clip 21. Pull the release ring to raise platform. Engage the 25. Remove the lifting brackets from the platform side platform maintenance prop (B) in the service joists.

  • Page 19: Operation

    OPERATION Theory A — Lip F — Platform Release Ring L — Platform Maintenance Prop Q — Shock Absorber B — Lip Maintenance Prop G— Ratchet Pawl M— Hold-Down Mechanism R — Safety Leg Linkage C — Platform H — Ratchet Bar N —...

  • Page 20: Operating Instructions

    OPERATION Operating Instructions 12 in. (305 mm) Stay clear of dock leveler when freight carrier is entering or leaving dock area. DO NOT raise or lower the dock leveler if anyone is under or in front of leveler. 12 in. (305 mm) Keep hands and feet clear of pinch points.

  • Page 21: Ramp Loading/Unloading Instructions

    OPERATION Operating Instructions — Continued Ramp Loading/Unloading Instructions NOTE: If end unloading is required, see End 7. Make sure that the lip is fully extended and Loading/Unloading Instructions on page 20. supported on the truck/trailer along the entire width of the platform with at least 4 in. (102 mm) 1.

  • Page 22: End Loading/Unloading Instructions

    OPERATION Operating Instructions — Continued End Loading/Unloading Instructions NOTE: 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 truck/trailer bed. 1. Check to make sure truck/trailer is positioned squarely against dock bumpers.

  • Page 23: Maintenance

    MAINTENANCE Service Dock Leveler Safely A— Lip Maintenance Prop B — Platform Maintenance Prop C — U-Bracket D — Prop Pin & Clip Whenever maintenance is to be performed under the dock leveler platform, support the platform with the Always post safety warnings and barricade the platform maintenance prop (B).

  • Page 24: Periodic Maintenance

    MAINTENANCE Periodic Maintenance • A — Lip Hinge Grease Fittings D — Platform Hinge Area G — Lift Arm Pivot K — Lip Lift Assist Pin B — Lip Maintenance Prop Pivot E — Lift Arm Roller Bushing H — Hold-Down Pivot/Pulley L —...
  • Page 25 MAINTENANCE Regular maintenance must be performed on a weekly and quarterly schedule. Weekly Maintenance Quarterly Maintenance • Operate the dock leveler through the complete • Lubricate the following areas with light-weight operating cycle to maintain lubrication. machine oil: NOTE: To thoroughly inspect the platform hinge area, (B)—...

  • Page 26: Adjustments

    ADJUSTMENTS Adjust Lift Arm Spring and Lip Assist Spring Tension A — Jam Nut C — Lip Assist Spring E — Lift Spring Bolt B — Adjustment Nut D — Lift Springs F — Hold-Down Mechanism Always post safety warnings and barricade the The platform maintenance prop MUST be in the work area at dock level and ground level to prevent service position when working under the dock...
  • Page 27 ADJUSTMENTS NOTE: Adjusting the tension of lift springs (D) usually 3. After lift spring adjustment is completed, check requires that the lip assist spring (C) also be operation of the lip. adjusted. • If the lip folds before the platform can be If the platform does not rise fully and/or lip does not walked down, tension of lip assist spring (C) extend fully, the lift spring tension may be set too low.

  • Page 28: Adjust Lip Stop Bolt

    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 29: Troubleshooting

    Dock leveler binds. Check for visible obstructions that could cause binding. Check weather seal if equipped. If no obstructions found, call Poweramp Technical Services. See inside back cover for phone number and address. Platform rises slowly or Heavy object(s) on platform. Remove object(s) from platform.

  • Page 30: Parts

    TROUBLESHOOTING Symptom Possible Cause Solution Platform rises to full Lip assist chain Connect or replace chain. height, but lip does not disconnected or broken. fully extend. Insufficient main spring Increase tension on main lift springs. (See Adjust Lift tension. Arm Spring and Lip Assist Spring Tension in the Adjustments section.) Insufficient lip assist force.

  • Page 31: Hold-Down Mechanism

    PARTS Hold-Down Mechanism Item Quantity Part Number Description DOTH-2563 Hold Down Assembly Complete, 31.5” Ratchet Bar DOTH-2564 Hold Down Assembly Complete, 34.5” Ratchet Bar DKIT-2575 Ratchet Bar and Pawl Assembly 31.5” Ratchet Bar DKIT-2576 Ratchet Bar and Pawl Assembly 34.5” Ratchet Bar 1751-0043 Decal, Warning DOTH-2559...

  • Page 32: Frame Components

    PARTS Frame Components 4111-0006 — Sept 2010...
  • Page 33 PARTS Frame Components Item Quantity Part Number Description DFRA____ Frame, Welded Assembly DFRA-____ Frame, Clean Sweep, Welded Assembly (Optional) DOTH-2555 Spring, Snubber DOTH-2416 Lap Link, 3/16 x 1.0 in. DPLA-2128 Chain, Lip Assist Link DOTH-2421 Cold Shut Link, 5/16 in. DFRA-0326 6 Foot Bolt, Spring Adjuster &...

  • Page 34: Platform Components

    PARTS Platform Components 4111-0006 — Sept 2010...
  • Page 35 PARTS Platform Components Item Quantity Part Number Description DLPA-____ Platform, Welded Assembly DOTH-1721 Decal, Warning DOTH-2424 Fitting, Grease DOTH-2075 Cap Screw, Lip Stop DOTH-2160 Nut, Hex 5/8-11 DOTH-2131 Nut, Nylon Lock DOTH-2214 Washer DOTH-2547 Spring, Lip Maintenance Prop DOTP-2006 Prop, Lip Maintenance DOTH-2062 Cap Screw DLIP-____...
  • Page 36 PARTS Platform Components Continued from previous page Item Quantity Part Number Description Lip Assist Assembly DPLA-2130 Rod, Lip Assist Adjuster, (1-1/8 in. x 34 in., Heavy Duty Short) DOTH-2548 Spring, STD, Lip Assist DOTH-2546 Spring, HD, Lip Assist DOTH-2061 Bolt, Shoulder DOTH-2131 Nut, Nylon Lock DOTH-2160...

  • Page 37: Toe Guard/Weather Seal-Optional

    PARTS Toe Guard/Weather Seal—Optional Item Quantity Part Number Description DOTH-2818 Channel, Weather Seal, 84” DOTH-2824 T-Rubber, Weather Seal, 84” DOTH-2820 Extrusion, Brush Weather Seal, 84” DOTH-2822 Brush Weather Seal, 1.58” x 84” DOTH-2043 Cap Screw DOTH-2207 Washer See Chart See Chart DOTH-2131 Nut, Nylon Lock See Chart...
  • Page 38 NOTES This page intentionally left blank 4111-0006 — Sept 2010...

  • Page 39: Miscellaneous

    (A) becomes lost or damaged. Name ___________________________________ Address _________________________________ Also, write down Poweramp’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.

  • Page 40: Warranty

    LOSS OF GOODWILL. PRODUCT SPECIFIC WARRANTY “CM” 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: • 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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