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Serco SafeTFrame AB Series User Manual

Air power dock leveler
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Air Powered Dock Levelers
AB Series
This User's Manual applies to
dock levelers manufactured
beginning December 2010 with
the serial numbers 61000001
and higher.
User's Manual
Do not install, operate or service this product unless you
Installation, Operations,
have read and understand the Safety Practices, Warnings,
Installation and Operating Instructions contained in this
Maintenance and Parts
User's Manual. Failure to do so could result in death or
serious injury.
Part No. 6004756F

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Summary of Contents for Serco SafeTFrame AB Series

  • Page 1 Air Powered Dock Levelers AB Series This User’s Manual applies to dock levelers manufactured beginning December 2010 with the serial numbers 61000001 and higher. User’s Manual Do not install, operate or service this product unless you Installation, Operations, have read and understand the Safety Practices, Warnings, Installation and Operating Instructions contained in this Maintenance and Parts User’s Manual.

  • Page 2: Table Of Contents

    Raising Leveler ............21 Storing Leveler .............22 Below Dock Level, End Loading ......22 InTroDUcTIon Welcome and thank you for choosing this dock leveler from Serco . This dock leveler may be equipped with the ® optional ENERGY GUARD dock leveler sealing system.

  • Page 3: Safety Practices

    sAfeTy PrAcTIces oPerATIon (continued) Do not use a fork truck or other material handling equipment Read these Safety Practices before installing, operating to lower the ramp. or servicing the dock leveler. Failure to follow the Safety Practices could result in death or serious injury. Move all equipment, material or people off dock leveler and store dock leveler at dock level before allowing the vehicle If you do not understand the instructions, ask your supervisor...

  • Page 4: Owner's Responsibilities

    owner’s resPonsIbILITIes The owner’s responsibilities include the following: The owner should recognize the inherent danger of the interface between dock and transport vehicle. The owner should, therefore, train and instruct operators in the safe use of dock leveling devices. When a transport vehicle is positioned at the dock, there shall be at least 4"...

  • Page 5: Ramp And Lip Grades

    rAMP AnD LIP grADes Fig. 1 Ramp grade Lip grade VeHIcLe beD rAMP and LIP grades, % for each Dock leveler length VeHIcLe beD rAMP and LIP grades, % for each Dock leveler length PosITIon PosITIon 6' Leveler 8' Leveler 10' Leveler 6' Leveler 8' Leveler...

  • Page 6: Installation

    InsTALLATIon PIT cHecK 10. If conduit must be installed (replacing an existing 1. Check entire dock leveler pit for proper construction mechanical dock leveler) do so at this time. Refer to according to certified pit drawings (publication 826-010). the conduit requirements on the pit detail publication Check to be sure that the pit walls are square and plumb.
  • Page 7 InsTALLATIon, continued Fig. 4 InsTALLATIon of DocK LeVeLer noTe: Shims must be placed under the maintenance strut bracket, and on 18" and 20" lips, shims must also be welded in between the lip keepers and the vertical face of the curb angle. 10.
  • Page 8 InsTALLATIon, continued Fig. 6 12. Move the dock leveler back to the rear pit curb angle. See Fig. 6. With the rear leveler angle touching the rear pit angle, square up the sides of the pit to the sides of the leveler.
  • Page 9 InsTALLATIon, continued Fig. 8 LeVeLIng THe fronT frAMe 15. Remove and discard the shipping tie down straps located at the front hinged lip assembly. Raises Rear Before welding the rear frame, cover the weather seals Angle with a sheet of steel to prevent setting fire to the weather seals.
  • Page 10 InsTALLATIon, continued considerations (e.g. conduit runs, etc.). Fig. 11 Lip Keepers Not Parallel To Lip noTe: Shims must be placed under the maintenance strut bracket, Improper Installation and on 18" and 20" lips, shims must also be welded in between the lip keepers and the vertical face of the curb angle.
  • Page 11 InsTALLATIon, continued Fig. 13 19. Place leveler securely on the maintenance strut. If Air Bag Pan electrical power is available, use the electrical controls Retaining Bolt to raise the ramp and lip to their full above dock position. See operating instructions in this manual. If electrical power is not available, use a chain or other suitable lifting device.
  • Page 12 InsTALLATIon, continued Fig. 15 25. After the rear frame angle is welded check that all leveling feet are in contact with the floor of the pit. Once all feet are in contact with the floor. Torque each leveling screw to 25-40 ft.-lbs. counterclockwise. 26.
  • Page 13 Warning and Operating Instruction Placard noTe: If you have any problems or questions using or operating the dock leveler, contact your supervisor or local Serco distributor ® for assistance. he dock face must be flush with curb angle to assure proper bumper mounting.
  • Page 14 InsTALLATIon, continued InsTALLATIon TroUbLesHooTIng The following procedures apply after the leveler is level in the pit. ProbLeM PossIbLe cAUse soLUTIon 1) Leveler will not fit properly in pit. a) Pit is out of square with the sides. a1) Align the sides parallel and equally spaced with the rear frame angle touching the rear curb angle in one place.

  • Page 15: Service Tools

    serVIce TooLs Fig. 22 Before servicing the dock leveler, read and follow the Safety Practices on page 3 and the operation section of this manual. Be certain, before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler, that: 1) THE MAINTENANCE STRUT IS SECURElY IN PlACE.

  • Page 16: Pan Removal Tool

    serVIce TooLs, continued 4. To disengage the maintenance strut from its locked Fig. 24 upright position two people are needed: a. Push and hold the rAIse button on the control panel. b. Second person lift the maintenance strut up to release from locked position.
  • Page 17 serVIce TooLs, continued 1.3 Using both hands, pull down on handle. This will rotate Fig. 27 the pan removal tool on its wheels, pushing the pan assembly upwards. See Fig. 25. 1.4 Move the handle down to the pit floor. See Fig. 26. The removal tool will snap into position, supporting the pan in a raised position.

  • Page 18: Components And Specifications

    serVIce TooLs, continued 1.4 Push down on front of pan assembly to unhook the Fig. 30 back of the pan assembly. See Fig. 30. 1.5 Balancing the pan assembly on the removal wheel assy., roll the assembly to the front of the pit. Rollers will roll on pit floor.

  • Page 19: Wiring Diagram

    wIrIng DIAgrAM Before doing any electrical work, make certain the power is disconnected and properly tagged or locked off. All electrical work must be done by a qualified technician and meet all applicable codes. If it is necessary to make troubleshooting checks inside the control box with the power on, USE EXTREME CAUTION.

  • Page 20: Operation

    The maximum uncontrolled drop of a Serco AB leveler, ® if above dock is to the safety legs (approximately 2-1/2"...

  • Page 21: Raising Leveler

    oPerATIon, continued Fig. 34 Press To Raise Do not drive on dock leveler or lip until it is fully extended and supported by the vehicle floor. Never use a fork truck or other material handling equipment to lower the ramp and lip sections. rAIsIng LeVeLer Ensure a vehicle restraining device is engaged or wheel chocks in place before operating the dock leveler.

  • Page 22: Storing Leveler

    oPerATIon, continued Fig. 38 Press To Raise Before allowing vehicle to leave, always return the dock leveler to its dock level (stored) position with the lip stored in both lip keepers. See Fig. 37. Failure to do so may leave the dock leveler in a position below the level of the dock floor.

  • Page 23: Planned Maintenance

    PLAnneD MAInTenAnce Before servicing the dock leveler, read and follow the Be certain, before climbing into the dock leveler pit or Safety Practices on page 3 and the operation section of doing any maintenance or repair under the dock leveler, this manual.
  • Page 24 PLAnneD MAInTenAnce, continued Fig. 41 Legend Symbol Description Lubricate - Oil Light Oil - SAE 30 Lubricate - Grease Molybdenum Disulfide NLGI #2 Cleaning (Location - Frequency) Rear Hinge Pin Visually Inspect (Replace Damaged Or Worn) (Typ.) Air Bag Bolts 29-31 Ft-Lbs Pit - 3 Mo 6004756F —...
  • Page 25 PLAnneD MAInTenAnce, continued 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 your local authorized distributor for replacements. Fig.

  • Page 26: Troubleshooting

    Order the patch kit from your dealer or Serco® to repair holes. If holes are too large, replace bag assembly. (See page 32 for part number). c) Loose or misaligned bag fittings or c) Repair or replace as required.
  • Page 27 TroUbLesHooTIng, continued ProbLeM PossIbLe cAUse soLUTIon 3. Lip plate does not fully extend a) Debris or corrosion in the lip hinge. a) Clean and lubricate the lip hinge. when leveler is raised. b) Debris or corrosion in the rear b) Clean and lubricate the rear hinge. hinge.

  • Page 28: Lip Latch Adjustment

    LIP LATcH ADjUsTMenT noTe: 1) Always position traffic cones or a barricade behind Air bag unit not shown. No adjustment required to air bag/pan and in front of the dock leveler to warn fork truck assembly for this application. operators, vehicle traffic and pedestrians away from the dock leveler.
  • Page 29 LIP LATcH ADjUsTMenT, continued The lip spring acts through the bell crank and the lip assist 2. If the lip does not fully extend, check for binding of the bar to counter balance the weight of the lip. The lip spring is latch bar, debris in the lip hinge, or improper attachment attached by two chains to both the deck and to the frame.

  • Page 30: Parts List Dock Leveler

    PArTs LIsT — DocK LeVeLer Fig. 44 13 9 Quantity on washer (234-141) on lip latch varies from 1-3. See Fig. 43, page 28. 9 13 57 65 Optional Reflex Leg 6004756F — Air Power Dock Levelers — AB Series — Safe Frame March 2012 ©2012 4Front Engineered Solutions, Inc.
  • Page 31 PArTs LIsT — DocK LeVeLer, continued Model and Part number Item qty. Part Description Ab 600 Ab 800 Ab1000 Toe Guard, 2nd stage, left 586-1659 586-0440 586-1045 Toe Guard, 2nd stage, right 586-1660 586-0441 586-1044 Toe Guard, 2nd stage, left 586-1657 586-0438 586-1043...
  • Page 32 PArTs LIsT — DocK LeVeLer, continued Model and Part number Item qty. Part Description Ab 600 Ab 800 Ab1000 Rod Spacer 586-1999 586-1999 586-1999 Lip Latch Return Assy 6000708 6000708 6000708 SLK PIN 1/4x1-1/2 231-123 231-123 231-123 Chain – Lip Latch (36/44/45 links) 586-3077 6000825 6001018...
  • Page 33 6000613 6000613 6000613 Clevis Pin – 1/2" DIA x 2-3/4 lg 231-502 231-502 231-502 Compression Spring 333-069 333-069 333-069 Brand Identifier Label – Serco 921-185 921-185 921-185 ® Warning Leveler Info. Label 6008485 6008485 6008485 Trip Warning Label 138-837 138-837...

  • Page 34: Air Bag/ Pan Assembly

    PArTs LIsT — AIr bAg/PAn AsseMbLy Fig. 45 19 13 2 21 6004756F — Air Power Dock Levelers — AB Series — Safe Frame March 2012 ©2012 4Front Engineered Solutions, Inc.
  • Page 35 PArTs LIsT — AIr bAg/PAn AsseMbLy, continued Item quantity Description Ab 600, 800, 1000 Screw, Button Flg. hD 1/4-20 x 3/4" 131-483 LN 1/4-20 ESLOK 214-502 3/8-16 UNC "J" Nut Retainer 214-855 hhMB 3/8-16 x 1-1/4" 212-104 3/8 Flat Washer 234-101 3/8-16 Nylock Nut 214-538...

  • Page 36: Fan/Piping Assembly

    PArTs LIsT — fAn/PIPIng AsseMbLy Fig. 46 Item quantity Description Ab 600, 800, 1000 Motor, Air 2 Stage 120V 6008185 Filter housing 712-748 Filter, Fan 712-196 Nipple 155-578 Cord w/plug 712-027 housing, Fan 712-813 115V Control Station 908-753 6004756F — Air Power Dock Levelers — AB Series — Safe Frame March 2012 ©2012 4Front Engineered Solutions, Inc.

  • Page 37: Energy Guard

    10' Lower seal. 6008172 Aluminum strip 6' upper 6008174 Aluminum strip 8' upper 6008176 Aluminum strip 10' upper 6008178 6' Serco rear seal 6007674 6.5' Serco rear seal 6007675 7' Serco rear seal 6007676 Tech screws (not shown) 215702 Chain cup seal...
  • Page 38 noTes: 6004756F — Air Power Dock Levelers — AB Series — Safe Frame March 2012 ©2012 4Front Engineered Solutions, Inc.

  • Page 39: Warranty

    SERCO warrants that this DOCK LEVELER will be free from flaws in material and workmanship under normal use for a period of one (1) year from the earlier of 1) 60 days after the date of initial shipment by SERCO, or 2) the date of installation of the DOCK LEVELER by the original purchaser, provided that the owner maintains and operates the DOCK LEVELER in accordance with this User’s Manual.

  • Page 40: Distributor Information

    Please direct questions about your dock leveler to your local distributor or to 4Front Engineered Solutions, Inc. Corporate head Office: Your local Serco distributor is: ® 1612 hutton Dr. Suite 140 Carrollton, TX. 75006 Tel. (972) 466-0707 Fax (972) 323-2661 ©2012 4Front Engineered Solutions, Inc.

This manual is also suitable for:

Safetframe ab 800Safetframe ab 1000Safetframe ab 600

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