Poweramp AP SERIES User Manual

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AP Series

Dock Leveler

Owner’s/User’s Manual

POWERAMP • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022

800.643.5424 • fax: 262.257.7399 • www.docksystemsinc.com • techservices@docksystemsinc.com

Manual No. 4111-0009

Aug 2012

Jan 2013

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 .............................................................................. 7

Dock Leveler Stock Specifications ..................................................... 7

Component Identification ..................................................................... 8

Theory ................................................................................................... 8

Installation

Prepare Pit ............................................................................................. 9

Prepare Dock Leveler .......................................................................... 10

Install Dock Leveler ............................................................................. 11

Install Control Panel and Wiring ........................................................ 16

Put New Leveler Into Service.............................................................. 17

Operation

Operating Instructions ........................................................................ 18

Ramp Loading/Unloading Instructions ........................................ 19

End Loading/Unloading Instructions ........................................... 20

Maintenance

Service Dock Leveler Safely ............................................................... 21

Periodic Maintenance .......................................................................... 22

Adjustments

Adjust Lip Latch and Lip Actuator Springs ...................................... 24

Adjust Lip Stop .................................................................................... 26

Troubleshooting

Troubleshooting ................................................................................... 28

Parts

Electrical ............................................................................................... 30

Control Box .......................................................................................... 31

Below Dock Control ............................................................................. 33

Pit Extension Kit .................................................................................. 34

Airbag and Support Pallet ................................................................... 35

Frame and Platform ............................................................................. 36

Lip Activation ....................................................................................... 38

Weather Seal, ...................................................................................... 39

Motor and Blower Assembly ............................................................. 40

Miscellaneous

Customer Information ......................................................................... 41

Warranty ................................................................................ Back Cover

SAFETY

Recognize Safety Information

Safety - Alert Symbol

The Safety-Alert Symbol identifies import safety messages on equipment, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury of 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.

General Operational Safety Precautions

Read and understand the operating instructions 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.

The use of the word WARNING signifies presence of a serious hazard of unsafe practice which may result in personal injury or death.

The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury.

IMPORTANT

The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage.

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Do not start the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone.

Remove 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.

4111-0009 — Aug 2012 Jan 2013

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 carrier is entering or leaving area.

Do not move or use the dock leveling device if anyone is under or in front of it.

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

Chock/restrain all freight carriers. Never remove the wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away.

Do not use a broken or damage dock leveling device. Make sure proper service and maintenance procedures have been performed before using.

Make sure lip overlaps onto trailer at least 4 in. (102 mm).

Keep a safe distance from both side edges.

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Jan 2013

Do not use dock leveling device if freight carrier is too high or too low.

SAFETY

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.

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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 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 NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded

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.

DO NOT grind or weld if un contained 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.

The maintenance prop must be in the upright “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 device.

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Safety Decal’s

Every 90 days (quarterly) inspect all safety labels and tags to ensure they are on the dock le veler and are easily legible. If any are missing or require replacement, please call 1-800-643-5424 for replacements.

1751-0727

(decal placed on

front header)

SAFETY

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 death or serious injury. Refer to owner’s/user’s manual for proper use.

1751-0727 Rev A

1751-0730 (x2)

SAFETY INFORMATION

DANGER

Unsupported dock leveler ramps can lower unexpectedly.

Before allowing vehicle to leave the dock always:

! Ensure no equipment,

material or people are on dock leveler.

! Return dock leveler to its

Failure to follow posted instructions will result in death or serious injury.

stored position at dock level.

OPERATION 7. Stay clear of hinges and front and

1. Read and follow all instructions and sides of moving dock leveler. warnings in owner’s/user’s manual. 8. Ne ve r us e d am a ge d o r

2. Use of dock leveler restricted to malfunctioning dock leveler. Report trained operators problems immediately to supervisor.

3. Always chock trailer wheels or engage truck restraint before operating dock leveler or beginning to load or unload.

4. Never use hands or equipment to move ramp or lip

5. Before activating dock leveler: ¥ Ensure trailer is backed in against bumpers.

¥ Remove any end loads if required. ¥ Check trailer alignment to avoid lip

interference. If lip does not lower to trailer bed, reposition vehicle.

6. Ensure truck bed supports extended lip or leveler frame supports the ramp before driving on ramp.

Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.

(decal placed in same position on both sides)

1751-0329 (x2)

DO NOT

FORK THIS SIDE

(decal placed in same position on both sides)

1751-0330 (x2)

(decal placed in same position on both sides)

1751-0729

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.

1751-0731

1751-0726

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. Fail ure to comply will result in death or serious injury.

DANGER

CRUSH HAZARD

DO NOT ENTER PIT unless dock leveler is safely 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.

MAINTENANCE/SERVICE

1. Read and follow all instructions, warnings and maintenance schedules in the owner’s/user’s manual.

2. Maintenance/Service of dock leveler restricted to trained personnel.

3. Place barriers on the driveway and dock floor to indicate service work is being performed.

4. DO NOT ENTER PIT unless dock leveler is securely supported by maintenance prop.

5. If electrically powered turn off and use OSHA lockout/tagout procedures.

FORK HERE

1751-0729 Rev A

1751-0731

1751-0726 Rev A

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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. 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.

2. 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 support while in the working range of the equipment.

3. 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.

4. 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.

5. Manufacturer’s 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.

6. 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.

7. 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 modification and shall also satisfy all safety requirements of the manufacturer for the particular application of the leveling device.

8. 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 trailers with air-ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize trailer bed drop.

9. 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.

10. When selecting loading dock safety equipment, it is important to consider not only present requirements but also future plans and any possible adverse conditions, environmental factors or usage.

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INTRODUCTION

General Information

Congratulations on your choice of a Poweramp dock leveler. This manual covers the Air Bag, AP model air powered 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 revolutionary air bag system efficiently controls and operates every function. To obtain maximum performance and longest possible use, a simple program of preventive maintenance is recommended.

Dock Leveler Stock Specifications

AP-Series dock levelers are available in the following sizes, weight capacities, and options:

Width: AP

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 (3048 mm)

Capacity (CIR*)

25,000 lb (11 340 kg) 30,000 lb (13 608 kg) 35,000 lb (15 876 kg) 40,000 lb (18 144 kg) 45,000 lb (20 412 kg) 50,000 lb (22 680 kg)

* CIR (Comparative Industry Rating)

All docks are available in 115V motors only.

The AP dock leveler comes equipped with an electrical control panel, which allows push button operation of the dock leveler functions. Each AP dock leveler unit and control panel has been factory prewired and tested to ensure satisfactory operation.

To illustrate which connections are to be made in the field at installation, electrical drawings are included with each order or by contacting Poweramp Technical Services.

Once again, thank you and congratulations on your purchase of a Poweramp AP dock leveler.

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INTRODUCTION

Component Identification

G H

A — Lip B — Below Dock Control C —Lip Linkage Assembly D — Lip Latch Assembly

E — Lip Maintenance Prop Pivot F — Lip Snubber Spring G — Lip Actuator Chain H — Lip Actuator Chain Adjustment Link

THEORY

The AP dock leveler uses a blower motor and one-button operation for ease of use.

The dock leveler can be operated remotely using the RAISE button (P) on the control panel . This activates an electric blower motor (N). The blower forces air into the air bag (K), causing the platform to rise. Releasing the RAISE button allows the platform to lower.

When the platform rises to the point where there is 2 — 3 in. (51 — 76. mm) from 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. The lip assist spring (not shown) also helps keep the lip extended. 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.

I — Air Bag Support Pallet J — Lip Keepers (2 used) K — Air Bag L — Main Frame

M — Maintenance Prop N —Blower Motor O —Toe Guard (2 used) P —Raise Button Q —Safety Legs

To lower the platform, release the Raise button (P). The platform will lower until the extended lip rests on

the truck bed. If the lip did not fully extend or there is no truck at the dock the platform will lower until one of the following conditions occur:

-- Lip is resting on 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.

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Prepare Pit

INSTALLATION

A—Distance (Pit Width)

(Front and Rear)

10”

B— Distance (Dock Floor-to-Pit

Floor) (All Four Corners)

14”

Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before installation has been completed.

Failure to follow the installation instructions can result in damage to dock leveler, the facilities, and/ or serious personal injury or death.

C— Distance (Pit Length) (Both Sides of Pit)

1. Before lowering the dock leveler into the pit, the following must be performed:

2. Remove all debris from the pit and sweep the pit clean.

3. 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:

D— Distance (Pit Corner- to-Corner) (Top, Bottom, and Both Sides)

Only trained installation professionals with the proper equipment should install this product.

IMPORTANT

DO NOT remove the shipping bands around the dock leveler lip until instructed to do so.

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• Measure pit width distance (A) at both front

and rear of pit.

• Measure dock floor-to-pit floor distance (B)

at all four corners.

• Measure pit length distance (C) at sides.

• Measure corner-to-corner (criss-cross) dis-

tance (D) at both sides. Take measurements at dock floor level and at pit floor level.

If any measurement is off by more than 1/8 in. (3.18 mm), contact Poweramp Technical Services before proceeding.

4. Make sure the field junction box for the dock leveler (E) is at the correct location per pit diagrams.

INSTALLATION

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 brackets (A) fastened to the platform side joists.

IMPORTANT

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.

IMPORTANT

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.

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.

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 truck) having the appropriate lifting capacity and reach.

4. Remove wood blocks that are attached to the leveler frame before putting the dock leveler into the pit.

5. Attach a temporary, switched, power supply to the blower before lowing leveler into pit. Keep power cables clear of frame members, shim locations and pinch points. DO NOT CONNECT POWER AT THIS TIME.

6. Remove 3 plastic ties that hold the bag and bag support skid to the underside of the leveler during shipping before lowering leveler into pit.

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INSTALLATION

Install Dock Leveler

Shim

Stacking Methods

A— Distance (Leveler Frame

Height)

B— Shim Locations (Under

Rear Vertical Supports)

C— Shim Location (Under

Lip Keepers)

D— Shim Locations (Under

Lip Keepers) E— Dock Floor F— Rear Pit Curb Angle G— String H— Rear Hinge Frame Angle J— Distance (Dock Floor-to-

Pit Floor)

K— Distance (Top of Shim

Stack-to-Dock Floor) L— Shim Stack M— Dock Leveler Frame N — Pyramid (Preferred) P— Stepped (Acceptable) Q— Offset (Not Acceptable) R — Straight (Not Acceptable) S— Removable Frame Section T— Shim Location Under Snubber Spring) U— Shim Location

(Maintenance Prop)

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INSTALLATION

NOTE: Poweramp dock levelers are designed with a nominal 1/2 in. (12.7 mm) shimming distance to allow for pit inconsistencies.

1. Determine height of shim stack (L) for each shim location (B) 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.

IMPORTANT

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.

4. For all AP models, put a 1/4 in. (6.6 mm) thick shim at locations (C and D).

NOTE: A 1/4 in. (6.6 mm) thick shim at locations (C and D) 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 (H) is tight against rear pit curb angle (F) 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.

2. Using the results obtained in step 1, create the individual shim stacks on the pit floor at locations (B). Build each shim stack (L) using the pyramid method (N) (preferred) or stepped method (P) 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 (Q) or straight method (R).

NOTE: To assist in obtaining an accurate measurement of distance (K), use a string (G) 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 (K) [top of shim stack (L) to dock floor]. Distance (K) must equal the dock leveler height (A).

7. For all AP models, add shims at front shim locations (C and D) so front of dock leveler will stay level with dock floor when leveler is resting fully on shims.

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INSTALLATION

A— Front of Dock Pit B— Dock Leveler Frame

3/8 in. (9.5 mm)

C— Side Pit Curb Angle D— Gap [3/4 in. (19 mm)

Minimum]

6 in. (152 mm)

8. With rear hinge frame angle (F) tight against rear pit curb angle (G), perform/check the following:

• Pry 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 leveler operation.

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.

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INSTALLATION

12. With the leveler square in the pit and flush with the surrounding dock, remove the banding on the lip of the leveler.

13. Connect the blower motor to the temporary power supply.

14. Slowly raise the platform. Check for binding as platform is being raised.

Two people are required to engage the maintenance prop: one person to operate the lifting device, the other person to engage the maintenance prop.

15. 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.

16. All AP models - Once leveler is flush, square and does not bind:

a. Install shims under maintenance prop (C)

where prop attaches to leveler frame. Make sure prop is solidly shimmed.

b. Using the leveler’s blower motor, 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.

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.

17. Disconnect power supply from motor.

18. Remove air bag and pallet support from the leveler by disconnecting air bag positioning rods from hooks on the underside of platform.(figure

1) and removing the band clamp from the motor coupler. (figure 2)

19. Remove or protect the blower motor from weld sparks and splatter.

20. 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.

figure 1

IMPORTANT

DO NOT weld before disconnecting all electrical components.

DO NOT weld before removing air bag, air bag support pallet and hoses from leveler.

Protect or remove the blower motor before welding. Failure to follow these instructions may result

damage to these components from stray sparks and weld splatter.

figure 2

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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.

INSTALLATION

IMPORTANT

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 13 shows a typical

weld pattern. The weld pattern will vary slightly depending on size of dock leveler.

21. All model levelers: Install shims at locations (B, p.11) using the pyramid or stepped shimming method. Make sure the platform is level from sideto-side as well as from front-to-back and flush with dock floor.

IMPORTANT

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

22. Weld front of dock leveler frame (B) to shims located under the keepers, then weld the shims to the front pit curb steel.

23. Finish weld all shims using a fillet weld.

• Weld all shims within each shim stack to each other, then weld the shim stack to the leveler frame.

• Weld the front leveler frame shim stacks to the front pit curb steel.

24. 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.

* For left/right orientation of dock leveler, see inside back cover of

this manual.

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INSTALLATION

Install Control Panel and Wiring

The electrical power must be OFF prior to electrical installation. For maximum protection, use an OSHA approved locking device to lock out all power sources. Only the person installing the equipment should have the key to unlock the power source.

Failure to follow these instructions may result in serious personal injury or death.

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 B— Control Panel D— Placard

(provided by others) C— Distance, 48 in. (14 630 mm)

1. 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 electrical disconnect panel (A) if not already installed.

3. Install and connect the control wiring.

4. Re-install the air bag, air bag support pallet and blower motor.

5. Connect the dock leveler power cable to the outlet in the pit junction box. Refer to the electrical drawings supplied with the dock leveler.

6. After all electrical connections in the pit have been made, raise the leveler, disengage the maintenance prop and allow the platform to lower

7. Install the Placard(s) (D), in close proximity to the control box and in plain sight.

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Put New Dock Leveler Into Service

INSTALLATION

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 Poweramp Technical Services for further instructions.

3. Install the dock bumpers as required.

4. Turn the main electrical power ON.

5. Raise the leveler platform fully by pushing and holding the RAISE button .

6. Release the RAISE button to lower the platform. As long as there is no truck present at the dock, the platform will lower to the full below-dock position as the lip folds.

NOTE: If a truck is present, the platform will lower until the lip rests on the truck/trailer bed. (See Operating Instructions in Operation section.)

7. When the platform lowers to the full below-dock position, the lip will fold. Push and hold the RAISE button until the platform rises just enough to clear the lip keepers, then release the RAISE button to allow the platform to lower to the cross-traffic (stored) position (lip engages lip keepers).

8. 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.

9. Raise the platform fully. Hold the platform at this position using the RAISE button and move the maintenance prop to the service (upright) position. Release the RAISE button to allow the platform to lower until it is resting on the maintenance prop.

Always stand clear of platform lip when working in front of the dock leveler. Serious personal injury or death may result.

10. With the maintenance prop supporting the platform, remove the lifting brackets

11. Support the toe guards, remove the cotter pin used in shipping and carefully release the toe guards.

12. Push and hold the RAISE button until the maintenance prop drops to its stored position. Release the RAISE button and allow the platform to lower fully. Check operation of toe-guards.

13. When the platform lowers to the full below-dock position, the lip will fold. Push and hold the RAISE button until the platform rises just enough to clear the lip keepers, then release the RAISE button to allow the platform to lower to the cross-traffic (stored) position (lip engages lip keepers).

4111-0009 — Aug 2012 Jan 2013

OPERATION

Operating Instructions

Stay clear of dock leveler when freight carrier is entering or leaving dock area.

DO NOT move or use the dock leveler if anyone is under or in front of leveler.

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

Failure to follow these instructions may result in severe personal injury or death.

Only trained personnel should operate 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.

Truck/trailer wheels must be chocked unless the truck restraint is used. Never remove the wheel chocks until loading/unloading is finished and truck driver has been given permission to leave.

12in. (305mm)

The AP hydraulic dock leveler is designed to compensate for a maximum ± 12 in.* (305 mm) of height difference between the loading dock and the truck bed. DO NOT use the dock leveler if the truck/ trailer bed is more than 12 in. (305 mm) higher or lower than the dock floor.

*service height may vary with design specifications DO NOT overload the dock leveler. DO NOT operate any equipment while under the

influence of alcohol or drugs. DO NOT leave equipment or material unattended on

the dock leveler. Failure to follow these instructions may result in

personal injury and/or damage to equipment.

Make sure platform lip rests on the truck/trailer bed with at least 4 in. (102 mm) of overlap.

Maintain a safe distance from side edges of leveler during the loading/unloading process.

Failure to follow these instructions may result in serious personal injury or death.

The dock leveler operating instructions are divided into the two methods of loading and unloading:

• For ramp loading and unloading, see Ramp Loading/Unloading Instructions on page 19.

• For end loading and unloading, see End Loading/ Unloading Instructions on page 20.

4111-0009 — Aug 2012

Jan 2013

OPERATION

Operating Instructions—Continued

Ramp Loading/Unloading Instructions

NOTE: If end unloading is required, see End Loading/

Unloading Instructions on page 20. For ramp loading or unloading, the AP dock

leveler can be operated by using the RAISE button on the control panel.

1. Check to make sure truck/trailer 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 truck/trailer wheels or use the truck restraint if available.

Below Dock Loading/Unloading Instructions

NOTE: If end unloading is required, see End Loading/ Unloading Instructions on page 20.

7. Check to make sure truck/trailer is positioned squarely against dock bumpers.

8. Instruct driver to remain at the dock until the loading or unloading process has been completed.

9. Chock the truck/trailer wheels or use truck restraint if present.

10. Raise the platform by pushing the raise button (A) to fully raise the leveler and extend the lip.

11. Walk out on the leveler, Pull and Hold the release ring (see picture below) until the platform lowers onto the trailer. Make sure there is a minimum of 4” of lip overlapping the trailer.

A-RAISE Button

4. Extend the platform lip onto truck/trailer as follows: a. Raise the platform by pushing and holding

RAISE button .

b. Hold the RAISE button until the lip is fully

extended, then release the RAISE button. The platform will lower until the lip is resting on the truck/trailer bed.

c. Make sure that the lip is fully extended and

supported on the truck/trailer along the entire width of the platform with at least 4 in. (102 mm) of lip contacting the truck bed.

5. Proceed with loading or unloading the truck/trailer.

6. If below dock loading is necessary, see steps 7-11. If not, proceed to step 12. Unloading Instructions on page 20.

Loading/Unloading Completed - Reset Leveler

A—RAISE Button

12. When loading or unloading is finished, raise the platform by pushing and holding RAISE button (A) .

13. Hold the RAISE button until the lip folds enough to clear the truck/trailer bed, then release the RAISE button. The lip will fold and the platform will return to the cross-traffic position.

14. Remove chocks from truck/trailer wheels or release the truck restraint if used.

15. Indicate to driver that truck may leave the dock.

4111-0009 — Aug 2012 Jan 2013

OPERATION

Operating Instructions—Continued

End Loading/Unloading Instructions

NOTE: If ramp loading is required, see Ramp Loading/

Unloading Instructions on page 19. 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.

2. Instruct driver to remain at the dock until the loading or unloading process has been completed.

3. Chock the truck/trailer wheels or use the truck restraint if available.

6. Push the Raise button to 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 (B) (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-dock service position. The platform will drift down to the full below-dock position.

End Loading/Unloading — Platform at Cross-Traffic Position.

4. If truck/trailer 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. If truck/trailer bed is below the dock floor level, perform steps 6 –12.

9. Proceed with loading or unloading.

NOTE: When end unloading is finished and access

to the rest of the truck/trailer is still required, the platform lip will need to be extended. See Ramp Loading/Unloading Instructions on page 19 for further instructions.

10. When the loading or unloading is finished, return the dock leveler platform to the cross-traffic (stored) position.

11. Push the Raise button (B) until the lip clears the lip keepers. Release Raise button, leveler will return to the stored or cross traffic position.

12. Remove chocks from truck/trailer wheels or release the truck restraint if used.

13. Indicate to the driver that the truck may leave the dock.

End Loading/Unloading — Platform at Below-Dock Position.

4111-0009 — Aug 2012

Jan 2013

Service Dock Leveler Safely

MAINTENANCE

A— Lip Maintenance Prop B —Tag Out Device C — Lock Out Device D —Lip Prop E.—3 Styles of Lock

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 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.

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 will fold down after the platform has rested on the maintenance prop. The Lip Prop may 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 an OSHA approved lockout/tagout device* (C).

Whenever servicing the dock leveler, lock the electrical power disconnect in the OFF position. Use only an OSHA approved lockout/tagout device* (B).

Only the person servicing the equipment should have the capability to remove the lockout/tagout devices. The Tag out devices* must inform that repairs are in process and clearly state who is responsible for the lockout condition.

4111-0009 — Aug 2012 Jan 2013

* Refer to OSHA regulation 1910.147.

MAINTENANCE

Periodic Maintenance

A— Lip Hinge Area B— Lip Maintenance Prop

Pivot

C— Lip Link Pivots D— Platform Hinge Area

E— Lip Assist Pin F— Lip Linkage Pivot

G — Safety leg linkage

pivots

Air Filter, service under rear of platformUnder platform service

4111-0009 — Aug 2012

Jan 2013

MAINTENANCE

Regular maintenance must be performed on a weekly and quarterly schedule.

FOLLOW ALL SAFETY PRECAUTIONS

Weekly Maintenance

• 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 full 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 bag. Build-up of foreign material in this area may damage air bag components, causing abnormal operation.

• Inspect air bag and seams for signs of wear or

damage.

Quarterly Maintenance

• Perform Weekly Service Items

• Lubricate the following areas with light weight machine oil:

(A)— 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 belowdock position and lip is folded)

(D)— Platform hinge area (apply oil to top of all

platform hinges when platform is at the full below-dock position)

(E)— Lip lifter and lift cylinder pin

NOTE: Apply grease to lip hinge grease fittings if

equipped.

• Lubricate the following areas with light-weight machine oil:

(B)— Lip maintenance prop pivot

IMPORTANT

Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler.

Before performing any maintenance under the dock leveler, lock the electrical power source in OFF position and lock the maintenance prop in the service position using an approved locking device. (See Service Dock Leveler Safely in this section.)

Failure to follow these instructions may result in serious personal injury or death.

(C)— Lip link pivots (F)— Lip Linkage assembly pivot (G)— Safety leg linkage pivots

• Lubricate the following areas with white lithium grease (if equipped with grease fittings):

(A)— Lip hinge area (inject grease into all the lip

hinge grease fittings)

(D)— Platform hinge area (inject grease into all the

platform hinge grease fittings)

(E)— Lip assist pin

4111-0009 — Aug 2012 Jan 2013

ADJUSTMENTS

Adjusting the Latch and Lip Actuator Spring Tension

Always stand clear of the dock leveler lip when working in front of the dock leveler.

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

Adjustment

C— Lip Linkage Assembly

B— Lip Actuator Spring

Adjustment

4111-0009 — Aug 2012

Jan 2013

ADJUSTMENTS

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 extended 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 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. To increase spring tension, turn nut (A) clockwise.

3. To decrease spring tension, turn nut (A) counterclockwise.

4. Tighten jam nut.

Recheck operation of platform and lip. Readjust lip

latch spring tension and lip assist spring tension until proper operation is obtained.

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 AP 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 bag 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 (B).

2. To increase spring tension, turn nut (B) clockwise.

3. To decrease spring tension, turn nut (B) counterclockwise.

4. Tighten jam nut.

Recheck operation of platform and lip. Readjust lift spring tension and lip assist spring tension until proper operation is obtained.

4111-0009 — Aug 2012 Jan 2013

ADJUSTMENTS

Adjust Lip Stop Bolt

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.

Failure to follow these instructions may result in serious personal injury or death.

Check that lip (E) is fully resting on the lip keepers (D) and at the lowest part of the keeper cradle. If lip is not resting properly in keepers, perform the following adjustment.

1. Fully raise platform and engage the maintenacne prop. Manually raise the lip and engage lip maintenance prop.

2. Loosen jam nut (B).

A— Platform Frame B— Jam Nut C— Stop Bolt

D — Lip Keeper E — Lip

4. Tighten jam nut.

5. Disengage lip maintenance prop.

6. Push RAISE button, dis engage maintenance prop, allow platform to lower to cross-traffic (stored) position.

7. Check lip position in both keepers. Repeat procedure if necessary.

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).

4111-0009 — Aug 2012

Jan 2013

NOTES

4111-0009 — Aug 2012 Jan 2013

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TROUBLESHOOTINGTROUBLESHOOTING

TROUBLESHOOTING

Before performing the detailed troubleshooting procedures, check the following items first:

• Check all fuses and circuit breakers. Replace any blown fuse(s) with a fuse of equal specification and reset cir.

Always stand clear of the dock leveler lip when working in front of the dock leveler.

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.

• Make sure the correct voltages are present at the proper locations inside the control panel(s).

Symptom Possible Cause Solution

Platform does not rise. Motor does not energize.

Platform does not rise. Motor hums, but does not run.

Platform does not rise. Motor energizes, but does not run.

Motor fuse blown. Reset circuit panel or disconnect fuse. Determine

cause of overload.

Motor failure Check voltage to motor.

• If voltage is present and motor does not energize, replace motor.

• If voltage is not present, check all components in series with the motor.

Incorrect voltage is present on line.

Line voltage too low. • Check wiring to motor for high resistance.

Check line for proper voltage

• If proper voltage is not present, check all components in series with the motor.

• If proper voltage is present and motor does not run, check for obstructions.

• If no obstructions are found, replace motor.

• Check for loose or corroded connections.

• Check if gauge of wires to motor are of correct size and specification for load requirement. Replace if necessary.

4111-0009 — Aug 2012

Jan 2013

Symptom Possible Cause Solution

Platform rises slowly Air bladder or connecting

ducts punctured

TROUBLESHOOTING

Check air bladder and ducting replace as needed

Platform does not rise to full height.

Platform DOES rise to full height, but lip DOES NOT extend or extend fully.

Lip extends but does not remain extended as leveler drops.

Damaged or restricted ducting

Air intake clogged Remove intake filter, clean or replace as needed

Dock leveler binding Check for visible obstructions that could cause

See Platform Rises Slowly See Platform Rises Slowly

Lip actuator spring needs additional tension.

Lip latch spring needs additional tension.

Air bladder damaged

Replace damaged ducting or remove restriction

binding. Remove obstructions. If no obstructions found, call Poweramp Technical Services. See inside back cover for phone number and address.

See Periodic Maintenance in the Maintenance section.

Inspect lip actuator chain, repair or replace as needed.

See Adjustment Section: Lip Latch Spring.

• Increase tension as needed to keep latch engaged.

• Clean any debris from lip latch area.

• Lubricate as instructed in maintenance section.

• Replace air bladder

4111-0009 — Aug 2012 Jan 2013

Electrical

Controls

4111-0009 — Aug 2012

Jan 2013

Control Box

4-1/2

11.8FLA Amp Draw

Item Quantity Part Number Description

2-7/8

A 1 7141-0207 Push Button Controller, 9-RO-800-A-A B 1 1751-0474 Decal (English) C 1 1751-0477 Decal (English) D 1 1751-0736 Decal Arc Flash E 1 1751-0876 Placard,AP

4111-0009 — Aug 2012 Jan 2013

PARTS (BEFORE JAN 2012)

Lip Activation

A B

Item Quantity Part Number Description

B 2 DOTH-2404 C 1 DOTH-2076 D 1 DOTH-2160

1 9514-0107 Lip Latch Assy.( bolts on to DPLA-2130) 1 DPLA-2130 Lip Assist Rod Complete 34” LG. (Includes Items A-D)

Bearing

Bolt, 5/8-11 unc x 3-1/2”

Nut,Nylon

E 1 DOTH-2546 Spring, Lip assist

F 2 DOTH-2225 Washer G 1 DPLA-2126 Lip Banger H 2 DOTH-2061 Bolt, Shoulder 1/2” x 1-1/2Lg”

I 3 DOTH-2131 Nut, Nlyon lock 3/8”

J 1 5775-0004 Lip latch Assembly K 1 0941-0013 Lip Latch Rod Spring L 1 DOTH-2555 Spring,Snubber

M 1 DPLA-2128 Chain, Snuber Spring O 3 2101-0217 Quick Link

P 1 2101-0216 Quick Link

Q 1 DOTH-2421 Cold Shut R 3 DOTH-2214 Washer

S 1 DOTH-2547 Spring, Lip Maintenance T 1 DOTP-2006 Prop, Lip Maintenance

U 2 DOTH-2062 Bolt, Shoulder

V 1 DOTH-2351 Bolt,Clevis

W 1 DOTH-2163 Nut, Locking 1/2”

X 1 DOTH-2210 Washer Y 1 DOTH-2374 Cotter Pin

4111-0009 — Aug 2012

Jan 2013

Below Dock Control

PARTS

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

C 1 DOTH-6231 Spring, Leg (Included with the Safety Leg) D 1 DPLA-2122 Pull Bar Assembly, Safety Leg E 1 DOTH-2075 Cap Screw, Lip Stop 5/8-11 UNC F 1 DOTH-2356 Nut,Hex 5/8-11 UNC

G 1 DOTP-6647 Rod, Push

H 1 DOTH-2356 Pin, Clevis

I 1 DOTH-2374 Cotter Pin

J 1 7953-0131 Safety Chain kit 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

4111-0009 — Aug 2012 Jan 2013

PARTS

Pit Extension Kit

Item Quantity Part Number Description

1 1 8436-0035 4 inch Pit Extension Kit, For all size levelers

4111-0009 — Aug 2012

Jan 2013

Airbag and Support Pallet

PARTS

Item Quantity Part Number Description

1 3 5812-0045 Hold Down Rod, 45” long x 7/16” diameter 2 1 5811-0009 Air Bag Bladder 3 1 5811-0012 Skid, Air Bag Leveler 4 2 5813-0001 Skid BRKT, Air Bag Leveler, BM 5 4 2101-0098 Screw, HHCS, 5/16-18UNC x 1-1/2 long 6 4 2101-0214 Nut, Flange, Top L/N, 5/16 - 18UNC 7 4 2101-0058 Washer, Lock 5/16 8 6 2101-0224 Rod Clamps 9 4 2101-0079 Washers Flat 1/2 inch

10 2 2101-0230 Ring, Split 1.-3/4 od

3-7 1 5814-0029 Skid, Air Bag Leveler Assembly, Includes Items 3-7

4111-0009 — Aug 2012 Jan 2013

PARTS

Frame and Platform FROM Jan 2012

E GF

4111-0009 — Aug 2012

Jan 2013

Frame and Platform

Item Quantity Part Number Description

A 1 See Table A Lip, Welded Assembly B 1 7823-____

9202-0050 Pin, Lip Hinge 6’W

9202-0051 Pin, Lip Hinge 6.5W 9202-0052 Pin, Lip Hinge 7W DKIT-9179 Toe Guard Assembly 6 Foot (Both Sides and Hardware)

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 0015-____

I 3 9202-0002 Rear Hinge Pin

J 6 2101-0047 Cotter Pin, 1/4 x 2 in.

9224-0030 Maintenance Prop “39.50 K1

9224-0031 Maintenance Prop “43.50

9224-0079 Maintenance Prop “39.50 L 1 9201-0009 Prop Pin & Clip

M 1 1751-0010 Decal, Model / Serial ID

N 2 2101-0046 Cotter Pin, 1/4 x 1-1/4 in.

Platform, Welded Assembly

Frame,

PARTS

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.

LIPS (Table A) from JAN 2012

6.0 FOOT 20K 25/30K 35K 40K 45K 50K 116 0595-1500 0595-1503 0595-1506 0595-1509 0595-1512 0595-1515 118 0595-1501 0595-1504 0595-1507 0595-1510 0595-1513 0595-1516 120 0595-1502 0595-1505 0595-1508 0595-1511 0595-1514 0595-1517

6.5 FOOT 116 0595-1518 0595-1521 0595-1524 0595-1527 0595-1530 0595-1533 118 0595-1519 0595-1522 0595-1525 0595-1528 0595-1531 0595-1534 120 0595-1520 0595-1523 0595-1526 0595-1529 0595-1532 0595-1535

7.0 FOOT 116 0595-1536 0595-1539 0595-1542 0595-1545 0595-1548 0595-1551 11 120 0595-1538 0595-1541 0595-1544 0595-1547 0595-1550 0595-1553

8 0595-1537 0595-1540 0595-1543 0595-1546 0595-1549 0595-1552

4111-0009 — Aug 2012 Jan 2013

PARTS

Lip Activation JAN 2012

Item Quantity Part Number Description

A 1 DLIP-0305 Lip Assist Rod Complete 34” LG. B1

DOTH-2550 Spring, Lip Assist STD

DOTH-2546 Spring,Lip Assist Heavy Duty C 1 5775-0004 Lip latch Assembly D 1 DOTH-2351 Bolt,Clevis E 1 DOTH-2163 Nut, Locking 1/2” F 1 DOTH-2210 Washer

G 1 DOTH-2374 Cotter Pin H 1 DPLA-0338 Lip Assist Linkage

I 1 DPLA-0340 Bar, Lip Linkage

J 1 DOTH-2131 Nut, Nlyon Lock 3/8

K 1 DOTH-2547 Spring, Lip Prop

L 3 DOTH-2214 Washer

M 1 DOTH-2062 Bolt, Shoulder

N 1 DOTP-2005 Prop, Lip O 1 2101-0217 Quick Link P 1 DPLA-2128 Chain, Snubber Q 1 DOTH-2555 Spring, Snubber ( not shown) R 1 0941-0013 Spring, Lip Latch

4111-0009 — Aug 2012

Jan 2013

Weather Seal

PARTS

Item Quantity Part Number Description

1 0195-0018 Brush Seal and Track, 1 in (25mm)

1 0195-0021 Brush Seal and Track, 1 in. (25 mm) 1 0195-0024 Brush Seal and Track, 1 in. (25 mm) 1 0195-0027 Brush Seal and Track, 1 in. (25 mm) 1 0195-0030 Rubber Seal and Track, 1 in. (25 mm)

1 0195-0033 Rubber Seal and Track, 1 in. (25 mm) 1 0195-0036 Rubber Seal and Track, 1 in. (25mm) 1 0195-0039 Rubber Seal and Track, 1 in. (25mm)

C 1 0195-0044 Rear Brush Seal

Item Quantity Part Number Description

A 1 DOTH-2808 Foam Seal, Rear Hinge 84 inch long

Provide dock leveler serial number and size of platform when calling or faxing orders.

*Provide width of weatherstrip when replacing existing seals

4111-0009 — Aug 2012 Jan 2013

PARTS

Motor and Blower Assembly

Item Quantity Part Number Description

9395-0359 PPAC,Blower Assy, Includes 1-4,7,8,10-14 1 1 Fan / Motor, 115VAC, AP Series Levelers 2 1 Shroud, Fan End 3 1 Shroud, Motor End 4 1 9391-0021 Filter Element

61 7 1 Cord Set, 115V, 3 Conductor, 6’ (1828.8mm) long

8 1 Cord Grip 9 4 9391-0023 Clamp, Tube

10 3 Screw, Cap, Socket Head, 1/4-2 X 1-1/2 11 5 2101-0143 Nut, Hex, Nylon Locking, 1/4-2 12 2 2101-0007 Screw, Cap, Hex, 1/4-2 X 1 LG 13 8 2101-0005 Washer, Flat 1/4” 14 1 Adaptor, Hose, 1-1/2 to 1-1/4

9391-0022 Tube, 2” (50.8mm) OD, 36” (914.4mm) Length 6’ and 8’ Levelers 9391-0041 Tube, 2” (50.8mm) OD, 46” (914.4mm) Length 10’ levelers 9392-0047 Pipe, PVC, 1-1/2” SCH40 X 24” (38.1 X 609.6mm) 9392-0068 Pipe, PVC, 1-1/2” SCH40 X 24” (38.1 X 609.6mm) With 90Deg Elbow

4111-0009 — Aug 2012

Jan 2013

Customer Information

NOTE: Refer to illustration for left/right orientation of

dock leveler.

MISCELLANEOUS

The model/serial number decal (A) is located

on the right platform joist near the front (lip) of dock leveler.

When you receive your AP-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@docksystemsinc.com

Dock Leveler Information

Model ___________________________________

Serial No. ________________________________

Systems, Inc., Job No. ______________________

Original Owner Information

Name ___________________________________

Address _________________________________

________________________________

Installer Information

Name ___________________________________

Address _________________________________

_________________________________

Date of Installation ________________________

4111-0009 — Aug 2012 Jan 2013

STANDARD PRODUCT WARRANTY

SYSTEMS, INC. warrants that its products will be free from defects in design, materials and workmanship for a period of 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 manufacturer’s 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 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

“AP” SERIES LEVELER

In addition to the “Standard Product Warranty” provided with all Poweramp® Products, 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. 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 Poweramp sole discretion and expense including reasonable labor, materials, freight and travel. If Poweramp determines replacement is necessary, it will provide the original purchaser with a credit toward the purchase of the new replacement Poweramp. 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.

• 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 warranty specifically covers material and freight only and applies to; the air bladder, seals, hoses and motor assembly.

Poweramp AP SERIES User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual