Poweramp CM SERIES MECHANICAL User Manual

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Page 1

CM-Series

Dock Leveler

Owner’s Manual

Manual No. 4111-0006

July 2003

Rev. July 2006

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

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Page

Safety

Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 1

Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Maintenance Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

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

Installation

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

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

Install Dock Leveler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Operation

Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

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

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

Maintenance

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

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

Adjustments

Adjust Lift Arm Spring and Lip Assist Spring Tension . . . . . . . . . . 24

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

Troubleshooting

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Parts

Hold-Down Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Frame Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Platform Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Toe Guard/Weather Seal—Optional . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Miscellaneous

Customer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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

Table of Contents

4111-0006 — July 2005

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SAFETY

4111-0006 — July 2006

Recognize Safety Information

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 decals on the equipment unless replacing them.

General Operational Safety Precautions

DO NOT activate 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.

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.

Safety-Alert Symbol

The Safety-Alert Symbol identifies impor tant 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 the instructions in the safety message.

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

IMPORTANT

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

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

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SAFETY

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Learn the safe way to operate this equipment. Read and understand the manufacturer's instructions. If you have any questions, ask your supervisor.

Operational Safety Precautions

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 damaged 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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SAFETY

4111-0006 — July 2006

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.

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SAFETY

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Maintenance Safety Precautions

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.

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.

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.

The platform maintenance prop must be in the service (upright) 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

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Safety Decal on Leveler Frame

Safety Decal on Hold-Down Mechanism

Safety Decals

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SAFETY

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This page intentionally left blank

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INTRODUCTION

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General Information

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

Width

6 ft (1828.8 mm) 6-1/2 ft (1981.2 mm) 7 ft (2133.6 mm)

Length

5 ft (1424 mm) 6 ft (1828.8 mm) 8 ft (2438 mm) 10 ft (3048 mm)

Capacity (CIR*)

20,000 lb (9072 kg) 25,000 lb (11 340 kg) 30,000 lb (13 608 kg)

* CIR (Comparative Industry Rating)

Call Poweramp for your specific needs.

Dock Leveler Stock Specifications

Congratulations on your choice of a Poweramp dock leveler. This manual covers the CM-series mechanical dock leveler.

Designed by Poweramp to be a marvel of simplicity and efficiency, your dock leveler, when proper ly installed, will provide many years of trouble-free performance with an absolute minimum of maintenance. To obtain maximum performance and longest possible use, a simple program of preventive maintenance is recommended.

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

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INTRODUCTION

4111-0006 — July 2006

Component Identification

A — Lip B — Lip Maintenance Prop C — Platform D — Lip Link E — Lip Assist Spring

F — Platform Release Ring G — Ratchet Pawl H — Ratchet Bar J — Pawl Spring K — Main Frame

L — Platform Maintenance Prop M— Hold-Down Mechanism N — Safety Leg (2 used) P — Lip (Snubber) Spring Q — Lip Shock Absorber

R— Safety Leg Linkage S — Safety Leg Release Ring T — Lift Arm Assembly U — Lift (Main) Spring

Assembly

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INSTALLATION

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Prepare Pit

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

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

2. 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:

• 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 both sides.

• Measure cor ner-to-cor ner (criss-cross) distance (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.

A— Distance (Pit Width)

(Front and Rear)

B — Distance (Dock Floor-to-Pit

Floor) (All Four Corners)

C — Distance (Pit Length)

(Both Sides of Pit)

D — Distance (Pit Corner-to-Corner)

(Top, Bottom, and Both Sides)

IMPORTANT

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

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.

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

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INSTALLATION

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Poweramp dock levelers are designed with installation in mind. Each unit is shipped with lifting brackets (A) fastened to the platform side joists.

Prepare Dock Leveler

A— Lifting Bracket (2 used) B — Shipping Bands

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 the dock leveler and/or serious personal injury or death.

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.

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INSTALLATION

4111-0006 — July 2006

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.

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.

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.

IMPORTANT

DO NOT over-tighten the lifting bracket hardware.

Over-tightening can damage the weather seal, if equipped.

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INSTALLATION

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A— Distance (Leveler Frame

Height)

B— Shim Locations (Under

Rear Vertical Supports)

C— Shim Locations (Under

Lip Keepers and Prop) D— Dock Floor E— Rear Pit Curb Angle

F— String G— Rear Hinge Frame Angle H— Distance (Dock Floor-to-

Pit Floor)

J— Distance (Top of Shim

Stack-to-Dock Floor) K— Shim Stack L— Dock Leveler Frame M — Pyramid (Preferred) N— Stepped (Acceptable) P— Offset (Not Acceptable) Q — Straight (Not Acceptable)

Install Dock Leveler

Shim

Stacking Methods

EDF

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INSTALLATION

4111-0006 — July 2006

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 (K) for each shim location (B) by performing the following:

a. Measure leveler frame height distance (A). b. Measure dock floor-to-pit floor distance (H) at

each shim location (B). Wr ite down the dimensions obtained at each location.

c. Subtract distance (A) from distance (H) to

obtain the shim height. Repeat for each shim location.

5. Using an appropriate lifting device connected to the lifting brackets, lower dock leveler into the pit so rear hinge frame angle (G) is tight against rear pit curb angle (E) 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.

7. Add shims at front shim locations (C) so front of dock leveler will stay level with dock floor when leveler is resting fully on shims.

4. Put a 1/4 in. (6.6 mm) thick shim at locations (C) (under lip keepers/maintenance prop and safety legs). Make sure shims are larger than frame angle iron so pyramid or stepped stacking method can be used.

NOTE: A 1/4 in. (6.6 mm) thick shim at locations (C)

is used only as a starting point. The final shim stack height will be determined after the dock leveler is lowered into the pit.

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

NOTE: To assist in obtaining an accurate

measurement of distance (J), use a string (F) 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 (J) [top of shim stack (K) to dock floor]. Distance (J) must equal the dock leveler height (A).

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 frame rail and to provide a shelf for a fillet weld.

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.

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.

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INSTALLATION

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A— Front of Dock Pit B— Dock Leveler Frame

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

Minimum]

E— Pry Locations F— Rear Hinge Frame Angle

G— Rear Pit Curb Angle H— Flare Bevel Weld, Typical

(To Fit Spacing)

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

• Pr y 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.

9. If gap (D) cannot be obtained equally at both sides of leveler, grind or add mater ial at the rear edge of rear hinge frame angle (F) as needed.

10. Allow the dock leveler to rest fully on the shim stacks. Make sure the leveler is in the crosstraffic (stored) position with lip resting on lip keepers.

11. 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.

12. If leveler cannot be squared and made level as instructed in steps 8 – 10, contact Poweramp Technical Services.

6in. (152 mm)

3/8 in.

(9.5 mm)

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INSTALLATION

4111-0006 — July 2006

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

17. Pull and hold the release ring (located in recess at rear of platform) until the platform is fully raised. Check for binding as platform rises.

18. Slowly walk out onto the platform to lower the platform. Allow the platform to lower to the cross-traffic position. Check for binding as platform lowers.

19. If binding occurs, reposition leveler and/or add or remove shims as necessary. Raise and lower platform again. If platfor m still binds, contact Poweramp Technical Services for further instructions.

20. Check that the leveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly.

NOTE: The illustration on the previous page shows a

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

13. With the rear hinge frame angle (F) tight against the rear pit 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.

Alternate welding locations to distribute heat. Welding sequentially from one end to the other may cause warping or distortion.

15. With the leveler welded in place remove the shipping bands from around the lip and frame.

16. Disconnect lifting device and chains from the lifting brackets.

Make sure all personnel are outside of the leveler operating zone and stand clear of the platform lip before removing the shipping bands. Failure to do this may result in serious personal injury or death.

IMPORTANT

When activating the leveler, always pull AND hold the platform release ring until the platform is at the full-raised position. Releasing the ring while the platform is still rising may result in damage to the equipment.

IMPORTANT

Always ground welding equipment to the dock leveler frame, NEVER to the platform.

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 not to function correctly and shortening the lifespan of the affected components.

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

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.

Make sure all personnel are outside of the leveler operating zone and clear of the platform lip before activating the leveler. Failure to do this may result in serious personal injury or death.

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INSTALLATION

4111-0006 — July 2006

21. Pull the release ring to raise platform. Engage the platform maintenance prop (B) in the service (upright) position and lock the maintenance prop at this position using an OSHA approved locking device (D). Engage lip maintenance prop.

A— Safety Leg Chain Pull Ring B— Platform Maintenance Prop C — Shim Location (Under Lift Arm Pivot) D — Locking Device

25. Remove the lifting brackets from the platform side joists.

26. Disengage the platform maintenance prop.

27. Slowly walk out onto the platform to lower the platform until it is at the cross-traffic (stored) position.

28. Check operation of dock leveler by cycling the leveler at least four times.

• When the platform is at full height, lip will be

fully extended.

• Lip will begin to drop after full height is

reached, taking approximately 12 seconds to fully fold.

29. Check below-dock position by walking platform down before lip folds completely.

• Lip will be over lip keepers.

• Platform safety legs will be resting on frame.

30. Check full below-dock position by walking the platform down. Pull and hold safety leg chain (A) before lip folds completely.

31. If the lip does not extend fully or lip folds too quickly, see appropriate symptom in the Troubleshooting section.

32. Install the dock bumpers as required.

22. Install shims under lift ar m at locations (C) using the pyramid shimming method. The lift arm pivot must be solidly shimmed the entire length of the lift arm pivot. Make sure the lift arm pivot is level from side-to-side.

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 if not done previously.

24. When all welding has been completed, remove all slag then 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.

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OPERATION

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Theory

The CM-series mechanical dock leveler uses large lift springs (U) to apply force to lift arm (T). The lift ar m pushes against the underside of the platform (C), rolling on the cam (not pictured) forcing the platform to rise. The force of the spring tension is just enough to lift the weight of the platform.

The ratchet pawl disengages only when the platform release ring (F) is pulled AND held. Spring tension from pawl spring (J) causes the ratchet pawl to engage the ratchet bar when the release ring is let go.

When the platform rises to approximately 2 – 3 inches (51 – 76 mm) from its full raised height, the lip spring (P) and a chain pulls the lip link (D) forward. This, in conjunction with the lip assist spring (E), causes the lip linkage to push the lip out and up. The lip assist spring also helps control the amount of time required for the lip to fully fold.

To lower the platform, the operator walks out onto the platform. 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).

• Lip did not fully fold causing the platform to rest on safety legs (below-dock position).

• Lip did not fully fold and safety legs are retracted, causing the platform to rest on the safety stops (full below-dock position).

The hold-down ratchet assembly will keep the platform at the desired position until the platform release ring is pulled again.

To actuate the dock leveler platform, the operator pulls and holds the platform release ring (F) located in the recess at the rear of the platform. This causes ratchet pawl (G) to disengage from ratchet bar (H). With the ratchet pawl disengaged, spring tension from lift springs (U) forces the platform to rise.

NOTE: Ratchet pawl (G) and bar (H) are par t of the

hold-down mechanism (M)

A — Lip B — Lip Maintenance Prop C — Platform D — Lip Link E — Lip Assist Spring

F — Platform Release Ring G— Ratchet Pawl H — Ratchet Bar

J — Pawl Spring

K — Main Frame

L — Platform Maintenance Prop M— Hold-Down Mechanism N — Safety Leg (2 used) P — Lip Spring

Q — Shock Absorber R — Safety Leg Linkage S — Safety Leg Retract Pull Ring T — Lift Arm U — Lift Springs

IMPORTANT

When activating the leveler, always pull AND hold the platform release ring until the platform is at the full raised position. Releasing the ring while the platform is still rising may result in damage to the equipment.

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OPERATION

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Operating Instructions

The dock leveler operation 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.

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.

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.

The CM-series mechanical dock leveler is designed to compensate for ± 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.

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.

DO NOT activate the dock leveler until the truck/trailer is positioned squarely against the bumpers and the truck wheels are chocked.

Never remove the wheel chocks until loading and unloading is finished and truck driver has been given permission to leave.

DO NOT use the dock leveler if the freight carrier is too high or too low.

NEVER use a fork truck or any other material handling equipment to lower the dock leveler.

DO NOT drive any equipment onto the dock leveler until platform lip is resting on the truck/trailer with at least 4 in. (102 mm) of overlap.

Always maintain a safe distance from side edges of leveler during the loading and unloading process.

NEVER attempt to walk on an unsupported lip. NEVER allow untrained personnel to operate the

dock leveler. NEVER attempt to lift any part of the leveler by

hand. Failure to follow these instructions may result in

serious personal injury or death.

IMPORTANT

12 in. (305 mm)

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OPERATION

4111-0006 — July 2006

NOTE: If end unloading is required, see End

Loading/Unloading Instructions on page 20.

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 truck restraint if present.

Ramp Loading/Unloading Instructions

4. Raise the platform by pulling and holding the platform release ring (A).

5. Hold the release ring until the platform is at the fully-raised position and lip is fully extended.

9. When the loading or unloading process has been completed, return platform to cross-traffic (stored) position as follows:

a. Raise the platform to the full-raised position by

pulling and holding the platform release ring (A).

b. Lower platform by slowly walking out onto the

platform allowing time for the lip to fully fold and clear the truck/trailer. Continue walking out on platform until platform lowers to the cross-traffic position (lip engages in the lip keepers).

10. Remove chocks from truck/trailer wheels or

release truck restraint if used.

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

8. Proceed with loading or unloading.

NOTE: If end loading is necessar y, see End

Loading/Unloading Instructions on page 20.

6. Walk out onto the platform. The platform will lower until the lip rests on the truck/trailer bed.

NOTE: If the tr uck/trailer bed is below dock level, pull

and hold the safety leg retract pull ring (B) (located in a recess at front of the platform) until the platform lip is resting on the truck/trailer bed.

Operating Instructions — Continued

7. 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.

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OPERATION

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

End Loading/Unloading — Platform at Below-Dock 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. When finished, perform steps 9 and 10.

If truck/trailer bed is below the dock floor level, perform steps 5 – 10.

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.

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 truck restraint if present.

End Loading/Unloading Instructions

6. Slowly walk the platform down allowing enough time for the lip to fold. Just before the platform reaches the cross-traffic position, pull and hold the safety leg retract pull ring (B) (located in a recess at front of the platform). The platform will continue lowering to the full below dock position.

5. Pull and hold the platform release ring (A) until the platform is at the fully-raised position.

7. Proceed with loading or unloading.

NOTE: When end unloading is finished and

additional access to the truck/trailer requires that the platform lip be extended, see Ramp Loading/Unloading Instructions on page 19 for further instructions.

8. When loading or unloading is finished, raise the platform to the full-raised position by pulling and holding the platform release ring. Slowly walk the platform down, allowing enough time for the lip to fold. The platform will lower to the cross-traffic position (lip engages in the lip keepers).

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

10. Indicate to the driver that the truck may leave the

dock.

Operating Instructions — Continued

Page 23

MAINTENANCE

4111-0006 — July 2006

Service Dock Leveler Safely

Whenever maintenance is to be performed under the dock leveler platform, support the platform with the platform maintenance prop (B).

Put the platform maintenance prop in the service (upright) position so that the prop is cradled in the angle bracket (C). Lock the platform maintenance prop in this position by inserting the locking pin and attaching an OSHA approved lockout device* (D) and tagout device* (E).

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

If maintenance requires that the lip be in the extended position, raise the lip by hand and support the lip with the lip maintenance prop (A).

NOTE: Make sure to disengage the lip maintenance

prop and allow the lip to fold fully before disengaging the platform maintenance prop.

A— Lip Maintenance Prop B — Platform Maintenance Prop C — Angle Bracket D — Lockout Device E — Ta gout Device

* Refer to OSHA regulation 1910.147.

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.

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.

Page 24

MAINTENANCE

4111-0006 — July 2006

Periodic Maintenance

A — Lip Hinge Grease Fittings B — Lip Maintenance Prop Pivot C — Lip Link Pivots

D — Platform Hinge Area E — Lift Arm Roller Bushing F — E-Z Release Bellcrank Pivot

G — Lift Arm Pivot H — Hold-Down Pivot/Pulley

J — Safety Leg Linkage Pivots

K — Lip Lift Assist Pin L — Hold Down-to-Platform Pin

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.

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

•

Page 25

MAINTENANCE

4111-0006 — July 2006

Quarterly Maintenance

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

Weekly Maintenance

• Operate the dock leveler through the complete operating cycle to maintain lubrication.

NOTE: To thoroughly inspect the platform hinge area,

position 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 mater ial in the hinge areas will increase wear and cause abnormal operation.

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

(B)— Lip maintenance prop pivot (C)— Lip link pivots (F)— E-Z release bellcrank pivot (H)— Hold-down pivot/pulley (J)— Safety leg linkage pivots (L)— Hold down-to-platform pin

• Lubricate the following areas with white lithium grease:

(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)—Lift arm roller bushing (G)— Lift ar m pivot (K)— Lip assist pin

IMPORTANT

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

DO NOT lubricate the hold-down ratchet bar and pawl.

Page 26

ADJUSTMENTS

4111-0006 — July 2006

Adjust Lift Arm Spring and Lip Assist Spring Tension

A — Jam Nut B — Nut

C — Lip Assist Spring D — Lift Springs

E — Lift Spring Bolt F — Hold-Down Mechanism

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.

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

Page 27

ADJUSTMENTS

4111-0006 — July 2006

NOTE: Adjusting the tension of lift spr ings (D) usually

requires that the lip assist spring (C) also be adjusted.

If the platform does not rise fully and/or lip does not extend fully, the lift spring tension may be set too low.

If the platform cannot be walked down or is difficult to walk down, the lift spring tension may be set too high.

3. After lift spring adjustment is completed, check operation of the lip.

• If the lip folds before the platform can be walked down, tension of lip assist spring (C) may be set too low.

• If the lip does not fold fully or takes too long to fold, tension of lip assist spring (C) may be set too high.

4. Adjust lip assist spring tension as follows:

NOTE: Use two-tur n increments when adjusting lip

assist spring (C). Check lip operation after each adjustment. Repeat until proper operation is obtained.

a. Loosen jam nut (A). b. To increase spring tension, turn nut (B)

clockwise.

c. To decrease spring tension, turn nut (B)

counterclockwise.

d. Tighten jam nut.

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

1. Raise the platform and engage the platform maintenance prop. Lock the maintenance prop in the service position using an appropriate locking device.

2. Adjust tension of lift springs (D) as follows:

NOTE: Use 1/2 tur n increments when adjusting lift

spring bolt (E). Check platfor m operation after each adjustment. Repeat until proper operation is obtained.

• To increase lift spring tension, turn lift spring bolt (E) clockwise.

• To decrease lift spring tension, turn lift spring bolt (E) counterclockwise.

If the platform does not rise fully on its own, it may be necessary to use an external lifting device. Use a lifting device with the appropriate lifting capacity to safely raise the platform. Make sure to engage and lock the platform maintenance prop after raising the platform. Failure to do this may result in serious personal injury or death.

IMPORTANT

When using an external lifting device to raise the platform, make sure hold-down mechanism (F) is disengaged. Pull and hold platfor m release r ing during the lifting process to avoid shearing the ratchet pawl and ratchet bar teeth.

Page 28

ADJUSTMENTS

4111-0006 — July 2006

Adjust Lip Stop Bolt

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. Manually raise the lip and engage lip maintenance prop.

2. Loosen jam nut (B).

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).

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

D — Lip Keeper E — Lip

4. Tighten jam nut.

5. Disengage lip maintenance prop.

6. Walk platform down to cross-traffic (stored) position.

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

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.

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

Page 29

TROUBLESHOOTING

4111-0006 — July 2006

Symptom Possible Cause Solution

Platform does not rise. Heavy object(s) on platform. Remove object(s) from platform.

NOTE: For safety reasons, the dock leveler is

designed to lift only the platform’s own weight.

Disconnected or broken release cable.

Connect or replace cable.

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 does not rise to the full raised position.

Heavy object(s) on platform. Remove object(s) from platform.

NOTE: For safety reasons, the dock leveler is

designed to lift only the platform’s own weight.

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.

Insufficient main spring tension.

Increase tension on main springs. (See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section.)

Damaged or worn hold-down mechanism.

Clean and inspect hold-down mechanism.

Troubleshooting

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.

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

Page 30

TROUBLESHOOTING

4111-0006 — July 2006

Symptom Possible Cause Solution

Platform rises to full height, but lip does not fully extend.

Lip assist chain disconnected or broken.

Connect or replace chain.

Insufficient main spring tension.

Increase tension on main lift springs. (See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section.)

Insufficient lip assist force. Increase lip assist spring tension. (See Adjust Lift

Arm Spring and Lip Assist Spring Tension in the Adjustments section.)

Platform does not lower when operator walks out onto the platform.

Excessive main spring tension.

Reduce main spring tension. (See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section.)

Damaged or worn hold-down mechanism.

Clean and inspect hold-down mechanism.

Lip folds too fast during normal walk-down.

Insufficient lip assist force. Increase lip assist spring tension. (See Adjust Lift

Arm Spring and Lip Assist Spring Tension in the Adjustments section.)

Disconnected, worn, or broken shock absorber.

Inspect shock absorber. Connect or replace shock absorber.

Platform does not stay down.

Entangled release chain. Remove cause of entanglement.

Dirt impacted in ratchet bar teeth.

Clean and inspect ratchet bar and ratchet pawl teeth. DO NOT lubricate the ratchet assembly.

Broken or damaged ratchet assembly teeth.

Replace ratchet assembly. DO NOT lubricate the ratchet assembly.

Disconnected or broken hold-down pivot pins.

Replace hold-down pivot pins.

Damaged or worn hold-down mechanism.

Clean and inspect hold-down mechanism.

Lip does not fold after truck departs.

Lip hinge binding because of lack of lubrication

Inject grease into all of the lip hinge grease fittings. (See Periodic Maintenance in the Maintenance section.)

Excessive lip assist force. Decrease lip assist spring tension. (See Adjust Lift

Arm Spring and Lip Assist Spring Tension in the Adjustments section.)

Page 31

PARTS

4111-0006 — July 2006

Item Quantity Part Number Description

1 DOTH-2563 Hold Down Assembly Complete, 31.5” Ratchet Bar

1 DOTH-2563 Hold Down Assembly Complete, 34.5” Ratchet Bar A 1 DOTH-2355 Pin, Clevis B 1 DOTH-2375 Pin, Cotter C 1 DOTH-2575 Ratchet Bar and Pawl Assembly Set D 1 DOTH-2556 Spring, Pawl E 1 DOTH-2568 Bearing, Ratchet Bar F 1 DOTH-2565 Hold-Down Float Assembly G 1 DOTH-1763 Decal, Warning H 1 DOTH-2569 Arm, Release

J 1 DOTH-2559 Spring, Release Arm

Hold-Down Mechanism

Page 32

PARTS

4111-0006 — July 2006

Frame Components

Page 33

PARTS

4111-0006 — July 2006

Item Quantity Part Number Description

A 1

DOTH-____

Frame , Welded Assembly

DOTH-____

Frame, Clean Sweep, Welded Assembly (Optional) B 1 DOTH-2555 Spring, Snubber C 1 DOTH-2416 Lap Link, 3/16 x 1.0 in. D 1 DPLA-2128 Chain, Lip Assist Link E 3 DOTH-2421 Cold Shut Link, 5/16 in.

DOTH-____

Bolt, Spring Adjuster

DOTH-____

Plate, Spring Tensioner.

2 DOTH-2218 Washer

DOTP-6424

Lift Arm, Short, 25”

DOTP-6423

Lift Arm, Long, 27”

J 1 DOTH-2402 Roller Assembly, Cam

K AR*

DOTH-____

Spring, Lift

L 3 DOTH-2382 Pin, Cotter, 1/4 x 2 in. M 3 DOTH-9202 Pin, Rear Hinge N 1 DOTH-2061 Bolt, Shoulder P 2 DOTH-2433 Cold Shut Link Q 1 DOTH-2423 Ring, Chain R 3 DOTH-2434 Quick Link S 1 DOTH-2131 Nut, Nylon Lock

T 1 DOTP-6919

Chain, Release Pull, 9-1/2 in. (241 mm) length

U 1 DOTP-6929 Arm, E-Z Release

DOTP-6921

Chain, Hold-Down Release 5 ft (1524 mm) length

DOTP-6915

Chain, Hold-Down Release 6 ft (1829 mm) length

DOTP-6918

Chain, Hold-Down Release 8 ft (2438 mm) length

DOTP-6916

Chain, Hold-Down Release 10 ft (3048 mm) length

W 1

DOTP-____

Prop, Maintenance

X 2

DOTP-____

Keeper, Lip

Y 1 DOTH-2356 Pin, Clevis

Z 1 DOTH-2405 Roller, Hold-Down Release Chain

AA 1 DOTH-2375 Pin, Cotter AB

1 DOTH-2563 Hold-Down Assembly Complete, 31.5” Ratchet Bar

1 DOTH-2564 Hold-Down Assembly Complete, 34.5” Ratchet Bar AC 1 DOTH-2392 Pin, Roll AD 1 DOTH-2222 Washer AE 1 DRFA-1205 Pin

1 DOTH-6443 Lift Arm Pivot Assembly (Includes Items AD, AE, & AF)

1 DOTP-6920 Chain Assembly, Release Pull (Includes Items P, Q, R, and, T)

1 DOTP-6921 Chain Assembly, Hold-Down Release, 5 ft (1.5 m) (Includes Items P, R, and V)

1 DOTP-6922 Chain Assembly, Hold-Down Release, 6 ft (1.8 m) (Includes Items P, R, and V)

1 DOTP-6923 Chain Assembly, Hold-Down Release, 8 ft (2.4 m) (Includes Items P, R, and V)

1 DOTP-6924 Chain Assembly, Hold-Down Release, 10 ft (3.0 m) (Includes Items P, R, and V)

Frame Components

*AR = As Required

Provide dock leveler serial number, platform size, lip size and pit depth when calling or faxing orders.

Page 34

PARTS

4111-0006 — July 2006

Platform Components

Page 35

PARTS

4111-0006 — July 2006

Item Quantity Part Number Description

A 1

DOTH-____

Platform, Welded Assembly B 1 DOTH-1721 Decal, Warning C AR* DOTH-2424 Fitting, Grease D 1 DOTH-2075 Cap Screw, Lip Stop E 2 DOTH-2160 Nut, Hex 5/8-11

F 1 DOTH-2131 Nut, Nylon Lock G 1 DOTH-2214 Washer H 1 DOTH-2547 Spring, Lip Maintenance Prop

J 1 DOTP-2006 Prop, Lip Maintenance K 1 DOTH-2062 Cap Screw

L 1

DOTH-____

Lip, Welded Assembly

M 1

DOTH-____

Pin, Lip Hinge

N 2 DOTH-2382 Pin, Cotter

Shock Absorber Assembly

P 1 DOTH-2582 Shock Absorber Q 2 DOTH-2374 Pin, Cotter R 2 DOTH-2210 Washer S 2 DOTH-2351 Bolt, Clevis

T 2 DOTH-2163 Nut, Nylon Lock

1 DOTH-6465 Single Shock Absorber Assembly (Includes Items P – T)

Safety Legs Assembly

U 1 DOTH-2423 Ring, Chain V 1 DOTH-6895 Chain, Safety Leg

W 2 DOTH-2425 Quick Link

X 1 DOTH-2433 Cold Shut Link Y 1 DOTH-6231 Leg, Left Safety Assembly with Spring

Z 1 DOTP-6235 Pull Bar Rod Assembly, Safety Leg

AA 1 DOTH-2356 Pin, Clevis AB 1 DOTP-6647 Rod, Push AC 1 DOTH-2374 Pin, Cotter

AD 1 DOTH-6232 Leg, Right Safety Assembly with Spring

Platform Components

Continued on next page

*AR = As Required

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

Page 36

PARTS

4111-0006 — July 2006

Platform Components

Item Quantity Part Number Description

Lip Assist Assembly

AE* 1

DPLA-2130 Rod, Lip Assist Adjuster, (1-1/8 in. x 34 in., Heavy Duty Short) DPLA-2129 Rod, Lip Assist Adjuster, (1-1/8 in. x 44 in., Heavy Duty Long)

AF 1

DPTH-2550 Spr ing, STD, Lip Assist (For DPLA-2130 Rod)

DOTH-2553 Spring, HD, Lip Assist (For DPLA-2129 Rod) AG 1 DOTH-2061 Bolt, Shoulder AH 1 DOTH-2131 Nut, Nylon Lock

AJ 1 DOTH-2160 Nut, Nylon Lock, 5/8 -11 UNC AK 2 DOTH-2404 Bearing, Roller AL 2 DOTH-2211 Washer, 5/8”, 1-5/16 in. OD x 11/16 in. ID

AM 1 DOTH-6644 Spacer, 1-1/4 in. OD x 3/4 in. ID x 1 in. AN 1 DOTH-2076 Cap Screw, 5/8 -11 UNC x 3-1/2 in. AO 1 DPLA-2126 Link, Lip With Chain

AP 2 DOTH-2131 Nut, Nylon Lock, 3/8 -16 in.

AQ 2 DOTH-2061 Bolt, Socket-Head Shoulder, 3/8 -16 x 1-3/4 in.

Continued from previous page

*AE includes (2)AP,(2)AQ, (1)AS, and (1)AN

Item Quantity Part Number Description

Toe Guard / Weather Seal Options

A 1

DOTH-2842 Track, Weatherstrip, 5’ DOTH-2819 Track, Weatherstrip, 6’ DOTH-2187 Track, Weatherstrip, 8’ DOTH-2843 Track, Weatherstrip, 10’

C 1

DOTH-2850 Extrusion For Brush, 5’ DOTH-2821 Extrusion For Brush, 6’ DOTH-2820 Extrusion For Brush, 8’ DOTH-2851 Extrusion For Brush, 10’

E-K 1

DKIT-9178 Full Range Toe Guard Assembly, 5’ DKIT-9179 Full Range Toe Guard Assembly, 6’ DKIT-9180 Full Range Toe Guard Assembly, 8’ DKIT-9181 Full Range Toe Guard Assembly, 10’

Toe Guard and Weatherstripping shown on following page

Page 37

4111-0006 — July 2006

PARTS

Toe Guard/Weather Seal—Optional

Item Quantity Part Number Description

A 2 DOTH-2818 Channel, Weather Seal, 84” B 2 DOTH-2824 T-Rubber, Weather Seal, 84” C 2 DOTH-2820 Extrusion, Brush Weather Seal, 84”

CC 2 DOTH-2822 Brush Weather Seal, 1.58” x 84”

D 2 DOTH-2041 Cap Screw E 4 DOTH-2207 Washer

F 1 See Chart G 1 See Chart H 2 DOTH-2131 Nut, Nylon Lock

J 1 See Chart K 1 See Chart

Page 38

PARTS

4111-0006 — July 2006

This page intentionally left blank

Page 39

4111-0006 — July 2006

MISCELLANEOUS

Customer Information

NOTE: Refer to illustration for left/right orientation of

dock leveler. The model/serial number decal (A) is located

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

When you receive your CM-series dock leveler, wr ite down the dock leveler model and ser ial 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) 257-7349

Dock Leveler Information

Model ___________________________________

Serial No._________________________________

Systems, Inc., Job No. ______________________

Original Owner Information

Name ___________________________________

Address _________________________________

_________________________________

Installer Information

Name ___________________________________

Address _________________________________

_________________________________

Date of Installation _________________________

Page 40

PO WERAMP W ARRANTY

CM-SERIES MECHANICAL LEVELER

Systems, Inc., guarantees the materials, components, and workmanship in your Poweramp CM-Series dock leveler to be of the highest quality and to be free of defects in material and workmanship for a full One (1) Year Base Warranty on all components. The Base Warranty includes replacement par ts, labor, and freight.

Structural components carry a Ten (10) Year Pro-Rated Parts Warranty. Example: after two years customer is responsible for 20%, three years 30%, etc.

Specifically, the structural warranty includes the frame, deck section, lip section, rear hinge, and front hinge.

Systems, Inc., warrants all components to be free of defects in material and workmanship, under normal use, during the warranty period. This base warranty period begins upon the completion of the installation or the Sixtieth (60

) day after

shipment, whichever is earlier.

All guarantee claims will be settled on a timely basis when defects are found to be from other than improper installation, operating contrary to instructions or beyond rated load capacities, abuse, careless or negligent use, or failure to maintain the unit as recommended by the owner’s manual.

There are no guarantees, either expressed or implied, including any implied guarantees of merchantability or fitness for a particular purpose which shall extend beyond the guarantee periods indicated above. This guarantee is valid only if the unit(s) is unaltered from original condition as delivered from the factory and a survey is completed by a Poweramp representative.

Poweramp CM SERIES MECHANICAL User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual