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 Printed in U.S.A. Copyright © 2012 Manual No.
Table of Contents Page Safety Recognize Safety Information ............................................................. General Operational Safety Precautions ............................................ Operational Safety Precautions........................................................... Maintenance Safety Precautions ......................................................... Safety Decal’s........................................................................................
SAFETY Recognize Safety Information General Operational Safety Precautions 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. Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler.
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. 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.
SAFETY Do not use dock leveling device if freight carrier is too high or too low. Do not overload the dock leveling device. Do not operate any equipment while under the influence of alcohol or drugs. Do not leave equipment or material unattended on dock leveling device.
SAFETY Maintenance Safety Precautions 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. Hydraulic and electrical power must be OFF when servicing the equipment.
SAFETY Safety Decal’s Every 90 days (quarterly) inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible. If any are missing or require replacement, please call 1-800-643-5424 for replacements. 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.
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.
INTRODUCTION General Information 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) Congratulations on your choice of a Poweramp dock leveler. This manual covers the Air Bag, AP model air powered dock leveler.
INTRODUCTION Component Identification P B A E Q C D O G H N M K A — Lip B — Below Dock Control C —Lip Linkage Assembly D — Lip Latch Assembly F J I E — Lip Maintenance Prop Pivot F — Lip Snubber Spring G — Lip Actuator Chain H — Lip Actuator Chain Adjustment Link L 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 THEORY The AP dock leveler uses a blower motor and one-button o
INSTALLATION Prepare Pit A C B E 14” 10” D 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) 1.
INSTALLATION Prepare Dock Leveler 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. A 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 B A— Lifting Bracket (2 used) DO NOT over tighten the lifting bracket hardware.
INSTALLATION Shim Stacking Methods Install Dock Leveler N P Q K R T B U D T 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-toPit Floor) 4111-0009 — Aug 2012 Jan 2013 K— Distance (Top of Shim Stack-to-Dock Floor) L— Shim Stack M— Dock Leveler Frame N — Pyramid (Preferred) P— Stepped (Accept
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: 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. a.
INSTALLATION B A C C D D E F G A— Front of Dock Pit B— Dock Leveler Frame 3/8 in. (9.5 mm) 6 in. (152 mm) C— Side Pit Curb Angle D— Gap [3/4 in. (19 mm) Minimum] 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).
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. Two people are required to engage the maintenance prop: one person to operate the lifting device, the other person to engage the maintenance prop. 14. Slowly raise the platform. Check for binding as platform is being raised. 15. If binding occurs, lower the platform.
INSTALLATION IMPORTANT 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.
INSTALLATION Install Control Panel and Wiring A 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. D B C DO NOT make any final electrical connections until all welding has been completed.
INSTALLATION Put New Dock Leveler Into Service 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. 7. When the platform lowers to the full below-dock position, the lip will fold.
OPERATION Operating Instructions Stay clear of dock leveler when freight carrier is entering or leaving dock area. 12in. (305mm) 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.
OPERATION Operating Instructions—Continued Below Dock Loading/Unloading Instructions Ramp Loading/Unloading Instructions NOTE: If end unloading is required, see End Loading/ Unloading Instructions on page 20. 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. For ramp loading or unloading, the AP dock leveler can be operated by using the RAISE button on the control panel. 8.
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.
MAINTENANCE Service Dock Leveler Safely A C E A B B E C B A— Lip Maintenance Prop B —Tag Out Device C — Lock Out Device 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.
MAINTENANCE Periodic Maintenance A E B C D F G A— Lip Hinge Area B— Lip Maintenance Prop Pivot C— Lip Link Pivots D— Platform Hinge Area Under platform service 22 E— Lip Assist Pin F— Lip Linkage Pivot G — Safety leg linkage pivots Air Filter, service under rear of platform 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.
ADJUSTMENTS Adjusting the Latch and Lip Actuator Spring Tension 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. A B 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.
ADJUSTMENTS Adjusting Lip Latch Spring Tension Adjusting Lip Actuator Spring Tension This adjustment is set at the factory and should not require additional adjustment. 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. Unlike mechanical levelers, the lip will not immediately begin to fold as the platform returns to the stored position.
ADJUSTMENTS Adjust Lip Stop Bolt Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete. Failure to do this may result in serious personal injury or death. A B 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.
NOTES This page intentionally left blank 4111-0009 — Aug 2012 Jan 2013 27
TROUBLESHOOTING TROUBLESHOOTING Always stand clear of the dock leveler lip when working in front of the dock leveler. 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. The maintenance prop MUST be in the service position when working under the dock leveler.
TROUBLESHOOTING Symptom Platform rises slowly Possible Cause Air bladder or connecting ducts punctured Solution Check air bladder and ducting replace as needed Damaged or restricted ducting Replace damaged ducting or remove restriction Air intake clogged Remove intake filter, clean or replace as needed Dock leveler binding Check for visible obstructions that could cause binding. Remove obstructions. If no obstructions found, call Poweramp Technical Services.
Electrical Controls 30 4111-0009 — Aug 2012 Jan 2013
Control Box A B C 4-1/2 D 3 2-7/8 11.
PARTS (BEFORE JAN 2012) Lip Activation U I H I A B T J D C F G V W X Y E U I S R Q K L O M O P Item A B C D E F G H I J K L M O P Q R S T U V W X Y 32 Quantity 1 1 2 1 1 1 2 1 2 3 1 1 1 1 3 1 1 3 1 1 2 1 1 1 1 Part Number 9514-0107 DPLA-2130 DOTH-2404 DOTH-2076 DOTH-2160 DOTH-2546 DOTH-2225 DPLA-2126 DOTH-2061 DOTH-2131 5775-0004 0941-0013 DOTH-2555 DPLA-2128 2101-0217 2101-0216 DOTH-2421 DOTH-2214 DOTH-2547 DOTP-2006 DOTH-2062 DOTH-2351 DOTH-2163 DOTH-2210 DOTH-2374 Description * * * Lip
PARTS Below Dock Control D G H I E F B A J Item Quantity A B C D E F 1 1 1 1 1 1 9514-0108 9514-0109 DOTH-6231 DPLA-2122 DOTH-2075 DOTH-2356 Leg, Right Safety Assembly with Spring.
PARTS Pit Extension Kit 1 Item Quantity Part Number 1 1 8436-0035 34 Description 4 inch Pit Extension Kit, For all size levelers 4111-0009 — Aug 2012 Jan 2013
PARTS Airbag and Support Pallet Item Quantity Part Number 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.
PARTS Frame and Platform FROM Jan 2012 A N C B M D E F G J I H K K L 36 4111-0009 — Aug 2012 Jan 2013
PARTS Frame and Platform 1 2 Item Quantity A B 1 1 C 1 D 1 E F G H I J 2 4 2 1 3 6 K 1 L M N 1 1 2 Part Number See Table A 7823-____2 9202-0050 9202-0051 9202-0052 DKIT-9179 DKIT-9180 DKIT-9181 2101-0039 2101-0163 2101-0011 0015-____1 9202-0002 2101-0047 9224-0030 9224-0031 9224-0079 9201-0009 1751-0010 2101-0046 Description Lip, Welded Assembly Platform, Welded Assembly Pin, Lip Hinge 6’W Pin, Lip Hinge 6.
PARTS Lip Activation JAN 2012 A B N C F D E F G M J K L R I H P O P Q Item Quantity A 1 B 1 C D E F G H I J K L M N O P Q R 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 38 Part Number DLIP-0305 DOTH-2550 DOTH-2546 5775-0004 DOTH-2351 DOTH-2163 DOTH-2210 DOTH-2374 DPLA-0338 DPLA-0340 DOTH-2131 DOTH-2547 DOTH-2214 DOTH-2062 DOTP-2005 2101-0217 DPLA-2128 DOTH-2555 0941-0013 Description Lip Assist Rod Complete 34” LG.
PARTS Weather Seal C A B Item A B C Quantity Part Number 1 1 1 1 1 1 1 1 1 0195-0018 0195-0021 0195-0024 0195-0027 0195-0030 0195-0033 0195-0036 0195-0039 0195-0044 Description Brush Seal and Track, 1 in (25mm) Brush Seal and Track, 1 in. (25 mm) Brush Seal and Track, 1 in. (25 mm) Brush Seal and Track, 1 in. (25 mm) Rubber Seal and Track, 1 in. (25 mm) Rubber Seal and Track, 1 in. (25 mm) Rubber Seal and Track, 1 in. (25mm) Rubber Seal and Track, 1 in.
PARTS Motor and Blower Assembly Item Quantity Part Number 9395-0359 Description 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 5 1 6 1 7 1 Cord Set, 115V, 3 Conductor, 6’ (1828.8mm) long 8 1 Cord Grip 9 4 10 3 11 9391-0021 Filter Element 9391-0022 Tube, 2” (50.8mm) OD, 36” (914.4mm) Length 6’ and 8’ Levelers 9391-0041 Tube, 2” (50.8mm) OD, 46” (914.
MISCELLANEOUS Customer Information A 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 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.
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.
