CM-Series Dock Leveler Owner’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 © 2003 Manual No. 4111-0006 July 2003 Rev.
Table of Contents Page Safety Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY Recognize Safety Information General Operational Safety Precautions Safety-Alert Symbol The Safety-Alert Symbol identifies important safety messages on equipment, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow 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 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 uncontained hydraulic fluid or other flammable liquid is present. Stray sparks can ignite spills or leaks near the work area.
SAFETY Safety Decals Safety Decal on Hold-Down Mechanism Safety Decal on Leveler Frame 4111-0006 — July 2006 5
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INTRODUCTION General Information Dock Leveler Stock Specifications 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 6 ft 8 ft 10 ft Congratulations on your choice of a Poweramp dock leveler. This manual covers the CM-series mechanical dock leveler.
INTRODUCTION Component Identification D C E B F U S T A Q P R N M G H K J L A — Lip B — Lip Maintenance Prop C — Platform D — Lip Link E — Lip Assist Spring 8 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 4111-0006 — July
INSTALLATION Prepare Pit A C B 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) Before lowering the dock leveler into the pit, the following must be performed: 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.
INSTALLATION Prepare Dock Leveler A B A— Lifting Bracket (2 used) 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. 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.
INSTALLATION 1. Remove any bumpers that may be banded, or bolted to the frame of the dock leveler. DO NOT remove the shipping bands (B) around the platform lip and leveler frame at this time. IMPORTANT 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.
INSTALLATION Install Dock Leveler Shim Stacking Methods M A N A P Q B 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 12 C F— String G— Rear Hinge Frame Angle H— Distance (Dock Floor-toPit 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)
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 (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). Write down the dimensions obtained at each location. c. Subtract distance (A) from distance (H) to obtain the shim height. Repeat for each shim location.
INSTALLATION A B B 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 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. 14. Weld front of dock leveler frame (B) to shims located under the keepers, then weld the shims to the front pit curb steel.
INSTALLATION A C B D A— Safety Leg Chain Pull Ring B— Platform Maintenance Prop C — Shim Location (Under Lift Arm Pivot) D — Locking Device 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. 25. Remove the lifting brackets from the platform side joists. 26. Disengage the platform maintenance prop. 27.
OPERATION Theory B D C E F S T U A Q R P M N H G J K L 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 The CM-series mechanical dock leveler uses large lift springs (U) to apply force to lift arm (T). The lift arm pushes against the underside of the platform (C), rolling on the cam (not pictured) forcing the platform to rise.
OPERATION Operating Instructions Stay clear of dock leveler when freight carrier is entering or leaving dock area. 12 in. (305 mm) DO NOT raise or lower the dock leveler if anyone is under or in front of leveler. 12 in. (305 mm) Keep hands and feet clear of pinch points. Avoid putting any part of your body near moving parts. Failure to follow these instructions may result in severe personal injury or death.
OPERATION Operating Instructions — Continued Ramp Loading/Unloading Instructions 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. 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. 2.
OPERATION Operating Instructions — Continued End Loading/Unloading Instructions NOTE: End loading or unloading can be done with the dock at the cross-traffic position or below-dock position depending on the height of the truck/trailer bed. B 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. 6.
MAINTENANCE Service Dock Leveler Safely A C B D E A— Lip Maintenance Prop B — Platform Maintenance Prop Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete. Failure to do this may result in serious personal injury or death. Always stand clear of the dock leveler lip when working in front of the dock leveler. Failure to do this may result in serious personal injury or death.
MAINTENANCE Periodic Maintenance A D C B • E L K F J G H A — Lip Hinge Grease Fittings D — Platform Hinge Area G — Lift Arm Pivot B — Lip Maintenance Prop Pivot E — Lift Arm Roller Bushing H — Hold-Down Pivot/Pulley C — Lip Link Pivots F — E-Z Release Bellcrank Pivot J — Safety Leg Linkage Pivots 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.
MAINTENANCE Regular maintenance must be performed on a weekly and quarterly schedule. Weekly Maintenance Quarterly Maintenance • Operate the dock leveler through the complete operating cycle to maintain lubrication. • Lubricate the following areas with light-weight machine oil: NOTE: To thoroughly inspect the platform hinge area, position the platform in the full below-dock position. (B)— Lip maintenance prop pivot • Inspect the platform hinge and the lip hinge areas.
ADJUSTMENTS Adjust Lift Arm Spring and Lip Assist Spring Tension A B D C E F A — Jam Nut B — Nut C — Lip Assist Spring D — Lift Springs Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete. Failure to do this may result in serious personal injury or death. Always stand clear of the dock leveler lip when working in front of the dock leveler.
ADJUSTMENTS NOTE: Adjusting the tension of lift springs (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.
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.
TROUBLESHOOTING Troubleshooting Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete. Failure to do this may result in serious personal injury or death. Always stand clear of the dock leveler lip when working in front of the dock leveler. Failure to do this may result in serious personal injury or death. Symptom Platform does not rise.
TROUBLESHOOTING Symptom Platform rises to full height, but lip does not fully extend. Possible Cause 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.
PARTS Hold-Down Mechanism A B C D E J F G H Item Quantity Part Number A B C D E F G H J 1 1 1 1 1 1 1 1 1 1 1 DOTH-2563 DOTH-2563 DOTH-2355 DOTH-2375 DOTH-2575 DOTH-2556 DOTH-2568 DOTH-2565 DOTH-1763 DOTH-2569 DOTH-2559 4111-0006 — July 2006 Description Hold Down Assembly Complete, 31.5” Ratchet Bar Hold Down Assembly Complete, 34.
PARTS Frame Components F J K L G F M F AD AC E D AB N AE C R Q P B R R S AA V U Y A Z P T W X 30 4111-0006 — July 2006
PARTS Frame Components Item Quantity Part Number A 1 B C D E 1 1 1 3 1 1 2 1 1 1 AR* 3 3 1 2 1 3 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 F G J K L M N P Q R S T U V W X Y Z AA AB AC AD AE DOTH-____ 1 DOTH-____ 1 DOTH-2555 DOTH-2416 DPLA-2128 DOTH-2421 DOTH-____ 1 DOTH-____ 1 DOTH-2218 DOTP-6424 1 DOTP-6423 1 DOTH-2402 DOTH-____ 1 DOTH-2382 DOTH-9202 DOTH-2061 DOTH-2433 DOTH-2423 DOTH-2434 DOTH-2131 DOTP-6919 DOTP-6929 DOTP-6921 1 DOTP-6915 1 DOTP-6918 1 DOTP-6916 1 DOTP-____ 1 DOTP-____ 1 DOTH-23
PARTS Platform Components U M V L W X R N Q P S J G T D C E K H F AE C AB B AC AN A AH AA AM AG Y AJ Z AK AL AE AD AP AQ AF AO 32 4111-0006 — July 2006
PARTS Platform Components Item Quantity Part Number A B C D E F G H J K L M N 1 1 AR* 1 2 1 1 1 1 1 1 1 2 DOTH-____ 1 P Q R S T 1 2 2 2 2 1 DOTH-2582 DOTH-2374 DOTH-2210 DOTH-2351 DOTH-2163 DOTH-6465 U V W X Y Z AA AB AC AD 1 1 2 1 1 1 1 1 1 1 DOTH-2423 DOTH-6895 DOTH-2425 DOTH-2433 DOTH-6231 DOTP-6235 DOTH-2356 DOTP-6647 DOTH-2374 DOTH-6232 DOTH-1721 DOTH-2424 DOTH-2075 DOTH-2160 DOTH-2131 DOTH-2214 DOTH-2547 DOTP-2006 DOTH-2062 DOTH-____ 1 DOTH-____ 1 DOTH-2382 Description Platform, Welded As
PARTS Platform Components Continued from previous page Item Quantity AE* 1 AF 1 AG AH AJ AK AL AM AN AO AP AQ 1 1 1 2 2 1 1 1 2 2 Part Number DPLA-2130 DPLA-2129 DPTH-2550 DOTH-2553 DOTH-2061 DOTH-2131 DOTH-2160 DOTH-2404 DOTH-2211 DOTH-6644 DOTH-2076 DPLA-2126 DOTH-2131 DOTH-2061 Description Lip Assist Assembly Rod, Lip Assist Adjuster, (1-1/8 in. x 34 in., Heavy Duty Short) Rod, Lip Assist Adjuster, (1-1/8 in. x 44 in.
PARTS Toe Guard/Weather Seal—Optional B C CC A D K E F E G H J Item A B C CC D E F G H J K Quantity 2 2 2 2 2 4 1 1 2 1 1 4111-0006 — July 2006 Part Number DOTH-2818 DOTH-2824 DOTH-2820 DOTH-2822 DOTH-2041 DOTH-2207 DOTH-2131 Description Channel, Weather Seal, 84” T-Rubber, Weather Seal, 84” Extrusion, Brush Weather Seal, 84” Brush Weather Seal, 1.
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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 CM-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.
POWERAMP WARRANTY 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 parts, 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.
