AP 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. 4111-0009 Oct 2007 Jan.
Table of Contents Page Safety Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 1 Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 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 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 Decals Safety Decal on Leveler Frame Safety Decal on Leveler Frame Safety Decal on Leveler Frame 4111-0009 — Oct 2007 Jan 2009 5
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 P Component Identification A — Lip B — Lip Assist Rod C —Lip Linkage Assembly D — Lip Latch Assembly E — Lip Maintenance Prop Pivot) F — Lip Actuator Chain Spring G — Lip Actuator Chain H — Lip Actuator Chain Adjustment Link 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 operation for ease of use.
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 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 R T A— Distance (Leveler Frame Height) B— Shim Locations (Under Rear Vertical Supports) C— Shim Location (Under Maintenance Prop) *Same as (D) D— Shim Locations (Under Lip Keepers) E— Dock Floor F— Rear Pit Curb Angle G— String 10 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 A
INSTALLATION NOTE: Poweramp dock levelers are designed with a nominal 1/2 in. (12.7 mm) shimming distance to allow for pit inconsistencies. 4. For all AP models, put a 1/4 in. (6.6 mm) thick shim at locations (C and D) . 1. Determine height of shim stack (L) for each shim location (B) by performing the following: 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 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. 18. All model levelers: Install shims at locations (B, p.10) using the pyramid or stepped shimming method. Make sure the platform is level from side-to-side as well as from front-to-back and flush with dock floor. 19.
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. 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. 12 in. (305 mm) DO NOT move or use 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. Only trained personnel should operate the 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. 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.
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 Side View D A E B C 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 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.
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. • Perform Weekly Service Items 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 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.
NOTES This page intentionally left blank. 26 4111-0009 — Oct 2007 Jan.
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 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 does not rise. Pump operates in pressure relief mode. Platform rises slowly 4111-0009 — Oct 2007 Jan 2009 Possible Cause Solution 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. Remove obstructions. If no obstructions found, call Poweramp Technical Services.
TROUBLESHOOTING Symptom Possible Cause Solution Platform does not rise to See Platform Rises Slowly full height. See Platform Rises Slowly See Periodic Maintenance in the Maintenance section. Platform DOES rise to full height, but lip DOES NOT extend or extend fully. Lip actuator spring needs additional tension. Inspect lip actuator chain, repair or replace as needed. Logic block (valve) lever cable weight too low on cable. Adjust cable weight.
PARTS Controls A B C 4-1/2 3 2-7/8 11.8FLA Amp Draw Item Quantity Part Number Description A 1 7141-0207 Push Button Controller, 9-RO-800-A-A B 1 1751-____ Decal C 1 1751-____ Decal * Provide dock leveler serial number, voltage, phase, and options when calling or faxing controller orders.
PARTS Pit Extension Kit 1 Item Quantity Part Number 1 1 8436-0035 32 Description Pit Extension Kit, For all size levelers 4111-0009 — Oct 2007 Jan.
PARTS Airbag and Support Pallet Item Quantity Part Number 1 2 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 6 2101-0224 Rod Clamps 3-6 1 5814-0029 Skid, Air Bag Leveler Assembly, Includes Items 3-7 4111-0009 — Oct 2007 Jan 2009 Description 33
PARTS Frame and Platform A T B S U M R K P N Q L D C J E F G H V 34 4111-0009 — Oct 2007 Jan.
PARTS Frame and Platform Item Quantity Part Number A B C D E F G H J K L M N-P Q R S T 1 1 1 1 1 3 6 1 1 1 1 AR AR AR 1 1 2 0595-____ 7823-____2 9515-____1 9202-____1 0015-____1 9202-0002 2101-0047 2101-0039 7942-0006 2101-0163 2101-0012 2101-0039 2101-0163 2101-0011 0015-____1 1751-0010 2101-0046 Lip, Welded Assembly Platform, Welded Assembly Pin, Lip Hinge Toe Guard Welded Assembly, Left Frame, VH Rear Hinge Pin Cotter Pin, 1/4 x 2 in.
PARTS Weather Seal, Rubber Style A Item Quantity Part Number A 3 0192-____* Description Foam Seal, Rear Hinge NOTE: Kits are for existing dock leveler without weather seal. * Provide dock leveler serial number and size of platform when calling or faxing orders. *Provide width of weatherstrip when replacing existing seals 36 4111-0009 — Oct 2007 Jan.
PARTS Weather Seal, Brush Style 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) Ruber Seal and Track, 1 in. (25 mm) Ruber Seal and Track, 1 in. (25 mm) Ruber Seal and Track, 1 in. (25mm) Ruber Seal and Track, 1 in.
PARTS Motor and Blower Assembly Item Quantity Part Number 9395-0359 1 2 3 4 5 6 7 8 9 10 11 12 13 14 38 1 1 1 1 1 1 1 1 4 3 5 2 8 1 9391-0021 9391-0022 9392-0047 9391-0023 2101-0143 2101-0007 2101-0005 Description PPAC,Blower Assy, Includes 1-4,7,8,10-14 Fan / Motor, 115VAC, AP Series Levelers Shroud, Fan End Shroud, Motor End Filter Element Tube, 2” (50.8mm) OD, 36” (914.4mm) Length Pipe, PVC, 1-1/2” SCH40 X 24” (38.1 X 609.6mm) Cord Set, 115V, 3 Conductor, 6’ (1828.
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. Also, write down Systems, Inc.
NOTES 40 4111-0009 — Oct 2007 Jan.
NOTES 4111-0009 — Oct 2007 Jan 2009 41
POWERAMP WARRANTY AP-SERIES LEVELER Systems, Inc., guarantees the materials, components, and workmanship in your Poweramp AP-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. The electrical components carry a one (1) year warranty.
