Centra Power Operations Manual Owner’s/User’s Manual POWERAMP • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022 800.643.5424 • fax: 262.255.5917 • www.poweramp.com • techservices@docksystemsinc.com Printed in U.S.A. Copyright © 2009 Manual No. 4111-0030 Rev.
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 Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler. Never operate a dock leveler while a safety device or guard is removed or disconnected. Never remove DANGER, WARNING, or CAUTION signs or Decal’s on the equipment unless replacing them.
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. 4111-0030 — Nov.
SAFETY Maintenance Safety Precautions Hydraulic and electrical power must be OFF when servicing the equipment. For maximum protection, use an OSHA approved locking device to lock out all power sources. Only the person servicing the equipment should have the key to unlock the device. Always 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.
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. Refer to owner’s/user’s manual for proper use. Failure to comply will result in death or serious injury.
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.
INTRODUCTION General Information THEORY The Centra Power system eliminates individual hydraulic pumps located on each leveler. The Centra Power pump station will run multiable dock levelers and or truck restraints. When the leveler is raised or when a truck restraint is engaged a signal is sent to the pump station to turn on. Also a signal is sent to a valve assembly located under the leveler. When the valve is activated and the pump is running the leveler will raise or the restraint will engage.
INTRODUCTION Component Identification B H F G C D A E K M Pressure Line (Black L Return Line (Brass) A — Pump Station B — Pump Motor #1 C — Pump Motor #2 8 D — Site Glass E — Drain Plug F — Main System Relief G — Pump Station Door H — Distribution Manifold J — Leveler Manifold J K — Coil L — Ball Valves M —Control Panel 4111-0030 — Nov.
INSTALLATION Read carefully and under stand the installation manual for the leveler and or the restraint in to be installed in conjunction with the Centra Power manual. Read carefully and under stand the Centra Power Lay out drawing. The drawings will have all the required information on hose charts, fluid capacity and location of the mid run and end run valve blocks. The Centra Power pump station is typically located in the center of the dock levelers with even amount of doors on each side.
INSTALLATION Component Identification Pump Pressure Pump Return Pump Pressure 10 4111-0030 — Nov.
INSTALLATION Centra Power main control panel should be located near the Central Power pump station. The pump control panel has 2 lights located on the door. There is 3 position switch mounted in side the door. The switch on the system controls one or both motors when a leveler has been activated. The lights on the control indicate if one or both motor starters have tripped. If only one pump is being used, rotate motors every 6 months. This will make sure both motors are fresh and working. 4111-0030 — Nov.
INSTALLATION IMPORTANT DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed. DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler. Always ground welding equipment to the dock leveler frame, NEVER to the platform. Failure to follow these instructions may damage the motor, hoist cylinder, wiring, and/or control panel. 12 4111-0030 — Nov.
MAINTENANCE Service Dock Leveler Safely Side View F A A E B C When service under the dock leveler is required, always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop. Failure to do this may result in serious personal injury or death. Always stand clear of the dock leveler lip when working in front of the dock leveler. The maintenance prop MUST be in the service position when working under the dock leveler.
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MAINTENANCE Periodic Maintenance Regular maintenance must be performed on a weekly and quarterly schedule. For proper lube points see owners manual for the equipment to be maintained. Sight Glass 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.
ADJUSTMENTS Pressure relief: 1. Main pressure relief is pre set from the factory Call Tech Services before adjustments are made. 16 4111-0030 — Nov.
TROUBLESHOOTING Troubleshooting Before performing the detailed troubleshooting procedures, check the following items first: • Check all fuses inside the control panel(s). Replace any blown fuse(s) with a fuse of equal specification. Symptom Platform or restraint does work. Motor does not energize. • Make sure the correct voltages are present at the proper locations inside the control panel(s). Possible Cause Motor overload device tripped or fuse blown.
TROUBLESHOOTING Symptom Platform or restraint does not work correctly but Motor hums, but does not run. Possible Cause Solution No voltage is present on one line. Check for blown fuses at branch circuit disconnect. Replace fuse. Determine cause of blown fuse. NOTE: A motor that is missing voltage on one line is said to be single-phased. Check motor starter as follows: 1. Disconnect wires at load side of starter. 2. Energize the starter. 3. Measure line-to-line voltage at line side of starter. 4.
PARTS Centra Power Control Panel 4111-0030 — Nov.
PARTS Mid Run Valve W/O Hook D E E C H H K J G B A F I Item Quantity Part Number A B C D E F G H I 1 1 1 1 2 1 1 2 1 0581-0005 8581-0001 8581-0002 9301-0073 0521-0108 9301-0201 9301-0054 9904-0078 Valve Manifold Valve - Cartridge - 3 way Ball Valve - Bronze, Return Ball Valve - Steel, Pressure Fitting - 3/8 NPT Fitting - Pipe Plug Fitting - Elbow 90 male #8 JIC Fitting - Branch - Tee - Male #8 JIC Hyd Hose -3/8 x 35.
PARTS End Run Valve W/O Hook E C D E H H K L G B A I F Item Quantity Part Number Description A B C D E F G H I 1 1 1 1 2 1 1 2 1 0581-0005 8581-0001 8581-0002 9301-0073 0521-0108 9301-0201 0521-0017 9904-0014 Valve Manifold Valve - Cartridge - 3 way Ball Valve - Bronze, Return Ball Valve - Steel, Pressure Fitting - 3/8 NPT Fitting - Pipe Plug Fitting - Elbow 90 male Fitting - Elbow 90 Deg. Hyd Hose -3/8 x 35.
PARTS Mid Run Valve W/Hook C A I F J E D H G N B K O L Item Quantity Part Number A B C D E F G H I J K L 1 1 1 1 1 1 1 1 1 1 1 1 0581-0005 9301-0104 9301-0098 8581-0072 9301-0097 8581-0092 9301-0054 8581-0002 9301-0073 9301-0112 9301-0116 Valve Manifold Valve - Cartridge - 3 way Fitting #4 SAE Fitting - Male Branch Tee #10 JIC Ball Valve - Bronze 1/2 NPT Fitting - 3/8 NPT x 1/2 NPT Valve - Flow Control - 5 GPM Fitting - Branch - Tee - Male #8 JIC Ball Valve - Steel Fitting - 3/8 NPT Fitting
PARTS C End Run Valve W/ Hook A F I J E D H G B N K O L Item Quantity Part Number A B C D E F G H I J K L 1 1 1 1 1 1 1 1 1 1 1 1 0581-0005 9301-0104 9301-0099 8581-0072 9301-0097 8581-0092 9301-0017 8581-0002 9301-0073 9301-0112 9301-0116 Valve Manifold Valve - Cartridge - 3 way Fitting #4 SAE Fitting - Elbow 90 deg 1/2 NPT x #10 JIC Ball Valve - Bronze 1/2 NPT Fitting - 3/8 NPT x 1/2 NPT Valve - Flow Control - 5 GPM Fitting - Elbow 90 Deg 1/2 Npt x #10 JIC Ball Valve - Steel Fitting - 3
PARTS Pump Station T R J H IH R O U Q V W P K T N L M A K E B F G C D 24 4111-0030 — Nov.
PARTS Pump Station 1 2 Item Quantity Part Number Description A B 1 1 Enclosure Weldment Decal C 1 9394-0003 1751-0072 9301-0048 D E F G H I J K L M N 1 1 1 2 1 1 1 2 1 1 9301-0049 9571-0005 9301-0020 9301-____ 1 8581-0037 8583-0037 8585-0001 9301-0027 9904-0001 9904-0002 Site Glass (Includes O-Ring) Drain Plug Breather Cap 3/8” NPT Pump Assembly Valve Assembly, Centra Power Relief Valve Assembly, Includes Relief and Hose (Item O) Valve Assembly, Blending 0-Ring Hose, 17.50” Lg.
PARTS Pump and Motor T O N M L K J U A V C B G G W D S F E P G H R Q I 26 4111-0030 — Nov.
PARTS Pump and Motor Item A B C D E F G H I J K L M N O P Q R S T U V Quantity Part Number 1 1 1 3411-0043 3411-0045 - Motor 460 3 PH 1-1/2 hp Motor 460 3 PH 3 hp Drive Plate Description 1 1 1 1 1 3 1 1 1 1 1 1 1 1 4 2 2 1 1 1 1 9301-0027 9302-0065 9301-0204 9301-0205 9904-0001 9301-0007 9301-0206 9301-0009 0521-0014 9301-0024 9302-0009 9303-0003 9301-0014 9301-0016 2101-0016 9301-0003 9301-0004 9301-0069 9301-0106 9571-0006 9301-0145 O-Ring Coupler (Love Joy) Pump 5 GPM Pump 4 GPM Hose Assy - 3/8
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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. Dock Leveler Information Model ___________________________________ Serial No. ________________________________ Systems, Inc., Job No. ______________________ When you receive your dock leveler, write down the dock leveler model and serial number in the form provided.
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.
