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Poweramp CentraAir, Owner & User Manual, Page: 2 / 56

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Precautions

Recognize Precautionary Information ................................................ 1

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

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

Safety Decals ......................................................................................... 4

Placard ................................................................................................... 5

Owner’s/User’s Responsibilities.......................................................... 6

Introduction

General Information .............................................................................. 8

Component Identification ..................................................................... 9

Installation

Installation Precautions ......................................................................  10

Air Supply Requirements ....................................................................  11

Prepare Pit ............................................................................................  12

Install Dock Leveler .............................................................................  14

Install Control Panel- Electric .............................................................  20

Install Control Panel- Pneumatic ........................................................  21

Air Supply .............................................................................................  22

Placard Installation Instructions ........................................................  25

Put New Dock Leveler Into Service ....................................................  26

Operation

Operational Precautions ..................................................................... 27

Ramp Loading/Unloading Instructions .............................................. 28

End Loading/Unloading Instructions ................................................. 29

Maintenance

Maintenance Precautions .................................................................... 30

Periodic Maintenance .......................................................................... 32

Adjustments

Adjust Lip Latch & Lip Actuator Spring Tension ............................. 34

Adjust Lip Stop Bolt ............................................................................ 36

Adjust Lip Assist Chain and Shackle ................................................ 37

Troubleshooting

Troubleshooting ................................................................................... 38

Parts

Electric Control Box ............................................................................ 40

Pneumatic Control Box ....................................................................... 41

Electric/Pneumatic Operator Valve .................................................... 42

Lanyard Operator Valve ...................................................................... 43

Air Bellows and Regulator .................................................................. 45

Frame and Platform ............................................................................. 46

Lip Activation ....................................................................................... 48

Below Dock Control ............................................................................. 49

Weather Seals  ..................................................................................... 50

Miscellaneous

Customer Information ......................................................................... 57

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

Table of Contents

Summary of Contents for CentraAir

Page 1: ...Rights Reserved Manual No 4111 0034 Sept 2018 Poweramp Division of Systems LLC W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www poweramp com techservices poweramp com...

Page 2: ...ew Dock Leveler Into Service 26 Operation Operational Precautions 27 Ramp Loading Unloading Instructions 28 End Loading Unloading Instructions 29 Maintenance Maintenance Precautions 30 Periodic Mainte...

Page 3: ...or serious injury The use of the word CAUTION signifies possible hazard or unsafe practice which could result in minor or moderate injury The use of the word NOTICE indicates information considered im...

Page 4: ...t of it Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Chock restrain all transport vehicles Never remove the wheel chocks or release the restraining d...

Page 5: ...utions Do not use dock leveling device if transport vehicle 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 D...

Page 6: ...l Failure to follow posted instructions will result in death or serious injury Call 262 255 1510 for replacement placards warning labels or owner s user s manuals File Name 1751 0730 Rev B Decal Size...

Page 7: ...LL RESULT IN DEATH OR OTHER SERIOUS INJURY DANGER POWERED DOCK LEVELERS NORMAL OPERATION 1 Raise the platform by Pressing and holding the RAISE button 2 Hold the RAISE button until the lip is fully ex...

Page 8: ...e interface between the loading dock and the transport vehicle The owner user should therefore train and instruct all operators in the safe operation and use of the loading dock equipment in accordanc...

Page 9: ...oduct warranty the dock safety equipment must have been properly installed maintained and operated in accordance with all manufacturer s recommendations and or specified design parameters and not othe...

Page 10: ...s or wet environments The CA series dock leveler is an environmentally friendly addition to any material handling operation and will have minimal effect on the building s electrical footprint This lev...

Page 11: ...r Bellows K Main Frame L Maintenance Prop M Toe Guard 2 used N Raise Button Electric O Safety Legs P Air Control Valve Q Lanyard R Filter Regulator Lubricator S Raise Button Air T Lip Assist Spring Co...

Page 12: ...lure to follow these instructions may damage the motor hydraulics wiring and or control panel Installation Precautions DO NOT remove the shipping bands around the dock leveler lip until instructed to...

Page 13: ...3 8 u n i o n e l b o w 9 3 0 1 0 2 4 1 F t g 3 8 u n i o n t e e 9 3 0 1 0 2 4 4 F t g 1 2 u n i o n t e e 9 3 0 1 0 2 6 0 S h u t o f f 1 2 t e e f t g 3 8 s t r f t g 6 1 0 6 0 0 2 6 S h u t o f f...

Page 14: ...sure dock floor to pit floor distance B at all four corners Measure pit length distance C at both sides Measure corner to corner diagonal distance D at both sides Take measurements at dock floor level...

Page 15: ...sure the mounting hardware of lifting brackets A is snug The brackets should pivot without binding on the mounting cap screw 3 Attach lifting chains to lifting brackets A and to a lifting device i e h...

Page 16: ...ntenance Prop D Shim Locations Under Lip Keepers E Dock Floor F Rear Pit Curb Angle G String H Rear Hinge Frame Angle K Distance Dock Floor to Pit Floor L Distance Top of Shim Stack to Dock Floor M Sh...

Page 17: ...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 2 114 3 mm x 114 3 mm to support the full width of the frame rail and to provide a shelf f...

Page 18: ...p 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 m...

Page 19: ...e bellows and air valve with a fireproof blanket to protect from weld sparks and splatter 17 With the rear hinge frame angle F tight against the rear pit curb angle G weld the rear hinge frame angle F...

Page 20: ...at the correct dimensions until the leveler is permanently anchored into place Only then should it be removed There are four cap screws and nuts that fasten the T frame to the rest of the leveler fram...

Page 21: ...19 4111 0034 Sept 2018 2018 Systems LLC This page intentionally left blank INSTALLATION...

Page 22: ...ion c for a grounding electrode system B A C A Disconnect Panel B Control Panel provided by others C Distance 48 in 1219 mm Figure 14 INSTALLATION DO NOT connect the dock leveler electrical wiring and...

Page 23: ...to control panel valve and air bellows under dock leveler as shown on pages 22 23 3 After all pneumatic connections in the pit have been made raise the leveler disengage the maintenance prop and allow...

Page 24: ...pply INSTALLATION Supply From Regulator 1 2 or larger must be verified Pilot Supply from Control Box To Air Bellows Valve 1 2 line Provided by Others 3 8 line Installed at Factory 3 8 line Provided By...

Page 25: ...tems LLC Underground Air Supply INSTALLATION Supply From Regulator Valve To Air Bellows 1 2 line Provided by Systems 3 8 line Installed at Factory 3 8 line Provided By Systems End run Tee NOT Required...

Page 26: ...18 Systems LLC Lanyard Air Supply Electric Operator Air Supply INSTALLATION 3 8 line Installed at Factory 3 8 line Provided By Systems To Air Bellows To Air Regulator To Air Bellows To Air Regulator T...

Page 27: ...er and or vehicle restraint operations Suggested placement of placard is near control box attached to electrical conduit by using nylon cable tie If there is no control box present mount placard on wa...

Page 28: ...e cross traffic stored position lip engages lip keepers 7 Perform steps 4 6 at least four times to ensure proper operation with no binding Put New Dock Leveler Into Service 8 Raise the platform fully...

Page 29: ...l Precautions Stay clear of dock leveler and vehicle restraint when transport vehicle is entering or leaving dock area DO NOT move or use the dock leveler or restraint if anyone is under or in front o...

Page 30: ...holding the RAISE button or holding the pull ring until the lip folds enough to land in the lip keepers then release the RAISE button or pull ring The platform will return to the cross traffic positio...

Page 31: ...ss at the front of the platform This will cause the lip to extend away from the lip keepers and the safety legs to fold allowing the leveler to lower to the full below dock position See Figure 18 7 Wh...

Page 32: ...ion it is recommended and good safety practice to use an additional means to support the dock platform and lip anytime when physically working in front of or under the dock leveler This additional mea...

Page 33: ...maintenance prop behind front header plate D while staying clear of the lip The lip prop F should be used to keep the lip extended See Figures 22 and 23 Lock the maintenance prop in the service uprig...

Page 34: ...n actual configuration may be different based on application F If equipped with lubricator fill with Kill Frost or equivalent check weekly H 95 PSI Recommended I Drain water weekly or as required Adju...

Page 35: ...Quarterly Maintenance Complete Weekly Maintenance Inspect the following for damage abnormal wear Check welds for cracks Lip hinge pins and rear hinge pins Check full range toe guards if equipped for...

Page 36: ...other applicable head protection should always be worn when working under or around a dock leveler Always stand clear of platform lip when working in front of the dock leveler Unless the dock leveler...

Page 37: ...lly check air bellows and lines for possible leaks before adjusting the lip actuator spring Lip Latch Spring Tension Note Use two turn increments when adjusting lip assist spring Check lip operation a...

Page 38: ...he lip and engage lip maintenance prop not shown 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 A Turn stop bolt out countercl...

Page 39: ...mbly and the shackle The final number of links may vary depending on application 6 levelers 31 33 links 8 levelers 32 34 links 10 levelers 33 35 links If the maintenance prop cannot be raised to the b...

Page 40: ...able head protection should always be worn when working under or around a dock leveler Always stand clear of platform lip when working in front of the dock leveler Unless the dock leveler is equipped...

Page 41: ...iodic Maintenance in the Maintenance section Low Air pressure Minimum 80 PSI required at regulator if lower check air supply 95 PSI recommended Platform DOES rise to full height but lip DOES NOT exten...

Page 42: ...1 50 3 00 Decal Size 1 5 x 3 File Name 1751 0736 Rev A Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without...

Page 43: ...3 8 PARTS Pneumatic Control Box Item Quantity Part Number Description 1 2756 0001 Push Button Controller 9 V0 800 0 E Poweramp Decals A 2 9301 0249 3 8 Bulkhead fitting B 1 1751 0892 Decal English C 1...

Page 44: ...Fitting Breather Muffler Speed Control C 1 9301 0236 Fitting 3 8 NPT to 3 8 Tube D 1 9301 0250 Fitting 1 8 NPT to 3 8 Straight E 1 9301 0237 Fitting 3 8 NPT to 3 8 Swivel Elbow F A R 2101 0260 Clamp...

Page 45: ...rm D 2 2101 0116 Bolt x 2 Lg E 2 2101 0143 Lock Nut F A R R985 0001 Tubing G 1 8581 0158 Valve Operator Mechanical H 1 9512 2061 Lanyard Control Bracket I 1 9301 0236 Fitting Straight J 1 9301 0237 Fi...

Page 46: ...44 4111 0034 Sept 2018 2018 Systems LLC PARTS Item Quantity Part Number Description A 1 0941 0013 Spring Lip Latch Extension B 1 2101 0230 Ring Split 1 3 4 OD C 1 2101 0239 Link Chain snap 1 4 B A C...

Page 47: ...ption A 1 8586 0008 Regulator Assembly W Lubricator Flow Left To Right SHOWN 8586 0009 Regulator Assembly W Lubricator Flow Right to Left B 1 8581 0154 Filler Regulator C 1 8581 0153 Oil Lubricator Pi...

Page 48: ...NO DATE KRV 3 5 2014 8434 0821 WLDT LIP LATCH RELEASE 2014 P O W E R A M P D L M S Y S T E M S I N C L o a d i n g D o c k E q u i p m e n t This print is the property of Systems Inc and represents a...

Page 49: ...2 2101 0046 Cotter Pin x 1 in O 2 8432 0983 Lip Keeper 16 Lip 8432 0984 Lip Keeper 18 Lip 8432 0985 Lip Keeper 20 Lip P 1 8434 0821 Lip latch release from 4 2014 1 Provide dock leveler serial number p...

Page 50: ...g and Cable 16 long 5775 0005 Lip Latch Assembly Includes Spring and Cable 21 Long H 1 2101 0229 Bolt x 1 Lg DOTH 2351 I 5 DOTH 2210 Washer J 1 2101 0045 Cotter Pin 1 8 x 1 00 LG DOTH 2351 K 1 DOTH 21...

Page 51: ...l Bar Assembly Safety Leg E 1 DOTH 2075 Cap Screw Lip Stop 5 8 11 x 2 5 LG UNC GR5 2101 0243 F 1 DOTH 2356 Nut Hex 5 8 11 UNC 2101 0042 G 1 DOTP 6646 Rod Push Assy H 1 DOTH 2356 Pin Clevis I 1 DOTH 23...

Page 52: ...m Quantity Part Number Description B 1 0192 0098 Brush Refill 1 1 2 in 82 Lg C 1 0192 0085 Rubber Refill 1 1 2 in 82 Lg D 1 0192 0146 Replacement Channel Item Quantity Part Number Description E 1 0195...

Page 53: ...51 4111 0034 Sept 2018 2018 Systems LLC PARTS This page intentionally left blank...

Page 54: ...52 4111 0034 Sept 2018 2018 Systems LLC MISCELLANEOUS This page intentionally left blank...

Page 55: ...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 LLC P O Bo...

Page 56: ...IED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS LLC AND ITS SUBSIDIARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUDING THIRD...

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