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Poweramp CM Series, Owner & User Manual

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Poweramp CM Series Owner & User Manual Download Page 33

PARTS

31

4111-0006 — Sept 2010

Frame Components

*AR = As Required

1 

Provide dock leveler serial number, platform size, lip size and pit depth when calling or faxing orders.

Item Quantity  Part Number

Description

A

1

DFRA____ 

1

Frame, Welded Assembly

DFRA-____ 

1

Frame, Clean Sweep, Welded Assembly (Optional)

B

1

DOTH-2555

Spring, Snubber

C

1

DOTH-2416

Lap Link, 3/16 x 1.0 in.

D

1

DPLA-2128

Chain, Lip Assist Link

E

1

DOTH-2421

Cold Shut Link, 5/16 in.

F

1

DFRA-0326

6 Foot Bolt, Spring Adjuster & Plate, Spring Tensioner

1

DFRA-0327

8 Foot Bolt, Spring Adjuster & Plate, Spring Tensioner

1

DOTH-2222 

Washer

G

1

DOTP-6424 

1

Lift Arm, Short, 25”

1

DOTP-6423 

1

Lift Arm, Long, 27”

J

1

DOTH-2402

Roller Assembly, Cam

K

AR*

DOTH-____ 

1

Spring, Lift

L

5

DOTH-2382 

Pin, Cotter, 1/4 x 2 in.

M

3

9202-0002 

Pin, Rear Hinge

N

1

DOTH-2061

Bolt, Shoulder

P

4

DOTH-2432

Spring Snap, 3/16 in.

Q

1

DOTH-2423 

Ring, Chain

S

1

DOTH-2131

Nut, Nylon Lock

T

1

DLPA-1210

Chain, Release Pull

U

1

DOTH-6929 

Arm, E-Z Release

V

1

DOTP-6921 

1

Chain, Hold-Down Release 5 ft 

1

DOTP-6922 

1

Chain, Hold-Down Release 6 ft 

1

DOTP-6923 

1

Chain, Hold-Down Release 8 ft 

1

DOTP-6924 

1

Chain, Hold-Down Release 10 ft 

W

1

DOTP-____ 

1

Prop, Maintenance

X

2

DOTP-____ 

1

Keeper, Lip

Y

1

DOTH-2356 

Pin, Clevis

Z

1

DOTH-2405 

Roller, Hold-Down Release Chain

AA

1

DOTH-2375 

Pin, Cotter

AB

1

DOTH-2563

Hold-Down Assembly Complete, 31.5” Ratchet Bar

1

DOTH-2564

Hold-Down Assembly Complete, 34.5” Ratchet Bar

AD

1

DOTH-2222 

Washer

AE

1

DRFA-1205

Pin

Summary of Contents for CM Series

Page 1: ...Manual Printed in U S A Copyright 2003 Manual No 4111 0006 September 2010 POWERAMP Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www docksystemsinc com techservices docksystemsinc com ...

Page 2: ...ck Leveler 10 Install Dock Leveler 12 Operation Theory 17 Operating Instructions 18 Ramp Loading Unloading Instructions 19 End Loading Unloading Instructions 20 Maintenance Service Dock Leveler Safely 21 Periodic Maintenance 22 Adjustments Adjust Lift Arm Spring and Lip Assist Spring Tension 24 Adjust Lip Stop Bolt 26 Troubleshooting Troubleshooting 27 Parts Hold Down Mechanism 29 Frame Components...

Page 3: ... obstacles that could cause a person to trip or fall The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death 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 injur...

Page 4: ... if anyone is under or in front of it Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts 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 Do not use a broken or damaged dock leveling device Make sure proper service and maintenance procedures ...

Page 5: ...k 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 ...

Page 6: ...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 Failure to follow these instructions may result in serious personal injury or death 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 The ...

Page 7: ... problems immediately to supervisor Maintenance Service 1 Read and follow all instructions warnings and maintenance schedules in the owner s user s manual 2 Maintenance Service of dock leveler restricted to trained personnel 3 Place barriers on the driveway and on dock floor to indicate service work is being performed 4 DO NOT ENTER PIT unless dock leveler is securely supported by maintenance prop...

Page 8: ...the dock opening and in contact with both bumpers there shall be a minimum of 4 00 inches 100mm overlap of the leveling device and the transportation vehicle at all times during the loading and unloading process 4 Name plates placards decals instructions and posted warnings shall not be obscured from the view of the operator or maintenance personnel for whom such warnings are intended for Contact ...

Page 9: ... specific needs Dock Leveler Stock Specifications Congratulations on your choice of a Poweramp dock leveler This manual covers the CM series mechanical dock leveler Designed by Poweramp to be a marvel of simplicity and efficiency your dock leveler when properly installed will provide many years of trouble free performance with an absolute minimum of maintenance To obtain maximum performance and lo...

Page 10: ...ing 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 A E C B F D U T S Q R N M G H J P K L ...

Page 11: ...it floor level If any measurement is off by more than 1 8 in 3 18 mm contact Poweramp Technical Services before proceeding 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 IMPORTANT IMPORTANT DO NOT remove the shipping bands around the dock leveler lip until inst...

Page 12: ...hains 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 Failure to follow these instructions may result in damage to the dock leveler and or serious personal injury or death IMPORTANT IMPORTANT DO NOT remove the shipping bands B around the platform lip and leveler frame at this tim...

Page 13: ...e dock leveler is lowered into the pit 2 Make sure the mounting hardware of lifting brackets A is snug The brackets should pivot relatively freely on the mounting cap screw DO NOT over tighten 3 Attach lifting chains to lifting brackets A and to a lifting device i e hoist or fork truck having the appropriate lifting capacity and reach 4 Remove wood blocks that are attached to the leveler frame bef...

Page 14: ...and Prop D Dock Floor E Rear Pit Curb Angle F String G Rear Hinge Frame Angle H Distance Dock Floor to Pit 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 Install Dock Leveler M N P Q Shim Stacking Methods E D F K G L J H B C A ...

Page 15: ... a starting point The final shim stack height will be determined after the dock leveler is lowered into the pit 2 Using the results obtained in step 1 create the individual shim stacks on the pit floor at locations B Build each shim stack K using the pyramid method M preferred or stepped method N with the top shim having a minimum size of 4 1 2 x 4 1 2 in 114 3 x 114 3 mm and each successive lower...

Page 16: ...des 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 material at the rear edge of rear hinge frame angle F as needed 10 Allow the dock leveler to rest fully on the shim stacks Make sure the leveler is in the cross traffic stored position with lip resting on lip keepers 11 Check that a smoo...

Page 17: ...ame B to shims located under the keepers then weld the shims to the front pit curb steel 16 Disconnect lifting device and chains from the lifting brackets Make sure all personnel are outside of the leveler operating zone and stand clear of the platform lip before removing the shipping bands Failure to do this may result in serious personal injury or death IMPORTANT IMPORTANT When activating the le...

Page 18: ...position by walking the platform down Pull and hold safety leg chain A before lip folds completely 31 If the lip does not extend fully or lip folds too quickly see appropriate symptom in the Troubleshooting section 32 Install the dock bumpers as required 22 Install shims under lift arm at locations C using the pyramid shimming method The lift arm pivot must be solidly shimmed the entire length of ...

Page 19: ...resting on lip keepers cross traffic position Lip did not fully fold causing the platform to rest on safety legs below dock position Lip did not fully fold and safety legs are retracted causing the platform to rest on the safety stops full below dock position The hold down ratchet assembly will keep the platform at the desired position until the platform release ring is pulled again To actuate the...

Page 20: ...d on the dock leveler Failure to follow these instructions may result in personal injury and or damage to equipment DO NOT activate the dock leveler until the truck trailer is positioned squarely against the bumpers and the truck wheels are chocked Never remove the wheel chocks until loading and unloading is finished and truck driver has been given permission to leave DO NOT use the dock leveler i...

Page 21: ...ise the platform to the full raised position by pulling and holding the platform release ring A b Lower platform by slowly walking out onto the platform allowing time for the lip to fully fold and clear the truck trailer Continue walking out on platform until platform lowers to the cross traffic position lip engages in the lip keepers 10 Remove chocks from truck trailer wheels or release truck res...

Page 22: ... allowing enough time for the lip to fold Just before the platform reaches the cross traffic position pull and hold the safety leg retract pull ring B located in a recess at front of the platform The platform will continue lowering to the full below dock position 5 Pull and hold the platform release ring A until the platform is at the fully raised position 7 Proceed with loading or unloading NOTE ...

Page 23: ...prop A NOTE Make sure to disengage the lip maintenance prop and allow the lip to fold fully before disengaging the platform maintenance prop Refer to OSHA regulation 1910 147 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 The platform maintenance prop MUST be in the service position when working...

Page 24: ...sonal injury or death The platform 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 Failure to follow these instructions may result in serious personal injury or...

Page 25: ...ill increase wear and cause abnormal operation Lubricate the following areas with light weight machine oil B Lip maintenance prop pivot C Lip link pivots F E Z release bellcrank pivot H Hold down pivot pulley J Safety leg linkage pivots L Hold down to platform pin Lubricate the following areas with white lithium grease A Lip hinge area inject grease into all the lip hinge grease fittings D Platfor...

Page 26: ...he 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 Failure to follow these instructions may result in serious personal injury or death Always post safety warnings and barricade the work area a...

Page 27: ...ck operation of platform and lip Readjust lift spring tension and lip assist spring tension until proper operation is obtained 1 Raise the platform and engage the platform maintenance prop Lock the maintenance prop in the service position using an appropriate locking device 2 Adjust tension of lift springs D as follows NOTE Use 1 2 turn increments when adjusting lift spring bolt E Check platform o...

Page 28: ... stored position 7 Check lip position in both keepers Repeat procedure if necessary 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 The platform 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 ...

Page 29: ...mp Technical Services See inside back cover for phone number and address Insufficient main spring tension Increase tension on main springs See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section Damaged or worn hold down mechanism Clean and inspect hold down mechanism Troubleshooting Always stand clear of the dock leveler lip when working in front of the dock leveler Fa...

Page 30: ...t lip assist force Increase lip assist spring tension See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section Disconnected worn or broken shock absorber Inspect shock absorber Connect or replace shock absorber Platform does not stay down Entangled release chain Remove cause of entanglement Dirt impacted in ratchet bar teeth Clean and inspect ratchet bar and ratchet pawl...

Page 31: ...TH 2563 Hold Down Assembly Complete 31 5 Ratchet Bar DOTH 2564 Hold Down Assembly Complete 34 5 Ratchet Bar B 1 DKIT 2575 Ratchet Bar and Pawl Assembly 31 5 Ratchet Bar DKIT 2576 Ratchet Bar and Pawl Assembly 34 5 Ratchet Bar C 1 1751 0043 Decal Warning D 1 DOTH 2559 Spring Release Arm B D C ...

Page 32: ...PARTS 30 4111 0006 Sept 2010 Frame Components F C B D A E F K L M N F G J P Q P P S V W X Y Z P T U AB L AA AE AD ...

Page 33: ...OTP 64231 Lift Arm Long 27 J 1 DOTH 2402 Roller Assembly Cam K AR DOTH ____1 Spring Lift L 5 DOTH 2382 Pin Cotter 1 4 x 2 in M 3 9202 0002 Pin Rear Hinge N 1 DOTH 2061 Bolt Shoulder P 4 DOTH 2432 Spring Snap 3 16 in Q 1 DOTH 2423 Ring Chain S 1 DOTH 2131 Nut Nylon Lock T 1 DLPA 1210 Chain Release Pull U 1 DOTH 6929 Arm E Z Release V 1 DOTP 69211 Chain Hold Down Release 5 ft 1 DOTP 69221 Chain Hold...

Page 34: ...PARTS 32 4111 0006 Sept 2010 Platform Components AE AA AF X AH AN AG AM AJ AK AL AQ AO AP Y Z AE AC AD AB C C B D A E F K L M N G H J P Q R S U V T X ...

Page 35: ...ew L 1 DLIP ____1 Lip Welded Assembly M 2 DPLA 2101 Pin Lip Hinge 6 ft wide 2 DLPA 2102 Pin Lip Hinge 6 5 ft wide 2 DLPA 2103 Pin Lip Hinge 7 ft wide N 2 DOTH 2380 Pin Cotter Shock Absorber Assembly P 1 DOTH 2582 Shock Absorber Q 2 DOTH 2374 Pin Cotter R 2 DOTH 2210 Washer S 2 DOTH 2351 Bolt Clevis T 2 DOTH 2163 Nut Nylon Lock 1 DKIT 6465 Single Shock Absorber Assembly Includes Items P T Safety Le...

Page 36: ...ID AM 1 DOTH 6644 Spacer 1 1 4 in OD x 3 4 in ID x 1 in AN 1 DOTH 2076 Cap Screw 5 8 11 UNC x 3 1 2 in AO 1 DPLA 2126 Link Lip With Chain AP 2 DOTH 2131 Nut Nylon Lock 3 8 16 in AQ 2 DOTH 2061 Bolt Socket Head Shoulder Item Quantity Part Number Description Lip Assist Assembly A 1 DOTH 2842 Track Weatherstrip 5 DOTH 2819 Track Weatherstrip 6 DOTH 2817 Track Weatherstrip 8 DOTH 2843 Track Weatherstr...

Page 37: ...818 Channel Weather Seal 84 B 2 DOTH 2824 T Rubber Weather Seal 84 C 2 DOTH 2820 Extrusion Brush Weather Seal 84 CC 2 DOTH 2822 Brush Weather Seal 1 58 x 84 D 2 DOTH 2043 Cap Screw E 4 DOTH 2207 Washer F 1 See Chart G 1 See Chart H 2 DOTH 2131 Nut Nylon Lock J 1 See Chart K 1 See Chart CC C B D A E E F G H J K ...

Page 38: ...NOTES 36 4111 0006 Sept 2010 This page intentionally left blank ...

Page 39: ... if more information is required When ordering use part numbers and description to help identify 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 Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 Dock Leveler Information Model __________...

Page 40: ...NS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS SUBSIDARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUDING THIRD PARTIES FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO BREACH OF WARRANTY...

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