Serco SafeTFrame AB 1000 Page 1 User Manual Download

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User’s Manual

Installation, Operations,

Maintenance and Parts

Part No. 6004756F

Do not install, operate or service this product unless you

have read and understand the Safety Practices, Warnings,

Installation and Operating Instructions contained in this

User’s Manual. Failure to do so could result in death or

serious injury.

This User’s Manual applies to

dock levelers manufactured

beginning December 2010 with

the serial numbers 61000001

and higher.

Air Powered Dock Levelers

AB Series

Summary of Contents for SafeTFrame AB 1000

Page 1: ...read and understand the Safety Practices Warnings Installation and Operating Instructions contained in this User s Manual Failure to do so could result in death or serious injury This User s Manual ap...

Page 2: ...ystem This User s Manual contains information that you need to safely install operate and maintain the dock leveler It also contains a complete parts list and information about ordering replacement pa...

Page 3: ...vehicle restraining device and set brakes before loading or unloading Ensure lip avoids contact with vehicle sides and cargo If lip does not lower to vehicle floor reposition vehicle OPERATION continu...

Page 4: ...ould be kept Adock leveler that is structurally damaged or has experienced a sudden loss of support while under load such as might occur when a transport vehicle is pulled out from under the dock leve...

Page 5: ...16 2 2 8 15 5 8 0 7 4 20 3 5 6 18 3 4 5 17 2 10 0 10 2 23 2 7 7 20 5 6 1 18 9 12 0 13 0 26 1 9 8 22 7 7 8 20 6 Ramp and lip grade 7 lip crown 16 lip Lip grade Ramp grade VEHICLE BED POSITION from DOCK...

Page 6: ...th the lip maintenance bar and maintenance strut are undamaged and pins securely attached 5 Visually check that the foot assemblies at the rear of the leveler are in place and undamaged prepare site P...

Page 7: ...e lifting angle used Never allow anyone to stand on or near the dock leveler when it is lifted or placed into the pit Stand clear of the dock leveler when it is placed into the pit Failure to follow t...

Page 8: ...t with the pit floor and the top frame angle is flush with the rear curb angle See Fig 8 The rear edge of the dock leveler should be level or slightly 1 16 maximum below dock level The top surface of...

Page 9: ...rical cords from receptacles in the rear pit wall before welding Ground welder to dock leveler frame Failure to do so can result in product damage Be certain that the rear frame angle is touching the...

Page 10: ...should be level and parallel with the rear frame angle for proper operation Unequal shimming of the front supports may be required to obtain a level front edge 18 Lower the air bag pan assembly by rem...

Page 11: ...5 and the instruction label on maintenance strut c Air pressure or mechanical support may now be removed 20 Shim under frame struts directly below rollers of air bag fan 21 If electrical power is not...

Page 12: ...The lip is free to move downward when support is removed Anyone in the path of the lip when it moves downward can be struck Keep your hands fingers and head away from the lip when it is released They...

Page 13: ...ct when the leveler reaches full below dock Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury 31 Mount dock bumpers to fa...

Page 14: ...ims in weld noted in Fig 10 See Fig 19 b Align the leveler with the two square edges The gap on the sides should be even in the most narrow section 1 2 Max per side See Fig 20 c If large deformations...

Page 15: ...e control panel so leveler is fully raised b Second person raise the strut to vertical position c Release the maintenance strut ensure it has dropped into the locked position d Release the raise butto...

Page 16: ...trut IS SECURELY IN PLACE see page 15 and 2 The power is disconnected and properly tagged or locked off 3 The lip maintenance bar is in place 1 To raise the bag pan assembly 1 1 Positiondockleveleronm...

Page 17: ...event the handle from raising rapidly See Fig 27 2 2 Lower the pan assembly to the pit floor 2 3 Remove removal tool from pit Be certain before climbing into the dock leveler pit or doing any maintena...

Page 18: ...e removal wheel assy roll the assembly to the front of the pit Rollers will roll on pit floor See Fig 31 2 To install the bag pan assembly 2 1 Roll the pan assembly back in the pit and align with hook...

Page 19: ...r locked off All electrical work must be done by a qualified technician and meet all applicable codes If it is necessary to make troubleshooting checks inside the control box with the power on USE EXT...

Page 20: ...y 2 1 2 below dock level or if below dock is to a full below dock position Always return the dock leveler to its dock level stored position before allowing the vehicle to leave the dock If the vehicle...

Page 21: ...the dock leveler 1 Press the button on the control panel to raise leveler 2 Continue to press the button The lip will automatically extend when the leveler is fully raised 3A When the lip is fully ex...

Page 22: ...ry STORING LEVELER 1 To return the leveler to the stored position press the button As the leveler raises the lip will retract When the lip is fully retracted release the button The leveler will then f...

Page 23: ...all to the pendant position automatically See pages 28 29 for adjustment quarterly continued 5 Inspect the lip push out arm and lip counterbalance assemblies for damage and check the chain and springs...

Page 24: ...neered Solutions Inc planned maintenance continued Fig 41 Legend Symbol Description Lubricate Oil Light Oil SAE 30 Lubricate Grease Molybdenum Disulfide NLGI 2 Cleaning Location Frequency Visually Ins...

Page 25: ...ys 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 your local authorized distributor fo...

Page 26: ...e blown or breaker tripped b No electrical power to control panel c Push button is broken on control panel d Fan plug loose or unplugged in receptacle e Loose wires in control panel or junction box f...

Page 27: ...fully extending a Lip hinge is binding b Lip spring adjustment incorrect c Latch bar not releasing d Lip counterbalance spring is over tensioned a Clean and lubricate the lip hinge b Clean and lubrica...

Page 28: ...icle traffic and pedestrians away from the dock leveler 2 Always notify a foreman or supervisor that you are working under the equipment 3 Always make sure that the maintenance strut is securely in pl...

Page 29: ...strut Raise the lip maintenance support to prevent the lip from falling Check that the lip latch bar has locked into position Lubricate all pivots with S A E 30 oil and lip hinge tubes with general p...

Page 30: ...45 50 43 42 52 63 55 59 60 61 58 68 62 4 5 9 12 13 16 15 38 34A 44 49 50 63 54 51 59 57 56 9 10 13 19 25 26 18 28 30 22 24 23 31 35 40 32 34B 33 44 47 46 48 53 18 20 34C 9 13 63 44 49 7 63 8 9 13 44...

Page 31: ...6 I D 40 50K 234 141 234 141 234 141 11 1 Weldment Roller Arm PAL S L 6000609 6000609 6000609 12 1 Danger Label Maintenance Strut 921 074 921 074 921 074 13 3 Hex Nut 3 8 Nylock 30 35K 214 538 214 538...

Page 32: ...5 000 40 000 45 000 50 000 41 1 Lip Hinge Pin 6ft wide 586 0017 586 0017 586 0287 586 0287 586 0287 Lip Hinge Pin 6 5ft wide 586 1494 586 1494 586 1495 586 1495 586 1495 Lip Hinge Pin 7ft wide 586 020...

Page 33: ...3 1 Upper Air Bag Shield Small 155 295 1 Upper Air Bag Shield Large 155 400 155 400 54 4 Pin 3 4 DIA 586 1467 586 1467 586 1467 55 1 SQ Nut 3 8 16 UNC Plain 214 826 214 826 214 826 56 3 1180 Hitch Pin...

Page 34: ...6004756F Air Power Dock Levelers AB Series SafeTFrame March 2012 2012 4Front Engineered Solutions Inc parts list air bag pan assembly Fig 45 18 17 6 14 16 12 1 15 6 5 11 6 5 7 4 5 19 13 2 21 8 9 3 7...

Page 35: ...101 6 15 3 8 16 Nylock Nut 214 538 7 6 HHMB 3 8 16 x 1 212 103 8 4 KLIPRING 3 4 5304 75 TRUARC 236 110 9 2 Air Bag Roller Pin 521 001 10 2 Air Bag Roller 153 113 11 1 Pan Conv Reinf Angle Assy CP 3 47...

Page 36: ...olutions Inc Fig 46 parts list Fan Piping assembly 1 4 7 5 6 3 2 Item Quantity Description AB 600 800 1000 1 1 Motor Air 2 Stage 120V 6008185 2 1 Filter Housing 712 748 3 1 Filter Fan 712 196 4 1 Nipp...

Page 37: ...num strip 77 1 2 2 2 2 6008177 Aluminum strip 101 1 2 2 2 2 6008179 5 6 Lower seal 2 2 2 6008168 8 Lower seal 2 2 2 6008170 10 Lower seal 2 2 2 6008172 6 Aluminum strip 6 upper 2 2 2 6008174 Aluminum...

Page 38: ...38 6004756F Air Power Dock Levelers AB Series SafeTFrame March 2012 2012 4Front Engineered Solutions Inc Notes...

Page 39: ...ELER or the deficient portion s thereof without charge to the owner or 2 Alter or repair the DOCK LEVELER on site or elsewhere without charge to the owner This Limited Warranty does not cover any fail...

Page 40: ...stions about your dock leveler to your local distributor or to 4Front Engineered Solutions Inc Corporate Head Office 1612 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 Part...

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Serco SafeTFrame AB 1000, User Manual

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Summary of Contents for SafeTFrame AB 1000

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