Poweramp CM Manual Sept2010

CM-Series
Dock Leveler
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.docksystemsinc.com • [email protected]
Printed in U.S.A.
Copyright © 2003
Manual No. 4111-0006
September 2010
Table of Contents
Page
Safety
Recognize Safety Information..............................................................
General Operational Safety Precautions.............................................
Operational Safety Precautions............................................................
Maintenance Safety Precautions..........................................................
Safety Decals..........................................................................................
Owner’s/User’s Responsibilities..........................................................
1
1
2
4
5
6
Introduction
General Information............................................................................... 7
Dock Leveler Stock Specifications...................................................... 7
Component Identification...................................................................... 8
Installation
Prepare Pit.............................................................................................. 9
Prepare Dock Leveler........................................................................... 10
Install Dock Leveler............................................................................. 12
Operation
Theory...................................................................................................
Operating Instructions........................................................................
Ramp Loading/Unloading Instructions........................................
End Loading/Unloading Instructions...........................................
17
18
19
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.......................................................................
Frame Components.............................................................................
Platform Components.........................................................................
Toe Guard/Weather Seal—Optional...................................................
Miscellaneous
29
30
32
35
Customer Information......................................................................... 37
Warranty................................................................................. Back Cover
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.
Never operate a dock leveler while a safety device or
guard is removed or disconnected.
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.
The use of the word WARNING signifies the
presence of a serious hazard or unsafe practice
which may result in serious injury or death.
The use of the word CAUTION signifies possible
hazard or unsafe practice which could result in
personal injury.
IMPORTANT
The use of the word IMPORTANT is to draw
attention to a procedure that needs to be followed to
prevent machine damage.
Never remove DANGER, WARNING, or CAUTION
signs or decals on the equipment unless replacing
them.
on
Z
ng
ati
e
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e
Op
era
Op
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Zo
DO NOT activate the equipment until all unauthorized
personnel in the area have been warned and have
moved outside the operating zone.
Remove any tools or foreign objects from the operating
zone before starting.
Keep the operating zone free of obstacles that could
cause a person to trip or fall.
4111-0006 — Sept 2010
1
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.
Do not move or use the dock leveling device if
anyone is under or in front of it.
Do not use a broken or damaged dock leveling
device. Make sure proper service and maintenance
procedures have been performed before using.
Keep hands and feet clear of pinch points. Avoid
putting any part of your body near moving parts.
Make sure lip overlaps onto trailer at least 4 in.
(102 mm).
Keep a safe distance from both side edges.
2
4111-0006 — Sept 2010
Sept 2012
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.
4111-0006 — Sept 2010
Sept 2012
3
SAFETY
Maintenance Safety Precautions
DO NOT grind or weld if hydraulic fluid or other
flammable liquid is present on the surface to be
ground or welded
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.
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.
Failure to follow these instructions may result in
serious personal injury or death.
ALWAYS stand clear of dock leveler lip when
working in front of the dock leveler. Failure to do this
may result in serious personal injury or death.
The maintenance prop must be in the upright
“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 device.
PLACARD 1751-0877 MUST PLACED
IN CLOSE PROXIMITY AND IN CLEAR
VIEW OF THE LEVELER
4
4111-0006 — Sept 2010
Sept 2012
SAFETY
Safety Decals
5.06"
DANGER
1751-0727
CRUSH HAZARD
Maintenance prop must
support leveler behind bar.
Do not force maintenance
prop forward of bar to
support lip. Failure to
comply will result in death or
serious injury. Refer to
owner’s/user’s manual for
proper use.
2.40"
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.
1751-0730 (x2)
1751-0727 Rev A
Control Box Size:
9.12" 5.06 x 2.40
Decal Size:
File Name: 1751-0727 Rev A
SAFETY INFORMATION
DANGER
3.25"
Unsupported dock leveler
ramps can lower unexpectedly.
Before allowing vehicle to leave
the dock always:
Ensure no equipment,
material or people are on
dock leveler.
Return dock leveler to its
stored position at dock level.
OPERATION
1. Read and follow all instructions and
warnings in owner’s/user’s manual.
2. Use of dock leveler restricted to
trained operators
3. Always chock trailer wheels or
engage truck restraint before
operating dock leveler or beginning to
load or unload.
4. Never use hands or equipment to
move ramp or lip
5. Before activating dock leveler:
Ensure trailer is backed in against
bumpers.
Remove any end loads if required.
Check trailer alignment to avoid lip
interference. If lip does not lower to
trailer bed, reposition vehicle.
6. Ensure truck bed supports extended
lip or leveler frame supports the ramp
before driving on ramp.
Failure to follow posted instructions will result in death or serious injury.
7. Stay clear of hinges and front and
sides of moving dock leveler.
8. N e v e r u s e d a m a g e d o r
malfunctioning dock leveler. Report
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
dock floor to indicate service work is
being performed.
4. DO NOT ENTER PIT unless dock
leveler is securely supported by
maintenance prop.
5. If electrically powered turn off and use
OSHA lockout/tagout procedures.
Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.
(decal placed in same position on both sides)
Control Box Size:
Decal Size: 9.12 x 3.25
File Name: 1751-0730 Rev A
1751-0329 (x2)
DO NOT
FORK THIS SIDE
(decal placed in same position on both sides)
Control Box Size:
Decal Size: 13 x 2
File Name: 1751-0329
FORK
HERE
1751-0330 (x2)
(decal placed in same position on both sides)
Control Box Size:
Decal Size: 6 x 2
File Name: 1751-0330 REV A
1.43"
1751-0728
5.93"
DANGER
CRUSH HAZARD
Do not remove main springs until leveler is securely supported by a
suitable lifting device. Main springs contain stored energy. Be sure springs
are fully unloaded and ends are loose before removal. Failure to comply
will result in death or serious injury. Refer to owner’s/user’s manual for
proper maintenance procedure.
1751-0728 Rev A
1751-0788
1.02"
8.72"
Control Box Size:
DANGER
Decal Size: 5.93 x 1.40
CRUSH HAZARD
File
Name:
1751-0728
Rev
Do not work under dock leveler
unless
this maintenance
prop
hasAbeen secured in the upright
position. Failure to comply will result in death or serious injury. See owner’s/user’s manual for proper
1751-0788 Rev A
procedures.
5.05"
1751-0789
2.40"
Control Box Size:
Decal Size: 8.72 x 1.02
File Name: 1751-0788 Rev A
DANGER
CRUSH HAZARD
Open the pin latch and insert
through the maintenance
prop housing and prop
completely. Close the pin latch
to secure prop. Use every
time dock leveler is serviced.
Failure to comply will result
in death or serious injury.
1751-0789
Control Box Size:
Decal Size: 5.05 x 2.40
5.92"
File Name: 1751-0789
DANGER
CRUSH HAZARD
2.36"
1751-0726
DO NOT ENTER PIT unless dock leveler is
safely supported by maintenance prop. Place
barriers on driveway and dock floor to indicate
service work being performed. Failure to comply
will result in death or serious injury. Refer to
owner’s/user’s manual for proper maintenance
procedures.
1751-0726 Rev A
Control Box Size:
Decal Size: 5.92 x 2.36
File Name: 1751-0726 Rev A
4111-0006 — Sept 2010
Sept 2012
5
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. Effective operator training should also focus on the owner’s/user’s company
policies and operating conditions. Maintaining, updating and re training all operators on safe working
habits and operation of the equipment, regardless of previous experience, should be done on a regular
basis and should include an understanding and familiarity with all functions of the equipment. Owner’s/
user’s shall actively maintain, update and retrain all operators on safe working habits and operations of
the equipment.
2. The manufacturer shall provide to the initial purchaser all necessary information regarding Safety
Information, Operation, Installation and Safety Precautions, Recommended Initial and Periodic
Inspections Procedures, Planned Maintenance Schedule, Product Specifications, Troubleshooting
Guide, Parts Break Down, Warranty Information, and Manufacturers Contact Information, as well as
tables to identify the grade(slope) for all variations of length or configuration of the dock leveling device
and information identifying the maximum uncontrolled drop encountered when sudden removal of support
while in the working range of the equipment.
3. It is recommended that when the transportation vehicle is positioned correctly in 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. The Owner/User must review all name plates, placards, decals, instructions and posted warnings and
place the same in view of the operator or maintenance personnel for whom such warnings are intended
for. Contact manufacturer for any replacements.
5. Manufacturer’s recommended periodic maintenance and inspection procedures in effect at the date of
shipment shall be followed at all times. Written documentation of maintenance, replacement parts or
damage should be retained. In the event of damage notification to the manufacturer is required.
6. Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main
support while under load (such as what might occur when a transport vehicle pulls out from under the
leveling device) shall be removed from service, inspected by a manufacturer’s authorized representative,
and repaired or replaced as needed before being placed back in service.
7. Any modifications or alterations of loading dock equipment shall only be done with prior written approval
from the manufacturer and the same shall be at least as safe as the original equipment was prior to
the modification and shall also satisfy all safety requirements of the manufacturer for the particular
application of the leveling device.
8. When industrial moving devices are being used in the loading or unloading of product from the
transportation vehicle, this vehicle shall have the brakes and wheel chocks applied appropriately or
all other positive restraining device shall be fully utilized. It is recommended that trailers with air-ride
suspension systems shall have its air exhausted prior to performing loading and unloading operation to
minimize trailer bed drop.
9. Loading dock safety equipment should never be used outside of its intended use, vertical working range,
or capacity. Please consult the manufacturer if you have any questions as to the use, vertical working
range or capacity of the equipment. Only properly trained and authorized personnel should operate the
equipment.
10.When selecting loading dock safety equipment, it is important to consider not only present requirements
but also future plans and any possible adverse conditions, environmental factors or usage.
6
4111-0006 — Sept 2010
Sept 2012
INTRODUCTION
General Information
Dock Leveler Stock Specifications
CM-Series dock levelers are available in the following
sizes, weight capacities, and options:
Width
6 ft (1828.8 mm)
6-1/2 ft (1981.2 mm)
7 ft (2133.6 mm)
Length
5 ft
6 ft
8 ft
10 ft
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 longest possible use,
a simple program of preventive maintenance is
recommended.
(1424 mm)
(1828.8 mm)
(2438 mm)
(3048 mm)
Capacity (CIR*)
25,000 lb (11 340 kg)
30,000 lb (13 608 kg)
* CIR (Comparative Industry Rating)
Call Poweramp for your specific needs.
Once again, thank you and congratulations on your
purchase of a Poweramp mechanical dock leveler.
4111-0006 — Sept 2010
Sept 2012
7
INTRODUCTION
Component Identification
D
C
E
B
F
S
U
T
A
Q
P
R
N
M
G
H
K
J
L
A — Lip
B — Lip Maintenance Prop
C — Platform
D — Lip Banger
E — Lip Assist Spring
8
F — Platform Release Ring
G — Ratchet Pawl
H — Ratchet Bar
J — Release Arm 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
4111-0006 — Sept 2010
Sept 2012
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)
1. 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.
Failure to follow the installation instructions can
result in damage to dock leveler, the facilities, and/
or serious personal injury or death.
Only trained installation professionals with the
proper equipment should install this product.
IMPORTANT
DO NOT remove the shipping bands around the
dock leveler lip until instructed to do so.
4111-0006 — Sept 2010
Sept 2012
2. Remove all debris from the pit and sweep the pit
clean.
3. Check the entire dock leveler pit for proper
construction according to approved/certified pit
drawings. Make sure pit is square by making the
following measurements:
• Measure pit width distance (A) at both front and
rear of pit.
• Measure dock floor-to-pit floor distance (B) at all
four corners.
• Measure pit length distance (C) at both sides.
• Measure corner-to-corner (criss-cross) distance
(D) at both sides. Take measurements at dock
floor level and at pit floor level.
4. If any measurement is off by more than 1/8 in.
(3.18 mm), contact Poweramp Technical Services
before proceeding.
9
INSTALLATION
Prepare Dock Leveler
A
B
A— Lifting Bracket (2 used)
The dock leveler is heavy. Use a lifting device and
chains 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.
B — Shipping Bands
Poweramp dock levelers are designed with installation
in mind. Each unit is shipped with lifting brackets (A)
fastened to the platform side joists.
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.
Failure to follow these instructions may result in
damage to the dock leveler and/or serious personal
injury or death.
10
4111-0006 — Sept 2010
Sept 2012
INSTALLATION
1. Remove any bumpers that may be banded, or
bolted 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
DO NOT over-tighten the lifting bracket hardware.
Over-tightening can damage the weather seal, if
equipped.
NOTE: Overall width of platform and lifting
brackets (A) must be kept to a minimum to prevent
interference between the lifting brackets and the
pit walls as the 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 overtighten.
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 before putting the dock leveler into
the pit.
4111-0006 — Sept 2010
Sept 2012
11
INSTALLATION
Install Dock Leveler
Shim
Stacking Methods
M
PLACARD
N
A
P
Q
B
C
D
A— Distance (Leveler Frame
Height)
B— Shim Locations (Under Rear
Vertical Supports)
C— Shim Locations (Under Lip
Keepers and Prop)
D— Dock Floor
E— Rear Pit Curb Angle
F— String
G— Rear Hinge Frame Angle
12
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)
E
F
G
L
H
J
K
4111-0006 — Sept 2010
Sept 2012
INSTALLATION
NOTE: Poweramp dock levelers are designed with
a nominal 1/2 in. (12.7 mm) shimming distance to
allow for pit inconsistencies.
1. Determine height of shim stack (K) for each shim
location (B) by performing the following:
a.Measure leveler frame height distance (A).
b.Measure dock floor-to-pit floor distance (H) at each
shim location (B). Write down the dimensions
obtained at each location.
c.Subtract distance (A) from distance (H) to obtain
the shim height. Repeat for each shim location.
IMPORTANT
The minimum size 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 in. (114.3 x 114.3
mm) to support the full width of the frame rail and to
provide a shelf for a fillet weld.
Use the thickest shim stock possible for stability and
weld penetration purposes. DO NOT use multiple
layers of 1/8 in. (3.18 mm) or thinner shim stock.
4. Put a 1/4 in. (6.6 mm) thick shim at locations (C)
(under lip keepers/maintenance prop and safety
legs). Make sure shims are larger than frame angle
iron so pyramid or stepped stacking method can be
used.
The dock leveler is heavy. Use chains and a lifting
device with the appropriate lifting capacity and
reach. Failure to do so may result in damage to dock
leveler and/or serious personal injury or death.
NOTE: A 1/4 in. (6.6 mm) thick shim at locations
(C) is used only as a starting point. The final shim
stack height will be determined after the dock leveler
is lowered into the pit.
5. Using an appropriate lifting device connected to the
lifting brackets, lower dock leveler into the pit so rear
hinge frame angle (G) is tight against rear pit curb
angle (E) across full width of the leveler frame.
6. Allow rear of dock leveler to rest on the rear shims
while keeping the front of the dock leveler level with
the dock floor.
7. Add shims at front shim locations (C) so front of dock
leveler will stay level with dock floor when leveler is
resting fully on shims.
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 shim being larger so the shims can be welded
together using a fillet weld. DO NOT use offset
method (P) or straight method (Q).
NOTE: To assist in obtaining an accurate
measurement of distance (J), use a string (F) pulled
tight across the pit opening, directly over the shim
locations.
3. Verify that each shim stack is at the correct height
by measuring distance (J) [top of shim stack (K) to
dock floor]. Distance (J) must equal the dock leveler
height (A).
4111-0006 — Sept 2010
Sept 2012
13
INSTALLATION
A
B
B
C
C
D
D
E
F
G
A— Front of Dock Pit
B— Dock Leveler Frame
3/8 in.
(9.5 mm)
H
6 in.
(152 mm)
C— Side Pit Curb Angle
D— Gap [3/4 in. (19 mm)
Minimum]
E— Pry Locations
F— Rear Hinge Frame
Angle
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).
•Gap (D) must exist equally along both sides of
leveler so weather seal (if equipped) will not bind
during dock leveler operation.
G— Rear Pit Curb Angle
H— Flare Bevel Weld, Typical
(To Fit Spacing)
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 smooth and level transition exists
between the dock floor and the dock leveler
platform. Add or remove shims as necessary until
a smooth transition is obtained.
12.If leveler cannot be squared and made level
as instructed in steps 8 – 10, contact Poweramp
Technical Services.
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.
14
4111-0006 — Sept 2010
Sept 2012
INSTALLATION
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.
Failure to follow these instructions may result in
serious personal injury or death.
IMPORTANT
Always ground welding equipment to the dock
leveler frame, NEVER to the platform.
DO NOT weld continuously along the full length of
the rear hinge frame angle. This can put unnecessary
stress on the leveler components, causing the
leveler not to function correctly and shortening the
lifespan of the affected components.
NOTE: The illustration on the previous page shows
a typical weld pattern. The weld pattern will vary
slightly depending on size of dock leveler.
13.With the rear hinge frame angle (F) tight against
the rear pit curb angle (G), weld the rear hinge
frame angle (F) to the rear pit curb angle (G) using
a 3/8 in. (9.5 mm) flare bevel skip weld-each weld
being 6 in. (152 mm) long.
Start at each end with a 6 in. (152 mm) long
weld. Space all the other welds out evenly leaving
approximately 6 in. (152 mm) space between each
weld.
Alternate welding locations to distribute heat.
Welding sequentially from one end to the other
may cause warping or distortion.
14.Remove shipping bands at this time. Allow platform
to float. Add/Remove shims as necessary to bring
platform level/flush with floor.
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.
15.Weld front of dock leveler frame (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 clear of the platform lip before
activating the leveler. Failure to do this may result
in serious personal injury or death.
IMPORTANT
When activating the leveler, always pull AND hold
the platform release ring until the platform is at the
full-raised position. Releasing the ring while the
platform is still rising may result in damage to the
equipment.
17.Pull and hold the release ring (located in recess
at rear of platform) until the platform is fully
raised. Check for binding as platform rises.
18.Slowly walk out onto the platform to lower the
platform. Allow the platform to lower to the
cross‑traffic position. Check for binding as platform
lowers.
19.If binding occurs, reposition leveler and/
or add or remove shims as necessary. Raise
and lower platform again. If platform still binds,
contact Poweramp Technical Services for further
instructions.
20.Check that the leveler is flush with the dock floor
and that the platform lip contacts both lip keepers
evenly.
4111-0006 — Sept 2010
Sept 2012
15
INSTALLATION
A
C
B
D
A— Safety
A— Safety Leg
Leg Chain
Chain Pull
Pull Ring
Ring B— Platform
B— Platform Maintenance
Maintenance Prop
Prop C — Shim
C — Shim Location
Location (Under
(Under Lift
Lift Arm
Arm Pivot)
Pivot) D — Locking
D —Prop PinDevice
& Clip
21.Pull the release ring to raise platform. Engage
the platform maintenance prop (B) in the service
(upright) position and lock the maintenance prop
at this position using an OSHA approved locking
device (D). Engage lip maintenance prop.
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.
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 the lift
arm pivot. Make sure the lift arm pivot is level from
side-to-side.
23.Finish weld all shims using a fillet weld.
•Weld all shims within each shim stack to each
other, then weld the shim stack to the leveler frame.
•Weld the front leveler frame shim stacks to the front
pit curb steel if not done previously.
24.When all welding has been completed, remove all
slag then paint all the welds and shims.
25.Remove the lifting brackets from the platform side
joists.
26.Disengage the platform maintenance prop.
27.Slowly walk out onto the platform to lower the
platform until it is at the cross-traffic (stored)
position.
28.Check operation of dock leveler by cycling the
leveler at least four times.
•When the platform is at full height, lip will be fully
extended.
•Lip will begin to drop after full height is reached,
taking approximately 12 seconds to fully fold.
29.Check below-dock position by walking platform
down before lip folds completely.
•Lip will be over lip keepers.
•Platform safety legs will be resting on frame.
30.Check full below-dock 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.
16
4111-0006 — Sept 2010
Sept 2012
OPERATION
B
D
C
E
F
S
T
U
A
Q R
P
N
M
H
G
J
K
L
A — Lip
B — Lip Maintenance Prop
C — Platform
D — Lip Banger
E — Lip Assist Spring
F — Platform Release Ring
G— Ratchet Pawl
H — Ratchet Bar
J — Release Arm Spring
K — Main Frame
The CM-series mechanical dock leveler uses large
lift springs (U) to apply force to lift arm (T). The lift
arm pushes against the underside of the platform (C),
rolling on the cam (not pictured) forcing the platform to
rise. The force of the spring tension is just enough to
lift the weight of the platform.
IMPORTANT
When activating the leveler, always pull AND hold
the platform release ring until the platform is at the
full raised position. Releasing the ring while the
platform is still rising may result in damage to the
equipment.
To actuate the dock leveler platform, the operator
pulls and holds the platform release ring (F) located
in the recess at the rear of the platform. This causes
ratchet pawl (G) to disengage from ratchet bar (H).
With the ratchet pawl disengaged, spring tension from
lift springs (U) forces the platform to rise.
NOTE: Ratchet pawl (G) and bar (H) are part of the
hold-down mechanism (M)
4111-0006 — Sept 2010
Sept 2012
L — Platform Maintenance Prop
M— Hold-Down Mechanism
N — Safety Leg (2 used)
P — Snubber Spring
Q — Shock Absorber
R — Safety Leg Linkage
S — Safety Leg Retract Pull
Ring
T — Lift Arm
U — Lift Springs
The ratchet pawl disengages only when the platform
release ring (F) is pulled AND held. Spring tension
from pawl spring (J) causes the ratchet pawl to engage
the ratchet bar when the release ring is let go.
When the platform rises to approximately 2 – 3 inches
(51 – 76 mm) from its full raised height, the snubber
spring (P) and a chain pulls the lip link (D) forward.
This, in conjunction with the lip assist spring (E),
causes the lip linkage to push the lip out and up. The
lip assist spring also helps control the amount of time
required for the lip to fully fold.
To lower the platform, the operator walks out onto the
platform. The platform will lower until the extended lip
rests on the truck bed. If the lip did not fully extend or
there is no truck at the dock, the platform will lower
until one of the following conditions occur:
• Lip is 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.
17
OPERATION
Operating Instructions
Stay clear of dock leveler when freight carrier is
entering or leaving dock area.
12 in. (305 mm)
DO NOT raise or lower the dock leveler if anyone is
under or in front of leveler.
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.
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 if the freight carrier is
too high or too low.
12 in. (305 mm)
The CM-series mechanical dock leveler is designed
to compensate for ± 12 in. (305 mm) of height
difference between the loading dock and the truck
bed. DO NOT use the dock leveler if the truck/trailer
bed is more than 12 in. (305 mm) higher or lower
than the dock floor.
DO NOT overload the dock leveler.
DO NOT operate any equipment while under the
influence of alcohol or drugs.
DO NOT leave/store equipment
unattended on the dock leveler.
or
material
Failure to follow these instructions may result in
personal injury and/or damage to equipment.
NEVER use a fork truck or any other material
handling equipment to lower the dock leveler.
IMPORTANT
DO NOT drive any equipment onto the dock leveler
until platform lip is resting on the truck/trailer with at
least 4 in. (102 mm) of overlap.
When activating the leveler, always pull AND hold
the platform release ring until the platform is at the
full-raised position. Releasing the ring while the
platform is still rising may result in damage to the
equipment.
Always maintain a safe distance from side edges of
leveler during the loading and unloading process.
NEVER attempt to walk on an unsupported lip.
NEVER allow untrained personnel to operate the
dock leveler.
NEVER attempt to lift any part of the leveler by
hand.
Failure to follow these instructions may result in
serious personal injury or death.
18
The dock leveler operation instructions are
divided into the two methods of loading and
unloading:
• F
or ramp loading and unloading, see Ramp
Loading/Unloading Instructions on page 19.
• F
or end loading and unloading, see End
Loading/Unloading Instructions on page 20.
4111-0006 — Sept 2010
Sept 2012
OPERATION
Operating Instructions — Continued
Ramp Loading/Unloading Instructions
NOTE: If end unloading is required, see End Loading/
Unloading Instructions on page 20.
1.
Check to make sure truck/trailer is positioned
squarely against dock bumpers.
7.
Make sure that the lip is fully extended and
supported on the truck/trailer along the entire width
of the platform with at least 4 in. (102 mm) of lip
contacting the truck bed.
2.
Instruct driver to remain at the dock until the
loading or unloading process has been completed.
3.Chock the truck/trailer wheels or use truck restraint
if present.
8. Proceed with loading or unloading.
A
NOTE:If end loading is necessary, see End Loading/
Unloading Instructions on page 20.
A
4.
Raise the platform by pulling and holding the
platform release ring (A).
5.Hold the release ring until the platform is at the
fully-raised position and lip is fully extended.
9.When the loading or unloading process has been
completed, return platform to cross-traffic (stored)
position as follows:
a.Raise the platform to the full-raised position by
pulling and holding the platform release ring (A).
6.Walk out onto the platform. The platform will lower
until the lip rests on the truck/trailer bed.
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 restraint if used.
11. Indicate to driver that truck may leave the dock.
4111-0006 — Sept 2010
Sept 2012
19
OPERATION
Operating Instructions — Continued
End Loading/Unloading Instructions
NOTE: 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.
B
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.Chock the truck/trailer wheels or use truck restraint
if present.
End Loading/Unloading — Platform at Cross-Traffic
Position.
4.If truck/trailer bed is at or above dock floor level,
leave leveler at the cross-traffic position and
proceed with loading or unloading. When finished,
perform steps 9 and 10.
If truck/trailer bed is below the dock floor level,
perform steps 5 – 10.
A
5.Pull and hold the platform release ring (A) until the
platform is at the fully-raised position.
6.
Slowly walk the platform down 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.
End Loading/Unloading — Platform at Below-Dock Position.
7. Proceed with loading or unloading.
NOTE: When end unloading is finished and additional
access to the truck/trailer requires that the
platform lip be extended, see Ramp Loading/
Unloading Instructions on page 19 for further
instructions.
8.When loading or unloading is finished, raise the
platform to the full-raised position by pulling and
holding the platform release ring. Slowly walk the
platform down, allowing enough time for the lip
to fold. The platform will lower to the cross‑traffic
position (lip engages in the lip keepers).
9.Remove chocks from truck/trailer wheels or release
truck restraint if used.
10.Indicate to the driver that the truck may leave the
dock.
20
4111-0006 — Sept 2010
Sept 2012
MAINTENANCE
Service Dock Leveler Safely
A
B
D
C
A— Lip Maintenance Prop
B — Platform Maintenance Prop
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.
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 the maintenance
prop in the service position. Only the person
servicing the equipment should have the key to
unlock the maintenance prop.
C — U-Bracket
D — Prop Pin & Clip
Whenever maintenance is to be performed under the
dock leveler platform, support the platform with the
platform maintenance prop (B).
Put the platform maintenance prop in the service
(upright) position so that the prop is cradled in the
u-bracket (C). Lock the platform maintenance prop
in this position by inserting the prop pin and clip (D)
or attaching an OSHA approved lockout device* and
tagout device*, supplied by others.
Only the person servicing the equipment should have
the capability to remove the lockout device. The
tagout device must inform that repairs are in process
and clearly state who is responsible for the lockout
condition.
If maintenance requires that the lip be in the extended
position, raise the lip by hand and support the lip with
the lip maintenance prop (A).
NOTE:Make sure to disengage the lip maintenance
prop and allow the lip to fold fully before
disengaging the platform maintenance prop.
Failure to follow these instructions may result in
serious personal injury or death.
* Refer to OSHA regulation 1910.147.
4111-0006 — Sept 2010
Sept 2012
21
MAINTENANCE
Periodic Maintenance
A
D
C
B
•
E
L
K
F
J
G
H
A — Lip Hinge Grease Fittings
B — Lip Maintenance Prop Pivot
C — Lip Banger Pivots
D — Platform Hinge Area
E — Lift Arm Roller Bushing F — E-Z Release Bellcrank Pivot G — Lift Arm Pivot
H — Hold-Down Pivot/Pulley
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.
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.
22
J — Safety Leg Linkage Pivots
K — Lip Lift Assist Pin
L — Hold Down-to-Platform Pin
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 death.
4111-0006 — Sept 2010
Sept 2012
MAINTENANCE
Regular maintenance must be performed on a weekly
and quarterly schedule.
Weekly Maintenance
Quarterly Maintenance
• O
perate the dock leveler through the complete
operating cycle to maintain lubrication.
• L
ubricate the following areas with light-weight
machine oil:
NOTE: To thoroughly inspect the platform hinge area,
position the platform in the full below‑dock
position.
(B)— Lip maintenance prop pivot
• Inspect the platform hinge and the lip hinge areas.
The hinge areas must be kept free of dirt and debris.
Build-up of foreign material in the hinge areas will
increase wear and cause abnormal operation.
(F)— E-Z release bellcrank pivot
(C)— Lip banger pivots
(H)— Hold-down pivot/pulley
(J)— Safety leg linkage pivots
(L)— Hold down-to-platform pin
IMPORTANT
Failure to properly lubricate the dock leveler will
cause abnormal operation of the leveler.
• L
ubricate the following areas with white lithium
grease:
DO NOT lubricate the hold-down ratchet bar and
pawl.
(A)— Lip hinge area (inject grease into all the lip
hinge grease fittings)
(D)— Platform hinge area (inject grease into all the
platform hinge grease fittings)
(E)—Lift arm roller bushing
(G)— Lift arm pivot
4111-0006 — Sept 2010
Sept 2012
(K)— Lip assist pin
23
ADJUSTMENTS
Adjust Lift Arm Spring and Lip Assist Spring Tension
A
B
D
C
E
F
A — Jam Nut
B —Adjustment Nut
C — Lip Assist Spring
D — Lift Springs
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.
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.
24
E — Lift Spring Bolt
F — Hold-Down Mechanism
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 death.
4111-0006 — Sept 2010
Sept 2012
ADJUSTMENTS
NOTE: Adjusting the tension of lift springs (D) usually
requires that the lip assist spring (C) also be
adjusted.
3.
After lift spring adjustment is completed, check
operation of the lip.
• If the lip folds before the platform can be walked
down, tension of lip assist spring (C) may be set
too low.
• If the lip does not fold fully or takes too long to
fold, tension of lip assist spring (C) may be set
too high.
If the platform does not rise fully and/or lip does not
extend fully, the lift spring tension may be set too low.
If the platform cannot be walked down or is difficult to
walk down, the lift spring tension may be set too high.
4. Adjust lip assist spring tension as follows:
If the platform does not rise fully on its own, it may
be necessary to use an external lifting device. Use
a lifting device with the appropriate lifting capacity
to safely raise the platform. Make sure to engage
and lock the platform maintenance prop after raising
the platform. Failure to do this may result in serious
personal injury or death.
NOTE:Use two-turn increments when adjusting
lip assist spring (C). Check lip operation
after each adjustment. Repeat until proper
operation is obtained.
a.Loosen jam nut (A).
b.To increase spring tension, turn nut (B) clockwise.
IMPORTANT
When using an external lifting device to raise the
platform, make sure hold-down mechanism (F) is
disengaged. Pull and hold platform release ring
during the lifting process to avoid shearing the
ratchet pawl and ratchet bar teeth.
c.
To decrease spring tension, turn nut (B)
counterclockwise.
d.Tighten jam nut.
5.
Recheck 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 operation
after each adjustment. Repeat until proper
operation is obtained.
• To increase lift spring tension, turn lift spring
bolt (E) clockwise.
• To decrease lift spring tension, turn lift spring
bolt (E) counterclockwise.
4111-0006 — Sept 2010
Sept 2012
25
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.
C
E
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 death.
Check that lip (E) is fully resting on the lip keepers
(D) and at the lowest part of the keeper cradle. If lip is
not resting properly in keepers, perform the following
adjustment.
D
A— Platform
B— Jam Nut
C— Stop Bolt
D — Lip Keeper
E — Lip
4. Tighten jam nut (B).
5. Disengage lip maintenance prop.
6.Walk platform down to cross-traffic (stored) position.
1.
Fully raise platform. Manually raise the lip and
engage lip maintenance prop (not shown).
7.
Check lip position in both keepers. Repeat
procedure if necessary.
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” (counterclockwise) to hold
lip further away from platform (A).
26
4111-0006 — Sept 2010
Sept 2012
ADJUSTMENTS
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4111-0006 — Sept 2010
Sept 2012
27
TROUBLESHOOTING
Troubleshooting
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.
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.
Symptom
Platform does not rise.
Possible Cause
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 death.
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.
Disconnected or broken
release cable.
Connect or replace cable.
Dock leveler binds.
Check for visible obstructions that could cause
binding. Check weather seal if equipped.
If no obstructions found, call Poweramp Technical
Services. See inside back cover for phone number
and address.
Platform rises slowly or
does not rise to the full
raised position.
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. Check weather seal if equipped.
If no obstructions found, call Poweramp Technical
Services. See inside back cover for phone number
and address.
28
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.
4111-0006 — Sept 2010
Sept 2012
TROUBLESHOOTING
Symptom
Platform rises to full
height, but lip does not
fully extend.
Possible Cause
Lip assist chain
disconnected or broken.
Connect or replace chain.
Insufficient main spring
tension.
Increase tension on main lift springs. (See Adjust
Lift Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
Insufficient lip assist force.
Increase lip assist spring tension. (See Adjust Lift
Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
Platform does not lower Excessive main spring
when operator walks out tension.
onto the platform.
Lip folds too fast during
normal walk-down.
Platform does not stay
down.
Lip does not fold after
truck departs.
4111-0006 — Sept 2010
Sept 2012
Solution
Reduce main spring tension. (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.
Insufficient 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.
Entangled release chain.
Remove cause of entanglement.
Dirt impacted in ratchet bar
teeth.
Clean and inspect ratchet bar and ratchet pawl
teeth. DO NOT lubricate the ratchet assembly.
Broken or damaged ratchet
assembly teeth.
Replace ratchet assembly. DO NOT lubricate the
ratchet assembly.
Disconnected or broken
hold-down pivot pins.
Replace hold-down pivot pins.
Damaged or worn
hold‑down mechanism.
Clean and inspect hold-down mechanism.
Lip hinge binding because
of lack of lubrication
Inject grease into all of the lip hinge grease fittings.
(See Periodic Maintenance in the Maintenance
section.)
Excessive lip assist force.
Decrease lip assist spring tension. (See Adjust Lift
Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
29
TROUBLESHOOTING
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30
4111-0006 — Sept 2010
Sept 2012
PARTS
Hold-Down Mechanism
B
D
C
Item
Quantity
1
B
1
C
D
1
1
4111-0006 — Sept 2010
Sept 2012
Part Number
Description
DOTH-2563 Hold Down Assembly Complete, 31.5” Ratchet Bar
DOTH-2564 Hold Down Assembly Complete, 34.5” Ratchet Bar
DKIT-2575
Ratchet Bar and Pawl Assembly 31.5” Ratchet Bar
DKIT-2576
Ratchet Bar and Pawl Assembly 34.5” Ratchet Bar
1751-0043
Decal, Warning
DOTH-2559 Spring, Release Arm
31
PARTS
Frame Components
F
J
K
L
G
F
M
AD
F
L
E
AB
D
N
AE
AD
C
P
L
Q
P
B
P
S
AA
A
Z
V
Y
U
P
T
W
X
BASE FRAMES
ITEM
QTY
A
1
32
6’ LONG
8’ LONG
10’ LONG
6’ WIDE
20K/50K
6’ WIDE
20K/50K
6’ WIDE
20K/50K
16
DRFA-1003
16
DRFA-1012
16
DRFA-1021
18
DRFA-1004
18
DRFA-1013
18
DRFA-1022
20
DRFA-1005
20
DRFA-1014
20
DRFA-1023
6.5’ WIDE
20K/50K
6.5’ WIDE
20K/50K
6.5’ WIDE
20K/50K
16
DRFA-1006
16
DRFA-1015
16
DRFA-1024
18
DRFA-1007
18
DRFA-1016
18
DRFA-1025
20
DRFA-1008
20
DRFA-1017
20
DRFA-1026
7’ WIDE
20K/50K
7’ WIDE
20K/50K
7’ WIDE
20K/50K
16
DRFA-1009
16
DRFA-1018
16
DRFA-1027
18
DRFA-1010
18
DRFA-1019
18
DRFA-1028
20
DRFA-1011
20
DRFA-1020
20
DRFA-1029
4111-0006 — Sept 2010
Sept 2012
PARTS
Frame Components
Item Quantity Part Number
A
1
B
C
D
E
W
1
1
1
1
1
1
1
1
1
1
AR*
5
3
1
4
1
1
1
1
1
1
1
1
1
X
2
Y
Z
AA
1
1
1
1
1
1
1
F
G
J
K
L
M
N
P
Q
S
T
U
V
AB
AD
AE
DFRA____
DFRA-____ 1
DOTH-2555
DOTH-2416
DPLA-2128
DOTH-2421
DFRA-0326
DFRA-0327
DOTH-2222
DOTP-6424 1
DOTP-6423 1
DOTH-2402
DOTH-____ 1
DOTH-2382
9202-0002
DOTH-2061
DOTH-2432
DOTH-2423
DOTH-2131
DLPA-1210
DOTH-6929
DPLA-1211 1
DPLA-12111
DPLA-12111
DOTP-6924 1
DOTP-____ 1
8432-0983 1
8432-0984 1
8432-0985 1
8432-0986 1
8432-0987 1
8432-0988 1
DOTH-2356
DOTH-2405
DOTH-2375
DOTH-2563
DOTH-2564
DOTH-2222
DRFA-1205
1
Description
Frame, Welded Assembly (see page 32)
Frame, Clean Sweep, Welded Assembly (Optional)
Spring, Snubber
Lap Link, 3/16 x 1.0 in.
Chain, Lip Assist Link
Cold Shut Link, 5/16 in.
6 Foot Bolt, Spring Adjuster & Plate, Spring Tensioner
8 Foot Bolt, Spring Adjuster & Plate, Spring Tensioner
Washer
Lift Arm, Short, 25”
Lift Arm, Long, 27”
Roller Assembly, Cam
Spring, Lift
Pin, Cotter, 1/4 x 2 in.
Pin, Rear Hinge
Bolt, Shoulder
Spring Snap, 3/16 in.
Ring, Chain
Nut, Nylon Lock
Chain, Release Pull
Arm, E-Z Release
Chain, Hold-Down Release 5 ft
Chain, Hold-Down Release 6 ft
Chain, Hold-Down Release 8 ft
Chain, Hold-Down Release 10 ft
Prop, Maintenance
Keeper, 16” Lip, 20” Pit
Keeper, 18” Lip, 20” Pit
Keeper, 20” Lip, 20” Pit
Keeper, 16” Lip, 24” Pit
Keeper, 18” Lip, 24” Pit
Keeper, 20” Lip, 24” Pit
Pin, Clevis
Roller, Hold-Down Release Chain
Pin, Cotter
Hold-Down Assembly Complete, 31.5” Ratchet Bar
Hold-Down Assembly Complete, 34.5” Ratchet Bar
Washer
Pin
*AR = As Required
1 Provide dock leveler serial number, platform size, lip size and pit depth when calling or faxing orders.
4111-0006 — Sept 2010
Sept 2012
33
PARTS
Platform Components
U
M
V
X
L
X
R
N
Q
P
S
J
G
T
D
C
E
K
H
F
AE
C
AB
AC
AN
A
AH
AA
AM
AG
Y
AJ
Z
AK
AL
AE
AD
AQ
AP
AF
AO
34
4111-0006 — Sept 2010
Sept 2012
PARTS
Platform Components
Item
Quantity
A
C
D
E
F
G
H
J
K
L
1
AR*
1
2
1
2
1
1
1
1
2
2
2
See Page 34
DOTH-2424
DOTH-2075
DOTH-2160
DOTH-2131
DOTH-2214
DOTH-2547
DOTP-2006
DOTH-2062
See Page 34
DPLA-2101
DLPA-2102
DLPA-2103
Platform, Welded Assembly
Fitting, Grease
Cap Screw, Lip Stop
Nut, Hex 5/8-11
Nut, Nylon Lock
Washer
Spring, Lip Maintenance Prop
Prop, Lip Maintenance
Cap Screw
Lip, Welded Assembly
Pin, Lip Hinge 6 ft wide
Pin, Lip Hinge 6.5 ft wide
Pin, Lip Hinge 7 ft wide
N
2
DOTH-2380
P
Q
R
S
T
1
2
2
2
2
1
DOTH-2582
DOTH-2374
DOTH-2210
DOTH-2351
DOTH-2163
DKIT-6465
U
V
X
Y
Z
AA
AB
AC
AD
1
1
2
1
1
1
1
1
1
DOTH-2423
DOTH-2412
DOTH-2432
DOTH-6231
DPLA-2122
DOTH-2356
DOTP-6647
DOTH-2374
DOTH-6232
AE*
1
AF
1
AG
AH
AJ
AK
AL
AM
AN
AO
AP
AQ
1
1
1
2
2
1
1
1
2
2
DPLA-2130
DOTH-2548
DOTH-2546
DOTH-2061
DOTH-2131
DOTH-2160
DOTH-2449
DOTH-2211
DOTH-6644
DOTH-2076
DPLA-2126
DOTH-2131
DOTH-2061
Pin, Cotter
Shock Absorber Assembly
Shock Absorber
Pin, Cotter
Washer
Bolt, Clevis
Nut, Nylon Lock
Single Shock Absorber Assembly (Includes Items P – T)
Safety Legs Assembly
Ring, Chain
Chain, Safety Leg
Spring Snap 3/16 in
Leg, Left Safety Assembly with Spring
Pull Bar Rod Assembly, Safety Leg
Pin, Clevis
Rod, Push
Pin, Cotter
Leg, Right Safety Assembly with Spring
Lip Assist Assembly
Rod, Lip Assist Adjuster, (1-1/8 in. x 34 in., Heavy Duty Short)
Spring, STD, Lip Assist
Spring, HD, Lip Assist
Bolt, Shoulder
Nut, Nylon Lock
Nut, Nylon Lock, 5/8 -11 UNC
Bearing, Roller
Washer, 5/8”, 1-5/16 in. OD x 11/16 in. ID
Spacer, 1-1/4 in. OD x 3/4 in. ID x 1 in.
Cap Screw, 5/8 -11 UNC x 3-1/2 in.
Link, Lip With Chain
Nut, Nylon Lock, 3/8 -16 in.
Bolt, Socket-Head Shoulder
M
Part Number
Description
*AR = As Required
Continued on next page
1 Provide dock leveler serial number, platform size, and lip size when calling or faxing orders.
4111-0006 — Sept 2010
Sept 2012
35
PARTS
Platform Components
Continued from previous page
6’ Long
ITEM QTY
A
PLATFORMS
8’ Long
6.0’ Wide
6.5’ Wide
7.0’ Wide
6.0’ Wide
6.5’ Wide
10’ Long
7.0 FOOT
6.0’ Wide
6.5’ Wide
7.0’ Wide
1
25K DPLA-1008 DPLA-1029 DPLA-1050 25K DPLA-1015 DPLA-1036
DPLA-1057 25K DPLA-1022 DPLA-1043 DPLA-1064
1
30K DPLA-1009 DPLA-1030 DPLA-1051 35K DPLA-1016 DPLA-1037
DPLA-1058 35K DPLA-1023 DPLA-1044 DPLA-1065
L
LIPS
QTY.
25K
30K
6.0’
1
16 DLIP-1000
DLIP-1003
1
18 DLIP-1001
DLIP-1004
1
20 DLIP-1002
DLIP-1005
1
16 DLIP-1018
DLIP-1021
1
18 DLIP-1019
DLIP-1022
20 DLIP-1020
DLIP-1023
1
16 DLIP-1036
DLIP-1039
1
18 DLIP-1037
DLIP-1040
1
20 DLIP-1038
DLIP-1041
6.5’
1
7.0’
36
4111-0006 — Sept 2010
Sept 2012
PARTS
Platform Components
55
56
57
58
SEE CHART
DOTH-2570 SPRING MAIN 6620
SEE CHART
DOTH-2574 SPRING MAIN 6635
SEE CHART
DOTH-2576 SPRING MAIN 6820
SEE CHART
DOTH-2578 SPRING MAIN 6835
A
B
C
SEE CHART
DOTH-2550 REG LIP SPRING (ORANGE)
SEE CHART
DOTH-2546 HEAVY DUTY LIP SPRING (GREEN)
SEE CHART
DOTH-2548 STANDARD LIP SPRING (WHITE)
6’ LONG
6.0’ WIDE
25K
30K
(4)55
20
A
(4)55 A
(4)55 A
16
(2)55, (1)56
(2)55, (1)56
(2)55, (1)56
20
B
B
(2)55, (1)56 B
(2)55, (1)56
18
16
(1)55, (2)56
B
B
(1)55, (2)56 B
(1)55, (2)56
18
(1)55, (2)56
(1)55, (2)56
16
18
B
(4)55 B
(4)55 B
(4)55
6.5’ WIDE
B
B
(2)55, (1)56 B
7.0’ WIDE
20
8’ LONG
6.0’ WIDE
25K
B
B
(2)55, (2)56 B
30K
A
A
16
(3)55,
18
(3)55,
20
(2)55, (1)56
16
(2)55, (1)56
B
B
(2)55, (1)56 B
(2)55, (1)56
(2)55, (1)56
B
6.5’ WIDE
18
20
B
(2)55, (1)56 B
(2)55, (1)56 B
(2)55, (1)56
B
B
(4)57 B
(4)57
(4)57
B
B
B
7.0’ WIDE
B
B
(4)57 B
16
(4)57
(4)57
18
(4)57
(4)57
20
10’ LONG
6.0’ WIDE
25K
30K
16
(8)57
(8)57
(8)57
20
B
B
(8)57 B
(8)57
18
B
B
(8)57 B
16
(8)57
(8)57
(8)57
20
B
B
(8)57 B
(8)57
18
16
(4)57, (4)58
B
(4)57, (4)58 B
(4)57, (4)58 B
(4)57, (4)58
6.5’ WIDE
B
B
(8)57 B
7.0’ WIDE
18
20
4111-0006 — Sept 2010
Sept 2012
B
(4)57, (4)58 B
(4)57, (4)58 B
37
PARTS
Platform Components
B
C
CC
A
D
K
E
F
E
G
H
J
38
4111-0006 — Sept 2010
Sept 2012
PARTS
Toe Guard/Weather Seal—Optional
Item
A
B
C
CC
Quantity
2
2
2
2
D-K
1
1
Part Number
DOTH-2818
DOTH-2824
DOTH-2820
DOTH-2822
DKIT-9178
DKIT-9179
DKIT-9180
DKIT-9181
DKIT-9293
DKIT-9292
4111-0006 — Sept 2010
Sept 2012
Description
Channel, Weather Seal, 84”
T-Rubber, Weather Seal, 84”
Extrusion, Brush Weather Seal, 84”
Brush Weather Seal, 1.58” x 84”
Full Range Toe Guard Assembly, 5’
Full Range Toe Guard Assembly, 6’
Full Range Toe Guard Assembly, 8’
Full Range Toe Guard Assembly, 10’
Brush Weather Seal Kit (6’ & 8’ sides only)
T-Rubber Weather Seal Kit (6’ & 8’ sides only)
39
NOTES
This page intentionally left blank
40
4111-0006 — Sept 2010
Sept 2012
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 CM-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 Poweramp’s job number, the company
that installed the dock leveler, and the original owner’s
name. This will all help to identify the specific dock
leveler 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.
Dock Leveler Information
Model
Serial No.
Poweramp, Job No.
Original Owner Information
Name
Address
Installer Information
Name
Address
Date of Installation
For service, call or contact:
Systems, Inc.
P.O. Box 309
Germantown, WI 53022
Phone:(800) 643-5424
Fax: (262) 255-5917
4111-0006 — Sept 2010
Sept 2012
41
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. In order to
be entitled to the benefits of this warranty, the product must have been properly installed, maintained
and operated in accordance with all manufacturer’s recommendations and/or specified design
parameters and not otherwise have been subject to abuse, misuse, misapplication, acts of nature,
overloading, unauthorized repair or modification, application in a corrosive environment or lack of
maintenance. Periodic lubrication, adjustment and inspection in accordance with all manufacturers’
recommendations are the sole responsibility of the Owner/User.
In the event of a defect, as determined by SYSTEMS INC., covered by this warranty, SYSTEMS INC.
shall remedy such defect by repairing or replacing any defective equipment or parts, bearing the cost
for the parts, labor and transportation. This shall be exclusive remedy for all claims whether based on
contract, negligence or strict liability.
WARRANTY LIMITATIONS
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 SUBSIDIARIES 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, LOSS OF USE, LOSS OF PROFIT,
INTERRUPTION OF BUSINESS OR LOSS OF GOODWILL.
PRODUCT SPECIFIC WARRANTY
“CM” SERIES LEVELER
In addition to the “Standard Product Warranty” provided with all Poweramp® Products, Systems Inc.,
guarantees materials, components and workmanship to be free of defects for the following extended
periods:
• Structural Warranty – For a period of ten (10) years from the date of shipment, product will
carry a prorated structural warranty. This warranty specifically applies to; the deck section,
lip section, frame, rear hinge assembly and front hinge assembly only. This warranty covers
structural repairs to or replacement of dock leveler in Systems Inc sole discretion and
expense including reasonable labor, materials, freight and travel. If Systems Inc determines
replacement is necessary, it will provide the original purchaser with a credit toward the
purchase of the new replacement Systems Inc. product in the amount equal to the original
purchase price of the warranted product F.O.B. point of manufacture, discounted on a ten year
straight line basis by the number of years of use prior to replacement.