Poweramp CentraPower Manual Jan2014
Contents
1. 23 End Loading Unloading Instructions 24 Maintenance Service Dock Leveler Safely 12 Periodic Maintenance 13 Adjustments Adjust Main Pressure Relief 16 Troubleshooting Tr OD esSh o0tigu uyu sss EDD E 17 Parts Pump Station Control Panel 21 Valve BIOCKS a 22 PUMP ect 24 Pump and Motor 26 Miscellaneous Customer Information 29 uu Ua ss Back Cover Recognize Safety Information 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 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 dea2. Item Quantity Part Number Description A 1 Valve Manifold B 1 8581 0005 Valve Cartridge 3 way C 1 8581 0001 Ball Valve Bronze Return D 1 8581 0002 Ball Valve Steel Pressure E 2 9301 0246 Fitting 8ORB Male 3 8 F 1 0521 0108 Fitting 8 JICM Plug G 1 9301 0116 Fitting Elbow 90 male 8 JIC H 2 9301 0054 Fitting Branch Tee Male 8 JIC 1 9904 0078 Hyd Hose 3 8 x 35 00 Hose J 1 8583 0021 Centra Power Mid Run W O Restraint K 1 8581 0004 Delta Coil L 1 4301 0004 Cable Assembly M 2 0521 0021 Fitting 8 End Cap Not Shown 4111 0030 January 2014 21 PARTS Mid Run Valve W Hook Coil De Energized when lever or restraint is Engaged not in use Coil Energized when lever or restraint is Engaged IF used as run is end cap will be required 22 4111 0030 January 2014 Mid Run Valve W Hook PARTS Item Quantity Part Number Description A 1 Valve Manifold B 1 8581 0005 Valve Cartridge 3 way C 1 9301 0104 Fitting 4 SAE D 1 9301 0098 Fitting Male Branch Tee 10 JIC E 1 8581 0072 Ball Valve Bronze 1 2 NPT F 1 9301 0246 Fitting 3 8 NPT x 8 Male G 1 8581 0092 Valve Flow Control 5 GPM H 1 9301 0054 Fitting Branch Tee Male 8 1 8581 0002 Ball Valve Steel J 1 9301 0247 Fitting 1 2 NPT 8 ORB Male K 1 9301 0112 Fitting 8 ORB x 8 JIC L 1 9301 0116 Fitting Elbow 90 deg 8 ORB x 8 JIC M
3. Do not use a broken or damaged dock leveling Do not move or use the dock leveling device if device Make sure proper service and maintenance anyone is under or in front of it procedures have been performed before using CM _ or Keep hands and feet clear of pinch points Avoid Make sure lip overlaps onto the transport vehicles putting any part of your body near moving parts bed at least 4 in 102 mm Keep a safe distance from both side edges 2 4111 0030 January 2014 SAFETY Do not use dock leveling device if transport vehicle carrier is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device 4111 0030 January 2014 3 SAFETY Maintenance Safety Precautions ALWAYS disconnect electrical power source and ground wire before welding on dock leveler DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground to the dock leveler frame Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death Hydraulic and electrical power must be OFF when servicing the equipment For maximum protection DO NOT grind or weld if hydraulic fluid or other use an OSHA approved locking device to lock flammable liquid is present on the
4. For service call or contact Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0030 January 2014 29 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 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 manufacturers 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
5. 1 8583 0031 Centra Power Mid Run With Restraint amp Flow Limiter N 1 8581 0004 Delta Coil O 1 4301 0004 Cable Assembly P 1 0521 0021 Fitting 8 End Cap Not Shown Q 1 0521 0106 Fitting 410 End Cap Not Shown 4111 0030 January 2014 23 PARTS Pump Station a N M 4111 0030 January 2014 24 Pump Station PARTS Item Quantity Part Number Description A 1 9394 0003 Enclosure Weldment B 1 1751 0072 Decal C 1 9301 0048 Handle D 1 9301 0049 Site Glass Includes O Ring E 1 9571 0005 Drain Plug F 1 9301 0199 Breather Cap 3 8 NPT G 2 9301 _ Pump Assembly H 1 8581 0037 Valve Assembly Centra Power Relief 1 8583 0037 Valve Assembly Includes Relief and Hose Includes Items amp O J 1 8585 0001 Valve Assembly Blending K 2 9301 0027 O Ring L 1 9904 0090 Hose 17 50 Lg 8 JIC Swivel Both Ends M 1 9904 0082 Hose 21 75 Lg 8 JIC Swivel Both Ends N 1 9904 0106 Hose 28 00 Lg 8 JIC Swivel Both Ends O 1 9904 0107 Hose 9 00 Lg 8 JIC Swivel Both Ends p 1 9393 0008 Tee 8 Jic 9393 0009 Tee 10 Jic Q 1 0521 0032 Male Swivel Nut 3 8 NPTM x JICF Swivel R 1 8581 0002 Valve Ball 3 8 NPT Steel S 2 9904 0044 Hose 24 00 Lg 8 JICM 8JICF Swivel T 2 0521 0015 Male Connector 3 8 NP Tx 8 JIC
6. It is recommended that the following hydraulic fluids be used Ultra VIS HVI 15 Aero Shell Fluid 4 or Fluid 41 Mobile Aero HFA Mil HS606A or Aero HF Texaco Aircraft Hydraulic Oil 15 or 5606 Exxon Univis J13 These fluid brands can be mixed together Mixing with fluids that do not meet or exceed MIL H 5606 G may damage the equipment and WILL void warranty Use of hydraulic fluids with equivalent specifications to those listed here are acceptable ADJUSTMENTS Pressure relief Main pressure relief is pre set from the factory Call Tech Services before adjustments are made 16 4111 0030 January 2014 Troubleshooting When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death TROUBLESHOOTING Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler 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 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 Fa
7. January 2014 SAFETY Safety Decal s Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily leg ible If any are missing or require replacement please call 1 800 643 5424 for replacements DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar 1 75 1 0727 Do not force maintenance prop forward of bar to support lip Refer to owner s user s manual for proper use Failure to comply will result in death or serious injury 1751 0730 x2 ADANGER SAFETY INFORMATION and Unsupported dock leveler con lower unexpectedly Before allowing vehicle to leave ihe dock always e Ensure that no equipment material or people are on tl dock leveler e Return the dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or serious injury decal placed in same position on both sides 1751 0329 x2 decal placed in same position on both sides 1751 0330 x2 decal placed in same position on both sides ADANGER CRUSH HAZARD 1 75 1 0 1 3 8 DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance prop Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury 1751 0729 ADANGER CRUSH HAZARD Do not work under dock leveler unless this maintenance prop
8. 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 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 LOSS OF USE LOSS OF PROFIT INTERUPTION OF BUSINESS OR LOSS OF GOODWILL
9. has been secured in the upright position See owner s user s manual for proper procedures Failure to comply will result in death or serious injury 1751 0729 4 DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch 1 75 1 073 1 and insert through the maintenance prop housing Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury 4 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 1 75 1 0726 safely supported by maintenance prop Place barriers on driveway and dock floor to indicate service work being performed Refer to owner s user s manual for proper maintenance procedures Failure to comply will result in death or serious injury Note This is a example of dock leveler safety decals See manual for your specific model for correct safety decal sheet or consult Tech Services 4111 0030 January 2014 OWNER S USER S RESPONSIBILITIES 1 10 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 users company policies and operating conditions Maintaining updating a
10. surface to be out all power sources Only the person servicing ground or welded the equipment should have the key to unlock the device DO NOT grind or weld if un contained 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 post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the unit before int lete maintenance 15 complete 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 DANGER A Arc Flash and Shock Hazard PPE Personal Protection I I Mur 5 Equipment Required The maintenance prop must be in the upright service position when working under the dock leveler For maximum protection use an OSHA approved locking a sa device to lock the maintenance prop in the service PPE requirements This panel may contain more than one position Only the person servicing the equipment power source should have the key to unlock the device Hazardous Voltage Will Cause Sever Injury or Death De energize equipment before 4 4111 0030
11. the dock leveler through the complete operating cycle to maintain lubrication NOTE To thoroughly inspect the platform hinge area put the platform in the full below dock position e 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 cause abnormal operation Quarterly Maintenance IMPORTANT Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler IMPORTANT Use of fluids that do not have equivalent specifications to those in the following list will result in abnormal operation of the dock leveler and voiding of warranty 4111 0030 January 2014 MAINTENANCE Sight Glass e Fluid level must be checked periodically 1 Pit levelers with or without restraints levelers must be in the below dock cross traffic position level must read in the sight glass area 2 VS Levelers with or without restraints must be in the stored positon leveler should level must be in site glass area 3 Add hydraulic fluid if necessary Use only recommended fluid IMPORTANT A low fluid level or the use of hydraulic fluids not equivalent to the fluid types recommended will cause abnormal operation of the leveler and WILL void warranty To ensure normal operation of the dock leveler use only aircraft hydraulic fluid designed to meet or exceed military specification MIL H 5606 G
12. 111 0030 January 2014 MAINTENANCE 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 Whenever maintenance is to be performed under the dock leveler platform support the platform with maintenance prop A Position the maintenance prop behind front header plate D while staying clear of the lip The lip will fold down after the platform has rested on the maintenance prop Lock the maintenance prop in the service upright position using an OSHA approved lockout device C and tagout device B Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout device C and tagout device B Only the person servicing the equipment should have the capability to remove the lockout devices The tagout devices must inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to OSHA regulation 1910 146 Refer to OSHA regulation 1910 147 MAINTENANCE This page in intentional left blank 14 4111 0030 January 2014 Periodic Maintenance Regular maintenance must be performed on a weekly and quarterly schedule For proper lube points see owners manual for the equipment to be maintained Weekly Maintenance Operate
13. 226 DECAL FRENCH 1751 0393 DECAL SPANISH 2 1751 0163 DECAL b 1751 0081 DECAL ENGLISH 1751 0395 DECAL FRENCH 1751 0396 DECAL SPANISH 1 3053 0000 SWICH MTG BRACKET o 1 1751 0363 LABEL f 2 1751 0367 0808 2 1751 0394 jap f o 1 1751 0391 LABEL o Mt MIOL M2 M20L amp 2 9 3 TTD Q HINGE STANDARD WIRING M1 BOTH M2 T PIER PEINE OPTIONAL WIRING ntn ansia 1 1 22 2 215 5 MI OFF M2 554 1 1 PLACE STICKER NEAR e GRD TERM BLOCKS E ENCL PNL DO NOT MOUNT SWITCH DIRECTLY IN FRONT OF TERMINAL BLOCKS TABLE 1 OPTIONAL OPTIONAL NEMA 4X STAINLESS NEMA 4X FIBERGLASS ENL PNL 2751 0105 2751 0107 2751 016 2751 0107 2751 0163 2751 0065 TABLE 5 M1 BOTH M2 M1 OFF M2 92 46 S 84 42 S 42 2 575 v 35 5101 0100 4111 0030 January 2014 19 PARTS Mid Run Valve W O Hook Pressure Line Coil De Energized when lever or restraint is Engaged not in use Coil Energized when lever or restraint is Engaged IF used as run is end cap will be required Provide dock leveler serial number when calling or faxing orders 20 4111 0030 January 2014 Mid Run Valve W O Hook PARTS
14. 3 4 Lg S 1 9301 0069 Fitting Pipe Nipple 1 8 Npt x 5 Lg T 1 9301 0106 Fitting Plug Hollow Hex Str Thread U 1 9571 0006 Fitting 1 4 NPTM V 1 9301 0145 Fitting Elbow 90 Degree Swivel Nut W 1 0521 0016 Fitting Elbow 90 Degree Provide dock leveler serial number and size of platform when calling or faxing orders 4111 0030 January 2014 27 NOTES This page intentionally left blank 28 4111 0030 January 2014 MISCELLANEOUS Customer Information NOTE Hefer 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 Serial No of dock leveler Systems Inc Job No When you receive your dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keeping of the Original Owner Information numbers in the event the model serial number decal A becomes lost or damaged Also write down Systems Inc s job number the Roles 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 Address the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER Date of Installation
15. A Division of Systems Inc POWE Centra Power POWERAME POWERAMP Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www poweramp com techservices docksystemsinc com Printed in U S A Manual No 4111 0030 Copyright e 2014 January 2014 Table of Contents Page Safety Recognize Safety Information 1 General Operational Safety Precautions 1 Operational Safety Precautions 2 Maintenance Safety Precautions 4 Safety Decal Sararen a a a a a 5 Owner s User s Responsibilities 6 Introduction Th60 yu 2 2 6 General Information 6 Component Identification 8 Installation Prepare CT IE 9 Prepare DOCK Leveler 10 Operation TING ORY uum um a u eO E ERE MOIS 21 Operating Instructions 22 Ramp Loading Unloading Instructions
16. U 2 0521 0032 Male Swivel Nut 3 8 NPTM x 8 JICF Swivel 9301 0193 Male Swivel Nut 1 2 NPTM x 10 JICF Swivel V 2 8581 0001 Bronze Ball Valve 3 8 NPT 8581 0072 Bronze Ball Valve 1 2 NPT W 2 0521 0015 Male Connector 3 8 NPTM x 8 JICM 9301 0194 Male Connector 1 2 NPTM x 10 JICM 1 Provide dock leveler serial number and type of installation when calling or faxing orders Provide dock leveler serial number voltage and phase when calling or faxing orders 4111 0030 January 2014 25 PARTS Pump and Motor D MRE m KR 26 4111 0030 January 2014 Pump and Motor PARTS Item Quantity Part Number Description A 1 3411 0043 Motor 460 3 PH 1 1 2 hp 1 3411 0045 Motor 460 3 PH 3 hp B 1 Drive Plate C 1 9301 0027 O Ring D 1 9302 0065 Coupler Love Joy E 1 9301 0204 Pump 5 GPM 1 9301 0205 Pump 4 GPM F 1 9904 0001 Hose Assy 3 8 17 500 Lg 6 SAE to 8 JIC G 3 9301 0007 Fitting Elbow 90 Deg 3 8 NPTM X 3 8 H 1 9301 0206 Fitting 3 8 NPT x 4 1 2 1 9301 0009 Strainer J 1 0521 0014 Ball Steel K 1 9301 0024 Guide Ball Check L 1 9302 0009 Spring Pressure Relief M 1 9303 0003 Screw Adjusting N 1 9301 0014 Washer Nylon O 1 9301 0016 Acorn Nut High Crown P 4 2101 0016 Hex Head Capscrew 5 16 UNC x 3 1 2 Lg Q 2 9301 0003 Washer Aluminum R 2 9301 0004 Socket Head Cap Screw 3 8 UNC x 1
17. e See Leveler specific Pump runs Coil and manual valve are good Restraint does not See restraint specific operate Pump runs Coil manual and valve are good 18 4111 0030 January 2014 5 Centra Power Control Panel BILL OF MATERIAL LEGEND QIY PART NUMBER DESCRIPTION DOORS AS AED FROM E DOUCET 1 SEE TABLE 1 ENCLOSURE Y EXACT LOCATION OF COMPONENTS MAY BE DIFFERENT THAN WHAT IS SHOWN 1 2751 0108 MTG FEET IF NOT FGLASS PN 1 j SEETABET1 PANL 13 1431 0219 TERMNAL BLOCK 1 14501 0220 TERM BLOCK END 6 1431 0036 TERM BLOCK JUMPER 2 1431 0221 TERMBLOCK CLP FBi2 2 5101 0116 FUSE BLOCK Fu2 6 SEETABLE2 FUSE MiM2 2 7141 0143 CONTACTOR Cd LAY DOS DY Te TRIPPED WHEN ILLUMINATED OVERLOAD RELAY 460 V o We OVERLOAD RELAY 575 V 62 554 1 0961 0012 SELECTOR SWTCH Hee CONTACT BLOCK STANDARD WIRING CONTACT BLOCK OPTIONAL WIRING LEGEND PLATE OPTIONAL WIRING 0961 0516 LIGHT IF N4X FGLASS 118 9 0961 0374 INDICATOR LIGHT N4X FGLASS LT8 MOTOR OVERLOAD 1 TRIPPED WHEN ILLUMINATED HINGE LT9 MOTOR OVERLOAD 2 FBI FB2 FU2 OOO OOO RED LENS IF NOT N4X FGLASS RED LENS IF N4X FGLASS DECAL ENGLISH pag 1751 0392 DECAL SPANISH 1751 0224 DECAL ENGLISH 1751 0
18. e line Replace fuse Determine cause of blown fuse motor hums but does not rotate NOTE A motor that is Check motor starter as follows missing voltage on one line 1 Disconnect wires at load side of starter is said to be single phased 2 Energize the starter 3 Measure line to line voltage at line side of starter 4 Measure line to line voltage at load side of starter Line side and load side voltages should be approximately the same Replace starter if voltage values are considerably different from one another Check all wiring to motor for high resistance or no connection Platform does not rise to Low hydraulic fluid Add fluid as needed See Periodic Maintenance in full height the Maintenance section Motor rotates but Phase reversed Reverse any two legs at the branch circuit platform or restraint not disconnect operating Platform rises slowly Pressure relief set too low the factory contact tech before adjustments are made Only one Platform or Bad coil on Centra Power The coil will magnetized when energized Pump restraint not operating valve block Motor must be running Bad Valve on Centra Power Remove and clean spool valve or replace with new valve block or good working valve Platform or restraint Bad Valve on Centra Power Remove and clean spool valve or replace with new operates when other valve block or good working valve units have been activated Platform does not rais
19. hom such warnings are intended for Contact manufacturer for any replacements Manufacturers 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 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 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 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 a
20. ilure to do this may result in serious personal injury or death Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death Before performing the detailed troubleshooting procedures check the following items first Check all fuses inside the control panel s Replace any blown fuse s with a fuse of equal specification e Make sure the correct voltages are present at the proper locations inside the control panel s Platform or restraint will Motor overload device Heset 3phase overload relay Located next to pump not operate Motor does tripped or fuse blown station or replace fuse Reset 120 volt overload not energize relay or replace fuse in the individual control box s NOTE When replacing fuse s the new fuse must have the same specification as the old fuse No voltage at over loads or relays Check voltage at starter or relay coil e f voltage is present and starter or relay does not energize replace starter or relay If voltage is not present check all components in series with the starter or relay coil 4111 0030 January 2014 17 TROUBLESHOOTING Platform or restraint will No voltage is present on Check for blown fuses at branch circuit disconnect not operate correctly on
21. nd 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 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 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 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 w
22. nd unloading operation to minimize trailer bed drop 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 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 4111 0030 January 2014 THEORY The Centra Power System eliminates individual hydraulic pumps located on each leveler The Centra Power pump station will run multiple dock levelers and or vehicle restraints When a dock leveler or vehicle restraint are operated one electrical signal is sent to the pump station activating the hydraulic power unit A signal is also sent to the Centra Power valve at the door position being operated The combination of these two signals allow the dock leveler or restraint to operate The Centra Power pump station allows more than one leveler or vehicle restraint to operate at the same time 4111 0030 January 2014 INTRODUCTION General Information Congratulations on your choice of a Poweramp dock leveler This manual covers the Centra Power hydraulic system Designed by Poweramp to be a marvel of simplicity and efficiency your Cent
23. ock position Note On Centra Power Systems were both motors must operate simultaneously run all the time the rotation must be checked To check rotation run only one motor at a time the levelers will work but run slow 4111 0030 January 2014 9 INSTALLATION Component Identification Pump Pressure Pump Return Pump Pressure SECTION A A WITH MOTORS REMOVED 10 4111 0030 January 2014 INSTALLATION Centra Power main control panel should be located near the Centra Power pump station The pump control panel has 2 indicator lights located on the door There is 3 position switch mounted inside the door The switch on the system controls one or both motors when a leveler has been activated The lights on the control indicate if one or both motor starters have tripped If one pump systems is in operation use selector switch to rotate motors every 6 months This will insure proper operation of the systems 4111 0030 January 2014 11 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 un contained 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 f
24. ollow these instructions may result in serious personal injury or death 12 IMPORTANT DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground welding equipment to the dock leveler frame NEVER to the platform Failure to follow these instructions may damage the motor hoist cylinder wiring and or control panel 4111 0030 January 2014 Service Dock Leveler Safely When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler 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 Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 4
25. ra Power hydraulic system properly installed will provide many years of trouble free performance with an absolute minimum of maintenance Its revolutionary hydraulic system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended The Centra Power System comes equipped with an electrical control panel which allows push button operation of the dock leveler functions Each dock leveler and control panel has been factory prewired and tested to ensure satisfactory operation To illustrate which connections are to be made in the field at installation electrical drawings are included with each order or by contacting Poweramp Technical Services Once again thank you and congratulations on your purchase of a Poweramp Centra Power System INTRODUCTION Component Identification B Pressure Line Black Valve Steel Return Line Brass A Pump Station D Site Glass G Pump Station Door K Coil B Pump Motor 1 E Drain Plug H Distribution Manifold L Ball Valves C Pump Motor 2 F Main System Relief J Leveler Manifold M Control Panel 8 4111 0030 January 2014 INSTALLATION Head carefully and understand the installation manual for the leveler and or the restraint to be installed in conjunction with the Centra Power manual Read carefully and understand the Centra Power layou
26. t drawing The drawings will have all the required information on hose charts fluid capacity and location of the mid run and end run valve blocks The Centra Power pump station is typically located in the center of the dock levelers with even amount of doors on each side The pump station should be mounted a minimum of 72 off the finished floor out of the way of damage The Pump Station Control Box should be mounted a minimum of 72 off the finished floor next to the Pump Station Hose installation can be started at the pump station or at the furthest dock leveler Note when installing hose or valve blocks always keep shipping caps on fittings until hoses are connected to the manifolds Typical installation the pressure lines will have 8 JIC fittings and 1 2 dia lines The returns lines if without restraints will be 48 JIC with 1 2 dia hose Pay close attention not to allow lines to be swapped between pressure and return When levelers with Power Hooks are installed the return lines will have 10 JIC and 3 4 dia hose When all hoses valves and hydraulic connections are made and tight Fill the reservoir with oil see page 15 Fill the Pump Station reservoir capacity 12 gals to the full mark Starting from the furthest dock from the pump station operate all the levelers and the restraints through several cycles to purge all the air out of the system Once all levelers have been cycled several times have all the levers in the below d
27. th 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 4111 0030 January 2014 SAFETY General Operational Safety Precautions Head and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or guard is removed or disconnected Never remove DANGER WARNING or CAUTION signs or Decal s on the equipment unless replacing them Do not start the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone Hemove 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 SAFETY Operational Safety Precautions A Learn the safe way to operate this equipment Read and understand the manufacturer s instructions If you have any questions ask your supervisor we wer Stay clear of dock leveling device when transport Chock restrain all transport vehicles Never remove vehicle is entering or leaving area the wheel chocks until loading or unloading is finished and vehicles driver has been given permission to drive away NT ee
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