MP Owner`s/User Manual
Contents
1.2. 20 Maintenance Service Dock Leveler Safely essere 21 Periodic Maintenance 1 eere Leer Leer eene ranae nana 22 Adjustments Adjust Lift Arm Spring and Lip Assist Spring Tension 24 Adjust Lip Stop Bolt SE E 26 Troubleshooting TFEOUDIESHOGHNG een 27 Parts Hold Down Mechanism u een 29 Frame Components unsinnig 30 Platform Components 202222000a200nan00nununnununnnnnnnnnnunnnnunnnnenn 32 Toe Guard Weather Seal Optional 36 Miscellaneous Customer Information u a es 37 Recognize Safety Information Safety Alert Symbol The Safety Alert Symbol identifies NOTICE 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 death The use of the word CAUTION signifies possible hazar
3. 14 Gas Shock 18 Lift Springs The ratchet pawl disengages only when the platform release ring 6 is pulled AND held Spring tension from pawl spring 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 b1 76 mm from its full raised height the lip snubber spring 13 and a chain pulls the lip bell crank 4 down This in conjunction with the lip assist spring 5 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 e 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 OPERATION Operating Instructions Stay clear of dock leveler when transport vehicle is entering or leaving dock area DO NOT move or use the
4. E LO o O OI A x CN eo When ordering toe guards color must be specified Toe Guard Weather Seal Optional 35 Manual No 4111 0019 May 2015 NOTES This page intentionally left blank 36 Manual No 4111 0019 May 2015 MISCELLANEOUS Customer Information NOTE Hefer to illustration for left right orientation of dock leveler Dock Leveler Information The model serial number decal A is located Model on the right platform joist near the front lip of dock leveler McGuire Job When you receive your MP 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 Name Address Original Owner Information Also write down McGuire 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 Installer Information When ordering use part numbers and description to help identify the item ordered Do not use item Name numbers These are only for locating the position of the parts Always give dock leveler MODEL NUMBER Address and or SERIAL NUMBER For service call or contact Date of Installation McGuire P O Box 309 Germantown WI 53022 Phone 8
5. 58 SEE CHART DOTH 2578 SPRING MAIN 6835 6 FOOT LONG 6 0 FOOT 25K 30K 35K 40K 45K 55K 16 4 55 4 55 4 55 4 55 4 55 1 55 2 56 18 4 55 4 55 4 55 4 55 4 55 1 55 2 56 20 4 55 4 55 4 55 4 55 4 55 1 55 2 56 6 5 FOOT 16 4 55 4 55 4 55 4 55 4 55 1 55 2 56 18 4 55 4 55 4 55 4 55 4 55 1 55 2 56 20 4 55 4 55 4 55 4 55 4 55 1 55 2 56 7 0 16 4 55 4 55 4 55 4 55 2 55 2 56 2 55 2 56 18 4 55 4 55 4 55 4 55 2 55 2 56 2 55 2 56 20 4 55 4 55 4 55 4 55 2 55 2 56 2 55 2 56 8 FOOT LONG 6 0 FOOT 25K 30K 35K 40K 45K 55K 16 4 55 4 57 4 57 4 57 4 57 4 57 18 4 55 4 57 4 57 4 57 4 57 4 57 20 4 55 4 57 4 57 4 57 2 57 2 58 2 57 2 58 6 5 FOOT 16 4 57 4 57 4 57 4 57 2 57 2 58 2 57 2 58 18 4 57 4 57 4 57 2 57 2 58 2 57 2 58 2 57 2 58 20 4 57 4 57 4 57 2 57 2 58 2 57 2 58 2 57 2 58 7 0 16 4 57 4 57 4 57 4 57 2 57 2 58 4 58 18 4 57 4 57 4 57 4 57 2 57 2 58 4 58 20 4 57 4 57 4 57 2 57 2 58 2 57 2 58 4 58 10 FOOT LONG 6 0 FOOT 25K 30K 35K 40K 45K 55K 16 8 57 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 18 8 57 4 57 4 58 4 57 4 58 4 57 4 58 8 58 B 58 20 8 57 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 6 5 FOOT 16 4 57 4 58 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 18 4
6. E before lip folds completely If the lip does not extend fully or lip folds too quickly see appropriate symptom in the Troubleshooting section Install the dock bumpers as required clean weld splatter and touch up with spray paint Manual No 4111 0019 May 2015 OPERATION Theory WA OWING Sr 1 Lip 6 Hold Down Release Ring 10 Platform Maintenance Prop 15 Safety Leg Below Dock 2 Lip Maintenance Prop 7 Ratchet Pawl amp Bar 11 Main Base Frame Control 3 Platform 9 Hold down 12 Safety Leg Assy 16 Safety Leg Retract Pull Ring 4 Lip Bell Crank 13 Snubber Spring 17 Lift Arm 5 Lip Assist Spring The MP series mechanical dock leveler uses large lift springs 18 to apply force to lift arm 17 The lift arm pushes against the underside of the platform 3 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 and extend lip To actuate the dock leveler platform the operator pulls and holds the platform release ring 6 located in the recess at the rear of the platform This causes ratchet pawl 7 to disengage from ratchet bar 8 With the ratchet pawl disengaged spring tension from lift springs 18 forces the platform to rise NOTE Ratchet pawl 7 and bar 8 are part of the hold down mechanism 9 Manual No 4111 0019 May 2015
7. 57 4 58 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 20 4 57 4 58 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 7 0 FOOT 16 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 8 58 18 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 8 58 20 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 8 58 34 4111 0019 2015 PARTS FF LL LLI e m gt I e cc lt 2 LLI FF co N O O O LLI e Q gt IL e cc lt 2 LLI H O N O Q O O 0014 0076 TOE GUARD RH LOWER 0014 0084 TOE GUARD LOWER TOE GUARD LH LOWER 0014 0074 TOE GUARD LH LOWER 0014 0082 TOE GUARD LH LOWER TOE GUARD RH MIDDLE 0014 0072 TOE GUARD RH MIDDLE 0014 0080 TOE GUARD RH MIDDLE TOE GUARD RH LOWER SCHEW CAP TH 2207 WASHER LOCK NUT KIT 9179 FRTG COMPLETE R amp L DKIT 9180 FRTG COMPLETE R amp L DKIT 9181 FRTG COMPLETE R amp L OTH 2841 CHANNEL WEATHER SEAL DOTH 2840 CHANNEL WEATHER SEAL DOTH 2843 CHANNEL WEATHER SEAL DOTH 2824 T RUBBER WEATHER SEAL DOTH 2824 T RUBBER WEATHER SEAL CONSULT FACTORY lo DOTH 2822 BRUSH WEATHER SEAL DOTH 2822 BRUSH WEATHER SEAL CONSULT FACTORY DOTH 2821 EXTRUSION ALUM DOTH 2820 EXTRUSION ALUM CONSULT 0066 0064 Included in kits 014 0068 TH 2041 014 0062 TOE GUARD LH MIDDLE 014 014 TH 2131
8. Jam Nut 2 Adjustable Nut 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 24 3 Lip Assist Spring 4 Lift Springs 5 Lift Spring Bolt 6 Hold Down Mechanism 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 Manual No 4111 0019 May 2015 NOTE Adjusting the tension of lift springs 4 usually requires that the lip assist spring 3 also be adjusted 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 If the platform does not rise
9. Unloading Platform at Cross Traffic Position 4 If transport vehicles 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 transport vehicle bed is below the dock floor level perform steps 5 10 Ci 5 Pull and hold the platform release ring A until the platform is at the fully raised position 20 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 transport vehicle 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 transport vehicle wheels or release vehicle restraint if used 10 Indicate to the dri
10. are larger than frame front flat so pyramid or stepped stacking method can be used 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 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 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 INSTALLATION B EN mi gt n SIT 727202000057 TR 3 8 6 12 9 5 mm A Front of Dock Pit C Side Pit Curb Angle B Dock Leveler Frame D Gap 3 4 in 19 mm Minimum 8 With rear hinge frame angle F tight against rear 9 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
11. drive away NT ee 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 oe Keep hands and feet clear of pinch points Avoid Make sure lip overlaps onto transport vehicles bed putting any part of your body near moving parts at least 4 in 102 mm Keep a safe distance from both side edges 2 Manual No 4111 0019 May 2015 SAFETY Do not use dock leveling device if transport vehicle is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device Manual No 4111 0019 3 May 2015 Maintenance Safety Precautions Hydraulic and electrical power must be OFF when servicing the equipment For maximum protection use an OSHA approved locking device to lock out all power sources Only the person servicing the equipment should have the key to unlock the device 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 A maintenance prop permanently attached and hinged to the unit with means for lock out tag out requirements per OSHA 1910 147 is included with ea
12. to do this may result in serious personal injury or death 22 2 24 Install shims under lift arm at locations using the pyramid shimming method Page 12 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 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 e Weld the front leveler frame shim stacks to the front pit curb steel if not done previously When all welding has been completed remove all slag then paint all the welds and shims 16 25 26 27 28 29 30 31 32 D Prop Pin and Clip Safety Leg Pull Chain Remove the lifting brackets from the platform side joists Disengage the platform maintenance prop Slowly walk out onto the platform to lower the platform until it is at the cross traffic stored position 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 the unit begins to lower to truck bed Check below dock position by walking platform down before lip folds completely Lip will be over lip keepers e Platform safety legs will be resting on frame Check full below dock position by walking the platform down Pull and hold safety leg chain
13. 00 624 8473 Fax 262 255 5917 Manual No 4111 0019 37 May 2015 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 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 WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EX
14. 1 DOTH 2582 SHOCK GAS 31 1 DOTH 2351 BOLT CLEVIS 32 2 DOTH 2374 PIN COTTER 33 4 2210 WASHER FLAT 34 2 DOTH 2163 LOCK NUT LIP SHAFTS 2 DPLA 2101 6 0 FOOT x 2 DPLA 2102 6 5 FOOT 2 DPLA 2103 7 0 FOOT 36 2 DOTH 2355 PIN CLEVIS 37 2 DOTH 2373 PIN COTTER 39 2 2101 0079 WASHER FLAT Spring Information on page 34 38 LIPS 6 0 FOOT 25K 30K 35K 40 45K 55K 1 16 0595 5000 0595 5009 0595 5018 0595 5027 0595 5036 1 18 0595 5001 0595 5010 0595 5019 0595 5028 0595 5037 1 20 0595 5002 0595 5011 0595 5020 0595 5029 0595 5038 6 5 1 16 0595 5003 0595 5012 0595 5021 0595 5030 0595 5039 1 18 0595 5004 0595 5013 0595 5022 0595 5031 0595 5040 1 20 0595 5005 0595 5014 0595 5023 0595 5032 0595 5041 7 0 FOOT 1 16 0595 5006 0595 5015 0595 5024 0595 5033 0595 5042 1 18 0595 5007 0595 5016 0595 5025 0595 5034 0595 5043 1 20 0595 5008 0595 5017 0595 5026 0595 5035 0595 5044 1 Must provide dock leveler serial number platform size capacity any options and lip size when calling or faxing orders Manual No 4111 0019 May 2015 33 PARTS Platform Components 55 SEE CHART DOTH 2570 SPRING MAIN 6620 56 SEE CHART DOTH 2574 SPRING MAIN 6635 57 SEE CHART DOTH 2576 SPRING MAIN 6820
15. 502 089 HOLD DOWN SAME SAME 3 1 DOTP 6423 LIFTER ARM 27 IN DOTP 6424 LIFTER ARM 25 IN 6WD 25K DOTP 6416 LIFTER ARM DOTP 6423 LIFTER ARM 27 IN all others 4 1 9224 0030 MAINT PROP 9224 0031 MAINT PROP 9224 0079 MAINT PROP 5 1 9221 0028 MAINT PROP PIVOT SAME SAME 6 1 DOTH 2555 SPRING SNUBBER SAME SAME 3 DOTH 2356 CLEVIS SAME SAME 9 1 DOTH 2416 LAP LINK SAME SAME 10 1 DFRA 0323 PLATE SPRING DFRA 0322 PLATE SPRING DOTH 6875 PLATE SPRING 11 DPLA 1218 BAR ASSY DOTH 6425 BOLT SPRING ADJ 12 2 OTH 2218 WASHERS SAME SAME 13 1 DOTH 2185 NUT COUPLING NONE 14 2 DOTH 2222 WASHERS SAME SAME 15 4 DOTH 2374 PIN COTTER SAME SAME 16 1 DFRA 1205 PIN LIFTER ARM SAME SAME 17 1 5265 0012 CHAIN 6 FOOT 5265 0013 CHAIN 8 FOOT 5265 0014 CHAIN 10 FOOT 18 2 8432 1129 KEEPER LIP 16 SAME 8432 1132 24 INCH PIT 2 8432 1130 KEEPER LIP 18 SAME 8432 1133 24 INCH PIT 2 8432 1131 KEEPER LIP 20 SAME 8432 1134 24 INCH PIT 19 1 9201 0006 PROP PIN AND CLIP SAME SAME 20 1 DOTH 2401 CASTER WHEEL ASSY SAME SAME 21 1 DPLA 2128 CHAIN SNUBBER SAME SAME Must provide dock leveler serial number platform size lip size capacity any options and pit depth when calling or faxing orders Manual No 4111 0019 May 2015 PARTS Platform Components 29 28 272625 38 2 3 20 ae 491847 0 PLATFORMS ITEM QTY 6 FOOT 8 FOOT 10 FOOT 1 6 0 F
16. B Shipping Bands McGuire dock levelers are designed with installation in mind Each unit is shipped with lifting brackets A fastened to the platform side joists 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 Turn to page 11 for front pick up Manual No 4111 0019 May 2015 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 DO NOT overtighten the lifting bracket hardware Overtightening 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 over tighten 3 Attach lifting chains to lifting brackets A and to a lifting device i e hoist or fork truck having the appropriate lifting capacity and reach HEAR PICK UP INSTALLATION 4 Remove wood blocks that are attached to the leveler frame before putting the dock leveler into the pit 5 To pick up the unit from the rear slide forks into the fork slots and und
17. MP Series Dock Leveler A Division of Systems Inc Owner s User s Manual MCGUIRE e Division of Systems Inc e W194 N11481 McCormick Drive Germantown WI 53022 800 624 8473 fax 262 255 9399 www wbmcguire com techservices docksystemsinc com Printed in U S A Manual No 4111 0019 Copyright 2015 May 2015 Table of Contents Page Safety Recognize Safety Information eere 1 General Operational Safety Precautions 1 Operational Safety e 2 Maintenance Safety Precautions eese 4 DECAlS c 5 Owner s User s Responsibilities 6 Introduction General IHf ormallion nennen 7 Dock Leveler Stock Specifications 7 Component Identification 1 ce eeeee eere eee enne 8 Installation eR 9 Prepare Dock Leveler e eee nun eee rne 10 Install DOCK Leveler aD 12 Operation DaT e P M ee 17 Operating Instructions anne 18 Ramp Loading Unloading Instructions 19 End Loading Unloading Instructions
18. OOT 6 5 FOOT 7 0 FOOT 6 0 FOOT 6 5 FOOT 7 0 FOOT 6 0 FOOT 6 5 FOOT 7 0 FOOT 1 25K 9515 5000 9515 5004 9515 5008 25K 9515 5012 9515 5016 9515 5020 25K 9515 5024 9515 5028 9515 5032 1 30K 9515 5001 9515 5005 9515 5009 30K 9515 5013 9515 5017 9515 5021 30K 9515 5025 9515 5029 9515 5033 1 35K 9515 5002 9515 5006 9515 5010 35K 9515 5014 9515 5018 9515 5022 35K 9515 5026 9515 5030 9515 5034 1 40K 9515 5003 9515 5007 9515 5011 40K 9515 5015 9515 5019 9515 5023 40K 9515 5027 9515 5031 9515 5035 1 45K 9515 5036 9515 5038 9515 5040 45K 9515 5042 9515 5044 9515 5046 45 9515 5048 9515 5050 9515 5052 1 55K 9515 5037 9515 5039 9515 5041 55K 9515 5043 9515 5045 9515 5047 55K 9515 5049 9515 5051 9515 5053 32 Manual No 4111 0019 May 2015 Platform Components PARTS 2 1 DPLA 0338 LIP BANGER ASSY 3 2 DPLA 0341 BAR 4 1 DPLA 0353 BELOW DOCK PULL CHAIN 9 1 DPLA 0343 BELOW DOCK CONTROL ASSY 10 2 DOTH 2382 PIN COTTER 11 1 DOTH 2074 BOLT HEX 5 8 11 X 2 00 12 1 DOTH 2160 NUT HEX 5 8 11 17 1 DPLA 0360 PUSH ROD ASSY 18 1 DOTH 2060 BOLT SHOULDER 19 1 DOTH 2131 LOCK NUT 20 1 DOTH 6406 LIP ASSIST ROD 23 1 DOTH 2550 SPRING LIP ASSIST STD CONSULT FACTORY 24 1 DOTH 2546 SPHING LIP ASSIST HEAVY CONSULT FACTORY 25 1 DOTP 2006 LIP PROP BAR 26 1 DOTH 2062 SHOULDER BOLT 27 1 OTH 2131 LOCK NUT 28 2 OTH 2214 WASHER 29 1 DOTH 2547 SPRING COMPRESSION 30
19. PRESSED 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 MP SERIES LEVELER In addition to the Standard Product Warranty provided with all McGuire Products Systems Inc guarantees materials components and workmanship to be free of defects for the following extended periods e Structural Warranty For a period of five 5 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 five year straight line basis by the number of years of use prior to replacement
20. along the entire width of the platform with at least 4 in 102 of lip contacting the transport vehicles bed I Tere 8 Proceed with loading or unloading NOTE If end loading is necessary see End Loading Unloading Instructions on page 20 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 b Lower platform by slowly walking out onto the platform allowing time for the lip to fully fold and clear the transport vehicle Continue walking out on platform until platform lowers to the cross traffic position lip engages in the lip keepers 10 Remove chocks from transport vehicle wheels or release vehicle restraint if used 11 Indicate to driver that transport vehicle may leave the dock 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 Check to make sure transport vehicle is positioned squarely against dock bumpers Instruct driver to remain at the dock until the loading or unloading process has been completed and instructed to leave Chock the transport vehicle wheels or use vehicle if present End Loading
21. ch pit style dock leveler In addition it is recommended and good safety practice to use an additional means to support the dock platform and lip anytime when physically working in front of or under the dock leveler This additional means may include but not limited to a boom truck fork truck stabilizing bar or equivalent 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 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 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 4 DANGER AW Arc Flash andad Shock Hazard PPE Personal Protection Equipment Required De enemize
22. d or unsafe practice which could result in personal injury The use of the word NOTICE is to draw attention to a procedure that needs to be followed to prevent machine damage Manual No 4111 0019 May 2015 SAFETY General Operational Safety Precautions Head and understand the Owner s User s manual 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 decals on the equipment unless replacing them TIE ibt hie te EL gs is D IT 24 jJ 22 Si ES oec 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 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 we ww 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 transport vehicles driver has been given permission to
23. 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 Only trained personnel should operate the dock leveler DO NOT use a broken or damaged dock leveler Make sure proper service and maintenance procedures have been performed on leveler before using Transport vehicle wheels must be chocked unless the transport vehicle restraint is used Never remove the wheel chocks until loading unloading is finished and transport vehicle driver has been given permission to leave Make sure platform lip rests on the transport vehicle bed with at least 4 in 102 mm of overlap Maintain a safe distance from side edges of leveler during the loading unloading process Failure to follow these instructions may result in serious personal injury or death 18 305 The MP series mechanical dock leveler is designed to compensate for x 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 or material unattended on the dock leveler Failure to follo
24. e removal Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury ADANGER CRUSH HAZARD Do not work under dock leveler unless this maintenance prop 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 0788 DANGER CRUSH HAZARD Open the pin latch and insert through the maintenance 1751 0789 e 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 4 DANGER CRUSH HAZARD 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 Refer to owner s user s manual for proper maintenance procedures Failure to comply will result in death or serious injury 1751 0726 4111 0019 5 2015 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 users company policies and operati
25. ed at each location c Subtract distance A from distance H to obtain the shim height Repeat for each shim location 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 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 Toassistin 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 Manual No 4111 0019 May 2015 INSTALLATION 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
26. equipment before working on or inside Do not open cover without appropriate PPE Refer to NFPA 70E for FPE requirements Ths panel may contain mare than ane Power Hazardous Voltage Will Couse Sever Injury or Death Manual No 4111 0019 May 2015 SAFETY Safety Decals 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 Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always e Ensure that no equipment material or people are on the dock leveler e Return the dock leveler to its gt A rran N X 000 0 pi 00 D STS SW i uw decal placed in same position on both sides A DANGER CRUSH HAZARD Do not remove main springs until leveler is safely supported by maintenance prop Main springs contain stored energy Be sure springs are fully unloaded and ends are loose befor
27. er the cross member Shown below 6 To pick up the unit from the front move forks closer together and slide over the frame and under the cross member It may be necessary to unband the unit to gain access to the front by lifting the lip up then sliding the forks under the cross member FRONT PICK UP Decks not shown for clarity Manual No 4111 0019 May 2015 INSTALLATION Install Dock Leveler A Distance Leveler Frame Height B Shim Locations Under Rear Vertical Supports 4 5 Places TYP C Shim Locations Under Lip Keepers Lifter Arm and Prop D Dock Floor E Rear Pit Curb Angle 12 F String G Rear Hinge Frame Angle H Distance Dock Floor to Pit Floor J Distance Top of Shim Stack to Dock Floor K Shim Stack L Dock Leveler Frame M Pyramid Preferred N Stepped Acceptable P Offset Not Acceptable Q Straight Not Acceptable R Shim between lip keeper curb angle when required Shim Stacking Methods Manual No 4111 0019 May 2015 NOTE McGuire 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 obtain
28. 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 pin the platform maintenance prop after raising the platform Failure to do this may result in serious personal injury or death When using an external lifting device to raise the platform make sure hold down mechanism 6 is disengaged Pull and hold platform release ring during the lifting process to avoid shearing the ratchet pawl and ratchet bar teeth 1 Raise the platform and engage the platform maintenance prop Pin the maintenance prop in the service position using attached pin device 2 Adjust tension of lift springs 4 as follows NOTE Use 1 2 turn increments when adjusting lift spring bolt 5 Turn clockwise to increase tension and counterclockwise to decrease tension Check platform operation after each adjustment Repeat until proper operation is obtained To increase lift spring tension turn lift spring bolt 5 clockwise To decrease lift spring tension turn lift spring bolt 5 counterclockwise Manual No 4111 0019 May 2015 ADJUSTMENTS 3 After lift spring adjustment is completed check operation of the lip e f the lip folds before the platform can be walked down tension of lip assist spring 3 may be set too low e f the lip does not fold fully or takes too long to fold tension of lip assist sp
29. iew 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 transport vehicles with air ride sus
30. ing the equipment should have the key to unlock the maintenance prop Failure to follow these instructions may result in serious personal injury or death Platform does not rise Dock leveler binds Heavy object s on platform Remove object s from platform For safety reasons the dock leveler is designed to lift only the platform s own Weight Disconnected or broken Connect or replace chain release chain Check for visible obstructions that could cause binding Check weather seal if equipped If no obstructions found call McGuire Technical Services See inside back cover for phone number and address Platform rises slowly Heavy object s on platform Remove object s from platform does not rise to the full raised position Dock leveler binds Insufficient main spring tension For safety reasons the dock leveler is designed to lift only the platform s own Weight Check for visible obstructions that could cause binding Check weather seal if equipped If no obstructions found call McGuire Technical Services See inside back cover for phone number and address Increase tension on main springs See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section Damaged or worn Clean and inspect hold down mechanism hold down mechanism Manual No 4111 0019 May 2015 27 TROUBLESHOOTING Platform rises to full Lip assist chain Connect or replace chain height b
31. nds around the dock leveler lip until instructed to do so Manual No 4111 0019 May 2015 C Distance Pit Length D Distance Pit Corner to Corner Top Both Sides of Pit Bottom and Both Sides Before lowering the dock leveler into the pit the following must be performed 1 Remove all debris from the pit and sweep the pit clean 2 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 e Measure pit width distance A at both front and rear of pit e Measure dock floor to pit floor distance B at all four corners e Measure pit length distance C at both sides e Measure corner to corner crisscross distance D at both sides Take measurements at dock floor level and at pit floor level If any measurement is off by more than 1 8 in 3 18 mm contact Systems Inc Technical Services before proceeding INSTALLATION Prepare Dock Leveler 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 Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death NOTE A third sling may be used to install the unit as needed 10
32. ng 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 1 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 v
33. nism down mechanism Lip does not fold after Lip hinge binding because Inject grease into all of the lip hinge grease fittings truck departs of lack of lubrication See Periodic Maintenance in the Maintenance section Excessive lip assist force Decrease lip assist spring compression See Adjust Lift Arm Spring and Lip Assist Spring Compression in the Adjustments section 28 Manual No 4111 0019 May 2015 PARTS Hold Down PAWL AND RATCHET Item Quantity Part Number Description A 1 M512 986 Ratchet and Pawl Assembly Set Note used on 502 089 hold down only Manual No 4111 0019 29 May 2015 PARTS Frame Components 30 Manual No 4111 0019 May 2015 Frame Components PARTS BASE FRAMES ITEM QTY 6 FOOT 8 FOOT 10 FOOT 1 6 0 FOOT 25K 55K 6 0 FOOT 25K 55K 6 0 FOOT 25K 55K 1 16 8435 5000 16 8435 5003 16 8435 5006 1 18 8435 5001 18 8435 5004 18 8435 5007 1 20 8435 5002 20 8435 5005 20 8435 5008 6 5 6 5 FOOT 6 5 1 16 8435 5009 16 8435 5012 16 8435 5015 1 18 8435 5010 18 8435 5013 18 8435 5016 1 120 8435 5011 20 8435 5014 20 8435 5017 7 0 7 0 FOOT 7 0 1 16 8435 5018 16 8435 5021 16 8435 5024 1 18 8435 5019 18 8435 5022 18 8435 5025 1 20 8435 5020 20 8435 5023 20 8435 5026 1
34. o the front pit curb steel 16 Disconnect lifting device and chains from the lifting brackets 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 to malfunction and shorten the lifespan of the affected components 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 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 If binding occurs reposition leveler and or add or remove shims as necessary Raise and lower platform again If platform still binds contact Technical Services for further instructions Check that the leveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly INSTALLATION A Platform Release Ring B Platform Maintenance C Lip prop support 21 vr Prop Pull the release ring A to raise platform Engage the platform maintenance prop B in the service upright position and lock the maintenance prop at this position using an approved locking device supplied by others Engage lip maintenance prop C Make sure the platform is properly supported in the raised position before entering the pit to finish weld the shims Failure
35. ons may result in serious personal injury or death Manual No 4111 0019 May 2015 Whenever maintenance is to be performed under the dock leveler platform support the platform with maintenance prop B Position the maintenance prop behind front header plate D while staying clear of the lip Lock the maintenance prop in the service upright position using an OSHA approved lockout device B and tagout device A Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout device B and tagout device A 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 21 MAINTENANCE Periodic Maintenance V Ys SR Ir 2 WE 1 Lip Hinge Grease Fittings 4 Lift Arm Pivot 7 Lip Lift Assist Pin 2 Lip Maintenance Prop Pivot 5 Hold Down Pivot Pulley 8 Hold Down to Platform Pin 3 Lift Arm Roller Bushing 6 Safety Leg Linkage Pivots A maintenance prop permanently attached and hinged to the unit with means for lock out tag out requirements per OSHA 1910 147 is included with each pit style dock leveler In addition it is recommended and good safe
36. ous 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 shorten 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 otart at each end with a 6 in 152 long weld Space all the other welds out evenly leaving approximately 6 in 152 mm space between each weld 19 Alternate welding locations to distribute heat Welding sequentially from one end to the other may cause warping or distortion 20 Manual No 4111 0019 May 2015 INSTALLATION 14 Remove shipping bands at this time Allow platform to float Add Remove shims as necessary to bring platform level flush with floor Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or death may result 15 Weld front of dock leveler frame B to shims located under the keepers then weld the shims t
37. ous personal injury or death C Stop Bolt Check that lip E is fully resting on the lip keepers D 4 Tighten jam nut B and at the lowest part of the lip keepers If lip is not resting properly in lip keepers perform the following 5 Disengage lip maintenance prop adjustment 6 Walk platform down to cross traffic stored 1 Fully raise platform Manually raise the lip and position engage lip maintenance prop not shown 7 Check lip position in both keepers Repeat 2 Loosen jam nut B procedure if necessary 3 Adjust stop bolt C as necessary e Turn stop bolt in clockwise to allow lip to fold closer to platform A e Turn stop bolt out counterclockwise to hold lip further away from platform A 26 Manual No 4111 0019 May 2015 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 TROUBLESHOOTING 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 supplied by others Only the person servic
38. pension systems shall have its air exhausted prior to performing loading and unloading operation to minimize transport vehicle 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 Manual No 4111 0019 May 2015 General Information Congratulations on your choice of a McGuire dock leveler This manual covers the MP series mechanical dock leveler Designed by McGuire 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 Once again thank you and congratulations on your purchase of a McGuire mechanical dock leveler Manual No 4111 0019 May 2015 INTRODUCTION Dock Leveler Stock Specifications MP Series dock levelers are available in the following sizes weight capacities and options Width 6 ft 1828 8 mm 6 1 2 f
39. ring 3 may be set too high 4 Adjust lip assist spring tension as follows NOTE Use two turn increments when adjusting lip assist spring 3 Check lip operation after each adjustment Hepeat until proper operation is obtained a Loosen jam nut 1 b To increase spring compression turn nut 2 clockwise To decrease spring compression turn nut 2 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 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 result in serious personal injury or death Always stand clear of the dock leveler 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 D service position when working under the dock leveler For maximum protection use an OSHA approved locking device supplied by others to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop A Platform D Lip Keeper Failure to follow these instructions may result in B Jam Nut E Lip seri
40. t 1981 2 mm 7 ft 2133 6 mm Length 6ft 1828 8 mm 8 ft 2438 mm 10 ft 3048 mm Capacity CIR 25 000 Ib 11 340 kg 30 000 Ib 13 608 kg 35 000 Ib 15 876 kg 40 000 Ib 18 144 kg 45 000 Ib 20 412 kg 55 000 Ib 22 680 kg CIR Comparative Industry Rating Call McGuire for your specific needs INTRODUCTION Component Identification RN IN IN AT eee 19 NL AS Se dT IWS wa acie a M Q 1 Lip 6 Hold Down Release Ring 11 Main Base Frame 15 Safety Leg Pull Chain 2 Lip Maintenance Prop 7 Ratchet Pawl amp Bar 12 Safety Leg Assy 16 Lift Arm Assembly 3 Platform 9 Hold Down 13 Lip Snubber Spring 17 Lift Main Spring 4 Bell Crank 10 Platform Maintenance Prop 14 Lip Shock Absorber 18 Prop Pin and Clip 5 Lip Assist Spring 19 Working Range Toe Guards 8 Manual No 4111 0019 May 2015 INSTALLATION A Distance Pit Width B Distance Dock Floor to Pit Front and Rear Floor All Four Corners 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 DO NOT remove the shipping ba
41. 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 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 qs We w qq x qt E Pry Locations G Rear Pit Curb Angle F Rear Hinge Frame H Flare Bevel Weld Typical Angle 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 Technical Services Manual No 4111 0019 May 2015 DO 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 seri
42. ty practice to use an additional means to support the dock platform and lip anytime when physically working in front of or under the dock leveler This additional means may include but not limited to a boom truck fork truck stabilizing bar or equivalent 22 Manual No 4111 0019 May 2015 Regular maintenance must be performed on a weekly and quarterly schedule Follow all safety precautions Weekly Maintenance Operate 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 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 Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler Manual No 4111 0019 May 2015 MAINTENANCE Quarterly Maintenance Lubricate the following areas with light weight machine oil 2 Lip maintenance prop pivot 5 Hold down pivot pulley 6 Safety leg linkage pivots 8 Hold down to platform pin Lubricate the following areas with white lithium grease zerk fittings 1 Lip hinge area 3 Lift arm roller bushing 4 Lift arm pivot 7 Lip assist pin 23 ADJUSTMENTS Adjust Lift Arm Spring and Lip Assist Spring Tension DO 3 1
43. ut lip does not disconnected or broken fully extend Insufficient main spring Increase tension on main lift springs See Adjust tension Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section Insufficient lip assist force lip assist spring compression See Adjust Lift Arm Spring and Lip Assist Spring Compression in the Adjustments section Platform does not lower Excessive main spring Heduce main spring tension See Adjust Lift when operator walks out tension Arm Spring and Lip Assist Spring Tension in the onto the platform Adjustments section Damaged or worn hold Clean and inspect hold down mechanism down mechanism Lip folds too fast during Insufficient lip assist force lip assist spring compression See Adjust normal walk down Lift Arm Spring and Lip Assist Spring compression in the Adjustments section Disconnected worn or Inspect shock absorber Connect or replace gas broken gas strut strut Platform does not stay Entangled release chain Hemove cause of entanglement down Dirt impacted in ratchet bar Clean and inspect ratchet bar and ratchet pawl teeth teeth DO NOT lubricate the ratchet assembly Broken or damaged ratchet Replace ratchet assembly DO NOT lubricate the assembly teeth ratchet assembly Disconnected or broken Replace hold down pivot pins hold down pivot pins Damaged or worn hold Clean and inspect hold down mecha
44. ver that the transport vehicle may leave the dock Manual No 4111 0019 May 2015 Service Dock Leveler Safely MAINTENANCE A Platform Release Ring Platform Maintenance Prop C Lip Maintenance Prop D Prop Pin and Clip E Safety Leg Pull Chain Note Lockout amp Tagout Devices are not supplied with leveler They are to be supplied by others 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 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 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 instructi
45. w these instructions may result in personal injury and or damage to equipment 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 The dock leveler operation instructions are divided into the two methods of loading and unloading e For ramp loading and unloading see Ramp Loading Unloading Instructions on page 19 e For end loading and unloading see End Loading Unloading Instructions on page 20 Manual No 4111 0019 May 2015 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 transport vehicle 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 transport vehicle wheels or use vehicle restraint if present 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 6 Walk out onto the platform The platform will lower until the lip rests on the transport vehicle bed Manual No 4111 0019 May 2015 OPERATION 7 Make sure that the lip is fully extended and supported on the transport vehicle
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