“MA” SERIES Owner/User Manuall
Contents
1. u _ O 20 1 pupcsos ____ _ 4 23 1 sPRING LIPASSISTSTD 25K 55K 6 65 16 24 1 DOTH2546 SPRING LIP ASSIST HEAVY 7 WD 18 20 25K 7 18 20 30K 55K 25 1 2006 _ ooo 26 1 sHOUDERBOLT S 27 1 ora _ 29 2 p a s lt sS _2 eoror orrazi 2 zoroor a 0000 0 0 3e 2 Jus _ _ 7 2 2373 2 2101 0079 consult factory 36 4111 0021 November 2009 5 Toe Guard Weather Seal Optional 10 FOOT 0014 0062 GUARD LH MIDDLE 0014 0070 GUARD LH MIDDLE 0014 0078 TOE GUARD LH MIDDLE Factory 0014 0074 TOE GUARD LH LOWER 0014 0082 GUARD LH LOWER 12 2 2821 EXTRUSION ALUM DOTH 2820 EXTRUSION ALUM CONSULT FACTORY 0014 0064 GUARD RH MIDDLE 0014 0072 GUARD RH MIDDLE 0014 0080 GUARD RH MIDDLE 0014 0068 GUARD RH LOWER 0014 0076 GUARD RH LOWER 0014 0084 GUARD RH LOWER DKIT 9180 FRTG COMPLETE R amp L DKIT 9181 FRTG COMPLETE R amp L SCREW CAP same _6 oro 2 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 SEAL2. MA Series Dock Leveler E EE E a i A Division of Systems Inc W B MCGUIRE Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 624 8473 fax 262 257 7399 www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0021 Copyright 2008 November 2009 Table of Contents Page Safety Recognize Safety 1 General Operational Safety Precautions 1 Operational Safety Precautions 2 Maintenance Safety Precautions 4 Safety Decals o qd se ea 5 Introduction General Information 6 Dock Leveler Stock Specifications 6 Component Identification 7 TOCO chau RA NE Rs Ri comu w eee 7 Installation Prepare u y EET 8 Prepare Dock Leveler 9 Install Dock Leveler 10 Install Control Panel and Wiring 16 Put New Leveler Into Service 17 Operation Operating Instructions 18 Ramp Loading Unloading Instructions 19 End Loading Unloading Instructions 20 Maint
3. 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 4111 0021 November 2009 IMPORTANT DO NOT remove the shipping bands B around the platform lip and leveler frame at this time The shipping bands are needed to hold the leveler together during the installation process 1 Remove any control panel and bumpers that may be banded to the frame of the dock leveler DO NOT remove the shipping bands B around the platform lip and leveler frame at this time IMPORTANT DO NOT over tighten the lifting bracket hardware Over tightening can damage the weather seal if equipped NOTE Overall width of platform and lifting brackets A must be kept to a minimum to prevent interference between the lifting brackets and the pit walls as the dock leveler is lowered into the pit 2 Make sure the mounting hardware of lifting brackets A is snug The brackets should pivot relatively freely on the mounting cap screw DO NOT over tighten 3 Attach lifting chains to lifting brackets A and to a lifting device i e hoist or fork truck having the appropriate lifting capacity and reach 4 Remove wood blocks that are attached to the leveler frame before putting the dock leveler into the pit 5 Attach a temporary switched power
4. Operate the dock leveler through the complete Perform Weekly Service Items operating cycle to maintain lubrication Lubricate the following areas with light weight NOTE To thoroughly inspect the platform hinge machine oil area put the platform in the full below dock position A Lip hinge area unless equipped with grease fittings apply oil to the top of Inspect the platform hinge and the lip hinge areas the entire length of lip hinge when platform is The hinge areas must be kept free of dirt and at the full below dock position and lip is debris Build up of foreign material in the hinge folded areas will cause abnormal operation B Platform hinge area apply oil to top of all platform hinges when platform is at the full Inspect the area under the platform around and below dock position under the air bag Build up of foreign material in this area may damage air bag components causing abnormal operation NOTE Apply grease to lip hinge grease fittings if equipped Lubricate the following areas with light weight IMPORTANT machine oil Failure to properly lubricate the dock leveler will C Lip maintenance prop pivot cause abnormal operation of the leveler D Lip link pivots E Safety leg linkage pivots Lubricate the following areas with white lithium grease if equipped with grease fittings A Lip hinge area inject grease into all the lip hinge grease fittings B Platform h
5. The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury IMPORTANT The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 0021 November 2009 SAFETY General Operational Safety Precautions Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or guard is removed or disconnected Never remove DANGER WARNING or CAUTION signs or decals 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 Remove any tools or foreign objects from the operating zone before starting Keep the operating zone free of obstacles that could cause a person to trip or fall 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 Stay clear of dock leveling device when freight Chock restrain all freight carriers Never remove carrier is entering or leaving area the w
6. see Ramp Loading Unloading Instructions on page 19 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 1 Check to make sure truck trailer is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the truck trailer wheels or use the truck restraint if available eX End Loading Unloading Platform at Cross Traffic Position 4 If truck trailer bed is at or above dock floor level leave leveler at the cross traffic position and proceed with loading or unloading End Loading Unloading Platform Too High Use Below Dock Position 5 If truck trailer bed is below the dock floor level perform steps 6 12 End Loading Unloading Platform at Below Dock Position 20 6 Push the Raise button to the platform high enough to clear the lip keepers but not high enough to extend the lip 7 Walk out on the leveler pull and hold the safety leg retract pull ring B located in the recess at the front of the platform This will cause the lip to extend away from the lip keepers and the cross traffic safety legs to fold to allow the leveler to lower to the below dock position 8 When the platform lip clears the lip keepers continue to hold the pull chain as the leveler lowers to the below dock service po
7. and does not bind c Raise maintenance prop to the service upright position and lock prop in this a Install shims under maintenance prop C position using an OSHA approved locking page 10 where prop attaches to leveler device frame Make sure prop is solidly shimmed 17 Disconnect power supply from motor b Using the leveler s blower motor raise the dock to the fully open position IMPORTANT DO NOT weld before disconnecting all electrical components DO NOT weld before removing air bag air bag support pallet and hoses from leveler Protect or remove the blower motor before welding Failure to follow these instructions may result damage to these components from stray sparks and weld splatter that will void your warranty 18 Remove air bag and pallet support from the leveler by disconnecting air bag positioning rods from hooks on the underside of platform figure 1 and removing the band clamp from the motor coupler figure 2 19 Remove or protect the blower motor from weld sparks and splatter Proceed to step 17 figure 2 4111 0021 November 2009 13 INSTALLATION DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic IMPORTANT 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 l
8. 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 L using the pyramid method N preferred or stepped method P 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 Q or straight method R NOTE To assist in obtaining an accurate measurement of distance K use a string G 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 K top of shim stack L to dock floor Distance K must equal the dock leveler height A 4111 0021 November 2009 INSTALLATION 4 For all MA models put a 1 4 in 6 6 mm thick shim at locations and NOTE A 1 4 in 6 6 mm thick shim at locations B and C is used only as a Starting point The final shim stack height will be determined after dock leveler is lowered into the pit The dock leveler is heavy Use chains and a lifting device with the appropriate lifting
9. 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 For all MA models 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 11 INSTALLATION SG Z DV 7 ZS Yr yY A 2 3 8 6 9 5 152 A Front of Dock Pit C Side Pit Curb Angle E Pry Locations G Rear Pit Curb Angle B Dock Leveler Frame D Gap 3 4 in 19 mm F Rear Hinge Frame Angle H Flare Bevel Weld Typical Minimum To Fit Spacing 8 With rear hinge frame angle F tight against rear 9 If gap D cannot be obtained equally at both pit curb angle G perform check the following sides of leveler grind or add material at the rear edge of rear hinge frame angle F as needed Pry between the platform and rear hinge frame angle at locations E to make sure rear edge 10 Allow the dock leveler to rest fully on the shim of platform is parallel to the rear hinge f
10. 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 4111 0021 November 2009 Whenever performing maintenance under the dock leveler platform support the platform with the maintenance prop A Position the maintenance prop behind front header plate while staying clear of the lip The lip will fold down after the platform has rested on the maintenance prop The Lip Prop may be used to keep the lip extended D Additional supports should be used to prevent the lip from collapsing if working under the leveler Lock the maintenance prop in the service B position using an OSHA approved lockout tagout device E Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout tagout E Only the person servicing the equipment should have the capability to remove the lockout ta
11. supply to the blower before lowing leveler into pit Keep power cables clear of frame members shim locations and pinch points DO NOT CONNECT POWER AT THIS TIME 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 C Shim Under Snubber Spring Mount D Dock Floor E Rear Pit Curb Angle 10 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 Shim Stacking Methods Q 4111 0021 November 2009 NOTE McGUIRE dock levelers are designed with nominal 1 2 12 7 shimming distance to allow for pit inconsistencies 1 Determine height of shim stack L for each shim location B by performing the following a Measure leveler frame height distance A b Measure dock floor to pit floor distance J at each shim location B Write down the dimensions obtained at each location c Subtract distance A from distance J to obtain the shim height Repeat for each shim location IMPORTANT The minimum size of the shim that contacts the leveler frame i e the top shim of each shim stack must be
12. 05 Y DO NOT move or use the dock leveler if anyone is under or in front of leveler um in 305 mm Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts The MA pneumatic dock leveler is designed to Failure to follow these instructions may result in compensate for a maximum 12 in 305 mm of severe personal injury or death 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 Only trained personnel should operate the dock service height may vary with design specifications leveler DO NOT overload the dock leveler DO NOT use a broken or damaged dock leveler Make sure proper service and maintenance DO NOT operate any equipment while under the procedures have been performed on leveler before influence of alcohol or drugs using DO NOT leave equipment or material unattended Truck trailer wheels must be chocked unless the on the dock leveler truck restraint is used Never remove the wheel chocks until loading unloading is finished and truck Failure to follow these instructions may result in driver has been given permission to leave personal injury and or damage to equipment Make sure platform lip rests on the truck trailer bed The dock leveler operating instructions are with at least 4 in 102 mm of overlap divided into the two methods of loadin
13. 217 Link Quick 1 4 5 2 8432 1129 Keeper Lip 16 inch 2 8432 1130 Keeper Lip 18 inch 2 2101 0047 Cotter Pin 1 4 x 2 in 6 1 DOTH 2555 Spring Snubber 7 1 DOTH 6839 Linkage Lip Assist W SNUBBER 8 1 DOTH 2421 Cold Shut 9 1 9201 0006 Prop Pin and Clip 10 1 9224 0030 Maint Prop 6 foot 1 9224 0031 Maint Prop 8 foot 1 9244 0079 Maint Prop 10 foot 11 1 2101 0216 Link Quick 1 8 1 CONSULT FACTORY 34 4111 0021 November 2009 5 i a ma 6 LI E il 7 V V q fA PE gt 5 o 1 QW PLATFORMS menjar eror ___ ror ___ jseroor ssroor roroor eo roor 65 roroor e s roor zo Foor ask 9515 consult factory 4111 0021 November 2009 35 5 2 1 pPAose _ 000020 2 _ a 57750004 juetarcHassEMBY o s 1 oras _ e wasiea _ 7 oN __ _ _ e 1 Nmtock 2 4 9 1 pptacsco BELOWDOCKCONTROLASSY sFnsjsa 10 2 p corren o m ____ ooo 12 1 porezwo nur nex sea 8 17 1 peaoxo epc pus ron assy o 1 _ 1
14. 9 Adjusting Lip Latch Spring Tension This adjustment is set at the factory and should not require additional adjustment Unlike mechanical levelers the lip will not immediately begin to fold as the platform returns to the stored position After the platform is fully raised and the lip extends the lip latch is designed to hold the lip in the extended position until the platform drifts down to the below dock position If the lip does not remain extended as the platform lowers additional spring tension may be required NOTE Use half turn increments when adjusting lip assist spring Check lip operation after each adjustment Repeat until proper operation is obtained Adjust spring tension as follows a Loosen jam nut A b To increase spring tension turn nut B counter clockwise To decrease spring tension turn nut B clockwise d Tighten jam nut Hecheck operation of platform and lip Readjust lip latch spring tension and lip assist spring tension until proper operation is obtained 4111 0021 November 2009 ADJUSTMENTS Adjusting Lip Assist Spring Tension This adjustment is set at the factory and should not require additional adjustment Unlike mechanical levelers the lip will not immediately begin to fold as the platform returns to the stored position The MA leveler lip remains extended as the platform drifts down to the below dock position The lip will automatically fold when the pla
15. CONSULT FACTORY DOTH 2822 BRUSH WEATHER SEAL DOTH 2822 BRUSH WEATHER SEAL 0014 0066 TOE GUARD LH LOWER x X 1 179 COMPLETE R amp L G EREN 2 wfe EMES 37 4111 0021 November 2009 PARTS Motor and Blower Assembly Quantity Part Number Description 9395 0359 PPAC Blower Assy Includes 1 4 7 8 10 14 1 1 Fan Motor 115VAC AP Series Levelers 2 1 Shroud Fan End 3 1 Shroud Motor End 4 1 9391 0021 Filter Element 5 1 9391 0022 Tube 2 50 8 OD 36 914 4mm Length 6 1 9392 0047 Pipe PVC 1 1 2 SCH40 X 24 38 1 X 609 6mm 7 1 Cord Set 115V 3 Conductor 6 1828 8mm long 8 1 Cord Grip 9 4 9391 0023 Clamp Tube 10 9 Screw Cap Socket Head 1 4 2 X 1 1 2 11 5 2101 0143 Nut Hex Nylon Locking 1 4 2 12 2 2101 0007 Screw Cap Hex 1 4 2 X 1 LG 13 8 2101 0005 Washer Flat 1 4 14 1 Adaptor Hose 1 1 2 to 1 1 4 38 4111 0021 November 2009 MISCELLANEOUS Customer Information NOTE Refer to illustration for left right orientation of dock leveler The model serial number decal A is located on the right platform joist near the front lip of dock leveler When you receive your MA Series dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keeping of th
16. LEVELER BY POWERAMP INSTALLED BY OTHERS ENCLOSED STARTER BY POWERAMP INSTALLED BY OTHERS 9 800 4111 0021 November 2009 Controls PARTS 11 8FLA Amp Draw Item Quantity Part Number Description A 1 7141 0207 Push Button Controller B 1 1751 0725 Decal a a a Provide dock leveler serial number voltage phase and options when calling or faxing controller orders 4111 0021 November 2009 31 PARTS This Page Intentionally Left Blank 32 4111 0021 November 2009 Airbag and Support Pallet PARTS Item Quantity Part Number Description 1 3 5812 0045 Hold Down Rod 45 long x 7 16 diameter 2 1 5811 0009 Air Bag Bladder 3 1 5811 0012 Skid Air Bag Leveler 4 2 5813 0001 Skid BRKT Air Bag Leveler BM 5 4 2101 0098 Screw HHCS 5 16 18UNC x 1 1 2 long 6 4 2101 0214 Nut Flange Top L N 5 16 18UNC T 4 2101 0058 Washer Lock 5 16 8 6 2101 0224 Rod Clamps 9 4 2101 0079 Washer Flat 1 2 inch 10 2 2101 0230 Ring Split 1 75 O D 3 10 1 5814 0029 Skid Air Bag Leveler Assembly Includes Items 3 10 4111 0021 November 2009 33 5 Frame and Platform Item Quantity Part Number Description 1 1 8435 71 Frame Welded Assembly 2 1 7952 0001 Cable A C Assembly 14 00 Final length 3 1 0941 0013 Spring Lip Latch Ext 4 2 2101 0
17. acement please call 1 800 643 5424 for replacements 1751 0727 1751 0730 x2 ADANGER Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave operating dock leveler or beginning to Maintenance Service the dock always Ensure that no equipment Before activating dock leveler 2 Maintenance Service of dock leveler material or people are on the bumpers 3 Place barriers on the driveway and on dock leveler Return the dock leveler to its trailer bed reposition vehicle leveler is securely supported by stored position at dock level Failure to follow posted instructions will result in death or serious injury Cal 262 255 1610 for replacement placards waring labels or owner users 4 DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar 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 SAFETY INFORMATION Operation supports the ramp before driving on Read and follow all instructions and ramp warnings in the owner s user s Stay clear of hinges and front and anual sides of moving dock leveler Use of dock leveler restricted to Never use damaged or trained operators malfunctioning dock leveler Report Always chock trailer wheels or problems immediately to supervisor engage truck restraint before load or unload 1 Read
18. ailable in the following sizes weight capacities and options Width MA 6 ft 1828 8 mm 6 1 2 ft 1981 2 mm 7 ft 2133 6 mm Length 1828 8 mm 6 ft 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 45 000 Ib 20 412 kg 55 000 Ib 22 680 kg Mu Comparative Industry Rating All docks are available in 115V motors only 4111 0021 November 2009 INTRODUCTION Component Identification A Lip B Lip Assist Rod C Lip Linkage Assembly G Lip Actuator Chain D Lip Latch Assembly THEORY The MA dock leveler uses a blower motor and one button operation for ease of use The dock leveler can be operated remotely using the RAISE button O on the control panel This activates an electric blower motor M The blower forces air into the air bag J causing the platform to rise Releasing the RAISE button allows the platform to lower When the platform rises to the point where there is 2 3 in 51 76 mm from its full raised height the lip spring F and lip actuator chain G causes the lip linkage assembly to push the lip out and up The lip assist spring not shown also helps keep the lip extended When the lip is fully extended the lip latch cable engages the lip latch assembly locking the lip in the extended position The dock leveler has reached its full height when the lip is full
19. and follow all instructions Never use hands or equipment to wamings and maintenance schedules move the ramp or lip in the owner s user s manual Ensure trailer is backed in against restricted to trained personnel Remove any end loads if required dock floor to indicate service work is Check trailer alignment to avoid lip being interference If lip does not lower to DO NOT ENTER PIT unless dock maintenance prop If electrically powered tum off and use OSHA lockout tagout procedures Ensure that truck bed supports extended lip or the leveler frame 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 1751 0729 CRUSH HAZARD 1751 0731 1751 0726 A DANGER 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 0729 4 DANGER CRUSH HAZARD Open the pin latch and insert through the maintenance prop housing and prop completely Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury 1751 0731 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is safely supported by maintenance prop Place barriers on driveway a
20. der the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the device 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 4111 0021 November 2009 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 repl
21. e 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 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 Possible Cause Symptom Platform does not rise Make sure the correct voltages are present at the proper locations inside the control panel s Motor fuse blown Reset circuit panel or disconnect fuse Determine Motor does not energize cause of overload Motor failure Platform does not rise Motor hums but does on line not run Platform does not rise Motor energizes but does not run Line voltage too low 28 Incorrect voltage is present Check voltage to motor If voltage is present and motor does not energize replace motor If voltage is not present check all com
22. e numbers in the event the model serial number decal A becomes lost or damaged Also write down Systems Inc s job number the company that installed the dock leveler and the original owner s name This will all help to identify the specific dock leveler if more information is required When ordering use part numbers and description to help identify the item ordered Do not use item numbers These are only for locating the position of the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER For service call or contact McGUIRE P O Box 309 Germantown 53022 Phone 800 624 8473 Fax 262 255 5917 E mail techservices docksystemsinc com 4111 0021 November 2009 Dock Leveler Information Model Serial No Systems Inc Job No Original Owner Information Name Address Installer Information Name Address Date of Installation 39 40 5 4111 0021 November 2009 4111 0021 November 2009 NOTES 41 McGUIRE WARRANTY MA SERIES LEVELER Systems Inc guarantees the materials components and workmanship in your McGUIRE MA Series dock leveler to be of the highest quality and to be free of defects in material and workmanship for a full One 1 Year Base Warranty on all components The Base Warranty includes replacement parts labor and freight The electrical components carry a one 1 year warranty The lifting components which include sea
23. enance Service Dock Leveler Safely 21 Periodic Maintenance 22 Adjustments Adjust Lip Latch and Lip Actuator Springs 24 Adjust Lip SIOD ouo nba mem tus ny PIRE Er Rev Pare a 27 Troubleshooting Troubleshooting Ray Runs 28 Electrical Electrical 115 1 phase 30 Parts CONUOIS 2225556205 a gw 31 Pit Extension Kif nad don UAR ORC CER 32 Air Bladder and Support 33 Frane and Platform CREE 34 Weather Seal Rubber Style 36 Weather Seal Brush Style 37 Motor and Blower Assembly 38 Miscellaneous Customer Information 39 Warranty Back Cover 4111 0021 November 2009 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
24. er functions properly and there is no binding 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 9 Raise the platform fully Hold the platform at this position using the RAISE button and move the maintenance prop to the service upright position Release the RAISE button to allow the platform to lower until it is resting on the maintenance prop 10 With the maintenance prop supporting the platform remove the lifting brackets 11 If equipped with vertical weather seals position the seals so that the seals are directly under and aligned with the overhead door 12 Support the toe guards remove the bolt used in shipping and carefully release the toe guards 13 Push and hold the RAISE button until the maintenance prop drops to its stored position Release the RAISE button and allow the platform to lower fully Check operation of toe guards 14 When the platform lowers to the full below dock position the lip will fold Push and hold the RAISE button until the platform rises just enough to clear the lip keepers then release the RAISE button to allow the platform to lower to the cross traffic stored position lip engages lip keepers 17 OPERATION Operating Instructions Stay clear of dock leveler when freight carrier is l entering or leaving dock area 3
25. eveler to malfunction and shorten the life span of the affected components 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 NOTE The illustration on page 12 shows a typical weld pattern The weld pattern will vary Slightly depending on size of dock leveler Always keep a fire extinguisher of the proper type nearby when grinding or welding 20 With the rear hinge frame angle F tight against the rear pit curb angle and flush with the 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 Failure to follow these instructions may result in serious personal injury or death IMPORTANT DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed Start at each end with a 6 in 152 mm long weld Space all the other welds out evenly leaving approximately 6 in 152 mm space between each weld 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 wiring and or control panel 14 4111 0021 November 2009 Make sure the platform is proper
26. g and unloading Maintain a safe distance from side edges of leveler during the loading unloading process For ramp loading and unloading see Ramp Loading Unloading Instructions on page 19 Failure to follow these instructions may result in serious personal injury or death For end loading and unloading see End Loading Unloading Instructions on page 20 18 4111 0021 November 2009 Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 20 For ramp loading or unloading the MA dock leveler can be operated by using the RAISE button on the control panel 1 Check to make sure truck trailer is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the truck trailer wheels or use the truck restraint if available A RAISE Button 4 Extend the platform lip onto truck trailer as follows a Raise the platform by pushing and holding RAISE button b Hold the RAISE button until the lip is fully extended then release the RAISE button The platform will lower until the lip is resting on the truck trailer bed c Make sure that the lip is fully extended and supported on the truck trailer along the entire width of the platform with at least 4 in 102 mm of lip contacting the truck bed 5 Pr
27. gout devices The Tag out devices must inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to OSHA regulation 1910 147 21 MAINTENANCE Periodic Maintenance 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 Before performing any maintenance under the dock leveler lock the electrical power source in OFF position and lock the maintenance prop in the service position using an approved locking device See Service Dock Leveler Safely in this section Under platform service Failure to follow these instructions may result in serious personal injury or death Air Filter service under rear of platform 22 4111 0021 November 2009 MAINTENANCE Regular maintenance must be performed on a weekly and quarterly schedule Weekly Maintenance uarterly Maintenance
28. heel chocks until loading or unloading 15 finished and truck driver has been given permission to drive away NT Tee Do not use a broken or damage dock leveling Do not move or use the dock leveling device if device Make sure proper service and anyone is under or in front of it maintenance procedures have been performed before using _ or Keep hands and feet clear of pinch points Avoid Make sure lip overlaps onto trailer at least 4 in putting any part of your body near moving parts 102 mm Keep a safe distance from both side edges 4111 0021 November 2009 SAFETY Do not use dock leveling device if freight carrier is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device 4111 0021 November 2009 3 SAFETY 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 The maintenance prop must be in the upright service position when working un
29. inge area inject grease into all the platform hinge grease fittings F Lip assist pin 4111 0021 November 2009 23 ADJUSTMENTS Adjusting the Latch and Lip Actuator Spring Tension 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 and lip 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 A Lip Latch Spring B Lip Assist Spring Unless the dock leveler is equipped with a tethered susu Adjustment 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 24 4111 0021 November 200
30. ls hoses motor and air bladder carry an additional four 4 year total warranty Structural components carry an additional period of Four 4 Years on parts only after two years customer is responsible for 20 three years 30 etc Specifically the structural warranty includes the frame deck section lip section rear hinge and front hinge Systems Inc warrants all components to be free of defects in material and workmanship under normal use during the warranty period This base warranty period begins upon the completion of the installation or the Sixtieth 607 day after shipment whichever is earlier In the event of any defect covered by this guarantee Systems Inc will remedy said defect by repairing or replacing all defective parts bearing all of the costs for parts labor and transportation All guarantee claims will be settled on a timely basis when defects are found to be from other than improper installation operating contrary to instructions or beyond rated load capacities abuse careless or negligent use or failure to maintain the unit as recommended by the owner s user s manual There are no guarantees either expressed or implied including any implied guarantees of merchantability or fitness for a particular purpose which shall extend beyond the guarantee periods indicated above This guarantee is valid only if the unit s is unaltered from original condition as delivered from the factory and a survey is co
31. ly supported in the raised position before entering the pit to finish weld the shims Failure to do this may result in serious personal injury or death 21 22 23 24 All model levelers Install shims at locations B p 10 using the pyramid or stepped shimming method Make sure the platform is level from side to side as well as from front to back and flush with dock floor Weld front of dock leveler frame C to shims located under the keepers then weld the shims to the front pit curb steel 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 When all welding has been completed paint all the welds and shims Shim Stacking Methods P Q For left right orientation of dock leveler see inside back cover of this manual 4111 0021 November 2009 INSTALLATION 19 INSTALLATION Install Control Panel and Wiring The electrical power must be OFF prior to electrical installation For maximum protection use an OSHA approved locking device to lock out all power sources Only the person installing the equipment should have the key to unlock the power source Failure to follow these instructions may result in serious personal injury or death DO NOT make any final electrical connections until all welding has been c
32. mpleted by a McGUIRE representative
33. nd 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 0021 November 2009 General Information Congratulations on your choice of a McGUIRE dock leveler This manual covers the Air Bag MA model air powered 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 Its revolutionary air bag system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended m N TER V aY A T k MAN W WN W WAN AA AA y W X The MA dock leveler comes equipped with an electrical control panel which allows push button operation of the dock leveler functions Each MA dock leveler unit 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 McGUIRE MA dock leveler INTRODUCTION Dock Leveler Stock Specifications MA Series dock levelers are av
34. oceed with loading or unloading the truck trailer 6 If below dock loading is necessary see steps 7 11 If not proceed to step 12 4111 0021 November 2009 OPERATION Below Dock Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 20 7 Check to make sure truck trailer is positioned squarely against dock bumpers 8 Instruct driver to remain at the dock until the loading or unloading process has been completed 9 Chock the truck trailer wheels or use truck restraint if present 10 Raise the platform by pushing the raise button A to fully raise the leveler and extend the lip 11 Walk out on the leveler Pull and Hold the release ring see picture below until the platform lowers onto the trailer Make sure there is a minimum of 4 of lip overlapping the trailer A RAISE Button 12 When loading or unloading is finished raise the platform by pushing and holding RAISE button A 13 Hold the RAISE button until the lip folds enough to clear the truck trailer bed then release the RAISE button The lip will fold and the platform will return to the cross traffic position 14 Remove chocks from truck trailer wheels or release the truck restraint if used 15 Indicate to driver that truck may leave the dock 19 Operating Instructions Continued End Loading Unloading Instructions NOTE If ramp loading is required
35. ompleted Failure to do this may result in serious personal injury or death All electrical work including the installation of the disconnect panel control panel and final connections to the pit junction box must be performed by a certified electrician and conform to all local and applicable national codes 16 A Disconnect Panel provided by others B Control Panel C Distance 48 in 14 630 mm Mount the push button control panel B so bottom of control panel to dock floor distance C is 48 in 1219 2 mm Install electrical disconnect panel A if not already installed Install and connect the control wiring Re install the air bag air bag support pallet and blower motor Connect the dock leveler power cable to the outlet in the pit junction box Refer to the electrical drawings supplied with the dock leveler After all electrical connections in the pit have been made raise the leveler disengage the maintenance prop and allow the platform to lower 4111 0021 November 2009 Put New Dock Leveler Into Service 1 Disconnect the external lifting device and chains from the lifting brackets 2 Check that the leveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly an excessive transition exists between the dock floor and leveler and or lip does not contact both lip Keepers evenly contact Poweramp Technical Services for f
36. or 6 foot and 47 5 for 8 foot long The assembly is broken or missing Lip extends almost Lip actuator chain caught on Inspect lip actuator chain clean area insure chain is immediately when the debris or framework free from interference RAISE button is pushed Platform rises after lip is fully extended Lip extends but does not Lip latch spring needs See Adjustment Section Lip Latch Spring remain extended as additional tension Increase tension as needed to keep latch leveler drops engaged Clean any debris from lip latch area Lubricate as instructed in maintenance section 4111 0021 November 2009 29 ELECTRICAL TABLE 1 RECOMMENDED FIELD WIRE SIZE CIRCUIT LENGTH TABLE 2 TOTAL 1 PHASE FLA 11 8 A TABLE 3 MOTOR NAMEPLATE DATA MOTOR LOCATED AT DOCK LEVELER VOLTAGE 15 V 11 8 30 CUSTOMER SUPPLIED 115 V 1 PHASE 60 HZ FROM BRANCH CIRCUIT DISCONNECT SWITCH amp OVERCURRENT DEVICE BY OTHERS SELECT DISCONNECT SWITCH amp OVERCURRENT DEVICE PER THE NEC LOCATE A DISCONNECT SWITCH NEXT TO THE ENCLOSED STARTER DUAL ELEMENT TIME DELAY FUSES MUST BE USED FOR BRANCH CIRCUIT PROTECTION SEE TABLES 1 2 AND 3 L2 N GRD GROUNDING TERMINALS PLASTIC ENCLOSURE FOR METALLIC ENCLOSURE USE GROUNDING PROVISION IN ENCLOSURE BODY AND STUD ON ENCLOSURE COVER J BOX W DUPLEX AT REAR OF PIT WALL BY OTHERS NEMA TYPE 5 15 FLEX CORD W PLUG BY POWERAMP DOCK
37. ponents in series with the motor Check line for proper voltage If proper voltage is not present check all components in series with the motor If proper voltage is present and motor does not run check for obstructions If no obstructions are found replace motor Check wiring to motor for high resistance Check for loose or corroded connections Check if gauge of wires to motor are of correct size and specification for load requirement Replace if necessary 4111 0021 November 2009 TROUBLESHOOTING Platform rises slowly Air bladder or connecting Check air bladder and ducting repair or replace as ducts punctured needed Damaged or restricted Replace damaged ducting or remove restriction ducting Air intake clogged Remove intake filter clean or replace as needed Dock leveler binding Check for visible obstructions that could cause binding Remove obstructions If no obstructions found call Poweramp Technical Services See inside back cover for phone number and address Platform does not rise to See Platform Rises Slowly See Platform Rises Slowly full height See Periodic Maintenance in the Maintenance section Platform DOES rise to Lip assist spring needs Inspect lip actuator spring replace as needed full height but lip DOES additional tension NOT extend or extend fully Lip does not extend Check the snubber spring The chain is too long and needs to be shortened assembly OPEN HEIGHT 42 5 f
38. rame stacks Check that a smooth and level transition angle exists between the dock floor and the dock leveler platform Add or remove shims as Gap D must exist equally along both sides of necessary until a smooth transition is obtained leveler so weather seal if equipped will not bind during dock leveler operation 11 If leveler cannot be squared and or made level as instructed in steps 8 10 contact McGUIRE Technical Services 12 4111 0021 November 2009 INSTALLATION 12 With the leveler square in the pit and flush with the surrounding dock remove the banding on the lip of the leveler Two people are required to engage the maintenance prop one person to operate the lifting 13 Connect the blower motor to the temporary device the other person to engage the power supply maintenance prop 14 Slowly raise the platform Check for binding as platform is being raised 15 If binding occurs lower the platform Reposition DO NOT use the maintenance prop to support the leveler and or add or remove shims as raised platform until the maintenance prop has necessary Slowly raise platform again If platform been properly shimmed and welded The shims still binds contact Poweramp Technical Services must be welded to each other the leveler frame for further instructions and to the front pit curb steel Failure to do this may result in serious personal injury or death 16 All MA models Once leveler is flush square
39. s from the pit and sweep the pit unauthorized use of the dock leveler before clean installation has been completed 2 Check the entire dock leveler pit for proper Failure to follow the installation instructions can construction according to approved certified pit result in damage to dock leveler the facilities drawings Make sure pit is square by making the and or serious personal injury or death following measurements Measure pit width distance A at both front and rear of pit Measure dock floor to pit floor distance B at all four corners Measure pit length distance C at both sides Measure corner to corner criss cross distance D at both sides Take measurements at dock IMPORTANT floor level and at pit floor level DO NOT remove the shipping bands around the If any measurement is off by more than 1 8 in dock leveler lip until instructed to do so 3 18 mm contact Poweramp Technical Services before proceeding 3 Make sure the field junction box for the dock leveler E is at the correct location per pit diagrams 4111 0021 November 2009 INSTALLATION Prepare Dock Leveler H n A Lifting Bracket 2 used 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 The dock leveler is heavy Use a lifting device and chains with the appropriate lifting capacity and reach
40. sition The platform will drift down to the full below dock position 9 Proceed with loading or unloading NOTE When end unloading is finished and access to the rest of the truck trailer is still required the platform lip will need to be extended See Ramp Loading Unloading Instructions on page 79 for further instructions 10 When the loading or unloading is finished return the dock leveler platform to the cross traffic stored position 11 Push the Raise button A until the lip clears the lip keepers Release Raise button leveler will return to the stored or cross traffic position 12 Remove chocks from truck trailer wheels or release the truck restraint if used 13 Indicate to the driver that the truck may leave the dock 4111 0021 November 2009 Service Dock Leveler Safely A Maintenance Prop 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 B Prop Pin and Clip C Safety Leg Chain MAINTENANCE D Lip Prop E Lock Out Tag Out 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
41. tform when the dock is resting on the safety legs in the below dock position If the lip does not fully extend additional spring tension may be needed NOTE Use two turn increments when adjusting lip assist spring Check lip operation after each adjustment Repeat until proper operation is obtained Adjust spring tension as follows a Loosen jam nut A b To increase spring tension turn nut B clockwise C To decrease spring tension turn nut B counterclockwise d Tighten jam nut Hecheck operation of platform and lip Readjust lift spring tension and lip assist spring tension until proper operation is obtained 25 26 This page intentionally left blank 4111 0021 November 2009 Adjust Lip Stop Bolt Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death The platform maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Failure to follo
42. urther instructions 3 Install the dock bumpers as required 4 Turn the main electrical power ON Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or death may result 5 Raise the leveler platform fully by pushing and holding the RAISE button NOTE The platform of a properly operating dock leveler will automatically stop rising when it reaches approximately 2 3 inches from its full raised height at which point the lip extends When the lip is fully extended it has reached the full raised position If the lip does not extend or extend fully see Platform Rises to Full Height But Lip Does Not Fully Extend in the Troubleshooting section 6 Release the RAISE button to lower the platform As long as there is no truck present at the dock the platform will lower to the full below dock position as the lip folds NOTE lf a truck is present the platform will lower until the lip rests on the truck trailer bed See Operating Instructions in Operation section 4111 0021 November 2009 INSTALLATION 7 When the platform lowers to the full below dock position the lip will fold Push and hold the RAISE button until the platform rises just enough to clear the lip keepers then release the RAISE button to allow the platform to lower to the cross traffic stored position lip engages lip keepers 8 Perform steps 5 7 at least four times make sure the level
43. w these instructions may result in serious personal injury or death Check that lip E is fully resting on the lip keepers D and at the lowest part of the keeper cradle If lip is not resting properly in keepers perform the following adjustment 1 Fully raise platform Engage lip and maintenance prop 2 Loosen jam nut B 3 Adjust stop bolt C as necessary Turn stop bolt clockwise to allow lip to fold closer to platform frame A Turn stop bolt out counterclockwise to hold lip further away from platform frame A 4111 0021 November 2009 ADJUSTMENTS A Platform Frame D Lip Keeper B Jam Nut E Lip C Stop Bolt Tighten jam nut B Fully raise platform and disengage lip and maintenace prop Allow platform to lower to cross traffic stored position Check lip position in both keepers Repeat procedure if necessary 2 TROUBLESHOOTING 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 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 th
44. y extended 4111 0021 November 2009 E Lip Maintenance Prop Pivot F Lip Actuator Snubber Spring NW 1 WN TAM 2 C L Maintenance Prop M Blower Motor N Toe Guard 2 used O Raise Button P Safety Legs H Air bag support pallet I Lip Keepers 2 used J Air bag K Main Frame To lower the platform release the Raise button O The platform will lower until the extended lip rests on the truck bed If the lip did not fully extend or there is no truck at the dock the platform will lower until one of the following conditions occur Lip is resting on lip keepers cross traffic position Leveler went to the below dock position lip folds automatically leveler rests on the safety legs below dock position Leveler went to the below dock position with operator holding the safety leg retract cable not shown safety legs are retracted lip folds automatically causing dock to rest in the full below dock position INSTALLATION Prepare Pit A Distance Pit Width B Distance Dock Floor to Pit C Distance Pit Length D Distance Pit Corner to Corner Front and Rear Floor All Four Corners Both Sides of Pit Top Bottom and Both Sides Before lowering the dock leveler into the pit the following must be performed Post safety warnings and barricade the work area at dock level and ground level to prevent 1 Remove all debri
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