“HED” SERIES Owner/User Manual
Contents
1. 5 Postion bump blocks out approximately 5 8 out rom he edge ofthe inside lange of the bump block to the end ofthe base piate Posen the top of no tread over plate on the bump blocks to be fush with he top of the base pto Tack weld bump to dock stool 6 Place ramp plate in poston fush win top backside af baso piate Mark along ful length of back edge of ramp plate Sio ramp plate forward over dock lover ha wiih of bushing tool apprr matoly z 7 bushing oo on marked ine at each end of amp to ensure proper alignment both ends and tack weld ramp piate to dock levele to hold ramp ato in place while bushing A Sk Roto Hammer 736 or emir tool is recommended 6 Using the back edge ol the ramp pato as a uid concrete approximately 3147 deep by Z wide and shod be the entre length of ramp piate 9 Break tack welds holding ramp in pace ide ramo ale back nto postion win the top of Pe ramp pate fush wilh top of bo base pte Tack weld each end and center of ramp plata to base pal 0 DHL da by 5 deep holes through ramo plate at back edge instal anchor bos per manufacturers specifications and ten securely Weld anchor bot rus to ramp plate using flet wold al ho way ound ha Cut of portion ofthe anchor bat exposed through to nut pug wold around the top ol tha he anchor bol Ensure the top of he are well rounded fer smooth rover2. anus ne 48 6 E ELECTRICAL 1 Phase ET 2 ELECTRICAL 3 Phase a TROUBLESHOOTING Symptom Solution Unit raises but the lip plate will not retract Turn sequence valve clockwise approximately 1 4 tum and retest unit If the lip plate stil will not retract repeat the above adjustment until unit operates properly Unit raises but the li plate will not extend The unit raises slowly the motor is extremely noisy and the hydraulic hoses are vibrating Check the fluid level in power unit reservoir if low add fuid and operate leveler several times to remove any air from the system Tip Plate will not stay extended Turn sequence valve clockwise in 1 2 tum increments until lip plate remains extended but is stil yieldable to approximately thirty pounds of downward force The plate extends before the unit reaches full dock height Turn sequence valve clockwise in 1 2 tum increments until plate operates properly The motor runs but the unit wil not raise Check the motor for reverse polarity wiring consult the wiring diagram located on the motor
3. p moog INSTALLATION H E D Installation Instructions Ramp Mount Weld Bolt On Aramp 1 appicaton is used when adequate dock steel is securely anchored in the concrele at the dock edge but he existing dock height is too kw and dock velo must be instaled above this height lo corect his Steps 1 Remove al bumper material and protruding fom dock edge Clean and sweep dock edge of debris betore unt 2 chosen locaton for Edge of Dock leveler locato the cantar of space and mark a point hal of the base width to Pe lof and right 3 Athe points marked io each of center measure and mark points 7 34 below dock level less height he unit is t bo 664 to locale bottom of baso piata Tis wil locato the top of he base pao above dock ove 4 Using a proper iting device raise and positon the volo base plate to marked postion Wide hoking baso pato ight against dock face tack weld socuraly to dock steel on left hand end of levelet Check right hand end of base plata ensure that end is against dock soe and that he of the base plate is even wih he marks made previously Tack hand end to dock steel Support urit unti fnal weiding is ready to
4. 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 ALWAYS disconnect electrical power source and ground wire before welding on dock velo DO NOT ground weiding equipment to any hydraulic or electrical components of the dock Always ground tothe dock loveer Failure to follow these instructions may resultin damage to dock leveler andlor serious personal Injury or death DO NOT grind or weld if hydraulic fuid or other flammable liquid is present on the surface to bo ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other fammablo liquid is present Stray sparks can ignite spils or leaks near the work area Always up tho leaks and spils before proceeding with grinding or welding Always keep extinguisher of tho 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 Safety Decals 5 48 6 5 INTRODUCTION General Information HED Series Edge ol Dock levelers are available in the following sizes weight 099898 and options
5. Call McGuire to discuss available voltages phases and options to meet your specific needs Congratulations on your choice of a McGuire Edge 66009 leveer This manual covers the HED series mechanical Edge of Dack levelers Designed by McGuire to be a marvel of simplicity and eficiency your dock leveler when propery installed wil provide many years of touble ree performance wilh 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 edga at dock level Tho HED series Edgo of Dock lovolor comes equipped with an electrical control panel which allows pushbutton operation of tho dock leveler functions Each HED dock level unit and control panel has been factory prowired and tested to ensure Satisfactory operation To ilustrate which connections to be made in the feld at instalation electrical drawings are included With each order or by contacting Systems Inc Technical Services Once again thank you and congratulations on your purchase of a McGuire Hydraulic Edgo of Dock level INTRODUCTION Component Identification Anup re S enter Piste ST ey Prop THEORY The HED Edge ol Dock levelor uses a pressure operated valve block and single push button operation for ease of use
6. dock leveler to be of the highest quality and to be free of defects in material and workmanship for a period of one 1 year from date of shipment specifically the deck section lip section frame rear hinge front hinge McGuire further guarantees the hydraulic components all McGuire dock levelers for period of one 1 year from date of shipment Specifically this guarantee applies to Ali hydraulic cylinders Hydraulic pressure lines Hydraulic pump and motor The electrical components carry a one 1 year warranty In the event of any defect covered by this guarantee McGuire will remedy said defect by repairing or replacing defective parts bearing of the costs for parts labor and transportation 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 completed by a McGuire representative
7. MeGUIRE HED SERIES Hydraulic EOD Dock Leveler A Division af Systems Inc Owner s User s Manual MCGUIRE Division of Systems W194 1141 MeConrick Drive Germantown WI 53022 800 624472 ax 282 2577388 winrwbmequir com echservicestdocksystemsin com por um Table of Contents Safety Recognize Safety information General Operational Safety Precautions Operational Safety Precautions Maintenance Safety Precautions Safety Decals Introduction General Information Dock Leveler Stock Specifications Component Identification Installation Installation Details Flush Mount Weld On Ramp Mount Wold Boit Flush Mount Bolt On Ramp Mount Weld On Formed Angle Ramp and Face Plate Installation Check List Install Control Panel and Wiring Put New Dock Leveler Into Service Operation Operating Instructions Maintenance Periodic Maintenance Adjustments Adjust Main Pressure Raliet Adjust Lip Function Electrical Single Phase Three Phase Troubleshooting Troubleshooting Parts Miscellaneous Customer Information Warranty SAFETY Recognize Safety Information Safety Alert Symbol The Safety Aler Symbol identifies important safety messages on equipment safety signs manuals or elsewhere When you soo this symbol bo alert to the possibilty of personal injury or death Follow
8. The dock leveler can be operated remotely using the RAISE button J on the control panel Platform B is raised by pushing and holding the RAISE button J This activates an electric motor D which in tum drives a hydraulic pump The hydraulic Pump forces oil into tho platform cylinder G causing the platform to 56 Hold J unti ip fully extends mun Releasing the raise button wil allow the platform to down to the below dock position The wil stay extended unti the platform reaches the full below dock postion Pressing the raise button wal return the platform and lip to the stored position INSTALLATION INSTALLATION DETAILS Post safety warnings and barricade the work area dock level and ground level to prevent Unauthorized use of the dock leveler before Installation has been complete Failure to follow the instalation instructions can result n damage to dock leveler the facies andlor serious personal injury death Only trained installation professionals with the proper equipment should install this product IMPORTANT 00 NOT remove the shipping bands around the dock lover lip unti instructed to do DO NOT grind or weld I hydraulic fluid or other flammable liquid is present onthe surface to bo ground or welded DO NOT grind or weld if uncontainod hydraulic li
9. bolts per manufacturers specifcatons and tighten securely Wald anchor ot nuts to ramo plato using a flet weld al the way around he nut Cut of any porton of he anchor bot exposed through he and Hag weld around the top of ho nut he anchor bol Ensure o of he nuts are wel rounded for smth Apply a continuous flot wold at the created joint th plato and ramp Skip weiding shouldbe the proper method used to avoid warpage and a completa weld must be achieved INSTALLATION INSTALLATION CHECK LIST Date aus mE uns SYSTEMS INC Loading Dock Equipment E O D Installation Checklist Order No Serial Number Installer Customer Name Address City State Phone Company Unit is properly aligned and installed properly welding has been filly completed Welding slag has been removed Welds and othe affected areas have been painted 1 Springs have been property adjusted Units functioning propery without fut 1 hereby certify that installation and or repair work has been inspected and approved by Date Completed Signature copy of this document must be signed and faxed to Systems Ine at 262 257 7399 to the attention Customer Service Technical Service To be placed in job folder Copy as needed INSTALLATION his page intentionati iet
10. the instructions inthe safety message The use ofthe word DANGER signifies the presence of an extreme hazard or unsafe practice which will most Ikely result in severe injury or deat The use ofthe word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death The use ofthe word CAUTION signifies possible hazard or unsafe practico which could result in personal injury IMPORTANT use of the word IMPORTANT 6 to draw attantion to a procedure that needs lo bo followed prevent machine damage General Operational Safety Precautions Read and understand the operating instructions and become thoroughly familiar withthe equipment and is controls before operating the dock levolor Never operato a dock lovelor while 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 uni al unauthorized personnel in the area have been warned and have moved outside the operating zone Remove any tools or foreign objects the operating zone before starting Koap the operating zone 66 of obstacles that could cause person to or fal SAFETY Operational Safety Precautions Learn the safe way to operate this equipment Read and understand the manufacturer s instructions If you have a
11. Add hydraulic fuid f necessary Use only recommended fui 5 Tum ON electrical power to the leveler 6 Retum the platform to the cross tratfic poston ADJUSTMENTS Adjust Main Pressure Relief When servico under the dock levelr is required always lock 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 n serious personal injury or death Always stand clear of the dock levler ip when working in front of the dock lovaer The maintenance prop MUST be in the service postion when working under the dock vele For maximum protection use an OSHA approved Jacking device to lock the maintenance prop inthe service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless tho dock lovlor 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 NOTE Tho main pressure relief may need to bo incroasod if the platform does not ri
12. Completo waldng of tacked parts as flows A continuous weld across top of each bumper and base plato to ramp Sp welding s accopatl to prevent warpage but C Fuly plug wold al holes in base piate 12 Installer must remove all welding slag and repaint Welded aas 15 Dri da by S deep holes in concrete through in lower cyinder mount and instal anchor bots wih washers and tighten securely 4 Fed mount con box bo insido wal Fed wire conto box and hydraulic power unt per electrical schematis provided Reed and comply win al oat codes 45 Before instalis completo instaler must fal operational chock of dock kveler o very al phases tal are correct Installer must compete ign retur the salon Check ist upon 2 INSTALLATION yun Ka Busreo uoqeeysu 10 wounsnipe Buunp Budda dues uy Ane ues Gupe q jo or 80 64 u pue dusi vod ns jo on Aaunoes mip oer INSTALLATION H E D Installation Instructions Flush Mount Bolt On Ash mount bot on appicaton is used when tera is no tod on dock edge andthe dock height adequate Additonal iod ramp pat and boling is required wih tis opo ofinstalaton clon Stop 1 Remove
13. DOTH 2208 WASHER FLAT DIA 8 4 DOTHZI28 NYLON LOCK NUT 16 14 UNC 58 page intron iet lank MISCELLANEOUS his page intentionati iet bani MISCELLANEOUS Customer Information NOTE The modeliserial number decal A is located the right joist near the front ip of dock When you recive your HED serios Edge Of Dock valor wile down the dock leveler model and serial number in the form provided This wil help ensure sate keeping of the numbers in the event the number decal A becomes lost or damaged Also writ down McGuire job number the company that installed the dock and the original owner s name This wil all help to identity tho speci dock evelar if more information 5 required When ordering use part numbers and description to help identity the hem ordered Do not use tam numbers These aro only for locating the position of the parts Always give dock lovelor MODEL NUMBER andlor SERIAL NUMBER For servic or contact McGuire PO Box 509 Fax 262 255 5917 Dack Levelar information 4 No McGure Job iginal Owner Information Name Installer information Name Date of instalation MCGUIRE Systems Inc McGuire guarantees the materials components and workmanship your McGuire
14. al bumper material and protruding objects fom dock edge Clean and swoop dock edge dotes ana fames chara efor nealing 2 At chosan locaton for Edge of Dock the of pace and mark port half of he basa plo se the lef and rh 3 marked io each sido of center measur and mark points 7 112 below dock level boc ramp alo to locale positon for botiom of base piate This positon wi placa the top of ho base plate above th dock foc This poston wil vary with ramp plate 4 ine connecting hes ports and postion support anges Postion anges shown in instalation craving provided Mark cortar of holes n each of be support anges 5 dil holes BIE dia by S deep h concrete Ital anchor bots wi washers rough Support anges rio holes in concrete Tighten bots uni support angles are secure Folow anchor 6 Using a proper iting devo raise and poston the baso poo o marked postion resing on the support angles Who holding baseplate dock face tack weid securely to support anges 7 Drit 58 by S deep holes in trough holes base plato and instal anchor bots wih washers and ton soc 8 Postion bump blocks cul approratnly SE out tom the edge f be inside fange o ho bump block o he end of no base piate Postion fhe tp of ho read over plate on fo bump blocks to bo above dock No
15. existing bumper material and protruding fom dock edge Clean and swoop dock edge dts ona fames efor rang 2 Review and low formed angle instalation instructions instalation 3 chosen locaton for Edge of Dock leveler the of space and mark a point half of he base plate walt he lef and 4 Atho ports markod o each side of center measure and mark pits 7347 below dock level less height he Unt k io bo raised io locate botiom of base piate This Wil locale ho lop ofthe aso plate X above dock level 6 Using a proper iting raise and poston the base piate to marked postion Whi holding base plate ight against dock face tack weld securely io dock steel on hand end of Check right hand fend of baso piate ensure that nd aget dock tel and that he bottom of ho base piate is even with tho marke made previously Tack right hand end to dock ted Support urit unt fal welding ready 5 6 Postion bump blocks out approratnly SE out tom the edge f be inside fango o ho bump block to he end of he base piate Postion fhe tp of the read over piate fe bump blocks to be wih he baso Tack weld bump blocks to dock steel 7 Place stool ramp pao in poston fush wih top backside of base Mark length of back c ramp piate Sido ramp plate forward over dock wid of bushing toc approx
16. mourt and instal anchor bolts wth Washers and tron securely 16 mount corri bov to wal wo control bax and power per schematics provided Reed and comply wih al local electrical odes 16 Boro instalis compel instaler must make a fal check of dock o vorty al phases of ar coro most compete ig and n INSTALLATION qun oi x fu 652 woe ges 6 Buddo dues ut ns ueo adod jo oe 9002 open dy pue dusi podkins 295 INSTALLATION Installation Instructions Formed Angle formed angle is used when thor is no existing dock steel and concrete at the dock edge has been damaged The formed angle is required to rebuild the damaged concrete edge for a proper instalation if the dock height is adequate instalation Step 1 Remove al bumper material and protruding objects from dock and sweep dock edge too dais awapi chemicals belare instaling un 2 Atchosen location for the formed angle locate the center of space and mark a point hal of ho ange wah to pe lef and ht 3 Using a proper ing devico raise and postion the formed and o marked positon sido angle against dock 66 4 Mark along length of back edge af farmed ange Side ang forward he at of brushing tool ap
17. to ramp piate Skip woking is to prevent warpage but complete weld bo completed B Weld botom of baseplate to support angles using 890 flawed 6 instaler must all woking stag and repaint welded areas DASE da by holes in concrete rough holes niower mourt and instal anchor bolts wth washers and ighin securely INSTALLATION 18 Field mount oorti box wal Fekd wire control box and hydraulc power unit por electrical schematics provided Read and comply wilh al kcal electical 19 Before instalis completa instaler must make a fna operational chock of dock leveier very al phases of tal are correct Instalor mut compete sn and rem 86 etalon Check st upon complet mn PF IBE Var 3H Securely block or support ramo and lip when in vertical postions Lack of proper bracing can result in ramp dropping during adjustment or installation Tes causing personal injury or damage to unit NM 15 INSTALLATION H E D Installation Instructions Ramp Mount Weld On w Formed Angle mounted on used wan a fred angle used when dock damaged is no dock sel soo rely anchored ro fhe cone andthe dock eights too ow and the leve must be installed above this height to correct his siuaton 96 1 Remove al
18. use the dock lever if anyone is under or in front of Keep hands and feet clear of pinch points Avoid Puting any part of your body near moving parts Failure to follow these instructions may result in severe personal injury or death Only trained personnel shouid operata the dock DO NOT use broken or damaged dock lavo Make sure propor service and maintenance procedures have been performed on levoler before using Truckrailer wheels must be chocked unless the truck restraint is used Never remove the wheel chocks unti loadinglunloading is finished and tuck driver has been given permission to leave Make wi at platform ip rests on the trucktaller bod st 4 in 102 mm of overlap Maintain a safe distance from side edges of lever during the leading unloading process Failure to follow these instructions may result in serious personal injury death Tho HED hydraulic Edgo of Dock leveler is designed to compensate for a maximum 5 in 127 mm of height diference between tho loading dock and the truck bed DO NOT use the dock leveker if the truckhraller bed is more than 5 in 127 mm higher or lower than the dock floor service height may vary with design specifications NOT overload the dock leveler DO NOT operate any equipment while under tho inf uence of alcohol or drugs DO NOT leave equipment or material unattended on the dock loveler Failure to fo
19. 862 5 14 Tem Plats Hinge Ansently 596050 5 14 TAS Center Pate Hinge 50 18 1 3 TRAGE 596622 2 7 Hinge Assembly 598955 1 3 Lg Center Ege DOT 2 7 Centar Pat Hinge _ 7 7 AT Piate amp Hings 882558 Hinge Pa BOTI 3 mones 4 785559 Hinge OTH 4 L Hinge Pin DOMES 1 12 TES Hinge Pin 596356 41 53 568255 Hinge Pin Duro T Ar 8685508592 207950 15565 T3 EDETE DOT 615 A ata Vert Pug 596277 w A Lip Cylinder A ose Assembly 307 sont 3713 AT Upper Cylinder Phe Euri m Ar Ma Cylinder Pis POTEST Mai POTETE 2 1 Ar Twa Cynder Mount Assen BOAR zo Ar zT Tse Resemity T zz A 80 Degree FEER OTE A Power Uni ISP 51 14 A Power URN Z30VHPH 598366 51 14 A Power Un 230VPH Power Uni 98650 A Carraige Bo AT lange ut Euri a PARTS BILL OF MATERIAL ITEM TY PART NO DESCRIPTION SE 1 1 DOTH 3556 1 PROJ X 12 BB WELDMENT HED 2 1 DOTH 3505 RUBBER TUF CORD 1213 3 DOTH 2056 HEX HEAD CAP SCREW 7614 X STE 4 4 90 2210 WASHER FLAT ZINC PLATED 112 DIA 5 4
20. UENCE VALVE CLOCKWISE IN TURN INCREMENT 2 F UP WILL NOT FULLY RETR WHEN RECYCLING PLATFORM TO STORED POSTON TURN INCREMENTS NOTE ALL AD HEARTED ADJUSTMENTS BE MADE SMALL INCREMENTS AND SHO RATION WHEN BACK T w ADJUSTMENTS When service under the dock lever is required always lock 81 electrical disconnects in the OFF position ater 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 levler before maintenance is completo Failure to do this may result in serious personal injury or death Always stand clear of to dock leveler lp when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock levoler For maximum protection use an OSHA approved locking device to lack the maintenance prop in the service poston Only the person servicing the equipment should have the key to unlock the maintenance prop Unless tho dock lever is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person lo engage the maintenance prop Failure to follow these instructions may result In serious personal injury or death
21. and reverse polarity according to the diagram Unit raises vary slow Check for voltage drop due to wrong size wiring Check fluid level Unit raises but control box shuts off during operation cycle Check the overload relay located in the control box and adjust if necessary Unit will nat raise to full dock height Check fluid level in reservoir Fluid level should be three inches below the top of the reservoir with all cylinders fully extended TROUBLESHOOTING his page intentionati iet bani anus ne 48 6 PARTS PARTS HEOD Model Edge of Dock FER 8 ar ibe i Ug Par bor T Tip amp tige Arsen Dorian 3 Lip amp Hinge Assembly 3 Lip Plate Asse 59868 TE amp Hinge Asser OTH TI TY amp Hinge Assembly 17 TED amp Hinge seni DOTS TI TEN Hoge Assembly 2 TI TER s amp Hinge seni TI Hage Assembly DORSET L3 ngs seni 663197 il Lg Pa amp Hanga Assos 2 a Center Pale amp Hinge ser 996096 5 14 3 Pate Hinge 50 4323 5 14 655 Center amp Hinge seri 59
22. bani 2 INSTALLATION Install Control Panel and Wiring Tho electrical power must be OFF prior to electrical Installation For maximum protection use an OSHA approved locking device to lock out power sources Only the person instaling the equipment should have the Key to unlock the power source Failure to follow these instructions may result in serious personal Injury death DO NOT make any final electrical connections unt all welding has been completed Fallure to do this may result in serious personal injury death All eloctical work including the instalation of tho disconnect panel control panel and final connections to the pit junction box must be performed by certified electrician and conform to local and applicable national codes Always stand clear of platform ip when working in front ofthe dock leveler Serious personal injury or death may result A Disconnect Panel provided by other B oniro Pani C An in 4636 mm Mount the pushbutton control panel B bottom of control panekiodock floor distance is 48 8 12492 mm Install electrical disconnect panel A if not already Installed by others Install and connect the control wiring Connect the dock lveler power cable to the field wires in the pit junction box Refer to the electrical drawings supplied with the dock levoler After all electrical connections have been made
23. d or other flammable liquid is present Stray sparks can ignite spils or leaks near the work area Always clean up the oil leaks and spils before proceeding with grinding or welding Always keep fre extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death INSTALLATION IMPORTANT DO NOT connect the dock lveler electrical wiring and ground connections unti all welding has baen completed DO NOT ground welding equipment to any hydraulic or electrical components the dock avelor Always ground welding equipment to the dock leveler frame NEVER to the patior Failure to follow these instructions may damage the motor hoist wiring andlor control panel IMPORTANT DO NOT wold continuously along the ful length of the base plate This can put unnecessary stress on the levelor components causing the lover lo malfunction and shorten the lifespan of ho affected components Tf the platform 8 raised using an external ting device or the hydraulic system is opened to atmosphere air wil enter into the hydraulic system Whenever this happens always cyto the lavelor at least times using the lover s own hydraulic power system before allowing the laveler to bo put Into service This is to make sure all air is purged from the hydraulic cyiinders Failure to do this may result n Serio
24. disengage the maintenance prop and lower the Platform using the extemal iting device connected to the platform iting brackets 24 INSTALLATION 1 Disconnect the extemal liting device 3 Install tho dock bumpers as required 3 Tum the main electrical power ON 4 Raise the leveler platform fully by pushing and holding the RAISE button NOTE The platform of a property operating dock l velor wil automaticaly stop rising when it reaches its ful raised height at which point Tho lip extends 5 Release the RAISE button to ower the platform As long as there is no tuck present at dock the platform wil lower to ho full bolow dock position the lip folds NOTE ifa truck is prosent tho platform wil unti the lip rests on the tuckfraler bod Seo Operating Instructions in Operation section 8 Perform stops 4 5 at least four times to purge any air that may bo in hydraulic system and to ensure proper operation Always stand clear of platform ip when working in front of he dock leveler Serious personal injury or death may result 1 Unless the dock leveler is equipped with a tethered remote two people ara required to engage the maintenance prop one person to operate he unit the othar person to engage the maintenance prop Operating Instructions Say clear of dock levelor when freight caters entering or leaving dock area DO NOT move or
25. e plate and the bump block flange back to the dock steel Top of he bump block cover plate should be flush with the top of the embed channel Tack weld bump blocks 6 dock steel 6 Check the positioning of the base plate and the bump blocks 7 Completo welding of tacked parts as follows A Apply a continuous weld across top of each bumper and base plato to dock steel Skip welding is acceptable to prevent warpage but completa weld across the top must be completed Weld vertically along each end of baseplate and on both inboard and outboard fanges of bump blocks Fully plug wold all holes in base plate Installar must remove all welding slag and repaint welded areas Dril 5 8 dia by 5 deep holes in concrete through holes in lower cyinder mount and install anchor bolts with washers and tighten securely Field mount control box to inside wall Feld wire control box and hydraulic power unit por electrical schomatic s provided Read and comply wth all local electrical codes Before install is complete installer must make final operational check of dock leveler to verify phases of install aro correct Installer must complete sign and return the Installation Check list upon completion 10 INSTALLATION o fi euos od Busneo uoneyasu waunsnipe Bump Dud oip duse ut mew nse ueo Buouiq sadad 504890 poer dy pue duse poddns
26. erial and protruding objects from dock edge Clean and sweep dock edge reo of debris and farmmatle chemicas betore inetaling unit 2 At chosen cation for th face plata cato the center space mark a pit half ofthe face plate width 1 he left and right 3 Using a proper iting raise and postion the face piate to marked poston and push face ato against dock face 4 Top of taoa plato should bo fush wh he top of dock mark center of holes in face piate into dock face Dril 5 da by 5 holes nb dock face Install anchor bots wih washers per manufacturers speciicatons and tighten securely 6 Place ramp pto to match each end of th face piata leading lorward edge of ramp should be hush wth dock aco 6 along length of back edge of ramp piate Sido ramp forward the with of bushing tool approximately 2 7 Place bushing tool on marked ine at each end of ramp to ensure proper alignment at boh ends ASHE Roto Hammer 736 or silar bol recommended 6 Tack weld ramp faco plate on each end io secure in place 6 Using he back edge the ramp pato as guido concrete approximately SI deep by Z wide and shouldbe the ene length of he lamp plate 10 Break tack wots and sido ramp back untl forward is fush wih dock Tack eld ramp on each and centar to face pto 518 dia by 5 deep holes through ramp piate back Install anchor
27. icate the dock lover wil cause abnormal operation of the leveler Platform hinge area apply to top of platform hinges when platform is at he full below dock postion Lubricate the folowing areas with white lithium grease Lip hinge area apply oil to each of lip and platform lugs when platform is at the full below dock position and lip is folded Both Hoist and Lip oyinder trunnions ULTRAVISHVIAS Flomite 530 ZF Aero Shell Fluid 4 or Fluid 41 Mobile Aero HFA Mi HSGOGA or Aero HF Texaco Aircraft Hydraulic O 15 or 5806 Boon Uns J13 mimm From Top of Resa IMPORTANT A iow fad level or the use of hydra lds not equivalent to the fluid types recommended cause abnormal operation ofthe levelor and WILL void warranty Chock reservoir uid evel OF 1 Put tho dock lover platform at tho full abovo dock position engage prop 2 Tum OFF all electrical power to tho leveler Before performing any maintenance under the dock levlr lock the electrical power source in OFF position and lock the maintenance prep in the service position using an approved locking device Seo Service Dock Leveler Safely in this section Failure to follow these instructions may result in serious personal injury or death 3 Measure fu level The fuid level should bo approximately 3 in 76 5 mm N fom top of reservoir M with platform raised on maintenance prop 4
28. imately Z 6 Place busting tool on marked ine at each end of o ensure proper aignment at boh ends and tack wold riso o dock levier to ramp pto in place who bushing A S Rolo Hammer 736 or simlar oo recommend 3 Using he back edge of no ramp piate as a guido grove concrete approximately by wise shou bo he entre lengh of ramp palo 10 Break tack welds holing ramp n place sido ramp back postion wih he top o the ramp pido ash wih ho top of ho base plate Tack weld each end end canter of ramp plata to base pisto Dil 55 by 5 deep holes trough ramp piste at beck edge ral anchor bots per manda specications and tighten securely Weld anchor bot o rap plate using flet wold al tho way around the nut Cut of any portion of te anchor bat exposed trough he nut and plug weld around the top fhe p the anchor bol Ensure Pe top of bo rus Wel rounded for smooth love 12 welding of tacked parts as falows A continuous waki across top of each bumper and base plato to ramp pate Skip woking is acceptable to prevent warpage but completo weld must bo completed Weld voricaly along each end of base piate and botn inboard and cuboard fanges of burp toda C Fuly plug weld al holes in base pato instaler must remove stag and repaint welded areas 14 87 da by holes in concrete through holes in lower
29. ny questions ask your supervisor eek Stay clear of dock leveling device when freight camer is entering or leaving area Chockirestrain freight carriers Never remove wheel chocks unt loading or unloading is finished and tuck driver has been given permission to drive Do not move or use the dock leveling device if anyone is under or in front of it Do not use a broken or damage dock leveling devico Make sure proper service and maintenance procedures have been perfomed before using Keep hands and feet clear of pinch points Avoid puting any part of your body near moving parts Mako sure lip overlaps onto trailor at least 4 in 102 mm Keep a safe distance from both side edges SAFETY Do not use dock leveling device if freight carier 8 too high or too low Do not overload the dock leveling device Do not operate any equipment while under tho of alcohol or drugs Do not equipment or material unattended on dock leveling device 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 il power sources Only the person servicing the equipment should have the key to unlock the device
30. proximately Z 5 Place brushing tool on marked ine at each end of formed angi ensure proper algnment at both ends AS Roto Hammer 736 or silar tool is 5 66 6 Using the back edge of the formed angie as guide groove concreta approximately 587 deep by Z wide and should bo the entre length of he formed ange 7 Side formed angle back unti ight against dock face dil 8 da by S deep holes through formed angle at back edge install anchor bo per manufacturers spociicatons and tighten securely Welt anchor bot mulso formed angle using a 1 4 flet weld al ho way around the nut Cut of any portion of he anchor bot exposed though the nut and plug weld around the top of he nut to the anchor bot Ensure the top f he nuts are wel rounded for smooth rover 6 S dia by 5 deep holes in dock ace through holes in formed angle Instal anchor bots with washers and icon securely por manufacturers m INSTALLATION HH i HE w 19 INSTALLATION E O D Installation Instructions Ramp and Face Plate Aramo mount requiring 66 pta appicaton used hen hare dock tal and the concrete at e dock edge has been damaged The dock hight can be ow high or adequate or this applcaton however he fone plato and ramp pae are requred ho damaged concreto Sieps 1 Remove al existing bumper mat
31. se or rises slowly and tho system operates in pressure relief mode Seo Troubleshooting ection The main pressure rallaf may need to be decreased i the pump motor loads down whem platform reaches the fl raised position See Troubleshooting section Breuer cap To adjust the main pressure relief Raise the platform fully and engage the maintenance prop in the service position 2 Tum OFF all electrical power to the dock leveler Attach safety lockout and tagout devices 3 Loosen locking nut 4 Adjust hex adjusting screw in smal 1 4 Increments as follows Tum clockwise to increase pressure Tum counterclockwise to decreaso pressura 5 Tighten the jam nut Tum ON electrical power to the dock lsveler 7 Disengage the maintenance prop Check leveler operation 9 Repeat stops 1 8 as necessary 2 ADJUSTMENTS Adjust Lip Function t RELEF VALVE IS FACTORY SET AT 1500 PSI THS VALVE IS MAIN SYSTEM RELEF 2 RELIEF VALVE ADJUSTMENT LOOSEN JAM NUT B TURN SCREW CLOCKWISE TO INCREASE PRE C TURN SCREW COUNTER CLOCKWISE TO D D TIGHTEN NUT LVE FACTORY SET AT 750 PSI TURN CLOCK COUNTER CLOCKWISE TO DECREAS ADJUSTMENT OOTING SECTION FOR FURTHER ADJUSTMENT PROCEDURES WEISE PRESSURE SE TO INCREASE SSURE THIS VALVE NORMALLY IF LP OPENS AS PLATFORM BEGINS TO RISE TURN SEQ
32. te at fis lacomant wil vary wih ramp palo 2555 Merk corer holes in bump block anges 8 Debs da by doopheles at conter marks Reposition bump biocks sat anchor bolts win washers and chon securely dock 66 40 scel ramp pao n poston fush with top backside of base Mark along ful length of back of ramp pate Sido ramp po forward ovr dock lever the wih of bushing tool approximately Z Paco busting ool on marked ine at each end of ramp to ensure proper arent at boh and tack wold dock lever 1o hod raro piate n place who bushing ASH Rolo Hammer 8738 or simar tool recommended 12 Using back edge ofthe ramp piate as a guido groove concrete approximately SE by Z wise and shou be entire of ramp palo 13 Break tack wos holing ramp n place side ramp rato back irto positon wih he top o o ramp ash wih ho top of ho base Tack weld each end and cone of ramp pilo to base pisto 14 58 da by 5 deep holes trough ramp plo at per manda spociioalons and tighten securely Weld anchor bot m s to ramp plate using wold al the way around tha nut Cut of any portion of te anchor bat exposed trough and plug weld around he lop nut io the anchor bol Ensure Pe pof bo rus Wel rounded for smooth love 45 Completo welding af tacked parts as falows A Apply continuous waki across op of each bumper and base plato
33. tow these instructions may result in personal injury and or damage to equipment OPERATING INSTRUCTIONS d certain all equipment and personnel lear of lovelor before operation 2 Tho truck should be against the bump blocks and wheels chocked before operation of the Always romove any end load while lovelor is in stored poston Figure 1 Press and hold RAISE A button unti leveler extends fully Figure 3 Release button Leveler wil lower to truck bed Figure 4 ar truck departs levelor will automaticaly retum to stored poston Figure 1 To remove leveler tom truck before departure operate RAISE A bution unl ip clears tuck bod folds up and retums Figure 2 then Teleaso button Levelor wil ten ratum to stored positon Figure 1 A Raise Button E Periodic Maintenance Regular maintenance must be performed on weekly and quarary schedule Weekly Maintenance Operate the dock aver through the complete operating cyclo to maintain lubrication NOTE To thoroughly inspect the platform hinge put the platform in tho ful bolow dock position Inspect the platform hinge and the ip hinge areas The hinge areas must be kept free of dirt and debris Buld up of foreign material in the hinge areas wil cause abnormal operation Quarterly Maintenance IMPORTANT Falura to propery lubr
34. us personal injury or death Two people are required to engage the maintenance prop one person to operate the fing device the other person to engage the maintenance prop INSTALLATION H E D Installation Instructions Flush Mount Weld On A fush mount wold on application 6 used when an S 8 wide minimum embed channel is securely anchored nto the concrete at the dock edge and the dock height is adequate 5 Installation Stops 1 Remove all existing bumper material and protruding objects from dock edge Clean and Sweep dock edge of debris and flammable chemicals before instaling unit 10 2 At chosen location for Edge of Dock leveler locato the center of space and mark a point half ofthe base plato width the lef and right 3 Using a proper ting device raise and position leveler on dock face with the top ofthe base Plate being flush with the top of the embedded Channel Position ends of base pate to match up with marks mado previously 4 Tack weld base plate to dock steel on let hand ond of the leveler Check right hand ond of base plate ensure that end is against dock steel and hat the top of the base plate stil flush with the op of the embedded channel Tack right hand end to dock steel 5 Postion bump blacks out approximately 5 8 ftom the edge of inside flange of the bump block to the end ofthe base pate This wil allow for vertical welding of both the bas
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