McGuire CentraAir® Manual May2015
Contents
1. cceee ee eeeeee 17 Operation Operating Instructions 11111Leeeee ecce NEEEEE EE eene nnn nennt 18 Ramp Loading Unloading Instructions 19 End Loading Unloading Instructions 20 Maintenance Service Dock Leveler Safely Leeeee ecce 21 Periodic Maintenance 1 e e eceee ee ieeee einer nennen anna anna 22 Adjustments Adjust Lip Latch and Lip Actuator Springs 24 AdJust Jo SIOD P T 26 Troubleshooting WHO UBISS OO NNO D 28 Parts NSC NC A SE PR Rc RR Y FFR YP 30 CODIO BOX GE 31 Air Control Valves cccsssssccssnssecccsnnseececnssseccnnnssececnnsseseenassesennnsees 32 Below Dock en EE 33 sa LA mali a KTL e 34 Bellows Te TI E 39 Frame arid Platform E 40 ie e RE 42 Weather Seal cc lt creeereeaeee anna na AKE A LLALL LL KENA KENA KEE K EENU KS 43 Miscellaneous Customer Information zs sednu FA eu Rea oku AW 44 Customer Information ee erreoeeea nenene aaa nana non 45 MW ATV o keel loula ohe ae oo oN Back Cover Recognize Safety Information Safety Alert Symbol The Safety Alert Symbol identifies NOTICE safety messages on eguipment safety signs in manuals or elsewhere When2. Read and follow all instructions warnings and maintenance schedules in the manual and on placards Operation and servicing of dock leveler is restricted to authorized personnel Always chock transport vehicle wheels or engage vehicle restraint and set parking brakes before operating dock leveler or beginning to load or unload Before activating dock leveler ensure lip avoids contact with transport vehicle sides and cargo If lip does not lower to transport vehicle bed reposition transport vehicle Ensure the transport vehicle floor supports extended lip or the leveler frame lip keepers or below dock endload supports supports the ramp before driving on ramp Stay clear of hinges and front and sides of moving dock leveler Never use hands or equipment to move the ramp or lip Never use damaged or malfunctioning dock leveler Report problems immediately to supervisor Always store dock leveler and remove people material equipment from ramp before vehicle leaves the dock DO NOT ENTER PIT unless dock leveler is securely supported by the maintenance prop Disconnect power and follow proper lockout tagout procedures for the dock leveler before entering the dock leveler pit or doing any repair or inspection under the dock leveler THESE INSTRUCTIONS COULD and RESULT IN DEATH OR OTHER SERIOUS INJURY Scan to view our owner s user s manuals online www DockSystemslnc com 1 800 643 5424 Call for additional placar
3. The regulator R supplies 95 psi to the bellows J below dock position ME e Leveler went to the below dock position with operator When the platform rises to with in 2 3 in 51 76 mm holding the safety leg retract cable not shown of its full raised height the lip spring F and lip actuator safety legs are retracted lip folds automatically chain G causes the lip linkage assembly to push the causing dock to rest in the full below dock position 4111 0038 May 2015 INSTALLATION Prepare Pit A Distance Pit Width B Distance Dock Floor to Pit C Distance Pit Length D Distance Pit Corner to Corner Top Front and Rear Floor All Four Corners Both Sides of Pit 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 unauthorized 1 Remove all debris from the pit and sweep the pit use of the dock leveler before installation has been clean 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 and drawings Make sure pit is sguare by making the or serious personal injury or death following measurements e Measure pit width distance A at both front and rear of pit e Measure dock floor to pit floor
4. Lock out Device MAINTENANCE D Lip Prop E Valve Air Supply Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Whenever 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 upright position using an OSHA approved lockout tag out device BAC Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout tag out device B Only the person servicing the eguipment should have the capability to remove the lockout tag out 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 146 Refer to OSHA regulation 1910 147 25 MAINTENANCE Periodic Maintenance B A Lip Hinge Area C Lip Link Pivots E Lip Assist Pin B Lip Maintenance P
5. The MA dock leveler uses Compressed Air with a lanyard lip out and up or single push button operation for ease of use The lip assist spring not shown also helps keep the lip The dock leveler can be operated three different ways extended When the lip is fully extended the lip latch 1 Depress RAISE button N on the control panel This cable engages the lip latch assembly locking the lip in activates an electric solenoid P The solenoid allows the extended position The dock leveler has reached its compressed air into the air bellows causing the platform full height when the lip is fully extended to rise Releasing the RAISE button allows the platform to lower To lower the platform release the lanyard Q or RAISE button N 2 RAISE button N on the control panel Allows allows A CO FED ali into the air bellows causing the platform The platform will lower until the extended lip rests on the to rise Releasing the RAISE button allows the platform transport vehicle bed If the lip did not fully extend or to lower there is no transport vehicle at the dock the platform will lower until one of the following conditions occur e Lip is resting in lip Keepers cross traffic position e Leveler went to the below dock position lip folds automatically leveler rests on the safety legs 3 Pull up and hold the Lanyard chain in the rear of the unit until platform and lip are fully extended Releasing the chain allows the platform to lower
6. gol Aq salen 3uign3 Z T Jo unoue UL 8100 9019 100 9019 9100 9019 ST00 90T9 T00 90T9 uoneuodo uoneuodo uoieuodo uojing usnd neuineud uojing usnd neuineud uojing usnd 5 neunoeud uoneuodo uoneuodo uojingysnd 214399jo uojingysnd 214329jo BALA pa3eJado Jo 9 aAIEN pa3eJado Jo 9 U0132n43su02 MAN 10J19My U0132n43Su02 MAN Ajddns sie punoussapun Ajddns sie peouJoA oO Ajddns sie peouJoAO SHJ1143A315I20d JIVEIDUS JO NOILVTIVISNI 404 GAYINOAY SLYVd OSIIN 21 4111 0038 May 2015 OPERATION Operating Instructions Stay clear of dock leveler when transport vehicle is entering or leaving dock area DO NOT move or use the dock leveler if anyone is under or in front of leveler Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Failure to follow these instructions may result in severe personal injury or death Only trained personnel should operate the dock leveler DO NOT use a broken or damaged dock leveler Make sure proper service and maintenance procedures have been performed on leveler before using Transport vehicle wheels must be chocked unless the vehicle restraint is used Never remove the wheel chocks until loading unloading is finished and transport vehicle driver has been given permission to leave Make sure platform lip rests on the transport vehicle bed with at least 4 in 102 mm of overlap Maintain a safe distance from side edges
7. A 2 9301 0249 3 8 Bulkhead fitting B 1 1751 0893 Decal English C 1 8581 0163 Valve Air 2 Position 3 Way Includes Knob D 2 9301 0248 3 8 Male Elbow E 1 2756 0002 Push Button Controller 9 V0 800 0 E McGuire DECAL Item Quantity Part Number Description A 1 9301 0241 Elbow 3 8 B 1 9301 0244 Tee 3 8 9301 0260 Tee 1 2 38 4111 0038 May 2015 PARTS Item Quantity Part Number Description A 1 5811 0002 Air Bellows B 1 9514 0160 Top Mounting Weldment C 1 9512 2090 Pin 49 64 X 10 Lo D 2 2101 0045 Cotter Pin E 8 2101 0273 3 8 16 UNC x 1 Lg F 8 2101 0258 Washer G 1 0521 0035 Air Line Connection W 9301 0237 Ftg 95 PSI Recommend for best performance NEIEN Cy Item Quantity Part Number Description A 1 8581 0154 Filler Regulator B 1 8581 0153 Oil lubricator C A R R980 0001 Nylon Air Line D A R R981 0001 Kil Frost 2 9301 0236 Fitting Straight F 1 9301 0237 Fitting Elbow 4111 0038 May 2015 39 PARTS Frame and Platform 40 4111 0038 May 2015 PARTS Frame and Platform Item Quantity Part Number Description A 1 See Table A Lip Welded Assembly B 1 9515 __ 2 Platform Welded Assembly DPLA 2101 Pin Lip Hinge GW C 2 DPLA 2102 Pin Lip Hinge 6 5 W DPLA 2103 Pin Lip Hinge 7 W D 1 DKIT 9179 Toe Gu
8. CentraAir leveler unit and control panel has been factory pre wired 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 Technical Services Once again thank you and e HM on your purchase of a McGuire CentraAir dock leveler 4111 0038 May 2015 INTRODUCTION Dock Leveler Stock Specifications CentraAir Series dock levelers are available in the following sizes weight capacities and options Width 6 ft 1828 8 mm 6 1 2 ft 1981 2 mm 7 ft 2133 6 mm Length 6 ft 1828 8 mm 8 ft 2438 mm 10 ft 3048 mm Capacity CIR 25 000 Ib 11 340 kg 30 000 Ib 13 608 kg 35 000 Ib 15 876 kg 40 000 Ib 18 144 kg 45 000 Ib 20 412 kg 50 000 Ib 22 680 kg ees uae ww ww T CIR Comparative Industry Rating All docks are available in 115V Controls pneumatic push button or lanyard INTRODUCTION Component ldentification E A A Lip E Lip Maintenance Prop Pivot Lip Keepers 2 used N Raise Button B Lip Assist Rod F Lip Actuator Chain Spring J Air Bellows O Safety Legs C Lip Linkage Assembly G Lip Actuator Chain K Main Frame P Air Control Valve D Lip Latch Assembly H Lip Actuator Chain Adjustment Link L Maintenance Prop Q Lanyard not shown M Toe Guard 2 used R Filter Regulator THEORY
9. after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the eguipment should have the key to unlock the maintenance prop Unless the dock leveler is eguipped with a tethered remote two people are reguired 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 e Check all fuses inside the control panel s Replace any blown fuse s with a fuse of egual specification e Make sure the correct voltages are present at the proper locations inside the control panel s 32 4111 0038 May 2015 TROUBLESHOOTING Minimum 80 Psi reguired at regulator if lower check Low Air pressure ai
10. and industry standards Effective operator training should also focus on the owner s user s company policies and operating conditions Maintaining updating and re training all operators on safe working habits and operation of the equipment regardless of previous experience should be done on a regular basis and should include an understanding and familiarity with all functions of the eguipment Owner s user s shall actively maintain update and retrain all operators on safe working habits and operations of the eguipment The manufacturer shall provide to the initial purchaser all necessary information regarding Safety Infor mation Operation Installation and Safety Precautions Recommended Initial and Periodic Inspections Procedures Planned Maintenance Schedule Product Specifications Troubleshooting Guide Parts Break Down Warranty Information and Manufacturers Contact Information as well as tables to identify the grade slope for all variations of length or configuration of the dock leveling device and information identi fying the maximum uncontrolled drop encountered when sudden removal of support while in the working range of the eguipment It is recommended that when the transportation vehicle is positioned correctly in the dock opening and in contact with both bumpers there shall be a minimum of 4 00 inches 100mm overlap of the leveling device and the transportation vehicle at all times during the loading and unloading process The Ow
11. cause abnormal operation of the leveler A maintenance prop permanently attached and hinged to the unit with means for lock out tag out reguirements per OSHA 1910 147 is included with each pit style dock leveler In addition it is recommended and good safety practice to use an additional means to support the dock platform and lip anytime when physically working in front of or under the dock leveler This additional means may include but not limited to a boom truck fork truck stabilizing bar or eguivalent 4111 0038 May 2015 Guarterly Maintenance Perform Weekly Service Items e Lubricate the following areas with light weight machine oil D Lip hinge area unless equipped with grease fittings apply oil to the top of the entire length of lip hinge when platform is at the full below dock position and lip is folded E Platform hinge area apply oil to top of all platform hinges when platform is at the full below dock position F Lip lifter and lift cylinder pin NOTE Apply grease to lip hinge grease fittings if equipped e Lubricate the following areas with light weight machine oil G Lip maintenance prop pivot H Lip link pivots h Safety leg linkage pivots Lubricate the following areas with white lithium grease if eguipped with grease fittings J Lip hinge area inject grease into all the lip hinge grease fittings K Platform hinge area inject grease into al
12. of leveler during the loading unloading process Failure to follow these instructions may result in 22 p in 305 mm a Lie in 305 mm The CentraAirf hydraulic dock leveler is designed to compensate for a maximum 12 in 805 mm of height difference between the loading dock and the transport vehicle bed DO NOT use the dock leveler if the transport vehicle bed is more than 12 in 805 mm higher or lower than the dock floor a ell es service height may vary with design specifications DO NOT overload the dock leveler DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave equipment or material unattended on the dock leveler Failure to follow these instructions may result in personal injury and or damage to equipment The dock leveler operating instructions are divided into the two methods of loading and unloading e For ramp loading and unloading see Ramp Loading Unloading Instructions on page 19 e For end loading and unloading see End Loading Unloading Instructions on page 20 4111 0038 May 2015 OPERATION Operating Instructions Continued Below Dock Loading Unloading Instructions NOTE If end unloading is reguired see End Ramp Loading Unloading Instructions j i Loading Unloading Instructions on page 20 NOTE If end unloading is required see End Loading Unloading Instructions on page 20 7 Check to make sure transpor
13. the cross traffic stored position 11 Pull the lanyard ring B or depress the RAISE button A until the lip clears the lip keepers Release lanyard ring or RAISE button leveler will return to the stored or cross traffic position 12 Remove chocks from transport vehicle wheels or release the vehicle restraint if used 13 Indicate to the driver that the transport vehicle may leave the dock 4111 0038 May 2015 Service Dock Leveler Safely A Maintenance Prop B Tag Out Device When service under the dock leveler is reguired always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the eguipment should have the key to unlock the maintenance prop Unless the dock leveler is eguipped with a tethered remote two people are reguired 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 0038 May 2015 C
14. you see this symbol be alert to the possibility of personal injury or death Follow the instructions in the safety message The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury The use of the word NOTICE is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 0038 May 2015 SAFETY General Operational Safety Precautions Read and understand the Owner s User s manual and become thoroughly familiar with the eguipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or guard is removed or disconnected Never remove DANGER WARNING or CAUTION signs or Decal s on the eguipment unless replacing them Do not start the eguipment 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 Learn the safe way to operate this eguipment
15. 038 May 2015 33 Electrical Controls 9 V0 800 0 E CUSTOMER SUPPLIED 115 V 1 PHASE 60 HZ L1 FROM BRANCH CIRCUIT DISCONNECT SWITCH N amp OVERCURRENT DEVICE BY OTHERS SELECT DISCONNECT SWITCH A OVERCURRENT DEVICE PER THE NEC 9708 1 2 ANP fra JUMPER SEE NOTE C k 53 A MD JU LL m 0D DOOR CONTACT SENOEC 4111 0038 May 2015 34 Control Box 4 DANGER A Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before PPE Refer to NFPA 70E for PPE requirements This panel may contain more than one 7 power source 6 00 Hazardous Voltage Will Cause Sever Injury or Death Main Supply OF Supply 0 5 FLA Amp Draw Item Quantity Part Number Description A 1 9 V0 800 0 B Push Button Controller B 1 1751 0818 Decal English C 1 1751 0736 Decal Arc Flash 4111 0038 May 2015 35 PARTS Item Quantity Part Number Description A 1 5265 0001 Cable Assembly Includes Pull Ring B 1 8103 0001 Weight Assembly C 1 5402 0009 Lanyard Arm D 2 2101 0008 Bolt 4 x 2 Lg E 2 2101 0143 Lock Nut 4 F A R R980 0001 3 Nylon Air Line G 1 8581 0158 Valve Operator Mechanical H 1 9512 0261 Lanyard Control Bracket 1 9301 0236 Fitting Straight J 1 9301 0237 Fitting Elbow K A R 8581 015
16. 2 Clamp Air Line Not Shown L 1 0521 0178 Down Speed Control Item Quantity Part Number Description A 2 2101 0008 Bolt 14 x 2 LG not Shown B 2 2101 0143 Lock Nut 14 not Shown C 1 4305 0580 Harness D 1 8591 0157 Valve Operator Electrical REF E 1 0521 0178 Valve Down Speed F A R 8581 0152 Clamp Air line not Shown G 1 9301 0236 Fitting Straight H 1 9301 0237 Fitting Elbow 1 8581 0159 Coil Solenoid valve 36 4111 0038 May 2015 PARTS Item Quantity Part Number Description A 1 0521 0048 Brass Reducer 1 4 NPT to 3 8 NPT B 1 0521 0178 Breather Muffler C 1 9301 0236 Fitting 3 8 NPT to 3 8 Tube D 1 9301 0261 Fitting 1 8 NPT to 3 8 Straight E 1 9301 0237 Fitting 3 8 NPT to 3 8 Swivel Elbow F A R 8581 0152 Clamp Air line not Shown G 1 8583 0070 Valve Assemble Below Dock Control B Item Quantity Part Number Description A 1 DPLA 0343 Below Dock Control Assy B 1 DPLA 0353 Below Dock Pull Chain E 1 DOTH 2074 Cap Screw Lip Stop 11 UNC F 1 DOTH 2160 Nut Hex 5 8 11 UNC G 1 DPLA 0360 Rod Push H 1 DOTH 2060 Bolt Shoulder 1 DOTH 2131 Lock Nut 4111 0038 May 2015 37 Control Box RAISE McGuIRE SYSTE TSEC A Division of Systema Main Supply Pilot Supply Item Quantity Part Number Description
17. INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS SUBSIDIARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUDING THIRD PARTIES FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERRUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY CENTRAAIR SERIES LEVELER In addition to the Standard Product Warranty provided with all McGuire Products Systems Inc guarantees materials components and workmanship to be free of defects for the following extended periods e Structural Warranty For a period of five 5 years from the date of shipment product will carry a prorated structural warranty This warranty specifically applies to the deck section lip section frame rear hinge assembly and front hinge assembly only This warranty covers structural repairs to or replacement of dock leveler in Systems Inc sole discretion and expense including reasonable labor materials freight and travel If Systems Inc determines replacement is necessary it will provide the original purchaser with a credit toward the purchase of the new replacement Systems Inc product in the amount equal to the original purchase price of the warranted product F O B point of manufacture discounted on a ten year straight line basis by the number of years of use prior to replacement e
18. Pneumatic Warranty For a period of four 4 years from the expiration of the Standard Product Warranty Systems will provide replacement component parts from defective lifting system This warranty specifically covers material and freight only and applies to Bellows hoses and valves
19. Read and understand the manufacturer s instructions If you have any questions ask your supervisor we wee Stay clear of dock leveling device when transport Chock restrain all transport vehicles Never remove vehicle is entering or leaving area the wheel chocks until loading or unloading is finished and transport vehicles driver has been given permission to drive away NT ee Do not use a broken or damaged dock leveling Do not move or use the dock leveling device if device Make sure proper service and maintenance anyone is under or in front of it procedures have been performed before using Bali e _ or Keep hands and feet clear of pinch points Avoid Make sure lip overlaps onto transport vehicles bed putting any part of your body near moving parts at least 4 in 102 mm Keep a safe distance from both side edges 4111 0038 May 2015 SAFETY od Do not use dock leveling device if transports vehicles bed is too high or too low Do not overload the dock leveling device Do not operate any eguipment while under the influence of alcohol or drugs Do not leave eguipment or material unattended on dock leveling device 4111 0038 May 2015 9 SAFETY Maintenance Safety Precautions Hydraulic and electrical power must be OFF when servicing the eguipment For maximum protection use an OSHA approved locking device to lock out all power sources Only the person servicing the equipment should have
20. Release both buttons NOTE If equipped depressing E STOP button will stop platform from lowering Item Quantity Part Number Description A 1 1751 0874 Placard CA 44 4111 0038 May 2015 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 the numbers in the event the model serial number decal A becomes lost or damaged Also write down McGuire 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 reguired 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 Systems Inc P O Box 309 Germantown WI 53022 Phone 800 624 8473 Fax 262 255 5917 E mail techservices docksystemsinc com 4111 0038 May 2015 MISCELLANEOUS Dock Leveler Information Model Serial No McGuire Job No Original Owner Information Name Address Installer Informatio
21. T CentraAire M C G U IRE Doc k Leve ler A Division of Systems Inc Owner s User s Manual MCGUIRE e Division of Systems Inc e W194 N11481 McCormick Drive Germantown WI 53022 800 624 8473 fax 262 255 5917 e www wbmcguire com e techservices docksystemsinc com Printed in U S A Manual No 4111 0038 Copyright 2015 May 2015 Table of Contents Page Safety Recognize Safety Information ccccccccssssseeeeeceesnseeeseeeeenseeesseeeeees 1 General Operational Safety Precautions 1 Operational Safety Precautions eese erre 2 Maintenance Safety Precautions e ceeeeeeee ess d oarety KE 5 Owner s User s Responsibilities 6 Introduction General Information 11 ee eee eeee eec anne e eee eene nnn n anna nna 7 Dock Leveler Stock Specifications 7 Component ldentification 11 eeeee ecce crecer eene 8 pij 8 Installation We PI rte AER 9 Prepare DOCK Leveler soe sanctus uut usunscxu pu geet GU aain 10 Install Dock LEVel l u E 11 Install Control Panel and Wiring 16 Put New Leveler Into Service
22. VER to the platform Failure to follow these instructions may damage the motor wiring and or control panel Shim Stacking Methods Q Z For left right orientation of dock leveler see inside back cover of this manual 4111 0038 May 2015 INSTALLATION DO NOT weld continuously along the full length of the rear hinge frame angle This can put unnecessary stress on the leveler components causing the leveler to malfunction and shorten the life span of the affected components NOTE The illustration on page 13 shows a typical weld pattern The weld pattern will vary slightly depending on size of dock leveler 18 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 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 19 All model levelers Install shims at locations B p 11 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 20 Weld front of dock leveler frame B to shims located under the keepers then weld the shims to the front pit curb steel 21 Finish weld all shims using a f
23. ard Assembly 6 Foot Both Sides and Hardware DKIT 9180 Toe Guard Assembly 8 Foot Both Sides and Hardware DKIT 9181 Toe Guard Assembly 10 Foot Both Sides and Hardware E 2 2101 0039 Nylon Lock Nut 5 16 18 UNC F 4 2101 0163 Washer 5 16 in Flat G 2 2101 0011 Cap Screw 5 16 18 UNC x 1 in H 1 8435 _ 1 Frame 2 DOTH 2373 PIn Cotter J 2 DOTH 2355 Pin Clevis P 2 2101 0079 Washer Flat 9224 0030 Maintenance Prop 3914 K 1 9224 0031 Maintenance Prop 431 9224 0079 Maintenance Prop 471 L 1 9201 0009 Prop Pin amp Clip M 1 1751 0010 Decal Model Serial ID N 2 2101 0046 Cotter Pin 4 x 1 in 8432 1129 Lip Keeper 16 Lip O 2 8432 1130 Lip Keeper 18 Lip 8432 1131 Lip Keeper 20 Lip 1 Provide dock leveler serial number platform size and lip size when calling or faxing orders 2 Provide length and width of inspection plate opening when calling or faxing orders For left right orientation of dock leveler see inside back cover of this manual ra LIPS ak sk bausk pK 0595 5309 0595 5318 0595 5327 0595 5336 0595 5310 05955319 0595 5328 0595 5337 0595 5311 05955320 losos 5329 0595 6338 0595 5317 o595 5335 0595 5344 4111 0038 May 2015 41 PARTS Lip Activation H CE Located on Deck Located on Lip Item Quantity Part Number Description A 1 9513 0092 Lip Assist Ro
24. d Air Supply Above Door Pneumatic Supply Kit 6106 0016 See Page 21 Supply From Regulator 1 2 or larger Verify Systems r5l T_l1 EE ie Ss pn TEE ji A Il p Valve pra 4 i Sg zem y sl TENET E III L1 1 2 NPT to 3 8 tube Provide by Systems mc Pilot Supply y iM Control Box to e T m TI A H J o o o 00 b IH To Air Bellows _ JI pou El o d Le WN E 1 2 line Provided by Others e 3 8 line Installed at Factory 3 8 line Provide By Systems 18 4111 0038 May 2015 INSTALLATION Underground Air Supply New Construction Kit 6101 0018 See Page 21 MEGUIRE D m d T1 Pilot Supply Control Box to To Air Bellows o 0 o o o 0 0 CT Valve End run Tee NOT Reguired N I EE Supply From Regulator 1 2 line Provided by Systems seeeeeee 3 8 line Installed at Factory 3 8 line Provide By Systems 4111 0038 May 2015 19 INSTALLATION Lanyard Air Supply See Page 21 To Air Regulator o o Oo O O O O O O O 0 O O O 0 0 To Air Bellows Electric Pneumatic Controls See Page 21 To Control Panel Air Regulator To Air Bellows To Air Regulator e 3 8 line Installed at Factory 3 8 line Provide By Systems 20 4111 0038 May 2015 INSTALLATION Sum eui Daa 4OSssoJdui02 y 03 92ue3sip JY pue oul JJ921u92 Joop eu3 uo poseg si
25. d Complete 34 Lg Includes Nuts B 1 2101 0221 Washer C 1 9511 0156 Spring Lip STD 9514 0114 opring Lip HD D 1 9513 0097 Lip Latch Plate E 1 2101 0051 Bolt 1 2 x 21 Lg 2 2101 0004 Washer G 2 2101 0103 Nut 1 Lock Nut H 1 2101 0222 Bolt Shoulder x x 1 1 2101 0223 Nut Nylon lock J 1 9514 0091 Prop Lip Maintenance Kit includes all hardware K 1 5775 0004 Lip Latch Assembly Includes Spring and Cable L 1 2101 0220 Bolt 1 x 1 Lg M 5 2101 0079 Washer N 1 2101 0045 Cotter Pin Vs 1 00 LG O 1 0941 0006 Snubber Spring P 1 DPLA 2128 Chain O 1 DOTH 2416 Lap Link 3 16 R 1 DOTH 2421 Cold Shut 5 16 S 1 DPLA 0341 Linkage Bar T 2 DOTH 2061 Bolt Shoulder U 2 DOTH 2131 Nut Lock Nut 42 4111 0038 May 2015 PARTS Weather Seal Weather Seal Kits Item Quantity Part Number Description A 1 0195 0021 Brush Kit Includes Seal and Track 1 1 2 in 82 Lg Both Sides B 1 0195 0033 Rubber Kit Includes Seal and Track 1 1 2 in 82 Lg Both Sides Individual Replacement Seals Item Ouantity Part Number Description C 1 0195 0021 Brush Refill 1 1 2 in 82 Lg D 1 0195 0033 Rubber Refill 1 1 2 in 82 Lg E 1 0192 0146 Replacement Channel Provide dock leveler serial number and size of platform when calling or faxing orders Provide width of weather strip when replacing existing seals 4111 0038 May 2015 43 PLACARD FAILURE TO FOLLOW ADANGER
26. distance B at all four corners Measure pit length distance C at both sides e Measure corner to corner criss cross distance D at both sides Take measurements at dock floor level and at pit floor level DO NOT remove the shipping bands around the l dock leveler lip until instructed to do so If any measurement is off by more than 1 8 in 3 18 mm contact Technical Services before proceeding When Required 3 Make sure the field junction box for the dock leveler E is at the correct location per pit diagrams 4 Make sure the conduit for the air lines E are at the correct location per the pit diagram 4111 0038 May 2015 INSTALLATION Prepare Dock Leveler te o gt E SC 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 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 CFM Leveler s Recommended Compressor Size 7 3 3 6 1 5 HP 20 GAL 90 PSI 17 5 6 amp up 5HP 60 GAL 100 PSI 10 DO NOT remove the shipping ba
27. djusting Lip Actuator Spring Tension This adjustment is set at the factory and should not reguire additional adjustment Unlike mechanical levelers the lip will not immediately begin to fold as the platform returns to the stored position The leveler lip remains extended as the platform drifts down to the below dock position The lip will automatically fold when the platform when the dock is resting on the safety legs in the below dock position 1 Check air bellows and hoses for possible leaks 2 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 1 Loosen jam nut A 2 To increase spring tension turn nut B clockwise 3 To decrease spring tension turn nut B counterclockwise 4 Tighten jam nut Recheck operation of platform and lip Readjust lift spring tension and lip assist spring tension until proper operation is obtained 29 ADJUSTMENTS Adjust Lip Stop Bolt Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death A Always stand clear of the dock leveler lip when working in front of the dock leveler Failure to do this ma
28. ds or manuals or with questions POWERAMP MCGUIRE DLM SYSTEMS INC Loading Dock Equipment regarding proper use maintenance and repair of dock leveler 1751 0874 A OPERATING INSTRUCTIONS POWERED DOCK LEVELERS mA z gg OQ E NORMAL OPERATION ils Raise the platform by depressing and holding the RAISE button 2 Hold the RAISE button until the lip is fully extended then release the RAISE button The platform will lower until lip is resting on the transport vehicle STORING LEVELER 1 Depress the RAISE button until the lip is completely folded When the lip is folded release the RAISE button The platform will lower returning to the cross traffic position BELOW DOCK ENDLOADING HYDRAULIC ONLY Depress and hold the RAISE button until the leveler is fully raised As the lip starts to extend release the RAISE button The leveler will lower to the below dock position provided the lip extension allows the lip to clear the lip keepers AIR POWERED ONLY Depress and hold the RAISE button until the leveler is 12 above dock level Pull the below dock level chain until the leveler passes the below dock position HYDRAULIC WITH INFINITE LIP CONTROL If eguipped raise the platform by depressing and holding the RAISE button When the lip is just above the lip keepers simultaneously depress and hold the RAISE button and the LIP OUT button until lip has extended beyond the lip keepers
29. ed 10 Allow the dock leveler to rest fully on the shim stacks Check that a smooth and level transition exists between the dock floor and the dock leveler platform Add or remove shims as necessary until a smooth transition is obtained 11 If leveler cannot be squared and or made level as instructed in steps 8 10 contact Technical Services 13 INSTALLATION 12 13 14 15 16 Wa With the leveler sguare in the pit and flush with the surrounding dock remove the banding on the lip of the leveler Lift Leveler with appropriate machinery Slowly raise the platform Check for binding as platform is being raised If binding occurs lower the platform Reposition leveler and or add or remove shims as necessary Slowly raise platform again If platform still binds contact Technical Services for further instructions All CentraAir models Once leveler is flush sguare and does not bind a Install shims under maintenance prop C where prop attaches to leveler frame Make sure prop is solidly shimmed b Using appropriate machinery raise the dock to the fully open position c Raise maintenance prop to the service upright position and lock prop in this position using an OSHA approved locking device Remove air bellows from the leveler by unbolting the bellows from the frame and the deck or wrap bellows with fire proof blanket to protect from weld sparks and splatter 14 Two people are
30. eveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly If an excessive transition exists between the dock floor and leveler and or lip does not contact both lip Keepers evenly contact Technical Services for further instructions 3 Install the dock bumpers as reguired 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 Pull lanyard cable and hold until leveler platform is fully raised OR Raise the leveler platform fully by depressing and holding the RAISE button 6 Release lanyard cable as is no transport vehicle present at the dock the platform will lower to the full below dock position as the lip folds OR Release the RAISE button to lower the platform As long as there is no transport vehicle present at the dock the platform will lower to the full below dock position as the lip folds NOTE lf a transport vehicle is present the platform will lower until the lip rests on the transport vehicle bed See Operating Instructions in Operation section 4111 0038 May 2015 re INSTALLATION When the platform lowers to the full below dock position the lip will fold Pull lanyard ring or depress and hold the RAISE button until the platform rises just enough to clear the lip keepers then release the lanyard ring or RAISE button to allow the platfor
31. if available Lee End Loading Unloading Platform at Cross Traffic Position 4 f transport vehicle 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 transport vehicle bed is below the dock floor level perform steps 6 12 End Loading Unloading Platform at Below Dock Position 24 6 Pull lanyard ring or depress the Raise button to position 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 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 position The platform will drift down to the full below dock position 9 Proceed with loading unloading NOTE When end unloading is finished and access to the rest of the transport vehicle is still reguired the platform lip will need to be extended See Ramp Loading Unloading Instructions on page 19 for further instructions 10 When the loading or unloading is finished return the dock leveler platform to
32. illet weld e 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 22 When all welding has been completed paint all the welds and shims Make sure the platform is properly supported in the raised position before entering the pit to finish weld the shims Failure to do this may result in serious personal injury or death INSTALLATION Install Control Panel and Wiring or Air Lines 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 eguipment 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 completed 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 Pneumatic Controls 1 Mount the push button control panel B so bottom of control panel to dock floor distance C is 48 in 1219 2 mm 2 Install pneumatic air lines to control panel 3 Re install
33. ity 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 A or straight method R NOTE Toassist 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 12 4 For all CentraAir models put a 1 4 in 6 6 mm thick shim at locations C D B R NOTE A 1 4 in 6 6 mm thick shim at locations C and D 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 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 levele
34. king Methods CC W E A Distance Leveler Frame K Dock Leveler Frame Height M Pyramid Preferred B Shim Locations Under N Stepped Acceptable G o Rear Vertical Supports O Offset Not Acceptable C Shim Location Under P Straight Not Acceptable Lip Keepers R Shim Location Bellows D Shim Locations Under Mounting Plate Both Maintenance Prop sides E Shim Locations Under S Shim between lip keeper Lip Spring curb angle when required F Dock Floor G Rear Pit Curb Angle H String I Rear Hinge Frame Angle J Distance Dock Floor to Pit Floor 4111 0038 May 2015 11 INSTALLATION NOTE McGuire dock levelers are designed with a nominal 1 2 in 12 7 mm shimming distance to allow for pit inconsistencies 1 Determine height of shim stack 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 The minimum size of the shim that contacts the leveler frame i e the top shim of each shim stack must be at least 4 1 2 x 4 1 2 in 114 3 x 114 3 mm to support the full width of the hoist cylinder storage prop weldment Use the thickest shim stock possible for stabil
35. l the platform hinge grease fittings L Lip assist pin Regulator M Check Kill frost level may be required more frequently depending on usage N Drain water may be required more frequently depending on usage and compressor size O Verify Line Pressure is at 95 psi 27 ADJUSTMENTS Adjusting the Latch and Lip Actuator Spring Tension When service under the dock leveler is reguired 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 QT 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 i T mios ae E d f m j 4 d M Lk KE er Ae ap i pa A 1 n c zg 2d d _ a e a 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 eguipment should have the key to unlock the
36. lt in death or serious injury decal placed in same position on both sides 1751 0329 x2 decal placed in same position on both sides 1751 0330 DERE decal placed in same position on both sides 1751 0729 ADANGER CRUSH HAZARD Do not work under dock leveler unless this maintenance prop has been secured in the upright position Failure to comply will result in death or serious injury See owner s user s manual for proper procedures 1751 0729 Rev A AA DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch 1 75 1 0731 and insert through the maintenance prop housing Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury amer A DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is safely supported by maintenance prop Place barriers on driveway and dock floor to indicate service work being performed Failure to comply will result in death or serious injury Refer to owner s user s manual for proper maintenance procedures 1751 0728 Rev A OWNER S USER S RESPONSIBILITIES 1 10 The owner user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle The owner user should therefore train and instruct all operators in the safe op eration and use of the loading dock equipment in accordance with manufacturer s recommendations
37. m to lower to the cross traffic stored position lip engages lip keepers Perform steps 5 7 at least four times make sure the leveler functions properly and there is no binding Two people are required to engage the maintenance prop one person to operate the lifting device the other person to engage the maintenance prop TO 11 12 13 Raise the platform fully Hold the platform at this position by pulling the lanyard ring or RAISE button and move the maintenance prop to the service upright position Release the lanyard ring or RAISE button to allow the platform to lower until it is resting on the maintenance prop With the maintenance prop supporting the platform remove the lifting brackets With toe guards support the toe guards remove the cotter pin used in shipping and carefully release the toe guards Pull lanyard ring or depress and hold the RAISE button until the maintenance prop drops to its stored position Release the lanyard ring or RAISE button and allow the platform to lower fully Check operation of toe guards When the platform lowers to the full below dock position the lip will fold Pull lanyard ring or depress and hold the RAISE button until the platform rises just enough to clear the lip keepers then release the lanyard ring or RAISE button to allow the platform to lower to the cross traffic stored position lip engages lip keepers INSTALLATION Overhea
38. maintenance prop Unless the dock leveler is eguipped with a tethered remote two people are reguired 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 A Lip Latch Spring B Lip Actuator Spring Adjustment Adjustment 28 4111 0038 May 2015 ADJUSTMENTS Adjusting Lip Latch Spring Tension This adjustment is set at the factory and should not reguire 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 check proper engagement of the lip latch 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 1 Loosen jam nut A 2 To increase spring tension turn nut B clockwise 3 To decrease spring tension turn nut B counterclockwise 4 Tighten jam nut Recheck operation of platform and lip Readjust lip latch spring tension and lip assist spring tension until proper operation is obtained 4111 0038 May 2015 A
39. n Name Address Date of Installation 45 STANDARD PRODUCT WARRANTY SYSTEMS INC warrants that its products will be free from defects in design materials and workmanship for a period of one 1 year from the date of shipment All claims for breach of this warranty must be made within 30 days after the defect is or can with reasonable care be detected In no event shall any claim be made more than 30 days after this warranty has expired In order to be entitled to the benefits of this warranty the product must have been properly installed maintained and operated in accordance with all manufacturer s recommendations and or specified design parameters and not otherwise have been subject to abuse misuse misapplication acts of nature overloading unauthorized repair or modification application in a corrosive environment or lack of maintenance Periodic lubrication adjustment and inspection in accordance with all manufacturers recommendations are the sole responsibility of the Owner User In the event of a defect as determined by SYSTEMS INC covered by this warranty SYSTEMS INC shall remedy such defect by repairing or replacing any defective eguipment or parts bearing the cost for the parts labor and transportation This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED
40. nds 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 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 e hoist or fork truck having the appropriate lifting capacity and reach 4 Remove wood blocks that maybe attached to the leveler frame before putting the dock leveler into the pit 5 Raise the leveler to allow the leveler sit on the maintenance prop Remove 3 plastic ties 2 Rear 1 Front before lowering into NOTICE pit Compressor pump MUST be filled with appropriate oil prior to initial start up Refer to manufactures manual for proper maintenance procedure ILIE 4111 0038 May 2015 INSTALLATION Shim Install Dock Leveler Stac
41. ner User must review all name plates placards decals instructions and posted warnings and place the same in view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for any replacements Manufacturer s recommended periodic maintenance and inspection procedures in effect at the date of shipment shall be followed at all times Written documentation of maintenance replacement parts or dam age should be retained In the event of damage notification to the manufacturer is reguired Loading dock eguipment that has been structurally damaged or has experienced a sudden loss of main support while under load such as what might occur when a transport vehicle pulls out from under the leveling device shall be removed from service inspected by a manufacturer s authorized representative and repaired or replaced as needed before being placed back in service Any modifications or alterations of loading dock eguipment shall only be done with prior written approval from the manufacturer and the same shall be at least as safe as the original eguipment was prior to the modification and shall also satisfy all safety reguirements of the manufacturer for the particular application of the leveling device When industrial moving devices are being used in the loading or unloading of product from the transporta tion vehicle this vehicle shall have the brakes and wheel chocks applied appropriately or all other positive
42. r into the pit so rear hinge frame angle H is tight against rear pit curb angle F 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 and D so front of dock leveler will stay level with dock floor when leveler is resting fully on shims 4111 0038 May 2015 JE LLL INSTALLATION TI ITF UN a SSSSS V B7 S e E ys Sy y Yf RAINE ARRAN KARA AUN SNR NR SS NA SVS S PA VV RRR AAA Ry he WA A S V A G 3 8 in 9 5 mm A Front of Dock Pit B Dock Leveler Frame C Side Pit Curb Angle D Gap 3 4 in 19 mm Minimum 8 With rear hinge frame angle F tight against rear pit curb angle G perform check the following e Pry between the platform and rear hinge frame angle at locations E to make sure rear edge of platform is parallel to the rear hinge frame angle F Gap D must exist equally along both sides of leveler so weather seal if equipped will not bind during dock leveler operation 4111 0038 May 2015 6 in 152 mm E Pry Locations F Rear Hinge Frame Angle G Rear Pit Curb Angle H Flare Bevel Weld Typical To Fit Spacing 9 If gap D cannot be obtained equally at both sides of leveler grind or add material at the rear edge of rear hinge frame angle F as need
43. r supply Check breakers if ok check voltage at control box and No voltage to solenoid oea Platform does not rase Lanyard Cable Adjustment Check Cable adjustment Incorrect Air Line Verify pilot and Main supply air line connections are Connections correct at control box Air bladder or connecting air Check air bladder and air line repair or replace as lines punctured Damaged or restricted air lines Minimum 80 Psi reguired at regulator if lower check Low Air pressure air Supply Check for visible obstructions that could cause Replace damaged air line or remove restriction Platform rises slowly Dock leveler binding binding Remove obstructions If no obstructions found call Poweramp Technical Services See Platform Rises Slowly See Platform Rises Slowly See Periodic Maintenance in the Maintenance Platform does not rise to section full height Minimum 80 Psi required at regulator if lower check Low Air pressure air Supply Platform DOES rise to full height but lip DOES Lip actuator spring needs _ Inspect lip actuator chain repair or replace as NOT extend or extend additional tension needed fully See Adjustment Section Lip Latch Spring Lip extends but does e Increase tension as needed to keep latch not remain extended as ER an RAM WEE engaged additional tension leveler drops Clean any debris from lip latch area e Lubricate as instructed in maintenance section 4111 0
44. raise the platform by pulling lanyard ring B or depressing and holding RAISE button A c Make sure that the lip is fully extended and supported on the transport vehicle along the entire width of the platform with at least 4 in 102 mm of lip contacting the transport vehicle bed 13 Pull lanyard ring B or hold the RAISE button A until the lip folds enough to clear the transport vehicle bed then release the RAISE button The lip will fold and the platform will return to the cross erg traffic position 5 Proceed with loading or unloading the transport 14 Remove chocks TOM Anon vehicle wheels or vehicle release the vehicle restraint if used 6 If below dock loading is necessary see steps 7 11 If not proceed to step 12 15 Indicate to driver that transport vehicle may leave the dock 4111 0038 May 2015 23 OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE If ramp loading is required see Ramp Loading Unloading Instructions on page 19 En loading or unloading can be done with the dock at the cross traffic position or below dock position depending on the height of the transport vehicle bed 1 Check to make sure transport vehicle is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the transport vehicle wheels or use the vehicle restraint
45. reguired to engage the maintenance prop one person to operate the lifting device the other person to engage the maintenance prop DO NOT use the maintenance prop to support the raised platform until the maintenance prop has been properly shimmed and welded The shims must be welded to each other the leveler frame and to the front pit curb steel Failure to do this may result in serious personal injury or death DO NOT weld before disconnecting all electrical components DO NOT weld before removing air bellows Failure to follow these instructions may result damage to these components from stray sparks and weld splatter 4111 0038 May 2015 DO NOT grind or weld if hydraulic fluid or other flammable liguid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liguid 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 DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed DO NOT ground welding eguipment to any hydraulic or electrical components of the dock leveler Always ground welding eguipment to the dock leveler frame NE
46. restraining device shall be fully utilized It is recommended that transport vehicles with air ride suspen sion systems shall have its air exhausted prior to performing loading and unloading operation to minimize transport vehicle bed drop Loading dock safety eguipment should never be used outside of its intended use vertical working range or capacity Please consult the manufacturer if you have any questions as to the use vertical working range or capacity of the eguipment Only properly trained and authorized personnel should operate the eguipment When selecting loading dock safety eguipment it is important to consider not only present reguirements but also future plans and any possible adverse conditions environmental factors or usage 4111 0038 May 2015 General Information Congratulations on your choice of a McGuire dock leveler This manual covers the CentrAir 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 bellows system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended The CentraAir dock leveler comes eguipped with an electrical control panel which allows push button operation of the dock leveler functions Each
47. rop Pivot D Platform Pivots G Safety leg linkage pivots Adiustina knob Clockwise increase PSI Justing no Counter Clockwise decrease PSI Lubricator Gentle turn clock wise Em untill it stops then turn back 1 2 turn for factory setting Recommend 95 Psi Supply line to dock leveler Fill line with Kill Frost or equivalent may not be on every unit N Drain water as needed Clean Filter as needed md PE DEON LR r 26 4111 0038 May 2015 MAINTENANCE Regular maintenance must be performed on a weekly and guarterly schedule Follow all safety precautions Weekly Maintenance A Check Kill frost level may be reguired more freguently depending on usage B Drain water may be reguired more freguently depending on usage and compressor size C Verify Line Pressure is at 95 psi e Operate the dock leveler through the complete operating cycle to maintain lubrication NOTE To thoroughly inspect the platform hinge area put the platform in the full below dock position Inspect the platform pivots and the lip hinge areas The hinge areas must be kept free of dirt and debris Build up of foreign material in the hinge areas will cause abnormal operation Inspect the area under the platform around and under the air bellows Build up of foreign material in this area may damage air bellows components causing abnormal operation Failure to properly lubricate the dock leveler will
48. t vehicle is positioned squarely against dock bumpers For ramp loading or unloading the MA dock leveler can be operated by pulling the lanyard 8 Instruct driver to remain at the dock until the chain or RAISE button on the control panel loading or unloading process has been completed A 9 Chock the transport vehicle wheels or use vehicle 1 Check to make sure transport vehicle is positioned restraint if present squarely against dock bumpers 10 Raise the platform by pulling lanyard ring B or 2 Instruct driver to remain at the dock until the loading depressing the RAISE button A to fully raise the or unloading process has been completed leveler and extend the lip 3 Chock the transport vehicle wheels or use the 11 Walk out on the leveler Pull and Hold the release vehicle restraint if available ring see picture below until the platform lowers onto the transport vehicle Make sure there is a minimum of 4 of lip overlapping the transport vehicle A RAISE Button B LANYARD Cable e 4 Extend the platform lip onto transport vehicle as follows a Raise the platform by pulling lanyard ring B or depressing and holding RAISE button A b Pull lanyard ring B or Hold the RAISE button until the lip is fully extended then release the lanyard ring or RAISE button A The platform will lower until the lip is resting on the transport vehicle bed TD 12 When loading or unloading is finished
49. the air bellows and connect pneumatic air line 4 After all pneumatic connections in the pit have been made raise the leveler disengage the maintenance prop and allow the platform to lower 5 Install the Placard s D in close proximity to the control box and in plain sight 4 DANGER Ld Arc Flash eared Shock Hazard PPE Personal Protection Equipment Required De oncngizco oquipment Iola wiodng ci Cg inc Do nof DG cova wiht oppaan PE ges des t POE cs Hazardous Voltage Will Couse Sawer DE 16 A Disconnect Panel Provided by others B Control Panel C Distance 48 in 14 630 mm D Placard Electric Controls 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 bellows and connect air line Connect the dock leveler power cable to coil 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 Install the Placard s D in close proximity to the control box and in plain sight 4111 0038 May 2015 Put New Dock Leveler Into Service 1 Disconnect the external lifting device and chains from the lifting brackets 2 Check that the l
50. the key to unlock the device Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete A maintenance prop permanently attached and hinged to the unit with means for lock out tag out requirements per OSHA 1910 147 is included with each pit style dock leveler In addition it is recommended and good safety practice to use an additional means to support the dock platform and lip anytime when physically working in front of or under the dock leveler This additional means may include but not limited to a boom truck fork truck stabilizing bar or equivalent ALWAYS disconnect electrical power source and ground wire before welding on dock leveler DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground to the dock leveler frame Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure
51. to follow these instructions may result in serious personal injury or death ALWAYS stand clear of dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death 4 DANGER Ay Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De enemjize equipment before working on or Inside Do mot open cover without appropriate PPE Refer to NFPA 70E for FPE requirements Ths panel may contain mare than ane power SOLI ce Hazardous Voltage Will Cause Sever Injury or Death 4111 0038 May 2015 SAFETY Safety Decal s Every 90 days guarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or reguire replacement please call 1 800 643 5424 for replacements 4111 0038 May 2015 AA DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar 1 751 0727 Do not force maintenance prop forward of bar to support lip Failure to comply will result in death or serious injury Refer to owner s user s manual for proper use 1751 0727 Rev A 1751 0730 x2 sides 8 Nev malfur al problems immediately to Before allowing vehicle to leave the dock always e Ensure no equipment material or people are on dock leveler e Return dock leveler to its y stored position at dock level Failure to follow posted instructions will resu
52. y 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 eguipment should have the key to unlock the maintenance prop A Platform Frame D Lip Keeper Failure to follow these instructions may result in B Jam Nut E Lip serious personal injury or death C Stop Bolt Check that lip E is fully resting on the lip keepers 4 Tighten jam nut D and at the lowest part of the keeper cradle If lip is not resting properly in keepers perform the following 5 Disengage lip maintenance prop adjustment 6 Walk platform down to cross traffic stored position 1 Fully raise platform Manually raise the lip and engage lip maintenance prop 7 Check lip position in both keepers Repeat procedure if necessary 2 Loosen jam nut B 3 Adjust stop bolt C as necessary e Turn stop bolt in clockwise to allow lip to fold closer to platform frame A e Turn stop bolt out counterclockwise to hold lip further away from platform frame A 30 4111 0038 May 2015 NOTES This page intentionally left blank 4111 0038 May 2015 31 TROUBLESHOOTING Troubleshooting When service under the dock leveler is reguired always lock all electrical disconnects in the OFF position
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