MEDLF Owner`s/User Manual
Contents
1. To put handle into maintenance prop position remove bolt and locknut at base of handle assembly Pull handle out of roller arm assembly and place into maintenance prop receiver Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before installation has been SAFETY Maintenance Safety Precautions completed ALWAYS stand clear of dock leveler lip when Failure to follow the installation instructions can working in front of the dock leveler Failure to do this result in damage to dock leveler the facilities and or serious personal injury or death Manual No 4111 0026 July 2011 May 2012 may result in serious personal injury or death SAFETY SAFETY INFORMATION Operation Supports the ramp before driving on Read and follow al instructions and ramp warnings in the owner sluser s 7 Stay clear of hinges and front and manual sides of moving dock leveler Use of dock leveler restricted to 8 Never use damaged or trained operators malfunctioning dock leveler Report Always chock trailer wheels or problems immediately to supervisor engage truck restraint before operating dock leveler or beginning to Maintenance Service load or unload 1 Read and follow all instructions Never use hands or equipment to warnings and maintenance schedules move the ramp or lip in the owner suser s manual Be2. a 1 I d 6 o 1 CONTINUOUS 1 4 9 Ex mra EE 1 T IL I I I I I I I I eb i T elt d li e e e e 5 e 1 lei 9 I 18 5 Le a 3 8 8 a 104 OR 110 m FOR 66 OR 72 WIDE UNITS Manual No 4111 0026 July 2011 15 May 2012 Using the back edge of the ramp plate as a guide groove concrete approximately 3 4 deep by 2 wide and should be the entire length of ramp plate Break tack welds holding ramp in place slide ramp plate back into position with the top of the ramp plate flush with the top of the base plate Tack weld each end and center of ramp plate to base plate Drill 5 8 dia by 5 deep holes through ramp plate at back edge Install anchor bolts per manufacturers specifications and tighten securely Weld anchor bolt nuts to ramp plate using a 1 4 fillet weld all the way around the nut Cut off any portion of the anchor bolt exposed through the nut and plug weld around the top of the nut to the anchor bolt Ensure the top of the nuts are well rounded for smooth rollover Complete welding of tacked parts as follows A Apply continuous weld across top of each bumper and base plate to ramp plate Skip welding is acceptable to prevent warpage but complete weld must be completed B Weld vertically along each end of base plate an
3. Deck Total Unit Width Comparative Industry Rating Width MEDLF 66 66 104 20 000 MEDLF 72 72 110 20 000 30 000 MEDLF 78 ne 35 000 N A for MEDLF 78 amp 84 MEDLF 84 84 122 Manual No 4111 0026 July 2011 May 2012 Congratulations on your choice of a McGuire Edge of Dock leveler This manual covers the MEDLF series mechanical Edge of Dock levelers Designed by McGuire to be a marvel of simplicity and efficiency your dock leveler when properly installed will provide many years of trouble free performance with an absolute minimum of maintenance To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended Once again thank you and congratulations on your purchase of a McGuire mechanical Edge of Dock leveler INSTALLATION INSTALLATION DETAILS GREASE FITTING ON LIP HINGES 8 C 11 58FT CHANNEL MINIMUM BY OTHERS CONTINUOUS WELD ACROS TOP OF BUMPER BLOCKS AND BASE PLATE BUMP BLOCK ASSEMBLY ANCHOR BOLT REASE FITTINGS ON 50 INCH BASE PLATE HINGES PREFERRED Only trained installation professionals with the Post safety warnings and barricade the work area at proper equipment should install this product dock level and ground level to prevent unauthorized use of the dock leveler before installation has been completed IMPORTANT DO NOT remove the shipping bands around the result in damage to do
4. 1 1 DOTH 3537 12 BB Weldment 2 2 DOTH 3514 Angle 12 BB Slide 3 2 DOTH 3515 Bar BB Sliding Stop 4 1 DOTH 3517 12 Sliding BB Plate w Rubber Manual No 4111 0026 31 July 2011 May 2012 MISCELLANEOUS This page intentionally left blank Manual No 4111 0026 32 July 2011 May 2012 MISCELLANEOUS 33 Dock Leveler Information Model Serial No McGuire Job No Original Owner Information Name Address Installer Information Name Address Date of Installation NOTE The model serial number decal A is located on the right platform joist near the front lip of dock leveler When you receive your MEDLF series Edge of 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 s job number the company that installed the dock leveler and the original owner s name This will all help to identify the specific dock leveler if more information is required When ordering use part numbers and description to help identify the item ordered Do not use item numbers These are only for locating the position of the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER For service call or contact McGuire P O Box 309 Germantown WI 53022 Phone 800 624 8473 Fax 26
5. Locknut Torsion Spring Adjustment Instructions Lift and secure leveler in full upright maintenance position to start Remove nut A from hex bolt B Place crescent wrench on torsion tube assembly apply enough downward force to tube assembly until hex bolt can be removed Continue to apply downward force until flange on tube assembly has the next hole in series come into alignment with hex bolt hole Insert hex bolt B through the flange on the tube assembly and tighten nut until secure Test leveler operation If spring tension is not sufficient repeat the previous steps until desired tension is achieved Return leveler to stored position 28 t 2 3 PARTS This page intentionally left blank Manual No 4111 0026 July 2011 29 May 2012 PARTS 885 3500 Complete 15 Projection Bumper Assembly DKIT 3540 Bumper amp All Hardware weldment not included Item Quantity Part Number Description 1 1 DOTH 3537 12 BB Weldment 2 1 DOTH 3505 Rubber Tuf Cord 3 4 DOTH 2056 Hex Head Cap Screw 4 4 DOTH 2210 Wahser Flat Zinc Plated 5 4 DOTH 2208 Washer Flat 6 4 DOTH 2129 Nylon Lock Nut 2 DBBS 3506 15 Projection x 18 high option Manual No 4111 0026 30 July 2011 May 2012 PARTS DBBS 3512 Complete 15 Projection Sliding Bumper Assembly Item Quantity Part Number Description
6. MEDLE SERIES Mechanical EOD Dock Leveler Owner s User s Manual A Division of Systems Inc MCGUIRE Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 624 8473 fax 262 255 9399 www wbmcguire com techservices docksystemsinc com Printed in U S A Manual No 4111 0026 Copyright 2010 July 2011 May 2012 Table of Contents Page Safety Recognize Safety Information General Operational Safety Precautions Operational Safety Precautions Maintenance Safety Precautions Safety Decals Owner s User s Responsibi E NN gt lt Introduction General Information 0 Dock Leveler Stock Specifications Installation Installation Details Flush Mount Weld On Ramp Mount Weld Bolt On Flush Mount Bolt On Ramp Mount Weld On w Formed Angle Formed Angle Ramp and Face Plate Installation Checklist Operation Operating instructiong LLULLU LLL III AA is aa 23 Maintenance Periodic Maintenance ssccessesseseessesssesssesesesssessseseseseseseenseens 24 Troubleshooting nnnm nnne nora tna nntnanan 25 Parts MEDLF Series Torsion Spring Components Bumper Components Sliding Bumper Components Miscellaneous Customer Information Warranty Back Cover SAFETY General Operational Safety Precautions ED Read and understand the operating instructions and becom
7. 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 Manual No 4111 0026 July 2011 23 May 2012 Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death Securely block or support ramp and lip when in vertical position Lack of proper bracing can result in ramp dropping during maintenance causing personal injury or damage to unit Quarterly Maintenance Lubricate the following areas with light weight machine oil Extend link arm pivots Lip linkage pivot Operating link pivots Torsion arm pivots Lubricate the following areas with white lithium grease Lip plate grease fittings Base plate grease fittings Note Failure to lubricate the dock leveler will cause abnormal operation of the leveler Manual No 4111 0026 July 2011 May 2012 MAINTENANCE When maintenance is to be performed in front of the dock leveler support the lip with the handle in the maintenan
8. bolt Ensure the top of the nuts are well rounded for smooth rollover Drill 5 8 dia by 5 deep holes in dock face through holes in formed angle Install anchor bolts with washers and tighten securely per manufacturers specifications 18 19 Manual No 4111 0026 July 2011 May 2012 div 40 H19N31 304 3I3HONOO NI 0089 X 8 cA 3804 NI LL LON o a e epis yore 6 soq Joyoue 81 ym ajue pouwoj no s NOLLdi ios3a INSTALLATION 5 8 dia by 5 deep holes through ramp plate at back edge Install anchor bolts per manufacturers specifications and tighten securely Weld anchor bolt nuts to ramp plate using a 1 4 fillet weld all the way around the nut Cut off any portion of the anchor bolt exposed through he nut and plug weld around the top of the nut to the anchor bolt Ensure the top of the nuts are well rounded for smooth rollover 11 Apply a continuous fillet weld at the created joint between the face plate and ramp Skip welding should be the proper method used to avoid warpage and a complete weld must be achieved Manual No 4111 0026 July 2011 May 2012 INSTALLATION E O D Installation Instructions mp and Face Plate Ra A ramp mount requiring a face plate application is used when there is no existing dock steel and the concrete at the dock edge has been damaged The dock height can b
9. on application is used when an 8 wide minimum embed channel is securely anchored into the concrete at the dock edge and the dock height is adequate Installation Steps Remove all existing bumper material and protruding objects from dock edge Clean and sweep dock edge free of debris and flammable chemicals before installing unit At chosen location for Edge of Dock leveler locate the center of space and mark a point half of the base plate width to the left and right Using a proper lifting device raise and position leveler on dock face with the top of the base plate being flush with the top of the embedded channel Position ends of base plate to match up with marks made previously Tack weld base plate to dock steel on left hand end of the leveler Check right hand end of base plate ensure that end is against dock steel and that the top of the base plate is still flush with the top of the embedded channel Tack right hand end to dock steel Position bump blocks out approximately 5 8 from the edge of the inside flange of the bump block to the end of the base plate This will allow for vertical welding of both the base plate and the bump block flange back to the dock steel Top of the bump block cover plate should be flush with the top of the embed channel Tack weld bump blocks to dock steel Check the positioning of the base plate and the bump blocks Complete welding of tacked parts as follows A Apply a continuou
10. the driveway and on Remove any end loads if required dock for to indicate service work is Check trailer alignment to avoid lip being performed 4 DO NOT ENTER PIT unless dock interference If ip does not lower to trailer bed reposition vehicle keete SE E 5 If electrically powered tum off and use OSHA lockouttagout procedures Ca 25256 TSO forepiacermerf POCOS waring bes orownersusers mank DANGER Ramp swings toward you Stand Clear Use maintenance strut while servicing Failure to do so will result in death or serious injury ADANGER Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always Ensure that no equipment material or people are on the dock leveler Return the dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or serious injury Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always Ensure that no equipment material or people are on the dock leveler Return the dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or serious injury O Safety Decals O Decal 2 will have two positions one on the outside of the left bumper and one on the outside of the right bumper Number 3 represents the placement of the serial tag Manual No 411
11. welds and slide ramp back until forward edge is flush with dock face Tack weld ramp on each end and center to face plate Drill 1 10 20 21 Manual No 4111 0026 July 2011 May 2012 PF NOLIDAS 8 HLONST 303 NI 30089 z X 8 dwe pue ad eoe yo uifue einue 80198 pjem aly snonunuoo dot 3lYld 3993 epis uoee 6 syoq Joyoue 1 B 1 ym albue pauuo NOlLdl ios3a LON i HSM 40014 2000 0 SAT4 31974 291 40 1 0cl 6 6 e 2 1 SNONNILNOO al o INSTALLATION 6 INSTALLATION CHECKLIST POWERAMP MCGUIRE DLM SYSTEMS INC Loading Dock Equipment E O D Installation Checklist Date Order No Serial Number Installer Customer Name Address City State Zip Phone l Unit is properly aligned and installed properly O 2 All welding has been fully completed O 3 Welding slag has been removed O 4 Welds and other affected areas have been painted O 5 Springs have been properly adjusted O 6 Unit is functioning properly without fault O I hereby certify that all installation and or repair work has been inspected and approved by Company Date Completed Name Signature A copy of this document must be signed and faxed to Systems Inc at 262 257 7399 to the attention Customer Service Technical Service To be placed in jo
12. 0026 26 July 2011 May 2012 PARTS 27 PART NUMBER 17 LIP DOTH 4069 DOTH 4071 DOTH 4073 DOTH 4075 DOTH 4077 DOTH 3179 DOTH 4081 DOTH 4083 DOTH 4085 DOTH 4087 PART NUMBER 15 LIP DOTH 4068 DOTH 4070 DOTH 4072 DOTH 4074 DOTH 4076 DOTH 4078 DOTH 4080 DOTH 4082 DOTH 4084 DOTH 4086 DOTH 4088 DOTH 4089 DOTH 4090 DOTH 4091 DOTH 4092 DOTH 4093 DOTH 4094 DOTH 4095 DOTH 4096 DOTH 4097 Consult Factory DOTH 3104 DOTH 4312 DOTH 3122 DOTH 4313 DOTH 3946 DOTH 3920 DOTH 2400 DOTH 2398 DBBS 3519 DOTH 3675 DOTH 3589 DOTH 3696 DOTH 3697 DOTH 3694 DOTH 3585 DOTH 3586 DOTH 3316 DOTH 2061 DOTH 2136 DOTH 3734 DOTH 3695 DESCRIPTION Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Base Plate amp Hinge Assembly Hinge Pin Hinge Pin Hinge Pin Hinge Pin Hinge Pin Hinge Pin Rivet Button Rivet
13. 0026 July 2011 May 2012 SAFETY Operational Safety Precautions A Learn the safe way to operate this equipment Read and understand the manufacturer s instructions If you have any questions ask your supervisor Pr Tr Tr IT ave SE Chock restrain all freight carriers Never remove the wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away e Do not use a broken or damage dock leveling device Make sure proper service and maintenance procedures have been performed before using Make sure lip overlaps onto trailer at least 4 in 102 mm Keep a safe distance from both side edges Manual No 4111 0026 July 2011 May 2012 Stay clear of dock leveling device when freight carrier is entering or leaving area Do not move or use the dock leveling device if anyone is under or in front of it Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts SAFETY Safety Decals Te Do not use dock leveling device if freight carrier is too high or too low e Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device Manual No 4111 0026 3 July 2011 May 2012
14. 1 0026 July 2011 May 2012 OWNER S USER S RESPONSIBILITIES The owner user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle The owner user should therefore train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer s recommendations and industry standards Effective operator training should also focus on the owner s 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 equipment Owner s user s shall actively maintain update and retrain all operators on safe working habits and operations of the equipment The manufacturer shall provide to the initial purchaser all necessary information regarding Safety Information Operation Installation and Safety Precautions Recommended Initial and Periodic Inspections Procedures Planned Maintenance Schedule Product Specifications Troubleshooting Guide Parts Break Down Warranty Information and Manufacturers Contact Information as well as tables to identify the grade slope for all variations of length or configuration of the dock leveling device and information identifying the maximum uncontrolled d
15. 2 255 5917 Manual No 4111 0026 July 2011 May 2012 STANDARD PRODUCT WARRANTY SYSTEMS INC warrants that its products will be free from defects in design materials and workmanship for a period of one 1 year from the date of shipment All claims for breach of this warranty must be made within 30 days after the defect is or can with reasonable care be detected In no event shall any claim be made more than 30 days after this warranty has expired In order to be entitled to the benefits of this warranty the product must have been properly installed maintained and operated in accordance with all manufacturers recommendations and or specified design parameters and not otherwise have been subject to abuse misuse misapplication acts of nature overloading unauthorized repair or modification application in a corrosive environment or lack of maintenance Periodic lubrication adjustment and inspection in accordance with all manufacturers recommendations are the sole responsibility of the Owner User In the event of a defect as determined by SYSTEMS INC covered by this warranty SYSTEMS INC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY
16. Flat Extra Hvy Duty Bumper Blocks HL Linkage Adder Assembly X Gusset NLIII Operating Link Assembly NLIII Operating Link Assembly NLII Handle Assembly Extend Link Arm Extend Link Arm Stop Pivot Block Shoulder Bolt Locknut Lip Stop NLII Handle Holder SIZE CAPACITY 6620 25 6630 6635 7220 25 7230 7235 7820 25 7830 8420 25 8430 6620 25 6630 6635 7220 25 7230 7235 7820 25 7830 8420 25 8430 ALL 6620 25 30 6635 7220 25 30 7235 7820 25 30 8420 25 30 All All All All All Al 35K Only Al Al Al Al Al Al Al Al QTY gt gt ISI IS IS AN gt ITEM o o s o o Manual No 4111 0026 July 2011 May 2012 Manual No 4111 0026 July 2011 May 2012 PARTS DOTH 3675 Torsion Spring Kit Includes all parts listed below Item Quantity Part Number Description 1 1 DOTH 3305 L amp R Gusset Assembly w Bearing 2 1 DOTH 3327 HL Model Gusset w Guide 3 1 DOTH 3679 HL Torsion Tube Assembly 4 1 DOTH 3676 HL Torsion Bar Assembly 5 1 DOTH 2509 Spring Torsion 6 1 DOTH 3316 Bar Pivot 7 3 DOTH 2033 HHCS Grade 2 Zinc Plated 8 1 DOTH 2121 Nylon Lock Nut 9 1 DOTH 3682 HL Plate Locking Torsion 10 2 DOTH 3617 Bar 6630 L Linkage 11 2 DOTH 2061 1 1 2 Shoulder Bolt 12 2 DOTH 2136 Center
17. OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS 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
18. aq snonunuoo Ajddy ad due yo do uy usny eq oj eyejd 18409 Jeduing pue leld eseq jo do NOlLditiosaa un 0j ebewep Jo Anfu jeuosjed Bursneo uonejeisur jueunsn pe Buunp Burddoup due u ueo BuroeJq Jedoud jo 4987 suonisod eonjeA ul ueym dij pue dwe poddns yoojq Aj eu1noes IL INSTALLATION Drill 5 8 dia by 5 deep holes at center marks Reposition bump blocks insert anchor bolts with washers and tighten securely to dock face Place steel ramp plate in position flush with top backside of base plate Mark along full length of base edge of ramp plate Slide ramp plate forward over dock leveler the width of bushing tool approximately 2 Place bushing tool on marked line at each end of ramp to ensure proper alignment at both ends and tack weld ramp plate to dock leveler to hold ramp plate in place while bushing A Skil Roto Hammer 736 or similar tool is recommended Using the back edge of the ramp plate as a guide groove concrete approximately 5 8 deep by 2 wide and should be the entire length of ramp plate Break tack welds holding ramp in place slide ramp plate back into position with the top of the ramp plate flush with the top of the base plate Tack weld each end and center of ramp plate to base plate Drill 5 8 dia by 5 deep holes through ramp plate at back edge Install anchor bolts per manufacturers specificati
19. b folder Copy as needed Manual No 4111 0026 22 July 2011 May 2012 OPERATION OPERATING INSTRUCTIONS 1 Grasp the captured operating handle and raise to Return handle to stored position its full extended length To remove leveler from truck repeat step number 2 Move handle toward you rotating center plate one until the lip clears the bed of the trailer Return leveler and handle to the stored position OR When the truck departs the unit will automatically back past vertical Lip plate extend link arm will engage at this time return to the stored position 3 Push forward on operating handle against the rivet rotating leveler out onto truck 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 Truck trailer wheels must be chocked unless the truck restraint is used Never remove the wheel chocks until loading unloading is finished and truck driver has been given permission to leave Make sure platform lip rests on the truck trailer bed with at least 4 in 102 mm of overlap Maintain a safe distance from side edges of leveler during the loading unloading process Failure to follow these instructions may result in serious personal injury or death Stay clear of dock leveler when freight carrier is entering or leaving dock area DO
20. ce prop position OR by other means Put handle into maintenance prop position by removing bolt and locknut at base of handle assembly Pull handle out of roller arm assembly and place into maintenance prop receiver If maintenance requires that the lip be in the extended position raise the lip by hand and support the lip with the lip maintenance prop Regular maintenance must be performed on a weekly and quarterly schedule Weekly Maintenance Operate the dock leveler through the complete operating cycle to maintain lubrication Inspect the platform hinge and the lip hinge areas The hinge areas must be kept free of dirt and debris Build up of foreign material in the hinge areas will increase wear and cause abnormal operation reference page 9 24 TROUBLESHOOTING Symptom Possible Cause Solution Unit does not operate Debris impacted on or around Clean out debris on or around leveler properly the leveler Insufficient lubrication Lubricate leveler Excessive weight on top of deck Remove weight from deck Main spring tension Adjust tension more or less for proper operation Extended link arm does Debris impacted in extended link Clean out debris from extended link arm not latch out lip or arm unlatch Extended link arm needs Lubricated extended link arm lubrication Manual No 4111 0026 July 1 25 May 2012 PARTS MEDLF Series Manual No 4111
21. ck leveler the facilities and dock leveler lip until instructed to do so or serious personal injury or death Failure to follow the installation instructions can Manual No 4111 0026 9 July 2011 May 2012 Installer must remove all welding slag and repaint welded areas Installer must adjust springs on all mechanical Edge of Dock levelers to provide desired tension for smooth operation Stand in front of leveler with the unit raised and secured in the maintenance position loosen jam nut on the underside of the linkage pin To start allow about 3 4 to 1 of threads between top of jam nut and linkage pin Using an open faced wrench hold locknut on inside of spring while tightening threaded bolt until washer on top side of spring closes up tight to jam nut Test operation of unit Further adjust spring tension if needed by advancing jam nut toward linkage pin and tightening threaded rod After desired unit operation is achieved tighten jam nut to outer washer on spring Springs must be adjusted alternately to have equal spring tension Before install is complete installer must make a final operational check of dock leveler to verify all phases of install are correct Installer must complete sign and return the Installation Checklist upon completion Reference page 22 Manual No 4111 0026 July 2011 May 2012 10 INSTALLATION E O D Installation Instructions Flush Mount Weld On A flush mount weld
22. d on both inboard and outboard flanges of bump blocks C Fully plug weld all holes in base plate Installer must remove all welding slag and repaint welded areas Installer must adjust main springs on all mechanical Edge of Dock levelers to provide desired tension for smooth operation Stand on ground in front of leveler with the unit raised and secured in the maintenance position loosen jam nut on the underside of the linkage pin To start allow about 3 4 to 1 of threads between top of jam nut and linkage pin Using an open faced wrench hold locknut on inside of spring while tightening threaded bolt until washer on top side sprint closes up tight to jam nut Test operation of unit Further adjust spring tension if needed by advancing jam nut toward linkage pin and tightening threaded rod After desired unit operation is achieved tighten jam nut to outer washer on spring Springs must be adjusted alternately to have equal spring tension Before install is complete installer must make a final operational check of dock leveler to verify all phases of install are correct Installer must complete sign and return the Installation Checklist upon completion Reference page 22 Manual No 4111 0026 July 2011 May 2012 10 12 13 14 15 INSTALLATION E O D Installation Instructions Ramp Mount Weld On w Formed Angle Aramp mount weld on used with a formed angle application is used when dock edge is damaged
23. e low high or adequate for this application however the face plate and ramp plate are required to rebuild the damaged concrete edge Installation Steps Remove all existing bumper material and protruding objects from dock edge Clean and sweep dock edge free of debris and flammable chemicals before installing unit At chosen location for the face plate locate the center of space and mark a point half of the face plate width to the left and right Using a proper lifting device raise and position the face plate to marked position and push face plate against dock face Top of face plate should be flush with the top of dock floor mark center of holes in face plate into dock face Drill 5 8 dia by 5 holes into dock face Install anchor bolts with washers per manufacturers specifications and tighten securely Place ramp plate to match each end of the face plate Leading forward edge of ramp plate should be flush with dock face Mark along full length of back edge of ramp plate Slide ramp forward the width of bushing tool approximately 2 Place bushing tool on marked line at each end of ramp to ensure proper alignment at both ends A Skil Roto Hammer 736 or similar tool is recommended Tack weld ramp to face plate on each end to secure in place Using the back edge of the ramp plate as a guide groove concrete approximately 5 8 deep by 2 wide and should be the entire length of the lamp plate Break tack
24. e thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or guard is removed or disconnected Never remove DANGER WARNING or CAUTION signs or decals on the equipment unless replacing them Operating Zone Do not start the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone Remove any tools or foreign objects from the operating zone before starting Keep the operating zone free of obstacles that could cause a person to trip or fall Recognize Safety Information Safety Alert Symbol The Safety Alert Symbol identifies important safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury or death Follow the instructions in the safety message The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury IMPORTANT The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage Manual No 4111
25. ete at the dock edge has been damaged The formed angle is required to rebuild the damaged concrete edge for a proper installation if the dock height is adequate Installation Steps 1 Remove all existing bumper material and protruding objects from dock edge Clean and sweep dock edge free of debris and flammable chemicals before installing unit At chosen location for the formed angle locate the center of space and mark a point half of the angle width to the left and right Using a proper lifting device raise and position the formed angle to marked position slide formed angle against dock face Mark along full length of back edge of formed angle Slide angle forward the width of bushing tool approximately 2 Place bushing tool on marked line at each end of formed angle to ensure proper alignment at both ends A Skil Roto Hammer 736 or similar tool is recommended Using the back edge of the formed angle as a guide groove concrete approximately 5 8 deep by 2 wide and should be the entire length of the formed angle Slide formed angle back until tight against dock face drill 5 8 dia by 5 deep holes through formed angle at back edge Install anchor bolts per manufacturers specifications and tighten securely Weld anchor bolt nuts to formed angle using a 1 4 fillet weld all the way around the nut Cut off any portion of the anchor bolt exposed through the nut and plug weld around the top of the nut to the anchor
26. f of the base plate width to the left and right At the points marked to each side of center measure and mark points 7 1 2 below dock level for 1 4 ramp plate to locate position for bottom of base plate This position will place the top of the base plate 1 4 above the dock floor This position will vary with ramp plate thickness Mark line connecting these points and position support angles Position angles as shown in installation drawing provided Mark center of holes in each of the support angels At center marks drill holes 5 8 dial by 5 deep in concrete Install anchor bolts with washers through support angles into holes in concrete Tighten bolts until support angles are secure Follow anchor manufacturers installation instructions for proper installation Using a proper lifting device raise and position the leveler base plate to marked position while resting on the support angles While holding base plate tight against dock face tack weld securely to support angles Drill 5 8 dia by 5 deep holes in concrete through holes in base plate and install anchor bolts with washers and tighten securely Position bump blocks out approximately 5 8 out from the edge of the inside flange of the bump block to the end of the base plate Position the top of the tread cover plate on the bump blocks to be 1 4 above dock level Note that this placement will vary with ramp plate thickness Mark centers of hole
27. fore activating dock leveler 2 Maintenance Service of dock leveler Ensure trailer is backed in against restricted to trained personnel bumpers 3 Place barriers on the driveway and or Remove any end loads if required dock floor to indicate service work is Check trailer alignment to avoid lip being performed 4 DO NOT ENTER PIT unless dock Interference If ip does not lower to leveler is securely supported by Ensure that truck bed supports maintenance prop 5 Melectrcaly powered tum off and us Gi fo ek aa OSHA lockouttagout procedures Ca AS TTD Torre placards waning iaces or owner users mona SAFETY INFORMATION Operation Supports the ramp before driving on Read and follow all instructions and ramp warnings in the owner sluser s 7 Stay dear of hinges and front and manual sides of moving dock leveler Use of dock leveler restricted to 8 Never use damaged or trained operators malfunctioning dock leveler Report Always chock trailer wheels or problems immediately to supervisor engage truck restraint before operating dock leveler or beginning to Maintonance Service load or unload 1 Read and allow all instructions Never use hands or equipment to wamings and maintenance schedules move the ramp or lip in the owner slusers manual Before activating dock leveler 2 Maintenance Service of dock leveler Ensure trailer is backed in against restricted to trained personnel bumpers 3 Place bamiers on
28. ons and tighten securely Weld anchor bolt nuts to ramp plate using a 1 4 fillet weld all the way around the nut Cut off any portion of the anchor bolt exposed through the nut and plug weld around the top of the nut to the anchor bolt Ensure the top of the nuts are well rounded for smooth rollover Complete welding of tacked parts as follows A Apply continuous weld across top of each bumper and base plate to ramp plate Skip welding is acceptable to prevent warpage but complete weld must be completed B Weld bottom of base plate support angles using a 1 4 fillet weld Installer must remove all welding slag and repaint welded area Installer must adjust main spring on all mechanical edge of dock levelers to provide desired tension for smooth operation Stand on ground in front Manual No 4111 0026 July 2011 May 2012 10 11 12 13 14 15 16 17 INSTALLATION E O D Installation Instructions Flush Mount Bolt On A flush mount bolt on application is used when there is no steel on dock edge and the dock height is adequate Additional steel ramp plate and bolting is required with this type of installation Installation Steps 1 Remove all existing bumper material and protruding objects from dock edge Clean and sweep dock edge free of debris and flammable chemicals before installing unit At chosen location for Edge of Dock leveler locate the center of space and mark a point hal
29. oward linkage pin and tightening threaded rod After desired unit operation is achieved tighten jam nut to outer washer on spring Springs must be adjusted alternately to have equal spring tension Before install is complete installer must make a final operational check of dock leveler to verify all phases of install are correct Installer must complete sign and return the Installation Checklist upon completion Reference page 22 Manual No 4111 0026 July 2011 May 2012 10 11 12 13 14 INSTALLATION E O D Installation Instructions Ramp Mount Weld Bolt On A ramp mount weld on application is used when adequate dock steel is securely anchored in the concrete at the dock edge but the existing dock height is too low and the dock leveler must be installed above this height to correct this situation Installation Steps 1 Remove all existing bumper material and protruding objects from dock edge Clean and sweep dock edge free of debris and flammable chemicals before installing unit At chosen location for Edge of Dock leveler locate the center of space and mark a point half of the base plate width to the left and right 3 At the points marked to each side of center measure and mark points 7 3 4 below dock level less height the unit is to be raised to locate bottom of base plate This will locate the top of the base plate X above dock level Using a proper lifting device raise and position the le
30. rop encountered when sudden removal of support while in the working range of the equipment It is recommended that when the transportation vehicle is positioned correctly in the dock opening and in contact with both bumpers there shall be a minimum of 4 00 inches 100mm overlap of the leveling device and the transportation vehicle at all times during the loading and unloading process The Owner User must review all name plates placards decals instructions and posted warnings and place the same in view of the operator or maintenance personnel for 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 damage should be retained In the event of damage notification to the manufacturer is required Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main support while under load such as what might occur when a transport vehicle pulls out from under the leveling device shall be removed from service inspected by a manufacturer s authorized representative and repaired or replaced as needed before being placed back in service Any modifications or alterations of loading dock equipment shall only be done with prior written approval from the manufacturer and the same shall be at least as
31. s in bump block flanges 14 INSTALLATION of lever with the unit raised and secured in the maintenance position loosen jam nut on the underside of the linkage pin To start allow about Securely block or support ramp and lip when in 3 4 to 1 of threads between top of jam nut vertical positions Lack of proper bracing can result and linkage pin Using an open faced wrench in ramp dropping during adjustment or installation hold locknut on inside of spring while tightening causing personal injury or damage to unit threaded bolt until washer on top side of spring closes up tight to ram nut Test operation of unit Further adjust spring tension if needed NOTE DESCRIPTION by advancing jam nut toward linkage pin and Top of base plate and bumper tightening threaded rod After desired operation is achieved tighten jam nut to outer washer on 1 cover plate to be flush with top of spring Springs must be adjusted alternately to have equal spring tension ramp plate Apply continuous bevel weld 2 across both bumpers and length of 18 Before install is complete installer must make base plate a final operation check of dock leveler to verify all phases of install are correct Installer must complete sign and return the Installation Checklist up on completion Reference page 22
32. s weld across top of each bumper and base plate to dock steel Skip welding is acceptable to prevent warpage but complete weld across the top must be completed B Weld vertically along each end of base plate and on both inboard and outboard flanges of bump blocks C Fully plug weld all holes in base plate 10 1 1 Manual No 4111 0026 July 2011 May 2012 E jun o ebewep Jo Anfu Ieuosi d Bursneo Jo uj amp uej pue ssedung ipa scans z uonejre1su jueusnipe Buunp Burddoup due u piem janaq snonunuoo Addy ueo BuroeJq Jedoud jo 4987 suonisod jeonjen jeuueuo p pp quu pue 10044 ypop ul dij pue dwe poddns Jo yoojq Ajeinoas Jo doy um usni eg ol oe ae 1 duinq pue leld aseq Jo doy NOLLAINOS30 LON Wy 1 D ZL YO 99 YON s YO vol E SEN g is So ap o 5 o own d Ae o a E M x o a I I I I LOI I I I I i SMONNILNOO B INSTALLATION and should be the entire length of ramp plate Break tack welds holding ramp in place slide ramp plate back into position with the top of the ramp plate flush with the top of the base plate Tack weld each end and center of ramp plate to base pla
33. safe as the original equipment was prior to the modification and shall also satisfy all safety requirements of the manufacturer for the particular application of the leveling device When industrial moving devices are being used in the loading or unloading of product from the transportation vehicle this vehicle shall have the brakes and wheel chocks applied appropriately or all other positive restraining device shall be fully utilized It is recommended that trailers with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize trailer bed drop Loading dock safety equipment should never be used outside of its intended use vertical working range or capacity Please consult the manufacturer if you have any questions as to the use vertical working range or capacity of the equipment Only properly trained and authorized personnel should operate the equipment When selecting loading dock safety equipment it is important to consider not only present requirements but also future plans and any possible adverse conditions environmental factors or usage Manual No 4111 0026 July 2011 May 2012 10 NOTES This page intentionally left blank Manual No 4111 0026 7 July 2011 May 2012 INTRODUCTION General Information MEDLF Series Edge of Dock levelers are available in the following sizes weight capacities and options Dimensions and Capacities Model
34. te Drill 5 8 dia by 5 deep holes through ramp plate at back edge Install anchor bolts per manufacturers specifications and tighten securely Weld anchor bolt nuts to ramp plate using a 1 4 fillet weld all the way around the nut Cut off any portion of the anchor bolt exposed through the nut and plug weld around the top of the nut to the anchor bolt Ensure the top of the nuts are well rounded for smooth rollover Complete welding of tacked parts as follows A Apply continuous weld across top of each bumper and base plate to ramp plate Skip welding is acceptable to prevent warpage but complete weld must be completed B Weld vertically along each end of base plate and on both inboard and outboard flanges of bump blocks C Fully plug weld all holes in base plate Installer must remove all welding slag and repaint welded areas Installer must adjust main springs on all mechanical Edge of Dock levelers to provide desired tension for smooth operation Stand on ground in front of leveler with the unit raised and secured in the maintenance position loosen jam nut on the underside of the linkage pin To start allow about 3 4 to 1 of threads between top of jam nut and linkage pin Using an open faced wrench hold locknut on inside of spring while tightening threaded bolt until washer on top side of spring closes up tight to jam nut Test operation of unit Further adjust spring tension if needed by advancing jam nut t
35. there is no dock steel securely anchored into the concrete and the dock height is too low and leveler must be installed above this height to correct this situation Installation Steps 1 Remove all existing bumper material and protruding objects from dock edge Clean and sweep dock edge free of debris and flammable chemicals before installing unit 2 Review and follow formed angle installation instructions prior to leveler installation Page 18 3 Atchosen location for Edge of Dock leveler locate the center of space and mark a point half of the base plate width to the left and right 4 Atthe points marked to each side of center measure and mark points 7 3 4 below dock level less height the unit is to be raised to locate bottom of base plate This will locate the top of the base plate X above dock level 5 Using a proper lifting device raise and position the leveler base plate to marked position While holding base plate tight against dock face tack weld securely to dock steel on left hand end of leveler Check right hand end of base plate ensure that end is against dock steel and that the bottom of the base plate is even with the marks made previously Tack right hand end to dock steel Support unit until final welding is ready to complete 6 Position bump blocks out approximately 5 8 out from the edge of the inside flange of the bump block to the end of the base plate Position the top of the tread cover plate on the b
36. ump blocks to be flush with the top of the base plate Tack weld bump blocks to dock Steel T Place steel ramp plate in position flush with top backside of base plate Mark along full length of back edge of ramp plate Slide ramp plate forward over dock leveler the width of bushing tool approximately 2 8 Place bushing tool on marked line at each end of ramp to ensure proper alignment at both ends and tack weld ramp plate to dock leveler to hold ramp plate in place while bushing A Skil Roto Hammer 736 or similar tool is recommended 16 7 Manual No 4111 0026 July 2011 May 2012 envi jun o abeuwep Anfu jeuosied Buisneo suononisuiuonejeisur fue 40 INC YOU p uuoj eos lBue peuuoj jesu oj An NI uonejeisur jueunsn pe Buunp Burddoup dwe ul woo Z X E ueo BuroeJq Jedoud jo 4987 suonisod Enn dures o oa jo SLL Aone 10 dues zl ui ueym dij pue dwe poddns yoolq Ajen2es peau ulBuel erejd dues 9060 oJ ae seq Jo Bue pue suedwing yjoq seng Z piem eg snonunuoo Ajddy ad dues Jo doi ym usny aq ol leld aaoo Jaduing pue ajejd eseq jo do NOLLdi iosF3a FLON e awe A ENDNMLIMO 3 INSTALLATION Manual No 4111 0026 July 2011 May 2012 INSTALLATION E O D Installation Instructions Formed Angle A formed angle is used when there is no existing dock steel and concr
37. veler base plate to marked position While holding base plate tight against dock face tack weld securely to dock steel on left hand end of leveler Check right hand end of base plate ensure that end is against dock steel and that the bottom of the base plate is even with the marks made previously Tack right hand end to dock steel Support unit until final welding is ready to complete Position bump blocks out approximately 5 8 out from the edge of the inside flange of the bump block to the end of the base plate Position the top of the tread cover plate on the bump blocks to be flush with the top of the base plate Tack weld bump blocks to dock Steel Place steel ramp plate in position flush with top backside of base plate Mark along full length of back edge of ramp plate Slide ramp plate forward over dock leveler the width of bushing tool approximately 2 Place bushing tool on marked line at each end of ramp to ensure proper alignment at both ends and tack weld ramp plate to dock leveler to hold ramp plate in place while bushing A Skil Roto Hammer 736 or similar tool is recommended Using the back edge of the ramp plate as a guide groove concrete approximately 3 4 deep by 2 wide 12 13 Manual No 4111 0026 July 2011 May 2012 ITI due ol esu jo Z L L Dee 10 dues zi peau ulBu l stet duet 9064 o ajejd aseq 40 uj amp ue pue sieduinq ujoq sso oe Dem jan
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