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MA Owner`s/User Manual

1. 16 Put New Leveler Into Service 17 Operation Operating uie ier eoe u esiste de deb et eae 18 Ramp Loading Unloading Instructions 19 End Loading Unloading Instructions 20 Maintenance Service Dock Leveler Safely 21 Maintenance xoci u ee ee ee ee 22 Adjustments Adjust Lip Latch and Lip Actuator Springs 24 uu uc 26 Snubber Spring Assembly 27 Troubleshooting RM 28 Parts 516 ere eR RS 30 C BOX a E NN Sener 31 a Za u doi les niti Em Sentus 32 Airbag and Support Pallel eto ee eee 35 Frame and aiino DP T 36 Below DOCK 38 Weather Seal 39 Motor and Blower Assembly 40 Below Dock Control 37 Miscellaneous Customer Information 55 coca aded oa cabo ee eset ee 41 erc Back Cover SA
2. 91 01 79 50 6 0 FI SENOS ST NIVAS JAN 380535 Ol QVIYHL 01 QO3l lddV 3114001 3018 3AVH OL SANO AANO TW Z 440 LNO YO NMOHS SV NO 1437 38 NVO 9 JHL NIVHD ONIYdS 108 3507083 OL Za ANO AINO HOVLIV SANN LL INNOD 1 ONINdS 33880NS 3Hl 30 M3lN3O JHL H NOYHL NIVHO ONINIVW3Y JHL 31004 19S SI 39NYS 3943 3ONO S 13033 SV SANIT 40 145384 IHL IYON OL ba ANM YANO IN3AUSRIPOV 3Hi ONINOIISOd38 8 HIONT TWYSAO 3HL 3SV3HONI Zt NVHL SSJI SI 39NYM 3943 900 3A08V 31 531 N3HM 03033N SV SWNT NIVHO 30 N38WAN 135349 JHL SSII OL 1 MANO IN3WISnr GV JNINOLISOd3S AB HLONST TWYSAO JHL 390038 1 3349349 SI 39NYM 30148435 900 JAQAY j ONUSIL N3HM 1 YANO ONY v2 Q IN3ACT34 INVA 6598 438 8270 90 410 ATEN3SSY ISISSV d 1910 9166 334 1X3 ND 170 10210210 NIGENNS ONiBdS 9000 1960 1 NOlldlH2S30 1 4 ALD JViJilvW 30 GSSZ HLOG WI 2 Snubber Spring assembly WLI A18W3SSV 1SISSY dN JHL WOM4 318VL Ni SANIT 30 Y3SWNN JHL OL 135384 SI HION31 TIVHGAO JHL Z ATGWISSY 9 445 NIVHO 5 30 HIONJI 3HL G3NIN33130 SHL 40 JONVY 3933 3200 JAQAY FHL L SALON SANO y O
3. B Platform hinge area inject grease into all the platform hinge grease fittings 23 ADJUSTMENTS Adjusting the Latch and Lip Actuator Spring Tension When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop and lip maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop PE B Lip Assist Spring A Lip Latch Spring Adjustment Unless the dock leveler is equipped with a tethered Adjustment remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 4111 0021 May 2015 Oct 2
4. 149530 JION Ca ANN OL 1 AINO NOHA SANIT NIVHO 01 ale ANIT 0 j 145484 804 J18V1 335 SANIT SANIT VE HLONST WIOL ee ale NI OL A JEN3SSV CLJ 151559 SANIT 13S323d WeDUJIvid Ne cd EVE 2 4111 0021 May 2015 Oct 2015 TROUBLESHOOTING When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage th
5. _ INSTRUCTIONS eme Indicates a type of safety sign or separate panel a safety sign where safety related instructions or procedures as described 4111 0021 May 2015 Oct 2015 SAFETY Operational Safety Precautions Learn the safe way to operate this equipment Read and understand the manufacturer s instructions If you have any questions ask your supervisor DANGER Te ee 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 driver has been given permission to drive away IN Tee Do not use a broken or damage dock leveling Do not move or use the dock leveling device if device Make sure proper service and maintenance anyone is under or in front of it procedures have been performed before using Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Make sure lip overlaps onto transport vehicle bed at least 4 in 102 mm Keep a safe distance from both side edges 4111 0021 May 2015 2 Oct 2015 SAFETY e Do not use dock leveling device if transport vehicle is too high or too low Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device 4111 0021 May 2015 3 Oct 2
6. COIRE Series Dock Leveler A Division of Systems Inc Owner s User s Manual MCGUIRE Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 624 8473 fax 262 255 5917 www wbmcguire com techservices docksystemsinc com Printed in U S A Manual No 4111 0021 Copyright 2015 May 2015 Oct 2015 Table of Contents Page Safety Recognize Safety Information 1 General Operational Safety Precautions 1 Operational Safety Precautions 2 Maintenance Safety Precautions 4 SeN DECAS sar tir ea 5 Owner s User s Responsibilities 6 Introduction General Informalloh ua a una e a eles a Perd t toda 7 Dock Leveler Stock Specifications 7 Component Identification 8 5 sane 8 Installation Prepare Pile tices dcm 9 Prepare Dock Leveler 10 install DOCK EGVelel xo sua bu a Q sue eade 11 Install Control Panel and Wiring
7. PPE Personal Protection Equipment Required De energize equipment before Working on or inside Do not open cover without appropriate PPE Refer to NFPA 7OE for PPE requirements Inis panel may contain more Than one power soumze Hazardous Voltage Will Cause Sever Injury or Death 16 A Disconnect Panel provided by others B Control Panel D Placard C Distance 48 in 14 630 mm 1 Mount the push button control panel B so bottom of control panel to dock floor distance C is 48 in 1219 2 mm Install electrical disconnect panel A if not already installed Install and connect the control wiring Re install the air bag air bag support pallet and blower motor Connect the dock leveler power cable to the outlet in the pit junction box Refer to the electrical drawings supplied with the dock leveler After all electrical connections in the pit have been made raise the leveler disengage the maintenance prop and allow the platform to lower Install the Placard s D in close proximity to the control box and in plain sight 4111 0021 May 2015 Oct 2015 Put New Dock Leveler Into Service 1 Disconnect the external lifting device and chains from the lifting brackets Check that the leveler 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 li
8. Place barriers on the driveway and dock floor to indicate service work is being performed leveler is securely supported by maintenance prop Ifelectrically powered turn off and use OSHAlockout tagout procedures Cal 262 285 1510 for replacement placards warning labels or owner user s manuals decal placed in same position on both sides 1751 0329 x2 decal placed in same position on both sides 1751 0330 x2 decal placed in same position on both sides 1751 0729 CRUSH HAZARD AADANGER 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 1751 0729 Rev A procedures 1751 0731 1751 0726 DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch 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 4 DANGER CRUSH HAZARD 1751 0731 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 1761 0726 Rev A OWNER S USER S RESPONSIBILITIES 10 T
9. 2015 Oct 2015 39 PARTS Motor and Blower Assembly Quantity Part Number 1 1 9395 0359 9391 0021 9391 0022 9391 0041 9392 0047 9392 0068 9391 0023 EE 2 2101 0143 2101 0007 2101 0005 Description PPAC Blower Assy Filter Element Included With 9395 0359 Tube 2 50 8mm OD 36 914 4mm Length 6 and 8 Levelers Tube 2 50 8mm OD 46 914 4mm Length 10 levelers Pipe PVC 1 1 2 SCH40 X 24 38 1 X 609 6mm Pipe PVC 1 1 2 SCH40 X 24 38 1 X 609 6mm With 90Deg Elbow Clamp Tube Nut Hex Nylon Locking 1 4 2 Screw Cap Hex 1 4 2 X 1 LG Washer Flat 1 4 4111 0021 May 2015 Oct 2015 Customer Information MISCELLANEOUS 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 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
10. NUT DOTH 2214 55000 0 O 1 sPRINGCOMPRESSION _ _ 00000 Las usis Em FOOT 2222 6 5 DPLA 2102 7 0 FOOT DPLA 2103 DOTH 2355 PIN CLEVIS aif DOTH 2373 PIN COTTER 2 lao 0079 WASHER FLAT eoroo ak sk 5 esror 212 4 zoror 4111 0021 May 2015 38 Oct 2015 PARTS Weather Seal Kits Item Quantity Part Number Description A 1 DKIT 9293 Brush Kit Includes Seal and Track 1 1 2 in 82 Lg Both Sides B 1 DKIT 9292 Rubber Kit Includes Seal and Track 1 1 2 in 82 Lg Both Sides Individual Replacement Seals Item Quantity Part Number Description C 1 DOTH 2822 Brush Refill 1 1 2 in 82 Lg C 1 DOTH 2820 Extrusion Aluminum D 1 DOTH 2824 Rubber Refill 1 1 2 in 82 Lg E 1 DOTH 2818 Replacement C Channel 6 FOOT DKIT 9179 2 2 0011 0043 TOE GUARD LH RH Lower o014 0045 TOE GUARD LH RH Lower 0014 0047 GUARD LH RH Lower _ 1 oo 40141 TOE GUARD middie _ 0014 0144 TOE GUARD RH Middle 0014 0147 GUARD RH Middie 1 0014 0142 GUARD LH Middle 6014 0145 TOE GUARD LH Middle 0014 0148 TOE GUARD LH Middie screwcap cae bae _ DOTH 2043 SCREW CAP e a porezy z 2lomeslkockwu y o 4111 0021 May
11. String G Rear Hinge Frame Angle H Distance Dock Floor to Pit Floor J Distance Top of Shim Stack to Dock Floor K Shim Stack L Dock Leveler Frame M Pyramid Preferred N Stepped Acceptable P Offset Not Acceptable Q Straight Not Acceptable R Lip Keeper Shim between lip keeper and curb angle as required INSTALLATION Shim Stacking Methods E 11 INSTALLATION NOTE McGuire dock levelers are designed with a nominal 1 2 in 12 7 mm shimming distance to allow for pit inconsistencies NOTE Poweramp 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 NOTICE 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 stability and weld penetration purposes DO NOT use multiple layers of 1 8 in 3 18 mm or thinner shim stock dimensions obtained at each location c Subtract distance A from distance J to obtain the shim height Repeat
12. dis proper equipment should install this product tance D at both sides Take measurements at dock floor level and at pit floor level NOTICE DO NOT remove the shipping bands around the before proceeding 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 4 Make sure the field junction box for the dock leveler E is at the correct location per pit diagrams 4111 0021 May 2015 Oct 2015 INSTALLATION Prepare Dock Leveler 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 10 NOTICE DO NOT remove the shipping bands B around the platform lip and leveler frame at this time The shipping bands are needed to hold the leveler together during the installation process NOTICE DO NOT over tighten the lifting bracket hardware Over tightening can damage the weather seal if equipped 1 Remove any control panel and bumpers th
13. 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 safe as the original equipment was prior to the modification and shall also satisfy all safety requi
14. 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 262 255 5917 E mail techservices docksystemsinc com 4111 0021 May 2015 Oct 2015 Air Bag serial number on left hand corner next to blower motor Serial No Systems Inc Job No Original Owner Information Date of Installation 41 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 determ
15. lockout device C and tagout device B Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout tagout device C and tagout device B Only the person servicing the equipment should have the capability to remove the lockout tagout 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 21 MAINTENANCE Periodic Maintenance A p TaT TA 1 1 ti her a sss P E n Se ll ms oL ee W x 4 i pS zl L m 2 LN prd Q ir o A Lip Hinge Area C Lip Link Pivots E Lip Assist Pins G Safety Leg Linkage B Lip Prop Pivot F Lip Linkage Pivot Pivots H Maintenance Prop Pivot Under platform service Air Filter service under rear of platform 4111 0021 May 2015 22 Oct 2015 Regular maintenance must be performed on a weekly and quarterly schedule FOLLOW ALL SAFETY PRECAUTIONS Weekly Maintenance Operate the dock leveler through the complete operating cycle to maintain lubrication NOTE To thoroughly inspect the platform hinge area put the platform in the full below dock position Inspect the platform hinge an
16. on cc inside Do nef meos wiih oaopropiigt PFE ka UE fo PFE requirements fis ponel ray more mon power SOURS Hazardous Voltage Wil Couse Sever Injury or Death 4 1 2 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 and 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 unde
17. or death Check that lip E is fully resting on the lip keepers D and at the lowest part of the keeper cradle If lip is not resting properly in keepers perform the following adjustment 1 Fully raise platform Engage lip and maintenance prop 2 Loosen jam nut B 3 Adjust stop bolt C as necessary Turn stop bolt in clockwise to allow lip to fold closer to platform frame A Turn stop bolt out counterclockwise to hold lip further away from platform frame A 26 A Platform Frame D Lip Keeper B Jam Nut E Lip C Stop Bolt Tighten jam nut B Fully raise platform and disengage lip and maintenance prop Allow platform to lower to cross traffic stored position Check lip position in both keepers Repeat procedure if necessary 4111 0021 May 2015 Oct 2015 ADJUSTMENTS OOLO ELGE 230 E LF WNOLLOYMA 539Nv43101 ONIMOTIOS ON JHL HUM 3 NI JUV SNOISN3MI TW 3385 1530 95 50 31 0 E 9 30 WC O S 33S AIBA3SSV NV ONISdS S3880NS LSISSV IM NMOINVINH39 SW3ISAS 30 NOISIAIQ CL JN V HM Od dV NO ONIINNON 5 16 50 810 F y 5310 0300 60 07 901 W18 8 SANN OL 3lL 3901 IMG 300v 90 62 90 900 901 2 HOANI ONIMdS JHL 30 1 32 FHL 2NIRON KN 7 WW
18. the platform when the dock is resting on the safety legs in the below dock position If the lip does not fully extend additional spring tension may be needed NOTE Use two turn increments when adjusting lip assist spring Check lip operation after each adjustment Repeat until proper operation is obtained Adjust spring tension as follows Loosen jam nut B 1 To increase spring tension turn nut B clockwise 2 To decrease spring tension turn nut B counterclockwise 3 Tighten jam nut Hecheck operation of platform and lip Readjust lift spring tension and lip assist spring tension until proper operation is obtained 25 ADJUSTMENTS Adjust Lip Stop Bolt Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death The platform maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Failure to follow these instructions may result in serious personal injury
19. 006 Prop Pin and Clip 1 9224 0030 Maint Prop 6 foot 10 1 9224 0031 Maint Prop 8 foot 1 9244 0079 Maint Prop 10 foot 11 1 2101 0216 Link Quick 1 8 1 CONSULT FACTORY 4111 0021 May 2015 36 Oct 2015 PARTS Frame and Platform PLATFORMS ITEM FO 6 FOOT m 8 FOOT 10 FOOT 6 0 FOOT 6 5 FOOT 7 0 FOOT FOOT 6 5 FOOT 7 0 FOOT 6 0 FOOT 6 5 FOOT 7 0 FOOT PET a 9515 5304 19515 5308 m 9515 5316 __ 9515 5320 s 5324 9515 5328 9515 5332 consult factory AR As Required 1 Provide dock leveler serial number platform size and lip size when calling or faxing orders 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 4111 0021 May 2015 Oct 2015 37 PARTS a piace lUPBANGERASSY o a 2 La 1 G moaaIIs e 2 pomo z a omes lomen _ _ NULLOGK 0000 2 DOTH 2163 NUT LOCK DPLA 0360 BELOW DOCK CONTROL ASSY DOTH 2382 PIN COTTER DOTH 2074 BOLT HEX 5 8 11 X 2 00 DOTH 2160 NUT HEX 5 8 11 17 DPLA 0360 BDC PUSH ROD ASSY DOTH 2060 BOLT SHOULDER DOTH 2131 LOCK NUT 3 8 16 DLIP 0305 LIP ASSIST ROD ASSY MA DOTH 2550 SPRING LIP ASSIST STD 25K 55K 6 6 5 WD 16 DOTH 2546 SPRING ASSIST HEAVY 7 WD 18 20 25K 77 18 20 30K 55K DOTP 2006 LIP PROP BAR DOTH 2062 SHOULDER BOLT 27 DOTH 2131 LOCK
20. 015 24 Adjusting Lip Latch Spring Tension This adjustment is set at the factory and should not require additional adjustment Unlike mechanical levelers the lip will not immediately begin to fold as the platform returns to the stored position After the platform is fully raised and the lip extends the lip latch is designed to hold the lip in the extended position until the platform drifts down to the below dock position If the lip does not remain extended as the platform lowers additional spring tension may be required NOTE Use half turn increments when adjusting lip assist spring Check lip operation after each adjustment Repeat until proper operation is obtained Adjust spring tension as follows 1 Loosen jam nut A 2 To increase spring tension turn nut A clockwise 3 To decrease spring tension turn nut A counterclockwise 4 Tighten jam nut Hecheck operation of platform and lip Readjust lip latch spring tension and lip assist spring tension until proper operation is obtained 4111 0021 May 2015 Oct 2015 ADJUSTMENTS Adjusting Lip Assist Spring Tension This adjustment is set at the factory and should not require additional adjustment Unlike mechanical levelers the lip will not immediately begin to fold as the platform returns to the stored position The MA leveler lip remains extended as the platform drifts down to the below dock position The lip will automatically fold when
21. 015 SAFETY Maintenance Safety Precautions DANGER Hydraulic and electrical power must be OFF when servicing the equipment For maximum protection use an OSHA approved locking device to lock out all power sources Only the person servicing the equipment should have the key to unlock the device Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete k fog ka R L A maintenance prop permanently attached anq 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 uncontaine
22. 4 LABEL OVERCURRENT DEMCE PER THE NEC 1751 0474 DECAL ENGLISH LOCATE A DISCONNECT SWITCH DECAL FRENCH NEXT TO THE ENCLOSED STARTER BE RAR E REH TOTAL 1 PHASE FLA 11 8 A MICE ne S 1751 0477 DECAL ENGLISH b CIRCUIT PROTECTION P 1751 0478 DECAL FRENCH b TABLE 3 SEE TABLES 1 2 AND 3 1751 0479 DECAL SPANISH b a COMPLETE LABEL AS SHOWN BELOW AFFIX TO MOTOR LOCATED AT DOCK LEVELER L2 N GRD LEFT INSIDE OF ENCLOSURE VOLTAGE FMA TERMINALS O PLASTIC ENCLOSURE FOR METALLIC ENCLOSURE USE GROUNDING PROVISION IN ENCLOSURE BODY AND STUD ON ENCLOSURE COVER 115 V 11 8 A Fu T1714 BOX W DUPLEX AT REAR n 2 OF PIT WALL BY OTHERS AL WRES UNLESS INDICATED OTHERMSE BY OTHERS XA di Poweramp DWG 9 0 800 115 Volts 1 Phase 60Hz 11 8 FLA ay DOE dub Te b AFFIX TO RIGHT OUTSIDE OF ENCLOSURE COVER INSTALLED BY OTHERS LL WRE CONNECTIONS BY OTHERS LL CONDUIT UNLESS INDICATED OTHERWISE BY OTHERS y WU POWERAMP MCGUIRE DLM S Y S S I C quipment FLEX CORD W PLUC ELECTRICAL ENCLOSED STARTER BY POWERAMP A FP DOCK LEVELER 115 VOLTS 1 PHASE 60 HERTZ INSTALLED BY OTHERS PHASE joraw 9 R0 000 A A Oct 2015 4111 0021 May 2015 30 Controls A DANGER A4 Arc Flash and Shock Hazard PPE Personal Protection Equipment Required Le n rgee equpmern Deine wording
23. FETY Recognize Safety Information General Operational Safety Precautions Safety Alert Symbol The Safety Alert Symbol identifies import safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury of death Read and understand the Owner s User s manual and Follow the instructions in the safety message become thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or DAN G guard is removed or disconnected 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 Never remove DANGER WARNING or CAUTION signs or Decal s on the equipment unless replacing 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 Do not start the equipment until all unauthorized personnel in the area have been warned and have The use of the word NOTICE is to draw attention moved outside the operating zone to a procedure that needs to be followed to prevent machine damage 9 Hemove any tools or foreign objects from the operating zone before starting
24. Its revolutionary air bag system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended The MA dock leveler comes equipped with an electrical control panel which allows push button operation of the dock leveler functions Each MA dock leveler unit and control panel has been factory prewired and tested to ensure satisfactory operation To illustrate which connections are to be made in the field at installation electrical drawings are included with each order or by contacting Technical Services Once again thank you and congratulations on your purchase of the dock leveler 4111 0021 May 2015 Oct 2015 GENERAL INFORMATION Dock Leveler Stock Specifications MA Series dock levelers are available in the following sizes weight capacities and options Width MA 6 ft 1828 8 mm 6 1 2 ft 1981 2 mm 7 ft 2133 6 mm Length 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 55 000 Ib 22 680 kg CIR Comparative Industry Rating All docks are available in 115V motors only INTRODUCTION Component Identification A Lip B Lip Assist Rod C Lip Linkage Assembly G Lip Actuator Chain D Lip Latch Assembly THEORY The MA dock leveler uses a blower motor
25. PARTS This page intentionally left blank 4111 0021 May 2015 33 Oct 2015 PARTS This page intentionally left blank 4111 0021 May 2015 34 Oct 2015 Airbag and Support Pallet PARTS Item Quantity Part Number Description 1 3 5812 0045 Hold Down Rod 45 long x 7 16 diameter 2 1 5811 0009 Air Bag Bladder 3 1 5811 0012 Skid Air Bag Leveler 4 2 5813 0001 Skid BRKT Air Bag Leveler BM 5 4 2101 0098 Screw HHCS 5 16 18UNC x 1 1 2 long 6 4 2101 0214 Nut Flange Top L N 5 16 18UNC T 4 2101 0058 Washer Lock 5 16 8 6 2101 0224 Rod Clamps 9 4 2101 0079 Washer Flat 1 2 inch 10 2 2101 0230 Ring Split 1 75 O D 3 10 1 5814 0029 Skid Air Bag Leveler Assembly Includes Items 3 10 4111 0021 May 2015 Oct 2015 35 PARTS Frame and Platform Lip latch Release Arm Up Grade Maybe required on some levelers manufactured emnes before 4 2014 l required if below dock is Item Quantity Part Number Description 1 1 8435 1 Frame Welded Assembly 2 1 7952 0001 Cable A C Assembly 14 00 Final length 3 1 0941 0013 Spring Lip Latch Ext 4 2 2101 0217 Link Quick 1 4 8432 1129 Keeper Lip 16 inch 20 pit 5 2 8432 1130 Keeper Lip 18 inch 20 pit 8432 1131 Keeper Lip 20 inch 20 pit 6 1 DOTH 2555 opring Snubber 7 1 DOTH 6439 Spring Snubber and Chain Kit 8 1 DOTH 2421 Cold Shut 9 1 9201 0
26. ailure to comply will result in death or serious injury Refer to owner s user s manual for properuse 1751 0727 Rev SAFETY INFORMATION OPERATION Read and follow all instructions and warnings in owner s user s manual Unsupported dock leveler Use of dock leveler restricted to trained operators koro 3 Always chock trailer wheels or engage truck restraint before 1 operating dock leveler or beginning to Before allowing vehicle to leave toad or unload oe 5 Never use hands or equipment to the dock always q e 2 move ramp or li 5 Before activating dock leveler e Ensure no equipment material or people are on dock leveler bumpers Remove any end loads if required Check trailer alignment to avoid lip interference If lip does not lower to trailer bed reposition vehicle Return dock leveler to its Ensure truck bed supports extended stored position at dock level lip or leveler frame supports the ramp before driving on ramp 7 Stay clear of hinges and front and 7 Read and follow all instructions 2 Maintenance Service of dock leveler Ensure trailer is backed in against 8 DO NOT ENTER PIT unless dock sides of moving dock leveler e e damaged or malfunctioning dock leveler Report problems immediately to supervisor MAINTENANCEISERVICE warnings and maintenance schedules in the owner sluser s manual restricted to trained personnel
27. ally leveler rests on the safety legs below dock position Leveler went to the below dock position with operator holding the safety leg retract cable not shown safety legs are retracted lip folds automatically causing dock to rest in the full below dock position 4111 0021 May 2015 Oct 2015 INTRODUCTION Prepare Pit A Distance Pit Width B Distance Dock Floor to Pit C Distance Pit Length D Distance Pit Corner to Corner Front and Rear Floor All Four Corners Both Sides of Pit Top Bottom and Both Sides 1 Before lowering the dock leveler into the pit the following must be performed 2 Remove all debris from the pit and sweep the pit Post safety warnings and barricade the work area at clean dock level and ground level to prevent unauthorized use of the dock leveler before installation has been 3 Check the entire dock leveler pit for proper completed construction according to approved certified pit drawings Make sure pit is square by making the Failure to follow the installation instructions can following measurements result in damage to dock leveler the facilities and or serious personal injury or death Measure pit width distance A at both front and rear of pit e Measure dock floor to pit floor distance B at all four corners e Measure pit length distance C at sides Only trained installation professionals with the Measure corner to corner criss cross
28. and one button operation for ease of use The dock leveler can be operated remotely using the RAISE button O on the control panel This activates an electric blower motor M The blower forces air into the air bag J causing the platform to rise Releasing the RAISE button allows the platform to lower When the platform rises to the point where there is 2 3 in 51 76 mm from its full raised height the lip spring F and lip actuator chain G causes the lip linkage assembly to push the lip out and up The lip assist spring not shown also helps keep the lip extended When the lip is fully extended the lip latch cable engages the lip latch assembly locking the lip in the extended position The dock leveler has reached its full height when the lip is fully extended E Lip Maintenance Prop Pivot F Lip Actuator Snubber Spring Air bag support pallet L Maintenance Prop Lip Keepers 2 used M Blower Motor J Air bag N Toe Guard 2 used K Main Frame O Raise Button P Safety Legs To lower the platform release the Raise button O The platform will lower until the extended lip rests on the transport vehicles If the lip did not fully extend or there is no transport vehicle at the dock the platform will lower until one of the following conditions occur Lip is resting on lip keepers cross traffic position Leveler went to the below dock position lip folds automatic
29. ansport vehicle along the entire width of the platform with at least 4 in 102 mm of lip contacting the transport bed Tere 5 Proceed with loading or unloading the transport vehicle 6 If below dock loading is necessary see steps 7 11 If not proceed to step 12 Unloading Instructions on page 20 4111 0021 May 2015 Oct 2015 OPERATION Below Dock Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 20 7 Check to make sure transport vehicle is positioned squarely against dock bumpers 8 Instruct driver to remain at the dock until the loading or unloading process has been completed 9 Chock the transport vehicle wheels or use vehicle restraint if present 10 Raise the platform by depressing the raise button A to fully raise the leveler and extend the lip 11 Walk out on the leveler Pull and Hold the release ring see picture below until the platform lowers onto the transport vehicle Make sure there is a minimum of 4 of lip overlapping the transport vehicle bed A RAISE Button 12 When loading or unloading is finished raise the platform by depressing and holding RAISE button 13 Hold the RAISE button 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 traffic position 14 Remove chocks from transport vehi
30. at 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 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 toa lifting device i e hoist or fork transport having the appropriate lifting capacity and reach 4 Remove wood blocks that are attached to the leveler frame before putting the dock leveler into the pit 5 Attach a temporary switched power supply to the blower before lowing leveler into pit Keep power cables clear of frame members shim locations and pinch points DO NOT CONNECT POWER AT THIS TIME 6 Remove 3 plastic ties that hold the bag and bag support skid to the underside of the leveler during shipping before lowering leveler into pit 4111 0021 May 2015 Oct 2015 Install Dock Leveler A Distance Leveler Frame Height B Shim Locations Under Rear Vertical Supports 4 5 Places TYP C Shim Locations Under Lip Keepers C Shim Under Snubber Spring Mount D Dock Floor E Rear Pit Curb Angle 4111 0021 May 2015 Oct 2015 F
31. been completed paint all the welds and shims NOTICE DO NOT weld before disconnecting all electrical components DO NOT weld before removing air bag air bag support pallet and hoses from leveler Protect or remove the blower motor before welding Failure to follow these instructions may result damage to these components from stray sparks and weld splatter figure 2 4111 0021 May 2015 14 Oct 2015 INSTALLATION NOTICE DO NOT weld continuously along the full length of the rear hinge frame angle This can put unnecessary DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded stress on the leveler components causing the leveler to malfunction and shorten the life span of the affected components 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 NOTE The illustration on page 15 shows a typical weld pattern The weld pattern will vary slightly depending on size of dock leveler 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 NOTICE DO NOT connect the dock leveler electrical wiring Make sure the platform is properly supported in the a
32. cle wheels or release the vehicle restraint if used 15 Indicate to driver that transport vehicle may leave the dock 19 OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE If ramp loading is required see Ramp Loading Unloading Instructions on page 19 End loading or unloading can be done with the dock at the cross traffic position or below dock position depending on the height of the 6 Depress the Raise button to the platform high transport vehicle bed enough to clear the lip keepers but not high enough to extend the lip 1 Check to make sure transport vehicle is positioned squarely against dock bumpers 7 Walk out on the leveler pull and hold the safety leg retract pull ring B located in the recess at 2 Instruct driver to remain at the dock until the the front of the platform This will cause the lip to loading or unloading process has been completed extend away from the lip keepers and the cross traffic safety legs to fold to allow the leveler to 3 Chock the transport vehicle wheels or use vehicle lower to the below dock position restraint if available 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 End Loading Unloading Platform at Cross Traffic Position NOTE When end unloading
33. clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 4111 0021 May 2015 Oct 2015 C Lock Out Device MAINTENANCE AEST 70 07 D Lip Prop 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 underthe dock leveler platform support the platform with the maintenance prop A Position the maintenance prop behind front header plate E while staying clear of the lip 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
34. d hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death ALWAYS stand clear of dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death DANGER 2 Arc Flash and Shock Hazard PPE Personal Protection Equipment Required equipment pelo Working on or inside Do oman cover withioul appreciate Redes to WE PPE mcquierrenis This panel recy Gorin mice Thon one Hazardous Voltage Will Cous Sever 4111 0021 May 2015 Oct 2015 Safety Decals Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or require replacement please call 1 800 643 5424 for replacements 4111 0021 May 2015 Oct 2015 1751 0727 decal placed on front header 1751 0730 x2 ADANGER Failure to follow posted instructions will result in death or serious injury SAFETY 4 DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar Do not force maintenance prop forward of bar to support lip F
35. d 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 bag Build up of foreign material in this area may damage air bag components causing abnormal operation e Inspect air bag and seams for signs of wear or damage NOTICE Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler DANGER 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 4111 0021 May 2015 Oct 2015 MAINTENANCE uarterly Maintenance e Weekly Maintenance e Lubricate the following areas with white lithium grease B Lip prop pivot C Lip link pivots E Lip Assist pins F Lip linkage pivots G Safety leg pivots G Safety leg linkage pivots H Maintenance Prop Pivot Inject white lithium grease in the flowing grease zerks A Lip hinge area inject grease into all the lip hinge grease fittings
36. d travel If McGuire determines replacement is necessary it will provide the original purchaser with a credit toward the purchase of the new replacement McGuire 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 ePneumatic Warranty For a period of four 4 years from the expiration of the Standard Product Warranty McGuire will provide replacement component parts from defective lifting system This warranty specifically covers material and freight only and applies to the air bladder seals hoses and motor assembly
37. e leveler functions properly and there is no binding Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop 9 Raise the platform fully Hold the platform at this 10 11 12 13 position using the RAISE button and move the maintenance prop to the service upright position Release the RAISE button to allow the platform to lower until it is resting on the maintenance prop With the maintenance prop supporting the platform remove the lifting brackets Support the toe guards remove the cotter pin used in shipping and carefully release the toe guards Depress and hold the RAISE button until the maintenance prop drops to its stored position Release the RAISE button and allow the platform to lower fully Check operation of toe guards When the platform lowers to the full below dock position the lip will fold Depress and hold the RAISE button until the platform rises just enough to clear the lip keepers then release the RAISE button to allow the platform to lower to the cross traffic stored position lip engages lip keepers Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or death may result 17 OPERATION Operating Instructions DANGER Stay clear of dock leveler when transport vehicle carrier is ent
38. e maintenance prop Failure to follow these instructions may result in serious personal injury or death Before performing the detailed troubleshooting procedures check the following items first Check all fuses and circuit breakers Replace any blown fuse s with a fuse of equal specification and reset circuit e Make sure the correct voltages are present at the proper locations inside the control panel s Symptom Possible Cause Platform does not rise Motor fuse blown Reset circuit panel or disconnect Determine Motor does not energize cause of overload Motor failure Check voltage to motor f voltage is present and motor does not energize replace motor f voltage is not present check all components in series with the motor Platform does not rise Incorrect voltage is present Check line for proper voltage Motor hums but does notion line run If proper voltage is not present check all components in series with the motor If proper voltage is present and motor does not run check for obstructions If no obstructions are found replace motor Platform does not rise Motor energizes but does not run Line voltage too low Check wiring to motor for high resistance Check for loose or corroded connections Check if gauge of wires to motor are of correct size and specification for load requirement Heplace if necessary 4111 0021 May 2015 28 Oct 2015 TROUBLESHOOTING Platform rises s
39. ering 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 12in 805mm 12in 805mm The MA pneumatic dock leveler is designed to compensate for a maximum 12 in 305 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 305 mm higher or lower than the dock floor 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 inst
40. f the leveler frame 7 Allow rear of dock leveler to rest on the rear shims while keeping the front of the dock leveler level with the dock floor 8 Forall AP models add shims at front shim locations D so front of dock leveler will stay level with dock floor when leveler is resting fully on shims 9 With rear hinge frame angle F tight against rear pit curb angle G perform check the following Pry between the platform and rear hinge frame angle at locations E to make sure rear edge of platform is parallel to 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 10 If gap D cannot be obtained equally at both sides of leveler grind or add material at the rear edge of 4111 0021 May 2015 Oct 2015 INSTALLATION I st ANS Yay Z S A A NA AAAS AAAS S S S e ARR 2 G 3 8 in 6 in 0 9 5 152 Front of Dock Pit C Side Pit Curb Angle E Pry Locations G Rear Pit Curb Angle B Dock Leveler Frame D Gap 3 4 in 19 mm F Rear Hinge Frame H Flare Bevel Weld Typical Minimum Angle To Fit Spacing rear hinge frame angle F as needed 14 Connect the blower motor to the temporary power supply 11 Allow the dock leveler to rest fully on the shim 12 stacks Check that a sm
41. for each shim location 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 or straight method 12 NOTE Toassistinobtaining an accurate measurement of distance K use a string G pulled tight across the pit opening directly over the shim locations 4 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 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 leveler height A 5 For all AP models put a 1 4 in 6 6 mm thick shim at locations D NOTE A 1 4 in 6 6 mm thick shim at locations D is used only as a starting point The final shim stack height will be determined after dock leveler is lowered into the pit 6 Using an appropriate lifting device connected to the lifting brackets lower dock leveler into the pit so rear hinge frame angle H is tight against rear pit curb angle F across full width o
42. he lip keepers simultaneously depress and hold the RAISE button and the LIP OUT button until lip has extended beyond the lip keepers Release both buttons PARTS regarding proper use maintenance and repair of dock leveler 4751 0874 Rev A NOTE If equipped depressing E STOP button will stop platform from lowering Item Quantity Part Number Description 7141 0207 Push Button Controller 1751 0725 Decal 1751 0477 Decal 1751 0736 Decal Arc Flash 1751 0874 Placard 0 4111 0021 2015 Oct 2015 31 PARTS 1 xi PIPER DLIP 0305 Lip Assist Rod Complete 34 Lg os 2550 Spring Lip Assist STD DOTH 2546 2546 Spring Lip Assist Heavy Duty 5775 0004 Lip latch Assembly 16 Long 3 2014 and older 5775 5775 0005 Lip latch Assembly 21 Long 4 2014 and newer Dp 1 DOTH 2351 Bolt Clevis DOTH 2163 Nut Locking 1 2 Washer LG l l CC Cs pH 1 DPLAOS38 LipAssist Linkage ooo 1 1 DPLAOMI Banliplnkage L1 L1 Nut Nylon Lock 3 8 DOTH 2214 N 1 DOTP205 P 1 21020002 Chain 1 4 Grade 40 43 34 links Ton Q 1 DOTH255 Spring Snubber notshown f o o R 1 09410013 Sprngliplath J 4111 0021 May 2015 e Oct 2015
43. he 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 drop encountered when sudden removal of support while in the working range of the equipment It
44. ims must be welded to each other the leveler frame and to the 19 Remove air bag and pallet support from the leveler front pit curb steel Failure to do this may result in by disconnecting air bag positioning rods from serious personal injury or death hooks on the underside of platform figure 1 and removing the band clamp from the motor coupler figure 2 leaving approximately 6 in 152 mm space between each weld 20 Remove or protect the blower motor from weld 22 All model levelers Install shims at locations B sparks and splatter 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 21 With the rear hinge frame angle F tight dock floor 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 using a 3 8 in 9 5 mm flare bevel skip weld each weld being 6 in 152 mm long 23 Weld front of dock leveler frame B to shims located under the keepers then weld the shims to the front pit curb steel Start at each end with a 6 in 152 mm long 24 Finish weld all shims using a fillet weld weld Space all the other welds out evenly Weld all shims within each shim stack to each other then weld the shim stack to the leveler frame Weld the front leveler frame shim stacks to the front pit curb steel 25 When all welding has
45. ined by SYSTEMS INC covered by this warranty SYSTEMS INC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS SUBSIDARIES 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 INTERUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY MA SERIES LEVELER In addition to the Standard Product Warranty provided with all McGuire Products guarantees materials components and workmanship to be free of defects for the following extended periods eStructural 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 McGuire sole discretion and expense including reasonable labor materials freight an
46. is finished and access to the rest of the transport vehicle is still required 9 Proceed with loading or unloading 4 f transport vehicle bed is at or above dock floor the platform lip will need to be extended level leave leveler at the cross traffic position and See Ramp Loading Unloading Instructions on proceed with loading or unloading page 19 for further instructions 10 When the loading or unloading is finished return the dock leveler platform to the cross traffic stored position RENE 11 Depress the Raise button B until the lip clears the lip keepers Release Raise button leveler will End Loading Unloading Platform Too High return to the stored or cross traffic position Use Below Dock Position 12 Remove chocks from transport vehicle wheels or 5 f transport vehicle bed is below the dock floor release the vehicle restraint if used level perform steps 6 12 13 Indicate to the driver that the transport vehicle may leave the dock End Loading Unloading Platform at Below Dock Position 4111 0021 May 2015 20 Oct 2015 Service Dock Leveler Safely T adm 74 49 A Maintenance Prop B Tag Out Device When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always stand
47. lowly Air bladder or connecting Check air bladder and ducting replace as needed ducts punctured Damaged or restricted Replace damaged ducting or remove restriction ducting Air intake clogged Hemowve intake filter clean or replace as needed Dock leveler binding Check for visible obstructions that could cause binding Remove obstructions If no obstructions found call Technical Services See inside back cover for phone number and address Platform does not rise to See Platform Rises Slowly See Platform Rises Slowly full height oee Periodic Maintenance in the Maintenance section Platform DOES rise to Lip actuator spring needs Inspect lip actuator chain repair or replace as full height but lip DOES additional tension needed NOT extend or extend fully Lip extends but does Lip latch spring needs See Adjustment Section Lip Latch Spring not remain extended as additional tension Increase tension as needed to keep latch leveler drops engaged Clean any debris from lip latch area Lubricate as instructed in maintenance section Air bladder damaged Replace air bladder 4111 0021 May 2015 Oct 2015 29 ELECTRICAL Controls BILL OF MATERIAL CUSTOMER SUPPLIED RECOMMENDED FIELD WIRE SIZE 115 V 1 PHASE 60 HZ QTY PART NUMBER DESCRIPTION e FROM BRANCH GROUT DISCONNECT SWTCH 5OFT 75 125 FT 175 FT m 10 AWG 8 AWG 6 AWG 4 ANG SELECT DISCONNECT SMTCH amp 1 1751 050
48. nd ground connections until all welding has been raised position before entering the pit to finish weld completed the shims Failure to do this may result in serious personal injury or death DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground welding equipment to the dock leveler frame NEVER to the platform Failure to follow these instructions may damage the motor wiring and or control panel Shim Stacking Methods 9 For left right orientation of dock leveler see inside back cover of this manual 4111 0021 May 2015 Oct 2015 15 INSTALLATION Install Control Panel and Wiring The electrical power must be OFF prior to electrical installation For maximum protection use an OSHA approved locking device to lock out all power sources Only the person installing the equipment should have the key to unlock the power source Failure to follow these instructions may result in serious personal injury or death DO NOT make any final electrical connections until all welding has been 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 4 DANGER Are Flash and Shock Hazard
49. ooth and level transition 15 Slowly raise the platform Check for binding as exists between the dock floor and the dock leveler platform is being raised platform Add or remove shims as necessary until a smooth transition is obtained 16 If binding occurs lower the platform Reposition leveler and or add or remove shims as necessary If leveler cannot be squared and or made level Slowly raise platform again If platform still binds as instructed in steps 8 10 contact Technical contact Technical Services for further instructions Services 13 With the leveler square in the pit and flush with the 17 All AP models Once leveler is flush square and 4111 0021 May 2015 surrounding dock remove the banding on the lip does not bind of the leveler 13 Oct 2015 INSTALLATION a Install shims under maintenance prop D page 11 where prop attaches to leveler frame Two people are required to engage the maintenance Make sure prop is solidly shimmed prop one person to operate the lifting device the other person to engage the maintenance prop b Using the levelers blower motor raise the dock to the fully open position c Raise maintenance prop to the service upright position and lock prop in this position DO NOT use the maintenance prop to support the using an OSHA approved locking device raised platform until the maintenance prop has been 18 Disconnect power supply from motor properly shimmed and welded The sh
50. p does not contact both lip Keepers evenly contact Technical Services for further instructions Install the dock bumpers as required Turn the main electrical power ON Raise the leveler platform fully by depressing and holding the RAISE button 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 If a transport vehicle is present the platform will lower until the lip rests on the transport vehicle bed See Operating Instructions in Operation section When drilling access hole in the control box DO NOT penetrate too deep components may be damaged DO NOT turn control upside down to drill any access holes To prevent damaged to electrical components from debris cover components prior to drilling Seal all conduit entrances to prevent moisture from entering the control box DO NOT use compressed air to clean control box Hecommended to vacuum debris from inside 4111 0021 May 2015 Oct 2015 INSTALLATION 7 When the platform lowers to the full below dock position the lip will fold Depress and hold the RAISE button until the platform rises just enough to clear the lip keepers then release the RAISE button to allow the platform to lower to the cross traffic stored position lip engages lip keepers Perform steps 5 7 at least four times make sure th
51. r the dock leveler FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR OTHER SERIOUS INJURY Scan to view our owner s user s POWERAMP MCGUIRE manuals online DLM www DockSystemsInc com SYSTEMS INC 1 800 643 5424 Loading Dock Equipment Call for additional placards or manuals or with questions OPERATING INSTRUCTIONS POWERED DOCK LEVELERS NORMAL OPERATION 1 Raise the platform by depressing and holding the RAISE button p 2 Hold the RAISE button until the lip is fully T T extended then release the RAISE button E 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 equipped raise the platform by depressing and holding the RAISE button When the lip is just above t
52. rements 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 transport vehicles with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize transport vehicle 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 4111 0021 May 2015 Oct 2015 22 Z lt lt Congratulations on your choice of a McGuire dock leveler This manual covers the Air Bag MA model air powered dock leveler Designed by McGuire to be a marvel of simplicity and efficiency your dock leveler when properly installed will provide many years of trouble free performance with an absolute minimum of maintenance
53. ructions are divided vehicle bed with at least 4 in 102 mm of overlap into the two methods of loading and unloading Maintain a safe distance from side edges of leveler during the loading unloading process For ramp loading and unloading see Ramp Loading Unloading Instructions on page 19 Failure to follow these instructions may result in serious personal injury or death Forendloading and unloading see End Loading Unloading Instructions on page 20 4111 0021 May 2015 18 Oct 2015 Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 20 For ramp loading or unloading the MA dock leveler can be operated by using the RAISE button on the control panel 1 Check to make sure transport vehicle is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the transport vehicle wheels or use vehicle restraint if available A RAISE Button 4 Extend the platform lip onto transport vehicle as follows a Raise the platform by depressing and holding RAISE button b Hold the RAISE button until the lip is fully extended then release the RAISE button The platform will lower until the lip is resting on the transport vehicle bed c Make sure that the lip is fully extended and supported on the tr

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