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MP-Series
Dock Leveler
Owner’s/User’s Manual
MCGUIRE • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022
800.624.8473 • fax: 262.255.9399 • www.wbmcguire.com • [email protected]
Printed in U.S.A.
Copyright © 2016
Manual No. 4111-0019
May 2015
July 2016
Table of Contents
Page
Safety
Recognize Safety Information ............................................................. 1
General Operational Safety Precautions ............................................ 1
Operational Safety Precautions ........................................................... 2
Maintenance Safety Precautions ......................................................... 4
Safety Decals ......................................................................................... 5
Owner’s/User’s Responsibilities ........................................................ 6
Introduction
General Information .............................................................................. 7
Dock Leveler Stock Specifications ..................................................... 7
Component Identification ..................................................................... 8
Installation
Prepare Pit ............................................................................................. 9
Prepare Dock Leveler .......................................................................... 10
Install Dock Leveler ............................................................................ 12
Operation
Theory .................................................................................................. 17
Operating Instructions ....................................................................... 18
Ramp Loading/Unloading Instructions ....................................... 19
End Loading/Unloading Instructions........................................... 20
Maintenance
Service Dock Leveler Safely .............................................................. 21
Periodic Maintenance ......................................................................... 22
Adjustments
Adjust Lift Arm Spring and Lip Assist Spring Tension .................. 24
Adjust Lip Stop Bolt ........................................................................... 26
Troubleshooting
Troubleshooting .................................................................................. 27
Parts
Hold-Down Mechanism ...................................................................... 29
Frame Components ............................................................................ 30
Platform Components ........................................................................ 32
Toe Guard/Weather Seal—Optional .................................................. 36
Miscellaneous
Customer Information ........................................................................ 37
Warranty ................................................................................ Back Cover
General Operational Safety
Precautions
SAFETY
Recognize Safety Information
Safety-Alert Symbol
The Safety- Alert Symbol is a graphic representation intended to convey a safety message without the use of words. When you see this symbol, be alert to the possibility of death or serious injury. Follow the instructions in the safety message panel.
The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will result in death or serious injury.
Read and understand the Owner’s/User’s Manual and become thoroughly familiar with the equipment and its controls before operating the transport vehicle restraint.
Never operate a transport vehicle restraint while a safety device or guard is removed or disconnected.
Never remove DANGER, WARNING, or CAUTION signs, Placards or Decal’s on the equipment unless replacing them.
The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which could result in death or serious injury.
Op era ting
Zon e
The use of the word CAUTION signifies possible hazard or unsafe practice which could result in minor or moderate injury.
Ope rati ng
Zo ne
NOTICE is used to address practices not related to physical injury.
Safety instruction(or equivalent) signs indicate specific safety-related instructions or procedures.
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.
Manual No. 4111-0019
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July 2016
1
SAFETY
Learn the safe way to operate this equipment. Read and understand the manufacturer’s instructions. If you have any questions, ask your supervisor.
Stay clear of dock leveling device when transport vehicle is entering or leaving area.
Chock/restrain all transport vehicles, Never remove the wheel chocks until loading or unloading is finished and transport driver has been given permission to drive away.
Do not move or use the dock leveling device if anyone is under or in front of it.
Do not use a broken or damage dock leveling device. Make sure proper service and maintenance procedures have been performed before using.
Keep hands and feet clear of pinch points. Avoid putting any part of your body near moving parts.
Failure to follow these instructions will result in death or serious injury.
Make sure lip overlaps onto transport vehicle bed at least 4 in. (102 mm).
2
Keep a safe distance from both side edges.
Failure to follow these instructions could result in death or serious injury.
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July 2016
Operational Safety Precautions
Do not use dock leveling device if transport vehicle is too high or too low.
Do not overload the dock leveling device.
Do not operate any equipment while under the influence of alcohol or drugs.
Do not leave equipment or material unattended on dock leveling device.
Failure to follow these instructions could result in death or serious injury.
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July 2016
SAFETY
3
SAFETY
Maintenance Safety Precautions
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 could result in death or serious injury.
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.
Failure to follow these instructions will result in death or serious injury.
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. Failure to follow these instructions could result in death or serious injury.
DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded
DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present. Stray sparks can ignite spills or leaks near the work area. Always clean up the oil leaks and spills before proceeding with grinding or welding.
Always keep a fire extinguisher of the proper type nearby when grinding or welding.
Failure to follow these instructions could result in death or serious injury.
ALWAYS stand clear of dock leveler lip when working in front of the dock leveler.
Failure to follow these instructions could result in death or serious injury.
1.50"
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. Failure to follow these instructions will result in death or serious injury.
4
Arc Flash and
Shock Hazard
PPE [Personal Protection
Equipment] Required
De-energize equipment before working on or inside. Do not open cover without appropriate
PPE. Refer to NFPA 70E for
PPE requirements. This panel may contain more than one power source.
Hazardous Voltage
Will Result in Death or Serious Injury
Manual No. 4111-0019
May 2015
July 2016
File Name: 1751-0736 Rev A
Decal Size: 1.5 x 3
SAFETY
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.
5.06"
DANGER
CRUSH HAZARD
Maintenance prop must support leveler behind bar.
Do not force maintenance
1751-0727
1751-0727
1751-0727 Rev A
1751-0730
(x2)
Control Box Size:
Decal Size: 5.06 x 2.40
9.12"
File Name: 1751-0727 Rev A
Decal Size: 5.06 x 2.40
DANGER
SAFETY INFORMATION
OPERATION
Operation supports the ramp before driving on ramp.
1.
Read and follow all instructions and warnings in the owner ’s/user ’s
Unsupported dock leveler ramps can lower unexpectedly.
Before allowing vehicle to leave
Use of dock leveler restricted to
Always chock trailer wheels or engage truck restraint before operating dock leveler or beginning to
4.
load or unload.
Never use hands or equipment to
Stay clear of hinges and front and
Never use damaged or malfunctioning dock leveler. Report problems immediately to supervisor.
MAINTENANCE/SERVICE
Maintenance/Service w a r n i n g s a n d m a i n t e n a n c e schedules in the owner‘s/user‘s in the owner ’s/user ’s manual.
warnings and maintenance schedules
Before activating dock leveler: Maintenance/Service of dock leveler
•
•
Ensure that no equipment,
Ensure no equipment, dock leveler.
dock leveler.
•
•
Return the dock leveler to its
Return dock leveler to its stored position at dock level.
Failure to follow posted instructions will result in death or serious injury.
3.
Remove any end loads if required.
interference. If lip does not lower to
4.
dock floor to indicate service work is being performed.
DO NOT ENTER PIT unless dock leveler is securely supported by
6.
trailer bed, reposition vehicle.
Ensure that truck bed supports
6. Ensure truck bed supports extended lip or leveler frame supports the ramp before driving on ramp.
5.
restricted to trained personnel.
Place barriers on the driveway and on
If electrically powered turn off and use
OSHA lockout/tagout procedures.
(decal placed in same position on both sides)
1751-0730 Rev B
Control Box Size:
Decal Size: 9.12 x 3.25
1751-0329
(x2) File Name: 1751-0730
1751-0330
(x2)
1751-0728
1751-0329 Rev A
Decal Size: 13 x 2
File Name: 1751-0329
File Name: 1751-0329 Rev A
Decal Size: 13 x 2
HERE
Control Box Size:
Decal Size: 6 x 2
5.93"
File Name: 1751-0330 REV C
Decal Size: 5.375 x 1.75
5.93"
DANGER springs are fully unloaded and ends are loose before removal. Refer are fully unloaded and ends are loose before removal. Failure to comply will result in death or serious injury. Refer to owner’s/user’s manual for proper maintenance procedure.
1751-0728 Rev B
8.72"
Control Box Size:
CRUSH HAZARD
DANGER
Decal Size: 5.93 x 1.40
CRUSH HAZARD
File Name: 1751-0728
Do not work under dock leveler unless this maintenance prop has been secured in the Control Box Size: will result in death or serious injury.
Decal Size: 5.93 x 1.40
File Name: 1751-0728 Rev B
5.05"
1751-0788
1751-0731
Control Box Size:
5.05"
1751-0789
DANGER
File Name: 1751-0788 Open the pin latch and insert
Material: Ritrama 3-1190 (3.5 mil thick) calendered vinyl
02 hi-tack permanent acrylic adhesive
Ritrama 3-7146 (1.0 mil thick) clear polyester laminate
to secure prop. Use every time dock leveler is serviced.
1751-0726
1751-0789
1751-0731 Rev A
Control Box Size:
Decal Size: 5.05 x 2.40
5.92"
File Name: 1751-0789
File Name: 1751-0731 Rev A
DANGER
DO NOT ENTER PIT unless dock leveler is
CRUSH HAZARD
DO NOT ENTER PIT unless dock leveler is barriers on driveway and dock floor to indicate barriers on driveway and dock floor to indicate will result in death or serious injury. Refer to or serious injury.
Control Box Size:
Decal Size: 5.92 x 2.36
File Name: 1751-0726
File Name: 1751-0726 Rev B
Decal Size: 5.92 x 2.36
Manual No. 4111-0019
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5
OWNER’S/USER’S RESPONSIBILITIES
1) The manufacturer shall provide to the initial purchaser and make the following information readily available to the owners/users and their agents, 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.
2) 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. The owners/users shall provide application information to the manufacturer to receive recommendations on appropriate equipment specifications and capacity.
3) The Owner/User must see all nameplates, placards, decals, instructions and posted warnings are in place and legible and shall not be obscured from the view of the operator or maintenance personnel for whom such warnings are intended for. Contact manufacturer for any replacements.
4) Dock leveling devices may become hazardous if the manufacturer’s instructions regarding modifications or adjustments are not followed. Modifications or alterations of dock leveling devices shall only be done made with prior written approval from the original manufacturer. These changes shall be in conformance with all applicable provisions of the MH30.1 standard and shall also satisfy all safety recommendations of the original equipment manufacturer of the particular application.
5) The owner/user should recognize the inherent dangers of the interface between the loading dock and the transport 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, operating conditions and the manufacturer’s specific instructions provided with the dock leveling device. Maintaining, updating and retraining 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.
6) An operator training program should consist of, but not necessarily be limited to, the following: a) Select the operator carefully. Consider the physical qualifications, job attitude and aptitude b) Assure that the operator reads and fully understands the complete manufacturer’s owners/users manual.
c) Emphasize the impact of proper operation upon then operator, other personnel, material being handled, and equipment. Cite all rules and why they are formulated.
d) Describe the basic fundamentals of the dock leveling device and components design as related to safety, e.g., mechanical limitation, stability, functionality, ect.
e) Introduce the equipment. Show the control locations and demonstrate functions. Explain how they work when used properly and maintained as well problems when they are used improperly.
f) Assure that the operator understands the capacity rating, nameplate data, placards and all precautionary information appearing on the dock leveling device.
g) Supervise operator practice of equipment.
h) Develop and administer written and practical performance tests. Evaluate progress during and at completion of the course.
i) Administer periodic refresher courses. These may be condensed versions of the primary course and include on-the-job operator evaluation.
7) Loading dock safety equipment should never be used outside of its vertical working range, or outside the manufacturer’s rated capacity. It shall also be compatible with the loading equipment and other conditions related to dock activity. Please consult the manufacturer if you have any questions as to the use, vertical
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Manual No. 4111-0019
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INTRODUCTION working range or capacity of the equipment. Only properly trained and authorized personnel should operate the equipment.
8) It is recommended that when the transportation vehicle is positioned as close as practical to the dock leveling device and in contact with both bumpers, there shall be a minimum of 4.00 inches (100mm) overlap between the front edge of the lip and the edge of the floor or sill of the transport vehicle at all times during the loading and unloading process.
9) When goods are transferred between the loading dock and the transport vehicle, this vehicle shall have the brakes and wheel chocks or positive restraints that provide the equivalent protection of wheel chocks shall be engaged. 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.
10) Manufacturer’s recommended maintenance and inspection of all dock leveling devices shall be performed in conformance with the following practices: A planned Maintenance schedule program must be followed, only trained and authorized personnel shall be permitted to maintain, repair, adjust and inspect dock leveling devices, and only the use of original equipment manufacturer parts, manuals, maintenance instructions, labels, decals and placards or their equivalent. Written documentation of maintenance, replacement parts or damage should be kept. In the event of damage, notification to the manufacturer is required.
11) Loading dock devices that are structurally damaged or has experienced a sudden loss of support while under load, such as might occur when a transport vehicle is pulled out from under the dock leveling device, shall be removed from service, inspected by a manufacturer’s authorized representative, and repaired or replaced as needed or recommended by the manufacturer before being placed back in service.
Dock Leveler Stock Specifications General Information
Congratulations on your choice of a McGuire dock leveler. This manual covers the MP-series mechanical dock leveler.
MP-Series dock levelers are available in the following sizes, weight capacities, and options:
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.
Width
6 ft (1828.8 mm)
6-1/2 ft (1981.2 mm)
7 ft (2133.6 mm)
Length
6 ft (1828.8 mm)
8 ft (2438 mm)
10 ft (3048 mm)
Once again, thank you and congratulations on your purchase of a McGuire mechanical dock leveler.
Capacity (CIR*)
25,000 lb (11 340 kg)
30,000 lb (13 608 kg)
35,000 lb (15 876 kg)
40 000 lb (18 144 kg)
45 000 lb (20 412 kg)
55 000 lb (22 680 kg)
* CIR (Comparative Industry Rating)
Call McGuire for your specific needs.
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INTRODUCTION
Component Identification
1 — Lip
2 — Lip Maintenance Prop
3 — Platform
4 — Bell Crank
5 — Lip Assist Spring
6 — Hold Down Release Ring
7 — Ratchet Pawl & Bar
9 — Hold Down
10 — Platform Maintenance Prop
11— Main Base Frame
12 — Safety Leg Assy.
13 — Lip (Snubber) Spring
14 — Lip Shock Absorber
15— Safety Leg Pull Chain
16 — Lift Arm Assembly
17 — Lift (Main) Spring
18 — Prop. Pin and Clip
19 — Working Range Toe Guards
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July 2016
Prepare Pit
A
B
D
C
INSTALLATION
A—Distance (Pit Width)
(Front and Rear)
B— Distance (Dock Floor-to-Pit
Floor) (All Four Corners)
Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the equipment before installation has been completed.
C— Distance (Pit Length)
(Both Sides of Pit)
D— Distance (Pit Corner-to-Corner) (Top,
Bottom, and Both Sides)
Before lowering the dock leveler into the pit, the following must be performed:
1. Remove all debris from the pit and sweep the pit clean.
Failure to follow the installation instructions could result in damage to equipment, the facilities, and/or death or serious injury.
construction according to approved/certified pit drawings. Make sure pit is square by making the following measurements:
Only trained installation professionals with the proper equipment should install this product. Failure to follow these instructions could result in death or serious injury.
• Measure pit width distance (A) at both front and rear of pit.
• Measure dock floor-to-pit floor distance (B) at all four corners.
• Measure pit length distance (C) at both sides.
• Measure corner-to-corner (crisscross) distance
(D) at both sides. Take measurements at dock floor level and at pit floor level.
If any measurement is off by more than 1/8 in. (3.18 mm), contact Technical Services before proceeding.
DO NOT remove the shipping bands around the dock leveler lip until instructed to do so.
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July 2016
9
INSTALLATION
Prepare Dock Leveler
A
B
A— Lifting Bracket (2 used)
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 could result in death or serious injury.
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.
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.
Turn to page 11 for front pick up.
NOTE: A third sling may be used to install the unit as needed.
DO NOT overtighten the lifting bracket hardware.
Overtightening can damage the weather seal, if equipped.
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INSTALLATION
1. Remove any bumpers that may be banded, or bolted to the frame of the dock leveler.
4. Remove wood blocks that are attached to the leveler frame before putting the dock leveler into the pit.
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.
5. To pick up the unit from the rear, slide forks into the fork slots and under the cross member. Shown below.
6. To pick up the unit from the front, move forks closer together and slide over the frame and under the cross member. It may be necessary to unband the unit to gain access to the front, by lifting the lip up then sliding the forks under the cross member.
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 overtighten.
3. Attach lifting chains to lifting brackets (A) and to a lifting device (i.e., hoist or fork truck) having the appropriate lifting capacity and reach.
REAR PICK UP FRONT PICK UP
Manual No. 4111-0019
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July 2016
Decks not shown for clarity.
11
INSTALLATION
Install Dock Leveler
Shim
Stacking Methods
M
N
P
Q
A— Distance (Leveler Frame
Height)
B— Shim Locations (Under
Rear Vertical Supports,
4-5 Places TYP)
C— Shim Locations (Under
Lip Keepers, Lifter Arm and Prop)
D— Dock Floor
E— Rear Pit Curb Angle
F— String
G— Rear Hinge Frame Angle
H— Distance (Dock Floor-to-
Pit Floor)
J— Distance (Top of Shim
Stack-to-Dock Floor)
K— Shim Stack
L— Dock Leveler Frame
M — Pyramid (Preferred)
N— Stepped (Acceptable)
P— Offset (Not Acceptable)
Q — Straight (Not Acceptable)
R — Shim between lip keeper curb angle when required.
D
H
J
E F
G
K
L
R
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INSTALLATION
NOTE: McGuire dock levelers are designed with a nominal 1/2 in. (12.7 mm) shimming distance to allow for pit inconsistencies.
1. Determine height of shim stack (K) for each shim location (B) by performing the following:
a. Measure leveler frame height distance (A).
at each shim location (B). Write down the dimensions obtained at each location.
c. Subtract distance (A) from distance (H) to obtain the shim height. Repeat for each shim location.
The minimum size of the shim that contacts the leveler frame (i.e., the top shim of each shim stack) must be at least 4-1/2 x 4-1/2 in. (114.3 x 114.3 mm) to support the full width of the frame rail and to provide a shelf for a fillet weld.
Use the thickest shim stock possible for stability and weld penetration purposes. DO NOT use multiple layers of 1/8 in. (3.18 mm) or thinner shim stock.
4. Put a 1/4 in. (6.6 mm) thick shim at locations (C)
(under lip keepers/maintenance prop and safety legs). Make sure shims are larger than frame front flat so pyramid or stepped stacking method can be used.
NOTE: A 1/4 in. (6.6 mm) thick shim at locations (C) is used only as a starting point. The final shim stack height will be determined after the dock leveler is lowered into the pit.
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 could result in death or serious injury.
2. Using the results obtained in step 1, create the individual shim stacks on the pit floor at locations
(B). Build each shim stack (K) using the pyramid method (M) (preferred) or stepped method (N) 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 (P) or straight method (Q).
NOTE: To assist in obtaining an accurate measurement of distance (J), use a string (F) pulled tight across the pit opening, directly over the shim locations.
3. Verify that each shim stack is at the correct height by measuring distance (J) [top of shim stack (K) to dock floor]. Distance (J) must equal the dock leveler height (A).
5. Using an appropriate lifting device connected to the lifting brackets, lower dock leveler into the pit so rear hinge frame angle (G) is tight against rear pit curb angle (E) across full width of the leveler frame.
6. Allow rear of dock leveler to rest on the rear shims while keeping the front of the dock leveler level with the dock floor.
7. Add shims at front shim locations (C) so front of dock leveler will stay level with dock floor when leveler is resting fully on shims.
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13
INSTALLATION
A— Front of Dock Pit
B— Dock Leveler Frame
C— Side Pit Curb Angle
D— Gap [3/4 in. (19 mm)
Minimum]
8. With rear hinge frame angle (F) tight against rear pit curb angle (G), perform/check the following:
E— Pry Locations
F— Rear Hinge Frame
Angle
G— Rear Pit Curb Angle
H— Flare Bevel Weld, Typical
(To Fit Spacing)
10. Allow the dock leveler to rest fully on the shim stacks. Make sure the leveler is in the crosstraffic (stored) position with lip resting on lip keepers. • 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).
11. Check that a smooth and level transition exists between the dock floor and the dock leveler platform. Add or remove shims as necessary until a smooth transition is obtained.
• Gap (D) must exist equally along both sides of leveler so weather seal (if equipped) will not bind during dock leveler operation.
9. If gap (D) cannot be obtained equally at both sides of leveler, grind or add material at the rear edge of rear hinge frame angle (F) as needed.
12. If leveler cannot be squared and made level as instructed in steps 8 – 10, contact Technical
Services.
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INSTALLATION
14. Remove shipping bands at this time. Allow platform to float. Add/Remove shims as necessary to bring platform level/flush with floor.
DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded.
DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present. Stray sparks can ignite spills or leaks near the work area. Always clean up the oil leaks and spills before proceeding with grinding or welding.
Always keep a fire extinguisher of the proper type nearby when grinding or welding.
Failure to follow these instructions could result in death or serious injury.
ALWAYS stand clear of dock leveler lip when working in front of the dock leveler.
Failure to follow these instructions could result in death or serious injury.
15. Weld front of dock leveler frame (B) to shims located under the keepers, then weld the shims to the front pit curb steel.
16. Disconnect lifting device and chains from the lifting brackets.
DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed.
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.
NOTE: The illustration on the previous page shows a typical weld pattern. The weld pattern will vary slightly depending on size of dock leveler.
13. With the rear hinge frame angle (F) tight against the rear pit curb angle (G), weld the rear hinge frame angle (F) to the rear pit curb angle (G) using a 3/8 in. (9.5 mm) flare bevel skip weld
— each weld being 6 in. (152 mm) long.
Start at each end with a 6 in. (152 mm) long weld. Space all the other welds out evenly leaving approximately 6 in. (152 mm) space between each weld.
Alternate welding locations to distribute heat.
Welding sequentially from one end to the other may cause warping or distortion.
DO NOT weld continuously along the full length of the rear hinge frame angle. This can put unnecessary stress on the leveler components, causing the leveler to malfunction and shorten the lifespan of the affected components.
DO NOT use the maintenance prop to support the raised platform until the maintenance prop has been properly shimmed and welded. The shims must be welded to each other, the leveler frame, and to the front pit curb steel. Failure to follow these instructions could result in death or serious injury.
17. Pull and hold the release ring (located in recess at rear of platform) until the platform is fully raised.
Check for binding as platform rises.
18. Slowly walk out onto the platform to lower the platform. Allow the platform to lower to the crosstraffic position. Check for binding as platform lowers.
19. If binding occurs, reposition leveler and/or add or remove shims as necessary. Raise and lower platform again. If platform still binds, contact
Technical Services for further instructions.
20. Check that the leveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly.
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July 2016
15
INSTALLATION
A— Platform Release Ring B— Platform Maintenance
Prop
C —Lip prop support D — Prop Pin and Clip E —Safety Leg Pull
Chain
21. Pull the release ring (A) to raise platform. Engage the platform maintenance prop (B) in the service
(upright) position and lock the maintenance prop at this position using an OSHA approved locking device, supplied by others Engage lip maintenance prop(C).
Make sure the platform is properly supported in the raised position before entering the pit to finish weld the shims. Failure to follow these instructions could result in death or serious injury.
22. Install shims under lift arm at locations using the pyramid shimming method. (Page 12)The lift arm pivot must be solidly shimmed the entire length of the lift arm pivot. Make sure the lift arm pivot is level from side-to-side.
23. Finish weld all shims using a fillet weld.
• Weld all shims within each shim stack to each other, then weld the shim stack to the leveler frame.
• Weld the front leveler frame shim stacks to the front pit curb steel if not done previously.
24. When all welding has been completed, remove all slag then paint all the welds and shims.
25. Remove the lifting brackets from the platform side joists.
26. Disengage the platform maintenance prop.
27. Slowly walk out onto the platform to lower the platform until it is at the cross-traffic (stored) position.
28. Check operation of dock leveler by cycling the leveler at least four times.
• When the platform is at full height, lip will be fully extended.
• Lip will begin to drop after the unit begins to lower to truck bed.
29. Check below-dock position by walking platform down before lip folds completely.
• Lip will be over lip keepers.
• Platform safety legs will be resting on frame. platform down. Pull and hold safety leg chain (E) before lip folds completely.
31. If the lip does not extend fully or lip folds too quickly, see appropriate symptom in the Troubleshooting section.
32. Install the dock bumpers as required, clean weld splatter and touch up with spray paint.
16
Manual No. 4111-0019
May 2015
July 2016
OPERATION
Theory
1 — Lip
2 — Lip Maintenance Prop
3 — Platform
4 — Lip Bell Crank
5 — Lip Assist Spring
6 — Hold Down Release Ring
7— Ratchet Pawl & Bar
9 — Hold down
10 — Platform Maintenance Prop
11— Main Base Frame
12 — Safety Leg Assy.
13 — Snubber Spring
14 — Gas Shock
15 — Safety Leg Below Dock
Control
16— Safety Leg Retract Pull Ring
17 — Lift Arm
18 — Lift Springs
The MP-series mechanical dock leveler uses large lift springs (18) to apply force to lift arm (17). The lift arm pushes against the underside of the platform (3), rolling on the cam (not pictured) forcing the platform to rise. The force of the spring tension is just enough to lift the weight of the platform and extend lip.
When activating the leveler, always pull swiftly AND hold the platform release ring until the platform is at the full raised position. Releasing the ring while the platform is still raising may result in damage to the equipment
To actuate the dock leveler platform, the operator pulls and holds the platform release ring (6) located in the recess at the rear of the platform. This causes ratchet pawl (7) to disengage from ratchet bar (8).
With the ratchet pawl disengaged, spring tension from lift springs (18) forces the platform to rise.
NOTE: Ratchet pawl (7) and bar (8) are part of the hold-down mechanism (9)
The ratchet pawl disengages only when the platform release ring (6) is pulled AND held. Spring tension from pawl spring causes the ratchet pawl to engage the ratchet bar when the release ring is let go.
When the platform rises to approximately 2 – 3 inches
(51 – 76 mm) from its full raised height, the lip snubber spring (13) and a chain pulls the lip bell crank (4) down. This, in conjunction with the lip assist spring (5), causes the lip linkage to push the lip out and up. The lip assist spring also helps control the amount of time required for the lip to fully fold.
To lower the platform, the operator walks out onto the platform. The platform will lower until the extended lip rests on the truck bed. If the lip did not fully extend or there is no truck at the dock, the platform will lower until one of the following conditions occur:
• Lip is resting on lip keepers (cross-traffic position).
• Lip did not fully fold causing the platform to rest on safety legs (below-dock position).
• Lip did not fully fold and safety legs are retracted, causing the platform to rest on the safety stops (full below-dock position).
The hold-down ratchet assembly will keep the platform at the desired position until the platform release ring is pulled again.
Manual No. 4111-0019
May 2015
July 2016
17
OPERATION
Operating Instructions
12 in. (305 mm)
Stay clear of dock leveler when transport vehicle carrier is entering or leaving dock area.
DO NOT move or use the dock leveler if anyone is under or in front of leveler.
Keep hands and feet clear of pinch points. Avoid putting any part of your body near moving parts.
Failure to follow these instructions will result in death or serious injury.
Only trained personnel should operate the dock leveler.
DO NOT use a broken or damaged dock leveler.
Make sure proper service and maintenance procedures have been performed on leveler before using.
Transport vehicle wheels must be chocked unless the vehicle restraint is used. Never remove the wheel chocks until loading/unloading is finished and transport vehicle driver has been given permission to leave.
Make sure platform lip rests on the transport vehicle bed with at least 4 in. (102 mm) of overlap.
Maintain a safe distance from side edges of leveler during the loading/unloading process.
Failure to follow these instructions could result in death or serious injury.
12 in. (305 mm)
The MP 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 could result in death or serious injury.
When activating the leveler, always pull swiftly AND hold the platform release ring until the platform is at the full raised position. Releasing the ring while the platform is still raising may result in damage to the equipment
The dock leveler operation instructions are divided into the two methods of loading and unloading:
For ramp loading and unloading, see Ramp
Loading/Unloading Instructions on page 19.
• For end loading and unloading, see End Loading/
Unloading Instructions on page 20.
18
Manual No. 4111-0019
May 2015
July 2016
OPERATION
Operating Instructions—Continued
Ramp Loading/Unloading Instructions
NOTE: If end unloading is required, see End Loading/
Unloading Instructions on page 20.
1. Check to make sure transport vehicle is positioned squarely against dock bumpers.
loading or unloading process has been completed.
3. Chock the transport vehicle wheels or use vehicle restraint if present.
supported on the transport vehicle along the entire width of the platform with at least 4 in. (102 mm) of lip contacting the transport vehicles bed.
A
8. Proceed with loading or unloading.
NOTE: If end loading is necessary, see End Loading/
Unloading Instructions on page 20.
A platform release ring (A).
5. Hold the release ring until the platform is at the fully-raised position and lip is fully extended.
6. Walk out onto the platform. The platform will lower until the lip rests on the transport vehicle bed.
9. When the loading or unloading process has been completed, return platform to cross-traffic (stored) position as follows:
a. Raise the platform to the full-raised position by pulling and holding the platform release ring (A).
b. Lower platform by slowly walking out onto the platform allowing time for the lip to fully fold and clear the transport vehicle. Continue walking out on platform until platform lowers to the crosstraffic position (lip engages in the lip keepers).
10. Remove chocks from transport vehicle wheels or release vehicle restraint if used.
11. Indicate to driver that transport vehicle may leave the dock.
Manual No. 4111-0019
May 2015
July 2016
19
OPERATION
Operating Instructions—Continued
End Loading/Unloading Instructions
NOTE: End loading or unloading can be done with the dock at the cross-traffic position or belowdock position depending on the height of the truck/trailer bed.
1. Check to make sure transport vehicle is positioned squarely against dock bumpers.
2. Instruct driver to remain at the dock until the loading or unloading process has been completed,
and instructed to leave.
3. Chock the transport vehicle wheels or use vehicle if present.
B
6. Slowly walk the platform down allowing enough time for the lip to fold. Just before the platform reaches the cross-traffic position, pull and hold the safety leg retract pull ring (B) (located in a recess at front of the platform). The platform will continue lowering to the full below dock position.
End Loading/Unloading — Platform at Cross-Traffic Position.
4. If transport vehicles bed is at or above dock floor level, leave leveler at the cross-traffic position and proceed with loading or unloading. When finished, perform steps 9 and 10.
If transport vehicle bed is below the dock floor level, perform steps 5 – 10.
A
5. Pull and hold the platform release ring (A) until the platform is at the fully-raised position.
End Loading/Unloading — Platform at Below-Dock Position.
7. Proceed with loading or unloading.
NOTE: When end unloading is finished and additional access to the transport vehicle requires that the platform lip be extended, see Ramp
Loading/Unloading Instructions on page 19 for further instructions.
8. When loading or unloading is finished, raise the platform to the full-raised position by pulling and holding the platform release ring. Slowly walk the platform down, allowing enough time for the lip to fold. The platform will lower to the cross-traffic position (lip engages in the lip keepers).
9. Remove chocks from transport vehicle wheels or release vehicle restraint if used.
10. Indicate to the driver that the transport vehicle may leave the dock.
20
Manual No. 4111-0019
May 2015
July 2016
Service Dock Leveler Safely
MAINTENANCE
B
A— Platform Release Ring B — Platform Maintenance Prop C— Lip Maintenance Prop D— Prop Pin and Clip E— Safety Leg Pull Chain
Note: Lockout & Tagout Devices are not supplied with leveler. They are to be supplied by others.
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 follow these instructions could result in death or serious injury.
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 follow these instructions could result in death or serious injury.
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.
Failure to follow these instructions could result in death or serious injury.
Whenever maintenance is to be performed under the dock leveler platform, support the platform with maintenance prop (B). Position the maintenance prop behind front header plate (D) while staying clear of the lip. Lock the maintenance prop in the service (upright) position using an OSHA approved lockout device* (B) and tagout device* (A).
Whenever servicing the dock leveler, lock the electrical power disconnect in the OFF position. Use only an
OSHA approved lockout device* (B) and tagout device
(A).
Only the person servicing the equipment should have the capability to remove the lockout devices. The tagout 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.
Manual No. 4111-0019
May 2015
July 2016
21
MAINTENANCE
Periodic Maintenance
1 — Lip Hinge Grease Fittings
2 — Lip Maintenance Prop Pivot
3 — Lift Arm Roller Bushing
4 — Lift Arm Pivot
5 — Hold-Down Pivot/Pulley
6— Safety Leg Linkage Pivots
7 — Lip Lift Assist Pin
8 — Hold Down-to-Platform Pin
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. Failure to follow these instructions will result in death or serious injury.
22
Manual No. 4111-0019
May 2015
July 2016
MAINTENANCE
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 and the lip hinge areas.
The hinge areas must be kept free of dirt and debris. Build-up of foreign material in the hinge areas will cause abnormal operation.
Quarterly Maintenance machine oil:
(2)— Lip maintenance prop pivot
(5)— Hold-down pivot/pulley
(6)— Safety leg linkage pivots
(8)— Hold down-to-platform pin
Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler.
grease: (zerk fittings)
(1)— Lip hinge area
(3)—Lift arm roller bushing
(4)— Lift arm pivot
(7)— Lip assist pin
Manual No. 4111-0019
May 2015
July 2016
23
ADJUSTMENTS
Adjust Lift Arm Spring and Lip Assist Spring Tension
1 — Jam Nut
2 — Adjustable Nut
3 — Lip Assist Spring
4— Lift Springs
5 — Lift Spring Bolt
6 — Hold-Down Mechanism
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 follow these instructions could result in death or serious injury.
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 follow these instructions could result in death or serious injury.
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.
Failure to follow these instructions could result in death or serious injury.
24
Manual No. 4111-0019
May 2015
July 2016
ADJUSTMENTS
NOTE: Adjusting the tension of lift springs (4) usually requires that the lip assist spring (3) also be adjusted.
If the platform does not rise fully and/or lip does not extend fully, the lift spring tension may be set too low.
If the platform cannot be walked down or is difficult to walk down, the lift spring tension may be set too high.
operation of the lip.
• If the lip folds before the platform can be walked down, tension of lip assist spring (3) may be set too low.
• If the lip does not fold fully or takes too long to fold, tension of lip assist spring (3) may be set too high.
If the platform does not rise fully on its own, it may be necessary to use an external lifting device. Use a lifting device with the appropriate lifting capacity to safely raise the platform. Make sure to engage and pin the platform maintenance prop after raising the platform. Failure to follow these instructions could result in death or serious injury.
4. Adjust lip assist spring tension as follows:
NOTE: Use two-turn increments when adjusting lip assist spring (3). Check lip operation after each adjustment. Repeat until proper operation is obtained.
a. Loosen jam nut (1).
When using an external lifting device to raise the platform, make sure hold-down mechanism (6) is disengaged. Pull and hold platform release ring during the lifting process to avoid shearing the ratchet pawl and ratchet bar teeth. maintenance prop. Pin the maintenance prop in the service position using attached pin device.
2. Adjust tension of lift springs (4) as follows:
NOTE: Use 1/2 turn increments when adjusting lift spring bolt (5).Turn clockwise to increase tension and counterclockwise to decrease tension. Check platform operation after each adjustment. Repeat until proper operation is obtained.
• To increase lift spring tension, turn lift spring bolt (5) clockwise.
• To decrease lift spring tension, turn lift spring bolt (5) counterclockwise. clockwise.
c. To decrease spring compression, turn nut (2) counterclockwise.
d. Tighten jam nut.
5. Recheck operation of platform and lip. Readjust lift spring tension and lip assist spring tension until proper operation is obtained.
Manual No. 4111-0019
May 2015
July 2016
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 follow these instructions could result in death or serious injury.
A
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.
Failure to follow these instructions could result in death or serious injury.
D
B
C
A— Platform
B— Jam Nut
C— Stop Bolt
D — Lip Keeper
E — Lip
Check that lip (E) is fully resting on the lip keepers (D) and at the lowest part of the lip keepers. If lip is not resting properly in lip keepers, perform the following adjustment.
4. Tighten jam nut (B).
5. Disengage lip maintenance prop.
position.
engage lip maintenance prop (not shown).
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 (A).
• Turn stop bolt “out” (counterclockwise) to hold lip further away from platform (A).
procedure if necessary.
E
26
Manual No. 4111-0019
May 2015
July 2016
TROUBLESHOOTING
Troubleshooting
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 follow these instructions could result in death or serious injury.
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.
Failure to follow these instructions could result in death or serious injury.
Symptom Possible Cause Solution
Platform does not rise.
Heavy object(s) on platform. Remove object(s) from platform.
NOTE: For safety reasons, the dock leveler is designed to lift only the platform’s own weight.
Disconnected or broken release chain.
Dock leveler binds.
Connect or replace chain.
Check for visible obstructions that could cause binding. Check weather seal if equipped.
If no obstructions found, call Technical Services.
See inside back cover for phone number and address.
Platform rises slowly or does not rise to the full raised position.
Heavy object(s) on platform. Remove object(s) from platform.
NOTE: For safety reasons, the dock leveler is designed to lift only the platform’s own weight.
Dock leveler binds.
Insufficient main spring tension.
Damaged or worn hold-down mechanism.
Check for visible obstructions that could cause binding. Check weather seal if equipped.
If no obstructions found, call McGuire Technical
Services. See inside back cover for phone number and address.
Increase tension on main springs. (See Adjust Lift
Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
Clean and inspect hold-down mechanism.
Manual No. 4111-0019
May 2015
July 2016
27
TROUBLESHOOTING
Symptom
Platform rises to full height, but lip does not fully extend.
Possible Cause
Lip assist chain disconnected or broken.
Insufficient main spring tension.
Solution
Connect or replace chain.
Increase tension on main lift springs. (See Adjust
Lift Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
Platform does not lower when operator walks out onto the platform.
Lip folds too fast during normal walk-down.
Insufficient lip assist force.
Increase lip assist spring compression. (See Adjust
Lift Arm Spring and Lip Assist Spring Compression in the Adjustments section.)
Excessive main spring tension.
Reduce main spring tension. (See Adjust Lift
Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
Damaged or worn holddown mechanism.
Clean and inspect hold-down mechanism.
Insufficient lip assist force.
Increase lip assist spring compression. (See Adjust
Lift Arm Spring and Lip Assist Spring compression in the Adjustments section.)
Disconnected, worn, or broken gas strut.
Inspect shock absorber. Connect or replace gas strut.
Platform does not stay down.
Entangled release chain.
Remove cause of entanglement.
Dirt impacted in ratchet bar teeth.
Clean and inspect ratchet bar and ratchet pawl teeth. DO NOT lubricate the ratchet assembly.
Broken or damaged ratchet assembly teeth.
Replace ratchet assembly. DO NOT lubricate the ratchet assembly.
Replace hold-down pivot pins.
Disconnected or broken hold-down pivot pins.
Damaged or worn holddown mechanism.
Clean and inspect hold-down mechanism.
Lip does not fold after truck departs.
Lip hinge binding because of lack of lubrication
Inject grease into all of the lip hinge grease fittings.
(See Periodic Maintenance in the Maintenance section.)
Excessive lip assist force.
Decrease lip assist spring compression. (See Adjust
Lift Arm Spring and Lip Assist Spring Compression in the Adjustments section.)
28
Manual No. 4111-0019
May 2015
July 2016
Hold-Down PAWL AND RATCHET
PARTS
Item Quantity Part Number
A 1 M512-986
Description
Ratchet and Pawl Assembly Set
Note: used on 502-089 hold down only
Manual No. 4111-0019
May 2015
July 2016
29
PARTS
Frame Components
30
Manual No. 4111-0019
May 2015
July 2016
PARTS
Frame Components
ITEM QTY
1
2
3
9
10
11
12
13
14
15
16
17
18
6
7
4
5
19
20
21
6.0 FOOT
1 16
1 18
1 20
6.5 FOOT
1 16
1 18
1 20
7.0 FOOT
1 16
1 18
1 20
6 FOOT
25K/55K
8435-5000
8435-5001
8435-5002
8435-5009
8435-5010
8435-5011
8435-5018
8435-5019
8435-5020
BASE FRAMES
8 FOOT
6.0 FOOT 25K/55K
16 8435-5003
18
20
8435-5004
8435-5005
6.5 FOOT
16 8435-5012
8435-5013
8435-5014
18
20
7.0 FOOT
16
18
20
8435-5021
8435-5022
8435-5023
10 FOOT
6.0 FOOT 25K/55K
16 8435-5006
18
20
8435-5007
8435-5008
6.5 FOOT
16 8435-5015
8435-5016
8435-5017
18
20
7.0 FOOT
16
18
20
8435-5024
8435-5025
8435-5026
1
1
M502-089
DOTP-6423
HOLD DOWN
LIFTER ARM 27 IN.
1 9224-0030 MAINT PROP
1 9221-0028 MAINT PROP PIVOT
1 DOTH-2555 SPRING, SNUBBER
3 DOTH-2356 PIN, CLEVIS
SAME SAME
DOTP-6424 LIFTER ARM 25 IN (6WD 25K) DOTP-6416 LIFTER ARM
DOTP-6423 LIFTER ARM 27 IN ( all others)
9224-0031 MAINT PROP
SAME
SAME
SAME
9224-0079 MAINT PROP
SAME
SAME
SAME
1
1
DOTH-2416 LAP LINK
DFRA-0323 PLATE SPRING
2 OTH-2218 WASHERS
1 DOTH-2185 NUT COUPLING
2 DOTH-2222 WASHERS
4 DOTH-2374 PIN, COTTER
1 DFRA-1205 PIN LIFTER ARM
1 5265-0012 CHAIN 6 FOOT
2 8432-1129 KEEPER LIP 16
2 8432-1130 KEEPER LIP 18
2 8432-1131 KEEPER LIP 20
1 9201-0006 PROP PIN AND CLIP
1 DOTH-2401 CASTER WHEEL ASSY.
1 DPLA-2128 CHAIN SNUBBER.
SAME
DFRA-0322 PLATE SPRING
DPLA-1218 T BAR ASSY
SAME
NONE
SAME
SAME
SAME
5265-0013 CHAIN, 8 FOOT
SAME
SAME
SAME
SAME
SAME
SAME
SAME
DOTH-6875 PLATE SPRING
DOTH-6425 BOLT SPRING ADJ
SAME
SAME
SAME
SAME
5265-0014 CHAIN, 10 FOOT
8432-1132 24 INCH PIT
8432-1133 24 INCH PIT
8432-1134 24 INCH PIT
SAME
SAME
SAME
Must provide dock leveler serial number, platform size, lip size, capacity, any options and pit depth when calling or faxing orders.
Manual No. 4111-0019
May 2015
July 2016
31
PARTS
Platform Components
ITEM QTY
1
6 FOOT
6.0 FOOT 6.5 FOOT 7.0 FOOT
PLATFORMS
8 FOOT
6.0 FOOT 6.5 FOOT
1 25K 9515-5000 9515-5004 9515-5008 25K 9515-5012 9515-5016
1 30K 9515-5001 9515-5005 9515-5009 30K 9515-5013 9515-5017
1 35K 9515-5002 9515-5006 9515-5010 35K 9515-5014 9515-5018
1 40K 9515-5003 9515-5007 9515-5011 40K 9515-5015 9515-5019
1 45K 9515-5036 9515-5038 9515-5040 45K 9515-5042 9515-5044
1 55K 9515-5037 9515-5039 9515-5041 55K 9515-5043 9515-5045
7.0 FOOT
10 FOOT
6.0 FOOT 6.5 FOOT 7.0 FOOT
9515-5020 25K 9515-5024 9515-5028 9515-5032
9515-5021 30K 9515-5025 9515-5029 9515-5033
9515-5022 35K 9515-5026 9515-5030 9515-5034
9515-5023 40K 9515-5027 9515-5031 9515-5035
9515-5046 45K 9515-5048 9515-5050 9515-5052
9515-5047 55K 9515-5049 9515-5051 9515-5053
32
Manual No. 4111-0019
May 2015
July 2016
PARTS
Platform Components
35
36
37
39
12
17
18
19
2
3
4
9
10
11
20
23
24
25
26
27
28
29
30
31
32
33
34
1 DPLA-0338
2 DPLA-0341
1 DPLA-0353
1 DPLA-0343
2 DOTH-2382
1 DOTH-2074
1 DOTH-2160
1 DPLA-0360
1 DOTH-2060
1 DOTH-2131
1 DOTH-6406
1 DOTH-2550
1 DOTH-2546
1 DOTP-2006
1 DOTH-2062
1 OTH-2131
2 OTH-2214
1 DOTH-2547
1 DOTH-2582
1 DOTH-2351
2 DOTH-2374
4 DOTH-2210
2 DOTH-2163
LIP SHAFTS
2 DPLA-2101
2 DPLA-2102
2 DPLA-2103
2 DOTH-2355
2 DOTH-2373
2 2101-0079
LIP BANGER ASSY.
BAR
BELOW DOCK PULL CHAIN
BELOW DOCK CONTROL ASSY.
PIN, COTTER
BOLT, HEX 5/8-11 X 2.00
NUT, HEX 5/8-11
BDC PUSH ROD ASSY
BOLT SHOULDER
LOCK NUT
LIP ASSIST ROD
SPRING ,LIP ASSIST STD (CONSULT FACTORY)
SPRING ,LIP ASSIST HEAVY (CONSULT FACTORY)
LIP PROP BAR
SHOULDER BOLT
LOCK NUT
WASHER
SPRING COMPRESSION
SHOCK GAS
BOLT CLEVIS
PIN COTTER
WASHER, FLAT
LOCK NUT
6.0 FOOT
6.5 FOOT
7.0 FOOT
PIN , CLEVIS
PIN, COTTER
WASHER, FLAT
Spring Information on page 34.
38
1
1
1
1
1
1
1
1
1
6.0 FOOT
16
18
20
6.5 FOOT
16
18
20
7.0 FOOT
16
18
20
25K
0595-5000
0595-5001
0595-5002
0595-5003
0595-5004
0595-5005
0595-5006
0595-5007
0595-5008
30K
0595-5009
0595-5010
0595-5011
0595-5012
0595-5013
0595-5014
0595-5015
0595-5016
0595-5017
LIPS
35K
0595-5018
0595-5019
0595-5020
0595-5021
0595-5022
0595-5023
0595-5024
0595-5025
0595-5026
40/45K
0595-5027
0595-5028
0595-5029
0595-5030
0595-5031
0595-5032
0595-5033
0595-5034
0595-5035
55K
0595-5036
0595-5037
0595-5038
0595-5039
0595-5040
0595-5041
0595-5042
0595-5043
0595-5044
1 Must provide dock leveler serial number, platform size, capacity, any options and lip size when calling or faxing orders.
Manual No. 4111-0019
May 2015
July 2016
33
PARTS
Platform Components
55
56
57
58
SEE CHART DOTH-2570
SEE CHART DOTH-2574
SEE CHART DOTH-2576
SEE CHART DOTH-2578
6.0 FOOT
16
18
20
6.5 FOOT
16
18
20
7.0 FOOT
16
18
20
6.0 FOOT
16
18
20
6.5 FOOT
16
18
20
7.0 FOOT
16
18
20
6.0 FOOT
16
18
20
6.5 FOOT
16
18
20
7.0 FOOT
16
18
20
25K
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
25K
(4) 55
(4) 55
(4) 55
(4) 57
(4) 57
(4) 57
(4) 57
(4) 57
(4) 57
25K
(8) 57
(8) 57
(8) 57
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
SPRING MAIN 6620
SPRING MAIN 6635
SPRING MAIN 6820
SPRING MAIN 6835
6 FOOT LONG
30K
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
35K
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55 (4)55
8 FOOT LONG
30K
(4) 57
(4) 57
(4) 57
(4) 57
(4) 57
(4) 57
(4)55
(4)55
(4)55
35K
(4) 57
(4) 57
(4) 57
(4) 57
(4) 57
(4) 57
40K
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
40K
(4) 57
(4) 57
(4) 57
(4) 57
(2)57, (2)58
(2)57, (2)58
45K
(4) 57
(4) 57
(2)57, (2)58
(2)57, (2)58
(2)57, (2)58
(2)57, (2)58
(4) 57
(4) 57
(4) 57
(4) 57
(4) 57
(4) 57
(4) 57
(4) 57
(2)57, (2)58
10 FOOT LONG
30K
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
35K
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
40K
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(2)57, (2)58
(2)57, (2)58
(2)57, (2)58
45K
(8) 58
(8) 58
(8) 58
45K
(4)55
(4)55
(4)55
(4)55
(4)55
(4)55
(2)55, (2)56
(2)55, (2)56
(2)55, (2)56
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(4) 57, (4) 58
(8) 58
(8) 58
(8) 58
(8) 58
(8) 58
(8) 58
(8) 58
(8) 58
(8) 58
55K
(4) 57
(4) 57
(2)57, (2)58
(2)57, (2)58
(2)57, (2)58
(2)57, (2)58
(4)58
(4)58
(4)58
55K
(1)55, (2)56
(1)55, (2)56
(1)55, (2)56
(1)55, (2)56
(1)55, (2)56
(1)55, (2)56
(2)55, (2)56
(2)55, (2)56
(2)55, (2)56
55K
(8) 58
(8) 58
(8) 58
(8) 58
(8) 58
(8) 58
(8) 58
(8) 58
(8) 58
34
Manual No. 4111-0019
May 2015
July 2016
Toe Guard/Weather Seal—Optional
9
10 12
11
PARTS
5
3
2
6
6
1
7
4
When ordering toe guards color must be specified.
6 FOOT
*1 1 0014-0062 TOE GUARD LH MIDDLE
*2 1 0014-0066 TOE GUARD LH LOWER
*3 1 0014-0064 TOE GUARD RH MIDDLE
*4 1 0014-0068 TOE GUARD RH LOWER
**5 2 DOTH-2041 SCREW CAP
8 FOOT
0014-0070 TOE GUARD LH MIDDLE
0014-0074 TOE GUARD LH LOWER
0014-0072 TOE GUARD RH MIDDLE
0014-0076 TOE GUARD RH LOWER
SAME
10 FOOT
0014-0078 TOE GUARD LH MIDDLE
0014-0082 TOE GUARD LH LOWER
0014-0080 TOE GUARD RH MIDDLE
0014-0084 TOE GUARD RH LOWER
SAME
**6 4 DOTH-2207 WASHER SAME SAME
**7 2 DOTH-2131 LOCK NUT SAME SAME
*
1 DKIT-9179 FRTG COMPLETE R&L DKIT-9180 FRTG COMPLETE R&L DKIT-9181 FRTG COMPLETE R&L
9 2 DOTH-2841 CHANNEL WEATHER SEAL DOTH-2840 CHANNEL WEATHER SEAL DOTH-2843 CHANNEL WEATHER SEAL
10 2 DOTH-2824 T-RUBBER WEATHER SEAL DOTH-2824 T-RUBBER WEATHER SEAL CONSULT FACTORY
11 2 DOTH-2822 BRUSH WEATHER SEAL DOTH-2822 BRUSH WEATHER SEAL CONSULT FACTORY
12 2 DOTH-2821 EXTRUSION ALUM.
** Included in kits
DOTH-2820 EXTRUSION ALUM.
CONSULT FACTORY
Manual No. 4111-0019
May 2015
July 2016
35
NOTES
36
This page intentionally left blank
Manual No. 4111-0019
May 2015
July 2016
MISCELLANEOUS
Customer Information
A
A
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 MP-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 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
Dock Leveler Information
Model
Serial No.
McGuire, Job No.
Original Owner Information
Name
Address
Installer Information
Name
Address
Date of
Installation
Manual No. 4111-0019
May 2015
July 2016
37
STANDARD PRODUCT WARRANTY
SYSTEMS, INC. warrants that its products will be free from defects in design, materials and workmanship for a period of one (1) year from the date of shipment. All claims for breach of this warranty must be made within 30 days after the defect is or can with reasonable care, be detected. In no event shall any claim be made more than 30 days after this warranty has expired. In order to be entitled to the benefits of this warranty, the product must have been properly installed, maintained and operated in accordance with all manufacturer’s recommendations and/or specified design parameters and not otherwise have been subject to abuse, misuse, misapplication, acts of nature, overloading, unauthorized repair or modification, application in a corrosive environment or lack of maintenance. Periodic lubrication, adjustment and inspection in accordance with all manufacturers’ recommendations are the sole responsibility of the Owner/User.
In the event of a defect, as determined by SYSTEMS INC., covered by this warranty, SYSTEMS INC. shall remedy such defect by repairing or replacing any defective 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 SUBSIDIARIES SHALL
NOT IN ANY EVENT BE LIABLE TO ANYONE, INCLUDING THIRD PARTIES, FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO,
BREACH OF WARRANTY, LOSS OF USE, LOSS OF PROFIT, INTERRUPTION OF BUSINESS OR
LOSS OF GOODWILL.
PRODUCT SPECIFIC WARRANTY
“MP” SERIES LEVELER
In addition to the “Standard Product Warranty” provided with all McGuire Products, Systems Inc., guarantees materials, components and workmanship to be free of defects for the following extended periods:
• Structural Warranty – For an additional period of four (4) years, for parts, labor and freight, product will carry a prorated structural warranty. This warranty specifically applies to; the deck section, lip section, frame, rear hinge assembly and front hinge assembly only. This warranty covers structural repairs to or replacement of dock leveler in Systems Inc sole discretion and expense including reasonable labor, materials, freight and travel. If Systems Inc determines replacement is necessary, it will provide the original purchaser with a credit toward the purchase of the new replacement
Systems Inc. product in the amount equal to the original purchase price of the warranted product
F.O.B. point of manufacture, discounted on a five year straight line basis by the number of years of use prior to replacement .
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