McGuire HP-H SERIES dock leveler Owner's Manual
The HP-H SERIES dock leveler is a hydraulically operated platform that safely and efficiently bridges the gap between your loading dock and a truck's bed. This manual provides instructions for using and maintaining your HP-H SERIES dock leveler.
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HP-H SERIES
Dock Leveler
Owner’s Manual
Printed in U.S.A.
Copyright
©
2007
MCGUIRE • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022
800.624 8473 • fax: 262.257.7399 • www.wbmcguire.com • [email protected]
Manual No. 4111-0018
July 2007
REV November 2009
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
Introduction
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dock Leveler Stock Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation
Prepare Pit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Prepare Dock Leveler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install Dock Leveler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install Control Panel and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Put New Leveler Into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operation
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ramp Loading/Unloading Instructions . . . . . . . . . . . . . . . . . . . . 19
End Loading/Unloading Instructions . . . . . . . . . . . . . . . . . . . . . 20
Maintenance
Service Dock Leveler Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjustments
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Adjust Main System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Adjust Auto Return To Dock (ARTD) Below Dock Control . . . . . . . 26
Adjust Down Speed andLip Extension . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical
Signal Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Three Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Signal Phase Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Three Phase Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Troubleshooting
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Parts
Frame and Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Weather Seal, Rubber Style and Brush Style . . . . . . . . . . . . . . . . . 50
Full Range Toeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Power Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Miscellaneous
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Customer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
4111-0018 — November 2009
Recognize Safety Information
Safety-Alert Symbol
General Operational Safety
Precautions
SAFETY
The Safety-Alert Symbol identifies important safety messages on equipment, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.
The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death.
Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler.
Never operate a dock leveler while a safety device or guard is removed or disconnected.
Never remove DANGER, WARNING, or CAUTION signs or decals on the equipment unless replacing them.
The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death.
O pe ra tin g Z on e
The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury.
IMPORTANT
The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage.
Op era tin g
Zo ne
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.
4111-0018 — November 2009
1
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.
Stay clear of dock leveling device when freight carrier is entering or leaving area.
Chock/restrain all freight carriers. Never remove the wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away.
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.
Make sure lip overlaps onto trailer at least 4 in.
(102 mm).
2
Keep a safe distance from both side edges.
4111-0018 — November 2009
SAFETY
Do not use dock leveling device if freight carrier 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.
4111-0018 — November 2009
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 may result in damage to dock leveler and/or serious personal injury or death.
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.
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 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.
The maintenance prop must be in the upright
"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 device.
4
4111-0018 — November 2009
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.
1751-0727
DANGER
CRUSH HAZARD
Maintenance prop must support leveler behind bar.
Do not force maintenance prop forward of bar to support lip. Refer to owner’s/user’s manual for proper use. Failure to comply will result in death or serious injury.
1751-0727
1751-0730
(x2)
DANGER
Unsupported dock leveler ramps can lower unexpectedly.
Before allowing vehicle to leave the dock always:
! Ensure that no equipment, material or people are on the dock leveler.
! Return the dock leveler to its stored position at dock level.
Failure to follow posted instructions will result in death or serious injury.
SAFETY INFORMATION
Operation
1. Read and follow all instructions and warnings in the owner’s/user’s manual.
2. Use of dock leveler restricted to trained operators
3. Always chock trailer wheels or engage truck restraint before operating dock leveler or beginning to load or unload.
4. Never use hands or equipment to move the ramp or lip
5. Before activating dock leveler:
¥ Ensure trailer is backed in against bumpers.
¥ Remove any end loads if required.
¥ Check trailer alignment to avoid lip interference. If lip does not lower to trailer bed, reposition vehicle.
6. Ensure that truck bed supports extended lip or the leveler frame supports the ramp before driving on ramp.
7. Stay clear of hinges and front and sides of moving dock leveler.
8. Never use damaged or malfunctioning dock leveler. Report problems immediately to supervisor.
Maintenance/Service
1. Read and follow all instructions, warnings and maintenance schedules in the owner’s/user’s manual.
2. Maintenance/Service of dock leveler restricted to trained personnel.
3. Place barriers on the driveway and on dock floor to indicate service work is being performed.
4. DO NOT ENTER PIT unless dock leveler is securely supported by maintenance prop.
5. If electrically powered turn off and use
OSHA lockout/tagout procedures.
Call 262.255.1510 for replacement placards, warning labels, or owner’s/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)
HERE
(decal placed in same position on both sides)
1751-0138
!
DANGER
CRUSH HAZARD
DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance prop. Refer to owner’s/user’s manual for proper maintenance procedure. Failure to comply will result in death or serious injury.
1751-0729
DANGER
CRUSH HAZARD
Do not work under dock leveler unless this maintenance prop has been secured in the upright position. See owner’s/user’s manual for proper procedures. Failure to comply will result in death or serious injury.
1751-0729
1751-0731
DANGER
CRUSH HAZARD
Open the pin latch and insert through the maintenance prop housing and prop completely. Close the pin latch to secure prop. Use every time dock leveler is serviced.
Failure to comply will result in death or serious injury.
1751-0731
1751-0726
DANGER
CRUSH HAZARD
DO NOT ENTER PIT unless dock leveler is safely supported by maintenance prop. Place barriers on driveway and dock floor to indicate service work being performed. Refer to owner’s/user’s manual for proper maintenance procedures. Failure to comply will result in death or serious injury.
1751-0726
4111-0018 — November 2009
5
General Information
Length
6 ft (1828.8 mm)
8 ft (2438 mm)
10 ft (3048 mm)
12 ft (3658 mm)
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 (24 948 kg)
75,000 lb (34 019 kg)
100,000 lb (45 359 kg)
INTRODUCTION
Dock Leveler Stock Specifications
HP/H dock levelers are available in the following sizes, weight capacities, and options:
Width: HP/H
6 ft (1828.8 mm)
6-1/2 ft (1981.2 mm)
7 ft (2133.6 mm)
Congratulations on your choice of a McGuire dock leveler. This manual covers the HP/H series hydraulic dock leveler.
Designed by McGuire. to be a marvel of simplicity and efficiency, your dock leveler, when properly installed, will provide many years of trouble-free performance with an absolute minimum of maintenance. Its revolutionary hydraulic system efficiently controls and operates every function. To obtain maximum performance and longest possible use, a simple program of preventive maintenance is recommended.
* CIR (Comparative Industry Rating)
Call McGuire, to discuss available voltages, phases and options to meet your specific needs.
The HP/H series dock leveler comes equipped with an electrical control panel, which allows pushbutton operation of the dock leveler functions. Each HP/H 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 McGuire Technical
Services.
Once again, thank you and congratulations on your purchase of a McGuire hydraulic dock leveler.
6
4111-0018 — November 2009
INTRODUCTION
Component Identification
C
A
B
D
E
F G
H
I
E
J
A — Lip
B — Platform
C — Lip Cylinder
THEORY
D — Powerpack (Motor/Pump/Reservoir)
E — Prop Pin and Clip
F — Platform Cylinder
G — Main Frame
H — Lip Keepers (2 used)
I — Maintenance Prop
J —Toe Guard (2 used)
The HP/H dock leveler uses hydraulics and one-button operation for ease of use.
Platform (B) is raised by pushing and holding the
RAISE button (K). This activates an electric motor (D) which, in turn, drives a hydraulic pump. The hydraulic pump forces oil into the platform cylinder(s) (F), causing the platform to rise. Releasing the RAISE button allows the platform to lower.
K
4111-0018 — November 2009
7
Prepare Pit
A
10”
14”
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 dock leveler before installation has been completed.
Failure to follow the installation instructions can result in damage to dock leveler, the facilities, and/or serious personal injury or death.
Only trained installation professionals with the proper equipment should install this product.
IMPORTANT
DO NOT remove the shipping bands around the dock leveler lip until instructed to do so.
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.
2. Check the entire dock leveler pit for proper construction according to approved/certified pit drawings. Make sure pit is square by making the following measurements:
• 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 (criss-cross) 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 Systems, Inc. Technical
Services before proceeding.
3. Make sure the field junction box for the dock leveler (E) is at the correct location per pit diagrams.
8
4111-0018 — November 2009
INSTALLATION
Prepare Dock Leveler
A
IMPORTANT
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 15 for front pick up.
1. Remove any control panel and bumpers that may be banded to the frame of the dock leveler.
DO NOT remove the shipping bands (B) around the platform lip and leveler frame at this time.
B
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. A third sling
may be used to install the unit.
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.
IMPORTANT
DO NOT overtighten the lifting bracket hardware.
Overtightening can damage the weather seal, if equipped.
NOTE: Overall width of platform and lifting brackets
(A) must be kept to a minimum to prevent interference between the lifting brackets and the pit walls as the dock leveler is lowered into the pit.
2. Make sure the mounting hardware of lifting brackets (A) is snug. The brackets should pivot relatively freely on the mounting cap screw. DO
NOT 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.
4. Remove shipping pallet, if present, before putting the dock leveler into the pit.
4111-0018 — November 2009
9
INSTALLATION
Install Dock Leveler
Shim
Stacking Methods
M
N
P
Q
A— Distance (Leveler Frame
Height)
B— Shim Locations (Under
Rear Vertical Supports)
C— Shim Location (Under
Maintenance Prop,Lip keepers, Main cylinder)
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)
10
4111-0018 — November 2009
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).
b. Measure dock floor-to-pit floor distance (H) 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.
IMPORTANT
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. For all HP/H models, put a minimum 1/4 in. (6.6
mm) thick shim at locations (B and C) .
NOTE: A 1/4 in. (6.6 mm) thick shim at locations (B and C) is used only as a starting point. The final shim stack height will be determined after dock leveler is lowered into the pit.
The dock leveler is heavy. Use chains and a lifting device with the appropriate lifting capacity and reach. Failure to do so may result in damage to dock leveler and/or serious personal injury or death.
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. For all HP/H models, 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.
4111-0018 — November 2009
11
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:
• 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.
E— Pry Locations
F— Rear Hinge Frame Angle
G— Rear Pit Curb Angle
H— Flare Bevel Weld, Typical
(To Fit Spacing)
9. If gap (D) cannot be obtained equally at both sides of leveler, grind or add material at the rear edge of rear hinge frame angle (F) as needed.
10. Allow the dock leveler to rest fully on the shim stacks. Check that a smooth and level transition exists between the dock floor and the dock leveler platform. Add or remove shims as necessary until a smooth transition is obtained.
11. If leveler cannot be squared and/or made level as instructed in steps 8 — 10, contact Systems,
Inc. Technical Services.
12
4111-0018 — November 2009
INSTALLATION
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 may result in serious personal injury or death.
IMPORTANT
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, hoist cylinder, 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.
IMPORTANT
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.
11. 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.
12. Weld front of dock leveler frame (B) to shims located under the keepers, then weld the shims to the front pit curb steel.
13. With leveler welded into place, remove the shipping bands from around lip and leveler frame.
If the platform is raised using an external lifting device or the hydraulic system is opened to atmosphere, air will enter into the hydraulic system.
Whenever this happens, always cycle the leveler at least 4 times using the leveler’s own hydraulic power system before allowing the leveler to be put into service. This is to make sure all air is purged from the hydraulic cylinders. Failure to do this may result in serious personal injury or death.
4111-0018 — November 2009
13
INSTALLATION
A— Platform Joists B—Platform Maintenace Prop C—Prop Pin and Clip
14. Using an external lifting device (i.e., crane or fork truck) attached to the platform lifting brackets, slowly raise the platform. Check for binding as platform is being raised.
15. If binding occurs, lower the platform. Reposition leveler and/or add or remove shims as necessary. Slowly raise platform again. If platform still binds, contact Systems, Inc. Technical
Services for further instructions.
16. All HP/H models: a. Install shims under maintenance prop (B) where prop attaches to leveler frame. Make sure prop is solidly shimmed.
b. Using the appropriate lifting device, attached to the platform lifting lugs, slowly raise the dock to the fully open position.
14
Two people are required to engage the maintenance prop: one person to operate the lifting device, the other person to engage the maintenance prop.
DO NOT use the maintenance prop to support the raised platform until the maintenance prop has been properly shimmed and welded. The shims must be welded to each other, the leveler frame, and to the front pit curb steel. Failure to do this may result in serious personal injury or death.
c.Raise maintenance prop (B) to the service
(upright) position and lock prop in this position using an OSHA approved locking device. (Supplied by others) d. Proceed to step 18.
4111-0018 — November 2009
INSTALLATION
Make sure the platform is properly supported in the raised position before entering the pit to finish weld the shims. Failure to do this may result in serious personal injury or death.
18. All model levelers: Install shims at locations (B)(C) (Ref.page 10) using the pyramid or stepped shimming method. Both platform cylinder trunnions must be solidly shimmed the entire length of the trunnion. Make sure the trunnions are level from side-to-side as well as from front-to-back.
19. 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.
20. When all welding has been completed, paint all the welds and shims.
NOTE:
To pick up 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. (Ref: page 9)
Shim
Stacking Methods
M
Front Pick Up
N
P
Rear Pick Up
Q
* For left/right orientation of dock leveler, see inside back cover of this manual.
4111-0018 — November 2009
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.
A
B
C
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.
A— Disconnect Panel
B— Control Panel
(provided by others)
C— Distance, 48 in. (14 630 mm), minimum.
1. Mount the pushbutton control panel (B) so bottom of control panel-to-dock floor distance (C) is a minimum 48 in. (1219.2 mm).
2. Install electrical disconnect panel (A) if not already installed.
3. Install and connect the control wiring.
4. Connect the dock leveler power cable to the field wires in the pit junction box. Refer to the electrical drawings supplied with the dock leveler.
5. After all electrical connections in the pit have been made, disengage the maintenance prop and lower the platform using the external lifting device connected to the platform lifting brackets.
16
4111-0018 — November 2009
INSTALLATION
Put New Dock Leveler Into Service
1. Disconnect the external lifting device and chains from the lifting brackets.
2. 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 lip does not contact both lip keepers evenly, contact Systems, inc.
Technical Services for further instructions.
3. Install the dock bumpers as required.
4. Turn the main electrical power ON.
Always stand clear of platform lip when working in front of the dock leveler. Serious personal injury or death may result.
7. When the platform lowers to the full below-dock position, push and hold the RAISE button until the lip retracts and platform rises just enough to have the lip 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).
NOTE: For dock levelers equipped with Auto Return
To Dock (ARTD), the platform will automatically return to the cross-traffic position if the ARTD is in NORMAL mode.
When the platform is about 1.00 inch from the full below-dock position, the platform will automatically rise to the cross-traffic position.(See below dock servicing and end loading for additional instructions)
8. Perform steps 5 – 7 at least four times to purge any air that may be in the hydraulic system and to ensure proper operation.
5.
Raise the leveler platform fully by pushing and holding the RAISE button .
NOTE: The platform of a properly operating dock leveler will automatically stop rising when it reaches its full raised height, at which point, the lip extends. (If the lip does not extend or extend fully, see Platform Rises to Full
Height, But Lip Does Not Fully Extend in the
Troubleshooting section.)
6. Release the RAISE button to lower the platform.
As long as there is no truck present at the dock, the platform will lower to the full below-dock position with the lip extended.
NOTE: If a truck is present, the platform will lower until the lip rests on the truck/trailer bed. (See
Operating Instructions in Operation section.)
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 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.
10. With the maintenance prop supporting the platform, remove the lifting brackets on both sides of the unit.
11. Push 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.
12. Perform step 7 if not equipped with ARTD.
4111-0018 — November 2009
17
OPERATION
Stay clear of dock leveler when freight 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 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.
Truck/trailer wheels must be chocked unless the truck restraint is used. Never remove the wheel chocks until loading/unloading is finished and truck driver has been given permission to leave.
Make sure platform lip rests on the truck/trailer bed with at least 4 in. (102 mm) of overlap.
Maintain a safe distance from side edges of leveler during the loading/unloading process.
Failure to follow these instructions may result in serious personal injury or death.
12 in. (305 mm)
12 in. (305 mm)
The HP/H hydraulic dock leveler is designed to compensate for a maximum ± 12 in.* (305 mm) of height difference between the loading dock and the truck bed. DO NOT use the dock leveler if the truck/trailer 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.
18
4111-0018 — November 2009
OPERATION
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 HP/H dock leveler can be operated by using the
RAISE button on the control panel.
1. Check to make sure truck/trailer 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 truck/trailer wheels or use the truck restraint if available.
A
C
B
5. Proceed with loading or unloading the truck/trailer.
6. If end loading is necessary, see End
Loading/Unloading Instructions on page 20.
A—RAISE Button B—ARTD Switch C-LIP OUT
A
A—RAISE Button
4. Extend the platform lip onto truck/trailer as follows: a. Raise the platform by pushing 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 truck/trailer bed.
c. Make sure that the lip is fully extended and supported on the truck/trailer along the entire width of the platform with at least 4 in. (102 mm) of lip overlapping the truck bed.
7. When loading or unloading is finished, raise the platform by pushing and holding RAISE button
(A) .
Hold the RAISE button until the lip folds enough to clear the truck/trailer bed, then release the
RAISE button. The lip will fold and the platform will return to the cross-traffic position.
8. Remove chocks from truck/trailer wheels or release the truck restraint if used.
9. Indicate to driver that truck may leave the dock.
4111-0018 — November 2009
19
OPERATION
Operating Instructions—Continued
End Loading/Unloading Instructions
B
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 truck/trailer bed.
A
C
1. Check to make sure truck/trailer is positioned squarely against dock bumpers.
2. Instruct driver to remain at the dock until the loading or unloading process has been completed.
A—ARTD Switch
6. Turn the ARTD switch (A) on the control panel to the BELOW DOCK position, if equipped.
3. Chock the truck/trailer wheels or use the truck restraint if available.
7. Push the Raise button (B) to the platform just enough to clear the lip keepers.
8. When the platform lip clears the lip keepers, push the Lip-Out button (C) just long enough to clear the lip keepers. Release Lip-Out button. The platform will drift down to the full below-dock position.
9. Proceed with loading or unloading.
End Loading/Unloading — Platform at Cross-Traffic Position.
4. If truck/trailer bed is at or above dock floor level, leave leveler at the cross-traffic position and proceed with loading or unloading.
End Loading/Unloading — Platform at Below-Dock Position.
5. If truck/trailer bed is below the dock floor level, and the dock is equipped with the optional lip-out button, perform steps 6 –12.
Whenever end loading or unloading with the platform in the below-dock position, make sure the
ARTD switch is in the OFF position. DO NOT turn the ARTD switch to the ON position until end loading or unloading is finished.
NOTE: When end unloading is finished and access to the rest of the truck/trailer is still required, the platform lip will need to be extended. See
Ramp Loading/Unloading Instructions on page 19 for further instructions.
10. When the loading or unloading is finished, return the dock leveler platform to the cross-traffic
(stored) position by performing one of the following:
• Turn the ARTD switch (A) to the NORMAL position, if equipped. The platform will automatically rise to the cross-traffic position.
OR
• Push the Raise button (B) until the lip clears the lip keepers. Release Raise button, leveler will return to the stored or cross traffic position.
11. Remove chocks from truck/trailer wheels or release the truck restraint if used.
12. Indicate to the driver that the truck may leave the dock.
20
4111-0018 — November 2009
Service Dock Leveler Safely
D
MAINTENANCE
Side View
B
A B
A— Tagout Device
B— Lockout Device
B —Maintenance
Prop
C — Prop Pin and Clip
D — Header Plate
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 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 the maintenance prop.
Failure to follow these instructions 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.
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 1910.147.
4111-0018 — November 2009
21
MAINTENANCE
Periodic Maintenance
A
F
D
B
E
C
A— Lip Hinge Area
B— Power Unit and Reservoir
C— Platform Hinge Area
D— Platform Cylinder Trunnion
E— Platform Cylinder Pins
F— Lip Cylinder Pins
Before performing any maintenance under the dock leveler, lock the electrical power source in
OFF position and lock the maintenance prop in the service position using an approved locking device.
(See Service Dock Leveler Safely in this section.)
Failure to follow these instructions may result in serious personal injury or death.
IMPORTANT
Use of fluids that do not have equivalent specifications to those in the following list will result in abnormal operation of the dock leveler and voiding of warranty.
To ensure normal operation of the dock leveler, use only aircraft hydraulic fluid designed to meet or exceed military specification MIL-L-5606. It is recommended that the following hydraulic fluids be used:
• ULTRA-VIS-HVI-15
• Flomite 530 ZF
• Aero Shell Fluid 4 or Fluid 41
• Mobile Aero HFA Mil-HS606A or Aero HF
• Texaco Aircraft Hydraulic Oil 15 or 5606
• Exxon Univis J13
These fluid brands can be mixed together. Mixing with fluids that do not meet or exceed MIL-L-5606 may damage the equipment and WILL void warranty. Use of hydraulic fluids with equivalent specifications to those listed here are acceptable.
22
4111-0018 — November 2009
N
MAINTENANCE
P
Q
Regular maintenance must be performed on a weekly and quarterly schedule.
Weekly Maintenance
• Operate the dock leveler through the complete operating cycle to maintain lubrication.
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
IMPORTANT
Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler.
M
M -- Reservoir
N- 3 in. (76.5mm)
From Top of Reservoir
P - Breather Cap
Q - Fluid Level
IMPORTANT
A low fluid level or the use of hydraulic fluids not equivalent to the fluid types recommended, will cause abnormal operation of the leveler and WILL void warranty.
• Lubricate the following areas with light weight machine oil:
(A)— Lip hinge area unless equipped with grease fittings (apply oil to the top of the entire length of lip hinge when platform is at the full below-dock position and lip is folded)
(C)— Platform hinge area (apply oil to top of all platform hinges when platform is at the full below-dock position)
(E)— Platform cylinder-to-platform frame pin
(F)— Lip cylinder-to-platform frame pin
• Lubricate the following areas with white lithium grease:
NOTE: Apply grease to lip hinge grease fittings if equipped.
Before performing any maintenance under the dock leveler, lock the electrical power source in
OFF position and lock the maintenance prop in the service position using an approved locking device.
(See Service Dock Leveler Safely in this section.)
Failure to follow these instructions may result in serious personal injury or death.
• Check reservoir fluid level (Q)(see note 3):
1. Put the dock leveler platform at the full above-dock position and the lip extended.
2. Turn OFF all electrical power to the leveler.
3. Measure fluid level. The fluid level should be approximately 3 in. (76.5 mm) (N) from top of reservoir (M) with platform raised on the maintenance prop.
4. Add hydraulic fluid if necessary. Use only recommended fluid. See page 22.
5. Turn ON electrical power to the leveler.
6. Return the platform to the cross-traffic position.
4111-0018 — November 2009
23
HYDRAULIC PUMP SCHEMATIC
LIP "C2"
MAIN DECK "C1"
103 BAR
1500 PSI
62 BAR
900 PSI
Pilot to Open
5:1
NV
3 to 1
P.C.
.89 BAR
13 PSI
138 BAR
2000 PSI
24
M
1.26 CC/REV
.077 IN3/REV
4111-0018 — November 2009
ADJUSTMENTS
Adjust Main Pressure Relief
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.
A
B
C
C
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.
E
D
F
G
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 the maintenance prop.
Failure to follow these instructions may result in serious personal injury or death.
NOTE: The main pressure relief may need to be increased if the platform does not rise or rises slowly and the system operates in pressure relief mode. See Troubleshooting section.
The main pressure relief may need to be decreased if the pump motor loads down when platform reaches the full raised position. See Troubleshooting section.
A— Shuttle Valve, Ramp
Speed, Lowering
B— Lip Check Relief
C—System P.O. Check
A/E MAIN ADJUSTMENT VALVES
D—Reservoir
E—Sequence Valve, Lip
Extension
F—Main System Relief Valve
G—P.O. Check Valve
To adjust the main pressure relief:
1. Raise the platform fully and engage the maintenance prop in the service position.
2. Turn OFF all electrical power to the dock leveler.
Attach safety lockout and tagout devices.
3. Loose nut on valve (F)
4. Adjust hex adjusting screw (F) in small 1/4 turn increments as follows:
• Turn clockwise to increase pressure relief.
• Turn counterclockwise to decrease pressure relief.
5. Tighten the jam nut.
6. Turn ON electrical power to the dock leveler.
7. Disengage the maintenance prop.
8. Check leveler operation.
9.
Repeat steps 1– 8 as necessary.
4111-0018 — November 2009
25
ADJUSTMENTS
Adjust Auto Return To Dock (ARTD)
C
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.
B
A
D
Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete. Failure to do this may result in serious personal injury or death.
A— ARTD ACTIVATE
B— ARTD DE-ACTIVATE
C— ARTD LIMIT SWITCH
D— ARTD SWITCH ARM
HP/H levelers are equipped with the optional Auto
Return To Dock (ARTD) if leveler not interlocked with a truck restraint.
The ARTD allows the platform to automatically return to the cross-traffic (stored) position after the truck departs.
Adjust the ARTD as Follows:
NOTE: Placement of (A, B and C) are typical factory settings. ATRD is set to engage approximatly one(1) in. before the front header hits the header stops.
1. Raise platform fully and engage the maintenance prop in the service position.
2. Turn OFF all electrical power to the dock leveler.
Attach safety lockout and tagout devices.
(Supplied by others)
3. Loosen nuts (A). Slide bolt up to engage ARTD higher below dock or slide down to engage ARTD lower below dock. Tighten nuts.
4. Turn power back on and run the unit through a full cycle and repeat if necassary.
5. Loosen nut (B) and slide bolt up to shut ARTD higher above dock or slide the bolt down to shut off the ARTD less above dock.
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 the maintenance prop.
Failure to follow these instructions may result in serious personal injury or death.
NOTE: The unit must raise enough to allow the lip to fully retract to have the lip rest in to the lip keepers.
NOTE: The ARTD Switch arm (D) must be between both (A) and (B) to work properly.
26
4111-0018 — November 2009
ADJUSTMENTS
Full Below-Dock Position
D
A
B
The Below Dock End Load Switch (E), controls the lip when end loading below dock. To activate turn the selector switch (F) to BELOW DOCK postion.
This will DE ACTIVATE the Auto Return to Dock feature.
Push and hold the RAISE button until the platform is fully open. The lip will extend until the switch opens up and stops the pump.
The lip will be extended only 2 - 3 inches to stay with in the bumper spacing.
The platform will float to the full below dock position and the trailer and be loaded/unloaded.
In the full below dock position the switch arm (D) will be activated by the front bolt (A) and trapped under the back bolt (B). The switch will active approximatly
1 inch before the front header is fully below dock.
As the platform starts to recycle the lip will pull in first and then the platform will start to raise. Once the platform is high enough to have the lip clear the lip keepers the back bolt (B) will de-activate the switch and turn off the pump and the platform will float down to rest in the lip keepers in the cross traffic position.
When complete, turn the Selector Switch(F) back to the
NORMAL position and the platform will start to Auto
Recycle to the cross traffic position.
NOTE:
When servicing trailers that are lower than dock height it is recommended the BELOW DOCK selector switch (F) be in the BELOW DOCK mode
AFTER the lip is in the bed of the trailer to prevent the Auto Return feature to activate inadvertently.
Below Dock End Load Switch
Whenever end loading or unloading with the platform in the below-dock position, make sure the ARTD switch is in the BELOW DOCK position. DO NOT turn the ARTD switch to the NORMAL position until end loading or unloading is finished.
E
F
4111-0018 — November 2009
27
ADJUSTMENTS
A
B
Down Speed Control Adjustment
Use 1/4 turn increments when adjusting the down speed control. Check platform lowering speed after each adjustment.
Lip Extension Sequence Valve
If the dock leveler did not lower, it is possible that the speed control requires adjustment. The speed control adjusting screw (A) is a thumb screw located on the left side looking from the tank end of the unit, the top valve.
Adjust the Sequence Valve if the lip does not extend all the way or if the lip starts to extend too soon.(B).
NOTE: If the platform lowers too fast, the platform will stop lowering and lock in “safety” mode.
1. If the lip extends while the platform is raising, loosen the jam nut and turn the valve IN or Clockwise to delay the lip from extending. Tighen the jam nut and run the unit through a complete cycle.
2. If the lip does not extend fully, first check fluid level, if full, than loosen the jam nut and turn the valve OUT or Counter Clockwise to cause the lip to come out sooner. Tighten the jam nut and run the unit through a complete cycle.
To adjust the speed control: a. Loosen the jam nut.
b. To decrease the lowering speed, turn adjusting screw (A) clockwise.
c. To increase the lowering speed, turn adjusting screw (A) counterclockwise.
d. Tighten the jam nut.
3. Repeat as needed to achieve proper function of the unit. Call Technical Services if proper function can not be achieved.
NOTE: Extreme cold and/or incorrect fluid may also cause cylinder to lock. Adjust downspeed to decrease lowering speed.
28
4111-0018 — November 2009
ELECTRICAL OVERVIEW
Motor: 1HP, TENV, No.56 frame, 15 minute duty cycle
Return Switch: Maintain-contact type oil-tight enclosure, spring-arm actuation
with adjustable tripper arrangement.
Lip Control Switch: Momentary contact, oil-tight enclosure. Actuated by lip
cylinder.
Fluid Content: UNIVIS HVI-26
Replacement Hydraulic Fluid: We strongly recommend using the
UNIVIS HVI-26, however you may replace the fluid with automatic transmission fluid type F or Dextron. Mixing any other fluid with UNIVIS HVI-26 will cause the fluid to break down. If in climates below zero we recommend replacing and refilling with UNIVIS HVI-26.
CAUTION: DO NOT USE ANY HYDRAULIC FLUID MENTIONED ABOVE.
Note: UNIVIS HVI-26 is designed for extremely cold climates and will break
down if mixed with any other fluid; however you may mix with any hydraulic fluid for emergency use. WE STRONGLY RECOMMEND DRAINING AND
REFILLING WITH FRESH UNIVIS HVI-26 or EQUIVELENT AS SOON AS
POSSIBLE.
Tank Capacity
25K To 75K Levelers…………...4 quarts
100K Levelers…………………...5 quarts
Motor Electrical Specifications
Motor
Voltage RPM Hz PHASE
AMP. DRAW
MOTOR
RUNNING
Elect. Serv.
Amperage
Req.
110/115/120 3450 60 1 14.4 30*
208 3450 60 1
220/230/240 3450 60 1
208 3450 60 3
220/240 3450 60 3
7.1 20
7.2
3.6
20
10
3.7 10
440-460-480 3450 60 3
575 3450 60 3
1.8 10
1.4 10
Guide to Wire Sizes
Length of Run
120/208
Volt
240Volt 220Volt 460Volt 575Volt
in Feet 1 Phase 1 Phase 3 Phase 3 Phase 3 Phase
Wire Size Wire Size Wire Size Wire Size Wire Size
#12 #12 0-25 #10 #12 #12
25-45 #8 #12 #12 #12 #12
45-75 #6 #8 #10 #10 #10
75-120 #6 #8 #10 #10 #10
120-150 #4 #6 #8 #8 #8
150-220 NR NR NR NR NR
CAUTION: Sufficient voltage must reach the Leveler Control Panel to operate the
1 HP motor. Voltage drop caused by long wire runs or undersized wire increase the Amp draw and will cause the breaker to trip and/or more serious damage to occur. Therefore, it is important for installation to be done to meet all codes by a licensed electrician.
IMPORTANT NOTE: The values given are intended to only be a guide. Be sure
to check all electrical codes before installation. This chart indicates the length of branch circuit having a 2% voltage drop at full load (start up) current in feet.
Values are for THHN copper wire only.
4111-0018 — November 2009
29
ELECTRICAL 1 PHASE
30
4111-0018 — November 2009
ELECTRICAL 1 PHASE
4111-0018 — November 2009
31
ELECTRICAL 3 PHASE
32
208 V | 3.8A |
4111-0018 — November 2009
ELECTRICAL 3 PHASE
4111-0018 — November 2009
33
CONTROL PANEL
3.50
6.50
8.30
6.00
4.50
10.25
10.75 Hole Centers
34
6.30
4111-0018 — November 2009
PARTS
Typical 3PH panel lay out
* Provide dock leveler serial number, voltage, phase, and options when calling or faxing controller orders
.
4111-0018 — November 2009
35
CONTROL BOX PARTS SINGLE PHASE
36
4111-0018 — November 2009
CONTROL BOX PARTS SINGLE PHASE
4111-0018 — November 2009
37
CONTROL BOX PARTS THREE PHASE
38
4111-0018 — November 2009
CONTROL BOX PARTS THREE PHASE
4111-0018 — November 2009
39
TROUBLESHOOTING
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 the maintenance prop.
Failure to follow these instructions may result in serious personal injury or death.
Before performing the detailed troubleshooting procedures, check the following items first:
• Check all fuses inside the control panel(s). Replace any blown fuse(s) with a fuse of equal specification.
Make sure to pull the fuses out of the circuit to test.
• Make sure the correct voltages are present at the proper locations inside the control panel(s).
Symptom Possible Cause
Platform does not rise.
Motor does not energize.
Motor overload device tripped or fuse blown.
Solution
Reset overload relay (three-phase) or replace fuse(s) (single-phase). Determine cause of overload.
NOTE: When replacing fuse(s), the new fuse must have the same specification as the old fuse.
Motor starter (three-phase) or motor relay
(single-phase) not energizing.
•
Check voltage at starter or relay coil.
If voltage is present and starter or relay does not energize, replace starter or relay.
• If voltage is not present, check all components in series with the starter or relay coil.
40
4111-0018 — November 2009
TROUBLESHOOTING
Symptom
Three-phase units only:
Platform does not rise.
Motor hums, but does not run.
Possible Cause
No voltage is present on one line.
Solution
Check for blown fuses at branch circuit disconnect.
Replace fuse. Determine cause of blown fuse.
NOTE: A motor that is missing voltage on one line is said to be single-phased.
Check motor starter as follows:
1. Disconnect wires at load side of starter.
2. Energize the starter.
3. Measure line-to-line voltage at line side of starter.
4. Measure line-to-line voltage at load side of starter.
5. Line-side and load-side voltages should be approximately the same. Replace starter if voltage values are considerably different from one another.
Check all wiring to motor for high resistance or no connection.
Three-phase units only:
Platform does not rise.
Motor runs in reverse
Phase reversed. Reverse any two legs at the branch circuit disconnect.
Single-phase units only:
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. Replace if necessary.
Defective motor centrifugal switch.
Replace motor.
Defective motor capacitor.
Replace motor.
Dock leveler equipped with ARTD: Platform does not automatically return to the cross-traffic position or operates abnormally.
The auto return limit switch not activating correctly.
Defective limit switch.
Adjust the bolts as needed. See Adjust Auto Return
To Dock (ARTD) in the Adjustment section.
Replace switch.
Broken wire. Loose or corroded wire connections.
Repair or replace wires and connections as necessary.
4111-0018 — November 2009
41
Symptom
Platform does not rise.
Pump operates in pressure relief mode.
TROUBLESHOOTING
Possible Cause Solution
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. The motor will continue to run which will result in melting the reservoir.
Dock leveler binds.
Check for visible obstructions that could cause binding. Remove obstructions. If no obstructions found, call Systems, Inc. Technical Services. See inside back cover for phone number and address.
Pressure relief set too low.
Increase pressure relief. See Adjust Main Pressure
Relief in the Adjustment section.
Platform rises slowly.
Low hydraulic fluid.
Contaminated hydraulic system.
NOTE: The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value* at any time, including when operating in pressure relief.
* The full load amp value can be found on the inside cover of the control panel.
Add fluid as needed. See Periodic Maintenance in the Maintenance section.
Clean and inspect valves. Flush contaminated oil from hydraulic system. Fill system with new oil. See
Periodic Maintenance in the Maintenance section.
Damaged or restricted hydraulic hose(s).
Replace damaged hose(s). Remove restriction.
Pressure relief set too low.
Increase pressure relief. See Adjust Main Pressure
Relief in the Adjustment section.
NOTE: The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value* at any time, including when operating in pressure relief.
* The full load amp value can be found on the inside cover of the control panel.
Pump motor loads down when platform reaches the full raised position.
Pressure relief set too high.
Decrease pressure relief. See Adjust Main Pressure
Relief in the Adjustment section.
NOTE: The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value* at any time, including when operating in pressure relief.
* The full load amp value can be found on the inside cover of the control panel.
42
4111-0018 — November 2009
TROUBLESHOOTING
Symptom
Platform does not rise to full height.
Possible Cause
Low hydraulic fluid.
Platform DOES rise to full height, but lip DOES
NOT extend or extend fully.
Low hydraulic fluid.
The BELOW DOCK switch is in the BELOW DOCK position
Lip does not extend.
Sequence valve out of adjustment
Solution
Add fluid as needed. See Periodic Maintenance in the Maintenance section.
Add fluid as needed. See Periodic Maintenance in the Maintenance section.
Turn the switch to the NORMAL position.
Adjust the sequence valve out( coutner clock wise) to get the lip to swing out sooner.
Lip extends almost immediately when the
RAISE button is pushed.
Sequence valve out of adjustment
Platform locks into
“safety” as platform lowers. Lip drops to vertical position.
Platform lowering speed is too fast.
Adjust the sequence value in( clock wise) to keep the lip from swinging out too soon.
Adjust platform down speed control.
See Down Speed Control in the Adjustment section.
NOTE: Extreme cold weather OR incorrect fluid may cause platform to lock. Adjustment is same.
4111-0018 — November 2009
43
PARTS
Frame - Platform - Lip
A
44
K
G
F
H
B
E
D
C
J
L
4111-0018 — November 2009
PARTS
Lip and Platform
ITEM
A
QTY
1
1
1
1
1
1
1
1
1
6.0 FOOT 25K
16 0595-5045
18 0595-5046
20 0595-5047
6.5 FOOT
16 0595-5048
18 0595-5049
20 0595-5050
7.0 FOOT
16 0595-5051
18 0595-5052
20 0595-5053
LIPS
30K
0595-5054
0595-5055
0595-5056
0595-5057
0595-5058
0595-5059
35K
0595-5063
0595-5064
0595-5065
0595-5066
0595-5067
0595-5068
40/45K
0595-5072
0595-5073
0595-5074
0595-5075
0595-5076
0595-5077
55K
0595-5081
0595-5082
0595-5083
0595-5084
0595-5085
0595-5086
0595-5060
0595-5061
0595-5062
0595-5069
0595-5070
0595-5071
0595-5078
0595-5079
0595-5080
0595-5087
0595-5088
0595-5089
PLATFORMS
ITEM QTY
B
1 25K
1 30K
1 35K
1 40K
1 45K
1 100K
ITEM QTY
B
1 55K
1 75K
1 25K
1 30K
1 35K
1 40K
1 45K
1 55K
1 75K
6.0 FOOT
9515-5054
9515-5055
9515-5056
9515-5057
9515-5102
9515-5103
9515-5104
9515-5105
6.0 FOOT
9515-5078
9515-5079
9515-5080
9515-5081
9515-5126
9515-5127
9515-5128
6 FOOT
6.5 FOOT
9515-5058
9515-5059
9515-5060
9515-5061
9515-5106
9515-5107
9515-5108
9515-5109
10 FOOT
6.5 FOOT
9515-5082
9515-5083
9515-5084
9515-5085
9515-5130
9515-5131
9515-5132
7.0 FOOT
9515-5062
9515-5063
9515-5064
9515-5065
9515-5110
9515-5111
9515-5112
9515-5113
7.0 FOOT
9515-5086
9515-5087
9515-5088
9515-5089
9515-5134
9515-5135
9515-5136
25K
30K
35K
40K
45K
55K
75K
25K
30K
35K
40K
45K
6.0 FOOT
9515-5066
9515-5067
9515-5068
9515-5069
9515-5114
55K
75K
9515-5115
9515-5116
100K 9515-5117
6.0 FOOT
9515-5090
9515-5091
9515-5092
9515-5093
9515-5138
9515-5139
9515-5140
1 100K 9515-5129 9515-5133 9515-5137 100K 9515-5141
1
Provide dock leveler serial number, platform size, and lip size when calling or faxing orders
.
* For left/right orientation of dock leveler, see inside back cover of this manual.
75K
0595-5090
0595-5091
0595-5092
0595-5093
0595-5094
0595-5095
0595-5096
0595-5097
0595-5098
8 FOOT
6.5 FOOT
9515-5070
9515-5071
9515-5072
9515-5073
9515-5118
9515-5119
9515-5120
9515-5121
12 FOOT
6.5 FOOT
9515-5094
9515-5095
9515-5096
9515-5097
9515-5142
9515-5143
9515-5144
9515-5145
100K
0595-5099
0595-5100
0595-5101
0595-5102
0595-5103
0595-5104
0595-5105
0595-5106
0595-5107
7.0 FOOT
9515-5074
9515-5075
9515-5076
9515-5077
9515-5122
9515-5123
9515-5124
9515-5125
7.0 FOOT
9515-5098
9515-5099
9515-5100
9515-5101
9515-5146
9515-5147
9515-5148
9515-5149
4111-0018 — November 2009
45
PARTS
C
H
J
K
F
G
D
E
LIP SHAFTS 25K-100K
2 6.0 FOOT DPLA-2101
2 6.5 FOOT
2 7.0 FOOT
DPLA-2102
DPLA-2103
4 DOTH-2355 PIN, CLEVIS
4 DOTH-2373 PIN, COTTER
2 DOTH-2160 NUT, HEX 5/8-11 UNC
2 DOTH-2074 BOLT, 5/8-11 UNC X 2.00 INCH
2 DOTH-2382 PIN, COTTER 1/4 X 2
1 9201-0006 PROP PIN AND CLIP
2 8432-1129
2 8432-1130
2 8432-1131
KEEPER LIP 16
KEEPER LIP 18
KEEPER LIP 20
K 2 8432-1132
2 8432-1133
2 8432-1134
KEEPER LIP 16 24 pit
KEEPER LIP 18 24 pit
KEEPER LIP 20 24 pit
ITEM QTY
L
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
BASE FRAMES
6 FOOT
6.0 FOOT 25K/55K
16 8435-5027
18 8435-5028
20 8435-5029
6.5 FOOT
16 8435-5039
18 8435-5040
20 8435-5041
6.0 FOOT
6.5 FOOT
8 FOOT
25K/55K
16 8435-5030
18 8435-5031
20 8435-5032
16 8435-5042
18 8435-5043
20 8435-5044
6.0 FOOT 25K/55K
16 8435-5033
6.5 FOOT
10 FOOT
24 INCH PIT
18 8435-5034
20 8435-5035
16 8435-5045
18 8435-5046
20 8435-5047
6.5 FOOT
12 FOOT
24 INCH PIT
6.0 FOOT 25K/55K
16 8435-5036
18 8435-5037
20 8435-5038
16 8435-5048
18 8435-5049
20 8435-5050
7.0 FOOT 7.0 FOOT 7.0 FOOT 7.0 FOOT
16 8435-5051
18 8435-5052
16 8435-5054
18 8435-5055
16 8435-5057
18 8435-5058
16 8435-5060
18 8435-5061
6.0 FOOT
20 8435-5053
75K (24 pit) 6.0 FOOT
20 8435-5056
75K(24 pit) 6.0 FOOT
20 8435-5059
75K(24 pit) 6.0 FOOT
20 8435-5062
75K(24 pit)
16 8435-5063
18 8435-5064
20 8435-5065
16 8435-5066
18 8435-5067
20 8435-5068
16 8435-5069
18 8435-5070
20 8435-5071
16 8435-5072
18 8435-5073
20 8435-5074
6.5 FOOT 6.5 FOOT 6.5 FOOT 6.5 FOOT
16 8435-5075
18 8435-5076
20 8435-5077
16 8435-5078
18 8435-5079
20 8435-5080
16 8435-5081
18 8435-5082
20 8435-5083
16 8435-5084
18 8435-5085
20 8435-5086
7.0 FOOT 7.0 FOOT 7.0 FOOT 7.0 FOOT
16 8435-5087
18 8435-5088
16 8435-5090
18 8435-5091
16 8435-5093
18 8435-5094
16 8435-5096
18 8435-5097
6.0 FOOT
20 8435-5089
100K(24 pit) 6.0 FOOT
20 8435-5092
100K(24 pit) 6.0 FOOT
20 8435-5095
100K(24 pit) 6.0 FOOT
20 8435-5098
100K(24 pit)
16 8435-5099
18 8435-5100
20 8435-5101
16 8435-5102
18 8435-5103
20 8435-5104
16 8435-5105
18 8435-5106
20 8435-5107
16 8435-5108
18 8435-5109
20 8435-5110
6.5 FOOT 6.5 FOOT 6.5 FOOT 6.5 FOOT
16 8435-5111
18 8435-5112
20 8435-5113
16 8435-5114
18 8435-5115
20 8435-5116
16 8435-5117
18 8435-5118
20 8435-5119
16 8435-5120
18 8435-5121
20 8435-5122
7.0 FOOT 7.0 FOOT 7.0 FOOT 7.0 FOOT
16 8435-5123
18 8435-5124
16 8435-5126
18 8435-5127
16 8435-5129
18 8435-5130
16 8435-5132
18 8435-5133
20 8435-5125 20 8435-5128 20 8435-5131 20 8435-5134
46
4111-0018 — November 2009
PARTS
4111-0018 — November 2009
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47
PARTS
Hydraulic Components
48
4111-0018 — November 2009
Hydraulic Components
1 0525-0106 MAIN CYLINDER 3 x 18”
2
3
0525-0107
111-275
111-274
0525-0108
MAIN CYLINDER 4 x 18” ( 75K and 100K)
SEAL KIT MAIN CYL.3 x 18”
SEAL KIT MAIN CYL.4 x 18”
LIP CYLINDER
4
5
6
111-094
111-374
111-375
111-077
SEAL KIT LIP CYLINDER
MOTOR PUMP ASSY. 1PH
MOTOR PUMP ASSY. 3PH
HOSE ASSEMBLE MAIN
7
8
8
9
7
7
111-075
111-078
111-078
111-074
111-079
111-212
10 111-170
11 111-071
11A 111-206
12 111-220
HOSE ASSEMBLY LIP 6 FOOTLONG
HOSE ASSEMBLY LIP 8 FOOT LONG
HOSE ASSEMBLY LIP 10 FOOT LONG
HOSE ASSEMBLY MAIN TO LIP 6-8 FOOT LONG
HOSE ASSEMBLY MAIN TO LIP 10 FOOT LONG
HOSE ASSEMBLY BOTTOM OF MAIN TO TOP
FITTING, ELBOW SWIVEL
FITTING, ELBOW
VALVE, SOLENIOD (OPTIONAL) REPLACES ITEM #11
FOR E-STOP OR INDEPENDANT LIP
FUSE, VELOCITY
12A 111-366
13 111-208
14 111-210
15 111-070
16 111-066
17 113-264
FUSE, VELOCITY WITH E-STOP
FITTING, TEE
FITTING, TEE
FITTING, ELBOW
FITTING, ELBOW SWIVEL
PIN, CLEVIS LIP
18 113-064 PIN, CLEVIS MAIN
19 113-073
20 112-071
PIN COTTER
WASHER, FLAT
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
2
2
2
2
PARTS
1
Provide length and diameter of hose when calling or faxing orders.
2 Provide dock leveler serial number, voltage, and phase when calling or faxing orders.
4111-0018 — November 2009
49
PARTS
Weather Seal, Rubber Style and Toe Guards
9
10
12
11
5
1
3
6
7
4
2
8 FOOT
6 FOOT
*
3
4
5
1
2
1 0014-0062 TOE GUARD LH MIDDLE
1 0014-0066 TOE GUARD LH LOWER
1 0014-0064 TOE GUARD RH MIDDLE
1 0014-0068 TOE GUARD RH LOWER
2 OTH-2043 SCREW CAP
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
*
6
7
6
2
OTH-2207
OTH-2131
WASHER
LOCK NUT
SAME
SAME
9 2 DOTH-2841 CHANNEL WEATHER SEAL DOTH-2840 CHANNEL WEATHER SEAL
10 2 DOTH-2824 T-RUBBER WEATHER SEAL DOTH-2824 T-RUBBER WEATHER SEAL
11 2 DOTH-2822 BRUSH WEATHER SEAL
12 2 DOTH-2821 EXTRUSION ALUM.
1 DKIT-9179 FRTG. COMPLETE R&L
DOTH-2822 BRUSH WEATHER SEAL
DOTH-2820 EXTRUSION ALUM.
DKIT-9180 FRTG. COMPLETE R&L
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
SAME
SAME
DOTH-2843 CHANNEL WEATHER SEAL
CONSULT FACTORY
CONSULT FACTORY
CONSULT FACTORY
DKIT-9181 FRTG. COMPLETE R&L
50
4111-0018 — November 2009
PARTS Motor and Pump
111-374
Reservoir, Pump with Motor Drive Plate Single Phase
111-375 Reservoir, Pump with Motor Drive Plate Three Phase
1
Provide dock leveler serial number and type of installation when calling or faxing orders.
2
Provide dock leveler serial number, voltage, and phase when calling or faxing orders.
4111-0018 — November 2009
51
NOTES
MISCELLANEOUS
52
4111-0018 — November 2009
MISCELLANEOUS
Customer Information
A
NOTE: Refer to illustration for left/right orientation of dock leveler.
The model/serial number decal (A) is located on the left platform joist near the front (lip) of dock leveler.
When you receive your HP/H 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:
Systems, Inc.
P.O. Box 309
Germantown, WI 53022
Phone: (800) 624-8473
Fax: (262) 255-9399
4111-0018 — November 2009
Dock Leveler Information
Model ___________________________________
Serial No. ________________________________
McGuire’s, Job No. ______________________
Original Owner Information
Name ___________________________________
Address _________________________________
________________________________
Installer Information
Name ___________________________________
Address _________________________________
_________________________________
Date of Installation ________________________
53
McGUIRE. WARRANTY
HP/H SERIES LEVELER
McGuire., guarantees the materials, components, and workmanship in your
McGuire HP/H dock leveler to be of the highest quality and to be free of defects in material and workmanship for a full One (1) Year Base Warranty on the structural, hydraulic and electrical. Additional 4 years pro rated based on application, from date of shipment, specifically the deck section, lip section, frame, rear hinge, front hinge for the HP series. The H series also carries the 4 year warranty and is NOT pro rated, based on application.
Specifically this guarantee applies to:
• All hydraulic cylinders
• Hydraulic pressure lines
• Hydraulic pump and motor.
In the event of any defect covered by this guarantee, McGuire, will remedy said defect by repairing or replacing all defective parts, bearing all of the costs for parts, labor, and transportation.
All guarantee claims will be settled on a timely basis when defects are found to be from other than improper installation, operating contrary to instructions or beyond rated load capacities, abuse, careless or negligent use, or failure to maintain the unit as recommended by the owner's manual.
There are no guarantees, either expressed or implied, including any implied guarantees of merchantability or fitness for a particular purpose which shall extend beyond the guarantee periods indicated above. This guarantee is valid only if the unit(s) is unaltered from original condition as delivered from the factory and a survey is completed by a McGuire representative.
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Key features
- Hydraulic operation
- One-button control
- Automatic return to dock
- Lip extension
- Safety features
- Easy maintenance
