Mechanical Dock Leveler MKA 1000LB MKA 1000HD

Mechanical Dock Leveler
MKA 1000LB
MKA 1000HD
MKA 1300
M-Series
Owner's Manual & Installation Instructions
Important: Thoroughly read and understand entire
contents of this manual prior to installation and/or
operation of this equipment.
Caution: Be sure that installation and maintenance
are performed by qualified personnel.
W.B. McGuire Company, Inc.
One Hudson Ave.
Hudson, NY 12534
1-800-624-8473
INTRODUCTION....
Congratulations! You have purchased the industry's finest mechanically operated dock leveler. Being dynamically
engineered, it will provide many years of service for you. As with all equipment using some mechanical function, a simple
maintenance program will insure proper operation. On-site maintenance personnel can follow the enclosed service
instructions or you can arrange for professional servicing through your authorized McGuire Distributor.
SAFETY INFORMATION...
• Never work under the dock leveler without proper placement of jack stands to brace leveler.
• Be sure truck wheels are chocked, or restraint device activated, before loading or unloading operations begin.
Personal injury and/or freight damage can result from careless work habits at the loading dock.
• Do not operate dock levelers with anyone standing directly on or in front of the leveler.
• Read and follow operating instructions to store dock levelers; at dock level after loading/unloading truck
departs.
• Periodic inspection should be made to insure there are no worn or damaged parts which could result in failure
of equipment and/or personal injury. Lubrication and adjustment is essential to proper operation of this product.
Follow maintenance recommendations for needed service information.
• Do not stand on any part of the leveler or stand near or touch the leveler while any load is being placed on it.
Never place your hands, arms, feet or legs in a position where a load moving onto the leveler could cause
injury. If in doubt don't do it.
WARNING...
Personal injury and/or structural damage to dock leveler can result from abuse or negligent use of this product.
IMPORTANT...
This manual assumes that the installer is very familiar with the operation, function and various parts of the
McGuire Mechanical Leveler. If this is not the case, it is imperative that the installer thoroughly understand the
operational and safety information contained in this manual first. An installation video is available from W.B.
McGuire Company. Call 1-800-624-8473 for a copy.
TABLE OF CONTENTS...
Introduction and Table of Contents
Overview of Potential Hazards
Installation Instructions & Shim Locations
Pit Dimensions
Bumper Mounting Details
Operating Sequence
Maintenance & Required Adjustments
Component Identification
Parts List
Trouble Shooting Procedures
Dock Leveler Warranty
1
2
3
4
5
6
7
8
9
10
Back Cover
NOTE: All information contained in this manual is applicable for all mechanical dock leveler models mentioned on the
cover. In specific instances, the difference between models is noted. Only structural differences and capacity ratings
occur between models. All instructions apply to any mechanical model.
McGuire shall not in any event be liable for any loss of the use of any equipment or incidental or consequential
injuries or damages of any kind as a result of misuse or improper operation of this product.
1
OVERVIEW OF POTENTIAL HAZARDS...
!
WARNING
Dock levelers are large, heavy objects that move with the help of springs under high tension. Since moving objects
and springs under tension can cause injuries, your safety and the safety of others depend on you reading the information in this manual. If you have questions or do not understand the information presented, call the McGuire
Technical Support team at 1-800-624-8473.
!
Moving Ramp can cause serious
injury or death.
Stay Clear when ramp is in motion.
WARNING: can cause serious
injury or death.
Moving Leveler
!
WARNING: can cause serious
injury or death.
Moving Truck
Do Not enter pit area until ramp
has been braced open and power
is turned off and locked out.
Moving Truck can cause serious
injury or death.
Stay Clear when truck is in motion.
Do Not stand between truck and
ramp when truck is entering or
leaving.
SAFETY INSTRUCTIONS
1. Read manual carefully before installing, operating, or servicing dock leveler.
2. Be sure truck wheels are chocked or truck is held in place by a restraining device before loading or unloading.
3. Make sure leveler is returned to its level, stored position after truck pulls away from dock.
4. Do not attempt to manually lift the dock leveler platform or lip. Do Not operate leveler with equipment, material
or people on the platform, lip or in front of the leveler.
5. Keep pedestrians and forklifts away from open door area when not loading or unloading truck.
6. If dock leveler appears to be broken or is not working properly, contact your authorized McGuire representative.
In the following sections the word:
Danger means that serious injury or death will occur from failure to follow instructions.
Warning means that serious injury or death can occur from failure to follow instructions.
Caution means that minor injury or property damage can occur from failure to follow instructions.
Note means that special attention should be given to the instruction.
2
CAUTION: Do Not Unband. Check unit
for damage, If damaged, do not install.
Contact factory immediately.
INSTALLATION INSTRUCTIONS...
1.
On arrival, the platform will be banded to the base. DO NOT UNBAND. Check unit for any
damage that may have occurred during transit. If any damage is detected, file a claim with the
transportation company delivering carrier immediately. DO NOT INSTALL ANY UNIT THAT
APPEARS TO BE DAMAGED. Contact factory immediately.
2.
Move the leveler into the pit using a fork truck. Use the fork lift slots at the front of the leveler
for moving. Do not attempt to pick up leveler from sides or back.
3.
Unband the platform from the base. Raise the platform so that the lip extends. SET THE BUILT-IN INSPECTION
LEG INTO POSITION. (See page 6).
4.
Use a 6 foot long pry bar to move the leveler to the rear until rear top angle is against rear curb
angle. Center the leveler in front so that there is I" clearance on both sides. Raise the rear of
the leveler until rear top angle and curb angle are flush and tight together. Check to see that
the leveler is still centered in front. Weld rear angle to curb angle. Use 4" weld with 12"
spacing minimum.
5.
IMPORTANT. Raise and lower the leveler several times before shimming in front.
Check to see that the leveler platform will be level with the dock floor.
6.
Lower the platform to the stored position.
7.
Shim under the frame. When platform is level with the dock, weld the shims together and to the base frame of
the leveler. See shim diagram below.
8.
Raise the platform so that the lip extends. Be sure to install the service leg to support platform
and lip. Shim frame at rear supports and weld in place.
9.
Attach bumper to face of dock. See bumper mounting detail, page 5.
10.
Leveler is now ready for operation.
3
PIT DIMENSIONS...
NOTE: 3" x 3' x 1/4" steel curb angle part 1, 2, 3, & 4 by others. Available by W.B. McGuire Co. at additional
cost. (Note: Part #4 may not be required. Consult factory or contractor.)
4
BUMPER MOUNTING DETAILS...
Bumpers are to be
mounted flush and tight
against the side and top
of the pit wall, on each
side of the leveler.
4" thick, 4-holed bumpers are standard. Two
included with each leveler.
Two-holed, molded bumpers are available. These
bumpers are used mainly for edge-of-dock units. Certain
applications may call for this size bumper.
4” thick, “AD” bumpers are standard on the M-Series
Mechanical leveler.
Drawings not to scale.
5
WARNING: Stay Clear when leveler or truck
is in motion. Do Not stand between truck and
leveler when truck is entering or leaving.
OPERATING SEQUENCE...
IMPORTANT Pull-chain controls operated from above the leveler deck require only moderate effort to function
properly. Excessive, forceful jerking or straining on these controls can prevent proper operation or even damage the leveler mechanism. Damage resulting from such forceful operation of the controls is considered abuse and can VOID the
warranty. The pull-chain activation is designed to be pulled straight up, out of the cup, at the rear of the leveler
Pulling the chain at an angle may cause improper operation.
1.
Position Truck: The truck should be backed into the dock against the bumpers and seals. Secure the
wheels with chocks or restraint device.
2.
Operate Leveler To operate the leveler, pull and hold the chain at the rear of the leveler, allowing the
deck to rise and extend the lip automatically.
3.
Lower Into Truck: When the deck has raised to its highest position, the weight of the dock
attendant walking onto the deck will cause it to lower and bring the lip to rest in the truck bed.
4.
Handle Material: When material handling procedures have been completed, the truck can pull
away from the dock. BE SURE THAT NO GOODS OR PEOPLE ARE STANDING ON THE
LEVELER PLATFORM AT THIS TIME. The hinged lip will automatically lower to its stored
position.
5.
End Loading: For end loads below dock level, perform steps 1, 2 & 3 first, then pull the
ring recessed in the deck near the front of the leveler. The deck can be lowered to either of
two supported positions below dock level.
6.
Store - Above Dock Level: When the deck is above dock level, the attendant walking onto
the leveler will lower it to a safe cross traffic stored position.
7.
Store - Below Dock Level: When the ramp is below dock level, pull the ramp operating ring at the rear of
the platform momentarily to allow the deck to raise several inches above dock level. The attendant can
then walk the leveler down to a safe, cross traffic position.
SETTING THE INSPECTION LEG...
The inspection leg is a built-in steel pipe which, when set in place properly, will support the platform in an
upright position for qualified personnel to perform maintenance or service. Setting the service leg requires two
people. THE INSPECTION LEG IS MEANT TO SUPPORT THE WEIGHT OF THE PLATFORM ONLY.
1 . Tag the leveler platform and surrounding area "Out of Service" to prevent accidental operation of the unit.
2. Place barriers on grade level in front of the leveler to prevent trucks from backing to the dock.
3. Raise the leveler platform. Have a second person help lift the lip slightly and place the leg in the cup.
4. To store the inspection leg, have a second person help lift the lip slightly. Reset the inspection leg to its stored
position.
5. Walk-down the leveler to its stored, cross traffic position.
WARNING: Do Not enter pit area until leveler
has been braced open with jack stands.
6
MAINTENANCE AND ADJUSTMENTS...
Reference the component identification diagram below to assist with understanding the maintenance and
adjustment points.
Leveler should be inspected quarterly by qualified maintenance personnel. Check all welds and structural members. If any members are damaged, DO NOT USE THIS UNIT UNTIL IT IS REPAIRED.
1.
2.
3.
4.
Keep the area around and under the leveler clean and free of debris.
Keep lip hinge clean and free of debris that would restrict free lip movement.
Every 3 months, lubricate points as indicated below.
In extremely dusty, high humidity or wet environments, general maintenance and lubrication
should be performed every 6 weeks or as required.
5.
There are two points of adjustment:
A.
Lip counterbalance - adjusting nut is located on lip counterbalance rod.
B.
Deck counterbalance - adjustments are made with a 1-1/2" wrench.
The adjusting nuts for the deck counterbalance are located on each side of the lifting arm, or in the
center depending on model.
THE McGUIRE MECHANICAL DOCK LEVELER MECHANISM
Function - As the platform rises, snubber chain is drawn tight to pull lip lug down and out with assist of momentum and counterbalance.
Lip Counterbalance - serves two functions: It spring pre-loads the lip so that a minimum force is required to
extend it. With the lip in the pendent position, it exerts pressure to hold it there. As the lip extends, the counterbalance
crosses the center line of the pivot point applying pressure to the lip. When properly adjusted, the lip becomes nearly
weightless as it approaches the pivot cross-over point. Adjustment is made with the nut on the clevis spring rod.
Penetrating Oil
Grease
Penetrating Oil
Grease
Light Oil
7
WARNING: Do Not enter pit area until
leveler has been braced open with jack
stands.
COMPONENT IDENTIFICATION...
5
1
2
4
3
6
1.
Hinged Lip - automatically extends as the deck rises and then rests on the truck bed when in working position.
2.
Spring Counterbalance - is the main force for raising the deck. The tension of the springs is adjusted
by the adjustment nut(s) located at the lifting arm.
3.
Hold Down - prevents the deck from raising until the release chain has been pulled to disengage it. The hold
down is designed to allow the deck to float with the upward or downward movement of the truck bed.
4.
Lip Counterbalance - is used as an assist in projecting the lip with the least amount of resistance.
The lip mechanism is designed to keep the lip extended until it positions itself on the bed of the truck.
This makes the lip yieldable.
5.
Cross Traffic Legs - provide a 3-position safety system and are retractable structural supporting
members that stop the deck from downward travel at dock level, and permit lowering of the deck onto
two safe, supported stops below dock level. The cross traffic legs support the deck when it is in a
cross traffic position.
6.
Cross Traffic Leg Pedestals.
8
ITEM
1
2
3
4
4
5
6
7
7
8
I
10
11
11
12
QTY
2
2
4
2
7
1
1
1
1
1
1
1
1
1
1
PART NAME
HOLDDOWN
PART NO.
502-089
ROLLPIN
113-0999999991
COTTERPIN
113-073
S P R I N G6 '
11 3 - 0 6 1
S P R I N G8 '
113-055
S N U B B E RS P R I N G
113-058
512-942
812-19
812-032
121-071
121-021
812-086
512-949
512-950
822-024
CHAIN
LIFT.ARM6'
LIFT.ARM8'
WASHER
HEX.NUT
SPRINGPADDLE
CHAIN6'
CHAIN8'
LIFT.ARMPIN
I
{
t
\-
l
I
t\-.
I
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\
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'i.'
\t
\
p
I
-
F € J
\ra
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p
(!J
I S V E L D E DN N T N
B E L L C R A N KA S S E M B L Y
T H E T N P E F T H E U P P E RP L A T F O R M ,
FNR EASEEF SHUVIN6
REMOVED
A S S E M B L EP
DO S I T I O N S .
SHOWN.
ONLYONE WEATHERSEAL
ONLYONE SET OF TOE GUARDSSHOWN.
\
o
CAPACITY
IPARTN U M B E R
ITEM
1
1
1
1
1
I
I
1
1
1
2
2
2
3
3
3
PART NAME
LIP ASSY 6FT X 16''
LIP ASSY 6 FT X 18''
LIP ASSY 6 FT X 20"
LIP ASSY6.5 FT X 16''
LIP ASSY 6.5 FT X 1B''
LIP ASSY 6.5 FT X 20"
LIP ASSY 7 FT X 16''
LIP ASSY7 FT X 18''
LIP ASSY 7 FT X 20"
LIP SHAFT6 FT
LIP SHAFT6.5 FT
LIP SHAFT7 FT
WEATHERSEAL
SET 6'
WEATHERSEAL
SET 8'
WEATHERSEAL
SET 1O'
25K
812-095
812-096
812-097
812-098
812-099
812-100
812-101
812-102
812-103
10
30K
812-104
812-105
812-106
812-107
812-108
812-109
812-10
812-111
812-112
821-006
821-013
821-014
531-452
531-453
531-454
35K
812-128
812-131
812-134
812-129
812-132
812-135
812-130
812-133
812-135
812-136
QTY
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
ITEM
4
4A
4B
4C
4D
4E
4
4A
48
4C
4D
4E
4
4A
48
4C
4D
4E
5
6
7
8
I
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
PART NO.
811-075
811-076
811-077
811-078
821-027
821-029
811-079
811-080
8 11 - 0 8 1
8 11 - 0 8 2
821-082
821-034
XXX-XXX
XXX.XXX
XXX.XXX
XXX.XXX
XXX-XXX
XXX-XXX
11 3 - 1 4 0
113-271
113-071
113-350
113-073
113-351
721-020
822-097
113-296
512-545
122-021
121-022
121-062
122-188
11 3 - 3 1 6
7 11 - 11 0
512-960
512-955
113-268
PARTNAME
6' LG.(RH)
TOEGUARD
1STSTAGE
6',LG.(LH)
TOEGUARD
1STSTAGE
6' LG.(RH)
TOEGUARD
2NDSTAGE
6' LG.(LH)
TOEGUARD
STAGE
zND
6' LG.(RH)
TOEGUARD
3RDSTAGE
6' LG.(LH)
TOEGUARD
3RDSTAGE
8' LG.(RH)
TOEGUARD
1STSTAGE
8' LG.(LH)
TOEGUARD
1STSTAGE
8' LG.(RH)
TOEGUARD
2NDSTAGE
I' LG.(LH)
TOEGUARD
2NDSTAGE
8',LG.(RH)
TOEGUARD
STAGE
3RD
B'LG.(LH)
TOEGUARD
sRD STAGE
10'LG.(RH)
TOEGUARD
1STSTAGE
1o',LG.(LH)
TOEGUARD
1STSTAGE
1o'LG.(RH)
TOEGUARD
2NDSTAGE
1o'LG.(LH)
TOEGUARD
2NDSTAGE
1o',LG.(RH)
TOEGUARD
3RDSTAGE
10'LG.(LH)
TOEGUARD
3RDSTAGE
MECH.LEVELER
SHOCKS,
PIN,ROLLSST.25X 1.50
X 1 314"
cLEVlS,PIN 112"
cLEVls PlN,5/8"X 1 518"
PIN,COTTER.125X 1.50L
X 1"
14GA518"
BUSHING
ARM
TOGGLE
SHOCKSPACER
X 5 718"
CLEVISPlN,112"
RODASSY
BALANCE
COUNTER
.75
16
X
BOLT,HEX .375
NUT,HEX.375 16 X 1"
WASH/FL1''ODX .375ID
TEKSCREW
BALANCE
COUNTER
SPRING
LEGASSY
X.TRAFFIC
BELLCRANKASSY
BELOWDOCKCHAIN
EXTENSION
SPRING,
ITEMSNOTSHOWNFOR CLARITY
FOLLOWING
131-005
LABEL,PRODUCT
1 3 1 -116
WARNING
LABEL,LEVELER
131-122
LABEL,LOGOMADEIN USA
131-132
.
DO NOT. .
LABEL,WARNING
1
31-154
TAPE,HAZARD
131-167
...
CERTIFIED
LABEL,MCGUIRE
'131-169
.
.
.
LABEL,STAYCLEAR
131-013
LABEL.TOEGUARD
11
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
4
21
5
1
1
2
2
2
4
4
8
2
1
1
1
1
1
1
1
1
1
.15
1
1
1
PARTS LIST...
PART NUMBER
DESCRIPTION
502-058
HOLD DOWN ASSEMBLY
COMMENTS
HOLD DOWN KIT
For levelers prior to 1990
Specify model & pit depth
502-085
SELF-RELEASING HOLD DOWN
113-219
LIP SHOCK
512-545
LIP COUNTERBALANCE ROD ASSEMBLY
113-316
LIP COUNTERBALANCE SPRING
522-240
SHOCK MOUNTING PIN
522-251
SHOCK SPACER
113-058
SNUBBER SPRING
113-122
SNUBBER CHAIN
512-566
BELOW DOCK RELEASE CHAIN
113-052
CROSS TRAFFIC LEG RETURN SPRING
113-056
S-HOOK
113-061
MAIN SPRING - RED 19.5" OVERALL LENGTH
113-055
MAIN SPRING - PURPLE 23.5" OVERALL LENGTH
Specify length required
LIFT ARM ASSEMBLY
Specify model & pit depth
SPRING PULL PADDLE
Specify model & pit depth
113-096
LIFT ARM CASTER
121-024
COUPLING NUT (For spring paddle)
121-071
WASHER (For spring paddle)
Contact your authorized McGuire distributor to order spare or replacement parts. When ordering, specify leveler model,
serial number, and pit depth.
To determine specific parts, contact the McGuire Technical Support Team at 1-800-624-8473.
9
TROUBLE SHOOTING PROCEDURES...
If the corrective action does not solve the problem, or you encounter a problem that is not covered in this section, consult
the McGuire Technical Support Team immediately. DO NOT USE THE LEVELER.
SYMPTOM
POSSIBLE CAUSE
CORRECTIVE ACTION
1. Leveler will not rise or rises slowly.
A. Sides of pit causing binding
against weatherseals.
A. Check clearances.
2. Leveler will not lower.
A. Physical obstruction.
B. Pit bowed up in center.
C. Spring tension too high.
A. Remove obstruction.
B. Reshim unit.
C. Adjust tension by:
A. Pit is sloped.
B. Improper installation.
A. Check pit with level gauge in
length and width. Relevel unit.
B. Relevel unit.
C. Frame damaged.
C. File claim with shipper.
A. Obstruction in hinge area.
B. Hold down not fully released.
C. Springs not working.
A. Remove obstruction.
B. Walk leveler to stored position.
Repeat operate procedure.
C. Check and replace if necessary.
A. Cross traffic legs not fully
retracted.
A. Pull and hold chain until fully
below dock.
B. Chain caught.
B. Check that cross traffic legs
rotate freely and grease shaft.
Make sure chain is not hung up.
3. Leveler not level in pit.
4. Lip will not extend.
5. Leveler will not go below dock.
10
W.B. McGUIRE COMPANY, INC.
Mechanical Dock Leveler Warranty
The W.B. McGuire Company, Inc. warrants that its mechanical dock leveler (see models below) will be free from defects
in materials and workmanship under normal use and service for the time period described below, depending on model,
effective from the date of installation. This warranty covers parts and labor.
McGuire's sole obligation under this warranty is limited to repairing or replacing any part which shall be determined by
McGuire to be defective, and is conditioned upon the buyer giving written notice of any such defect within the warranty
period. If McGuire concludes that repair or replacement is necessary, work will commence within a reasonable time
period after the decision to repair or replace has been made.
This warranty will not apply to any product which has been altered, modified, damaged or which has deteriorated due to
abuse, neglect, misuse or by accident. Warranty will be VOID if any repairs are made or attempted to be made by any
person not authorized by McGuire. Proper application, installation, maintenance and operation are required to keep
warranty in force.
Periodic maintenance and adjustment is the sole responsibility of the owner. Proper lubrication and adjustment is
necessary to maintain warranty coverage.
This warranty is McGuire's exclusive expressed warranty. Warranty is limited to value of components only. McGuire
assumes no liability for loss of the use of any equipment and expressly disclaims any liability for incidental or
consequential damages. Warranties implied by law are limited in duration to the five year period described above.
Models covered by this warranty:
M-Series (5 years)
MKA 1300 (1 year)
MKA 1000HD & MKA 1000LB (1 year)
Represented in This Area By:
One Hudson Ave.
Hudson, NY 12534
1-800-624-8473
518-828-7652 • Fax: 518-828-1262
www.wbmcguire.com
The specifications described herein were in effect at the time of printing. However, W.B. McGuire Company, Inc. reserves the right to change
specifications and designs or to discontinue models at any time without incurring obligation.
MECHLEV/31-5-2
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PRINTED IN U.S.A.