McGuire MT / MP Series Manual

McGUIRE
MT/ MP Series
MECHANICAL TRUSS
and PIANO HINGE DOCK
LEVELER
OWNER'S MANUAL
& INSTALLATION GUIDE
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 authorized personnel.
TABLE OF CONTENTS
Overview of Potential Hazards......................................................................................................2
Safety Practices.............................................................................................................................3
Installation Instructions..................................................................................................................4
Pit Details and Dimensions........................................................................................................... 5
Conversion Kit......................................................................................................................... ......6
Shim Kit provided by others...........................................................................................................7
Lip Keeper Installation.................................................................................................................. 8
Bumper Mounting Details & Dimensions...... ................................................................................9
Operating Sequence....................................................................................................................10
Setting Maintenance Leg.............................................................................................................11
Component Identification............................................................................................................. 12
Maintenance and Adjustments.....................................................................................................13
Spring Replacement 6' Only.........................................................................................................14
MP Platform Exploded View........................................................................................................ 15
Replacement Parts all 6' and 8' MP Mechanical Decks..............................................................16
MT Platform Exploded View........................................................................................................ 17
Replacement Parts all 6' and 8' MT Mechanical Decks.............................................................. 18
MP / MT Baseframe Exploded View............................................................................................19
Replacement Parts all 6' and 8' MT / MP Baseframes................................................................20
Label Placement..........................................................................................................................21
Trouble Shooting Procedures......................................................................................................22
Warranty........................................................................................................................Back Cover
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.
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 provide proper operation.
SAFETY INFORMATION...
• Never work under the dock leveler without sufficient bracing to safely secure the leveler from
any movement that may cause injury.
• Be sure truck wheels are chocked, or restraint device activated, before loading/unloading operations
begin, Personal injury and/or freight damage can result from careless work habits at 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, or failure to take proper precautions during maintenance or service.
IMPORTANT...
• It is imperative that the installer thoroughly understand the operational and safety information
contained in this manual first.
• McGuire recommends the use of 4 inch or larger Bumpers with Dock Levelers.
• Contact your authorized McGuire Distributor or the McGuire help Line at 1-800-929-2553
if there is anything you do not understand about this Equipment.
1
OVERVIEW OF POTENTIAL HAZARDS
2
SAFETY PRACTICES
!
!
WARNING: Read and understand all safety practices and operating instructions before
installing, operating or servicing the dock leveler. Failure to follow the safety practices
may result in property damage, serious bodily injury or death.
If you do not understand the safety practices or the instructions, ask your supervisor
to explain the safety practices and/or teach you how to use the dock leveler.
CAUTION: The installer and/or operator MUST be very familiar with the operation, function
and various parts of the W.B. McGuire MT or MP series dock levelers PRIOR to installation
and/or operation. If this is not the case, it is IMPERATIVE that the installer and/or operator
read, and fully understand, the entire contents of this manual. Be certain to read and
understand all warning and caution statements contained in this manual prior to any
installation, operation or servicing of this unit.
1. Do not operate this equipment while under the influence of drugs or alcohol.
2. Do not stand in the driveway between the dock leveler and a truck backing or pulling away.
3. Be sure the truck wheels are chocked, or the truck is held in place by a restraining device, before
attempting to load or unload the truck.
4. Do not use the dock leveler if it looks broken or does not seem to work right. Tell your supervisor
immediately.
5. Do not operate the leveler with equipment, material or people on the platform and/or lip or in front
of the leveler.
6. Be certain that equipment, material or people are not on the dock leveler before allowing a truck
to pull out.
7. Keep clear of the dock leveler when it is moving. Never place your hands, arms, feet or legs in a
position where a moving dock leveler or a moving load could cause injury. If in doubt, do not do it!
8. Do not attempt to manually lift the dock leveler platform or lip, with personnel or other equipment.
If the dock leveler is not working properly using the operation instructions in this manual, do not
use the dock leveler. Contact your authorized W.B. McGuire representative.
9. Never attempt to work under the dock leveler, for service or repair, without proper placement of
the attached Maintenance Leg or other bracing sufficient to safely secure the leveler from
any movement that may cause injury.
10. Damage to the dock leveler, personal injury or death can result from abuse and/or negligent use
of this equipment.
11. If you have any questions, or if a malfunction occurs which is not understood, ask your supervisor
to contact your authorized W.B. McGuire representative for assistance PRIOR to attempting any
corrective measures.
3
INSTALLATION INSTRUCTIONS
Do Not Unband prior to setting unit in pit. Check unit for damage. If damaged, do not
install, contact factory immediately.
PIT CHECK:
1. Check the pit for proper construction. Check the pit walls to be sure they are square and
plumb. Clean out any debris.
2. Measure the pit dimensions per certified pit drawings or from the pit dimensions on page 5.
Any parts of the pit that do not conform should be changed before dock leveler is installed.
INSTALL:
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.
IMPORTANT: If installing a McGuire Conversion Kit, please refer
to page 6 before going any further with installation.
3.
Move the leveler into the pit very carefully using
a fork truck. Insert the forks at the front of the
leveler over the front flat and in between stringer
channels for moving. You can also lift leveler from
back as shown in drawing. Pay special attention to
ensure properly fitting forks between stringer channels.
Do not pick up leveler from sides.
4.
Fork Lift
Hold Down Angle
Front Plate
Stringer
Channel
Move the leveler to the rear until the rear top angle is against rear curb angle.
5. Center the leveler in pit. There should be a 1" gap between the pit
and leveler (not including Weatherseal).
Fork Lift Forks
6. Raise rear angle flush with top of curb angle and tack weld on each end 1".
7.
Shim under each vertical upright at rear of frame. Tack weld in place and tack weld shims together
(see page 7).
8. Shim under front flat and shim at cross traffic leg points (under pedestals) flush with side
curb angle. Tack weld shims together (see page 7).
9. Cut bands on leveler. Open leveler, set up maintenance leg support system. Also use
blocks to secure safety.
10. Shim under lift arm and weld (see page 7).
11. Check front shims for level at front. If level, weld front shims together, to leveler and to curb
angle. Weld top rear angle to curb angle (6" weld on 12" center or 8" welds on 16" centers.)
12. Open and walk down leveler 4-5 times. Center bottom front flat in front of pit opening.
13. Locate shipping brackets / lip keepers (18" and 20" lips only) on front of base frame.
Remove by sliding upward. Store Lip Keepers in safe location and await for further
instruction on installation (see page 8).
14. Check operation and make adjustments
- Bring leveler up and walk down
- Check below dock operation
15. Clean and touch-up welds with matching paint.
4
PIT DETAILS AND DIMENSIONS
ITEM 1,2,3: ANCHOR
LAYOUT FOR CURB ANGLES
BY OTHERS
MP & MT SERIES DOCK LEVELER
Pit Dimensions
A
2
IMPORTANT: Curb Angles Nelson Studs
1/2” Dia. 6” Long Located As Shown
(ITEM 4/5 OPTIONAL)
B
3
C
Dock
Floor
(Optional)
4
D
(Optional)
5
1
Note: Part #4 of steel curb angle is optional. When part #4
is used, make part #3 dimension 3” less.
NOMINAL PIT SIZES
6’ x 6’
6’6” x 6’
7’ x 6’
6’ x 8’
6’6” x 8’
7’ x 8’
PIT WIDTH DIM A
74”
80”
85”
74”
80”
85”
74”
80”
85”
PIT LENGTH DIM B
65”
65”
65”
89”
89”
89”
113”
113”
113”
PIT DEPTH DIM C
PIT DEPTH D
19”
19”
19”
19”
19”
19”
19 1/2”
19 1/2”
19 1/2”
19 1/2”
19 1/2”
19 1/2”
6’ x 10’ 6’6” x 10’ 7’ x 10’
23
1/2”
24”
23
1 /2”
24”
23 1/2”
24”
CONTRACTOR’S BILL OF MATERIAL FOR NOMINAL PIT SIZES
ITEM
QTY
6’ x 6’ 6’6” x 6’
7’ x 6’
6’ x 8’
6’6” x 8’
7’ x 8’
6’ x 10’ 6’6” x 10’ 7’ x 10’
1. FRONT CURB ANGLE
3 x 3 x 1/4
1
74”
80”
85”
74”
80”
85”
74”
80”
85”
2. REAR CURB ANGLE
3 x 3 x 1/4
1
80”
86”
91”
80”
86”
91”
80”
86”
91”
3. SIDE CURB ANGLE
3 x 3 x 1/4
2
65”
65”
65”
89”
89”
89”
113”
113”
113”
OPTIONAL
4. TOP FRONTANGLE
3 x 3 x 1/4
2
18” RECOMMENDED MINIMUM LENGTH FOR ALL SIZES
5. TOP VERTICALANGLE
3 x 3 x 1/4
2
16.5” ANGLES FOR 19.5 ” DEEP PIT; 21” ANGLES FOR 24 ” DEEP PIT
CONSTRUCTION NOTES: 1. Concrete Behind Pit Steel Must Be Well Vibrated
3. All Curb Angle Joints To Be Welded Securely.
5
2. Rear Pit Wall Must Be Square With Dock Floor.
4. 1/2 Pitch Toward Front of Pit For Drainage.
CONVERSION KIT (SHIM LOCATION) OPTIONAL EQUIPMENT
The McGuire Conversion Kits are used on levelers 18-1/2" in height converting them to a height of
22-1/2". Please pay careful attention to the instructions and drawings below upon performing this process.
Installation Information: Drawings below show optional Conversion Kit position to provide
proper height for 24" pit.
• Support unit securely before working on leveler.
• Once attached, refer to page 4 to complete shimming and install procedures.
Tube to be centered and
welded to flat with 3 welds 1/4"
wide 3" long evenly spaced on
both sides and ends.
I-Beam must be centered
and square. To be welded
all around with 1/4" weld.
I-Beam must be centered
and square. To be welded
using 5 welds 1/4" wide 3"
long evenly spaced on
both sides and ends.
SHIM LOCATION
1/4” fillet all around
6
SHIM KIT PROVIDED BY OTHERS
INSTALLATION INFORMATION: Diagram on right shows
required shim positions to provide proper weight distribution to
pit floor. (Shims to be various thickness of mild, hot rolled steel
supplied by others).
Note: All shims must be tight under frame. Weld shims in
place to assure against frame shim movement. Weld to
bottom frame & pit steel as indicated under "Installation
Instructions".
7
LIP KEEPER INSTALLATION
Lip Keepers are designed to create a level and safe position for leveler storage when not in use.
Levelers shipped with 16" lips have lip keepers pre installed during production of unit. All 18" and 20"
lip levelers are shipped with lip keepers mounted to baseframe and to be installed during leveler
installation. Please perform the following steps to safely and accurately install the Lip Keepers
shipped with your new Leveler.
1.
Remove lip keepers from baseframe by sliding them upward from their shipping location.
2.
Align the edge of keeper to outside edge of baseframe stringer. See figure (A).
This will be the horizontal position. Be sure to perform this operation on both sides.
3.
Mechanically lift the leveler platform so it is flush (level) with the dock floor.
4.
From the horizontal position, move the lip keeper vertically so the tip of the lip rests in the
keeper. Move the keeper down 3/4" to allow for leveler to float into locking position.
Reference the location by marking it.
5.
Mechanically lift the leveler and secure in the full open position using the maintenance leg.
6.
Weld lip keeper in position at marked location with 1/4" fillet all around or 1/2" x 5" Rawl
Power Bolts or equivalent. *If not concrete face consult factory.
7.
Touch up all weld areas with matching color paint.
8
BUMPER MOUNTING DETAILS & DIMENSIONS
The bumper is primarily used as a shock absorber when positioning a truck into the loading dock area.
Along with protecting the dock, it creates a buffer between the loading dock equipment and the rear of
truck. Replacement bumpers can be ordered by calling W.B. Customer Service at 1-800-929-2553.
NOTE: Review with 3” curb angle on
face of dock. The Bumper cannot be
mounted flush with top of dock. It must
be dropped down approximately 2” to
allow for anchoring top hole of Bumper.
9
OPERATING SEQUENCE
WARNING: STAY CLEAR WHEN LEVELER OR TRUCK IS IN MOTION. DO NOT STAND
BETWEEN TRUCK AND LEVELER WHEN TRUCK IS ENTERING OR LEAVING.
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 (available
through W.B. McGuire Co,Inc.).
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 lip will automatically lower with lip in Lip Keepers. Return unit to stored
position.
5.
End Loading: For end loads below dock level, perform steps 1 & 2 first. Allow
the lip to fall to pendent position, then pull the ring recessed in the deck near the
front of the leveler. The deck can be lowered to full below dock level.
6.
Store From Above Dock Level: When the deck is above dock level and lip is
pendent, the attendant walking onto the leveler will lower it to a safe cross traffic
stored position in Lip Keepers.
7.
Store From Below Dock Level: When the ramp is below dock level, pull the
ramp operation ring at 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 stored position.
10
SETTING THE MAINTENANCE LEG
WARNING: DO NOT ENTER PIT AREA UNTIL LEVELER HAS BEEN BRACED OPEN WITH JACK
STANDS OR IN A MANNER THAT ASSURES SAFE AND SECURE INSPECTION.
The Maintenance 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 leg
requires two people. THE LEG IS DESIGNED 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. With unit fully open, remove the zip tie holding the leg.
4. Remove quick release pin from storage bracket.
5. Lift leg and place on bracket.
6. Have a second person help lift the lip and place the leg in the cup on backside of lip.
7. You can now enter the pit area.
8. To store the leg, have a second person help lift the lip slightly. Reset the leg to its
stored position.
9. Walk-down the leveler to its stored , cross traffic position.
3
4
5
6
11
COMPONENT IDENTIFICATION
1. Hinged Lip – Automatically extends as the deck rises and then rests on the truck bed
when in working position.
2. Deck 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. Self Releasing 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.
6. Cross Traffic Leg Pedestals.
MT Mechanical
Truss Hinge
1
2
3
MP Mechanical
Piano Hinge
4
5
6
12
MAINTENANCE AND ADJUSTMENTS
Reference the components 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 and rear hinge clean and free of debris that would restrict free 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 spring 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, the snubber chain is drawn tight to pull lip lug down and out with
assist of momentum and counterbalance.
Lip Counterbalance – Serves two functions: The 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.
MT Mechanical Truss Hinge
Adjusting Nut
Penetrating Oil
on Hinge Areas
Grease
MP Mechanical Piano Hinge
Light Oil
13
SPRING REPLACEMENT 6' MECHANICALS ONLY
Replacing the main springs may be necessary throughout the life of your leveler. If you are in need of
replacing the springs please follow these simple steps.
REMOVING SPRINGS
1.
2.
3.
4.
5.
Raise the leveler and insert the maintenance leg into correct position.
Barricade area not allowing any deliveries or shipments.
Locate the large nut on spring paddle and make a mark showing where the nut is.
Using a 1" wrench loosen the nuts located on the spring paddle as shown in VIEW "A".
Once nuts are loose and springs have no tension, remove the cotter pins and clevis pins
located in the rear of the leveler shown in the VIEW "B".
6. Slide rod slowly all the way out until it stops while keeping springs in place.
7. With rod slid out you can now remove springs from spring paddle.
8. Perform the same operation for the opposite side.
INSTALLING NEW SPRINGS
Upon removal of old springs, it is now time to install the new springs onto the leveler.
Follow the steps below to ensure proper installation.
1. The springs will have two visibly different ends. One end has a flat cut and the other
end has a tapered cut. The tapered cut is fed into the spring paddle.
2. Feed all three into the spring paddle. Have someone hold the springs in place for you
while you attach each one on the rod.
3. Slide the rod back into position and insert the cotter pin.
4. It is now necessary to re-adjust the spring tension.
5. Using the 1" wrench, tighten the nut until it is aligned with the mark made earlier.
You will have to make several adjustments to ensure proper response from leveler.
VIEW ”A”
VIEW ”B”
1" Nut
Springs
Rod
14
Cotter Pin
Clevis Pin
MP PLATFORM EXPLODED VIEW
15
REPLACEMENT PARTS ALL 6' AND 8' MP MECHANICAL DECKS
16
MT PLATFORM EXPLODED VIEW
17
REPLACEMENT PARTS ALL 6' AND 8' MT MECHANICAL DECKS
18
MP / MT BASEFRAME EXPLODED VIEW
19
REPLACEMENT PARTS ALL 6' AND 8' MT / MP BASEFRAMES
20
LABEL PLACEMENT
NOTE: The following labels shall be applied to structural toe guard as required.
131-132
131-122
131-116
131-013
133-169
131-184
DO NOT STAND IN FRONT . . .
McGUIRE LOGO
WARNING . . .
REMOVE FASTENERS
WARNING STAY CLEAR . . .
YELLOW / BLACK STRIPE
21
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 W.B. 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. Re-shim unit.
C. Adjust main spring tension.
3. Leveler not level in pit.
A. Pit is sloped.
B. Improper installation.
A. Check pit with level gauge in
length and width. Re-level
unit.
B. Re-level unit.
C. Frame damaged.
C. File claim with shipper.
A. Obstruction in hinge area.
B. Hold down not fully released.
A. Remove obstruction.
B. Walk leveler to stored
position. Repeat operate
procedure.
C. Check and replace if
necessary.
4. Lip will not extend.
C. Springs not working.
5. Leveler will not go
below dock.
A. Cross traffic legs not fully
retracted.
B. Chain caught.
22
A. Pull and hold chain until fully
below dock.
B. Check that cross traffic legs
rotate freely and grease shaft.
Make sure chain is not hung
up.
W. B. McGUIRE WARRANTY
MT & MP Series Levelers
The W. B. McGuire Company warrants that it’s MT & MP Series Mechanical dock levelers will be
free from defects in materials and workmanship for a period of one (1) year from date of shipment
acceptance on all structural components, and a two (2)year warranty on hold down. A lifetime warranty
is available on hinge assemblies and a ten (10) year warranty on structure is also available. Labor for
repair or replacement, done by W. B. McGuire authorized personnel, is included for a period of one
(1) year from the date of installation acceptance. After one (1) year, all labor charges will be the
responsibility of the owner.
W. B. McGuire's sole obligation under this warranty is limited to repairing or replacing any part,
which shall be determined by W. B. McGuire to be defective, and is conditioned upon the buyer giving
written notice of any such defect within the warranty period. If W. B. McGuire concludes that repair, or
replacement, is necessary, work will commence within a reasonable time period after the decision to
repair to replace is 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 W. B. 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.
This warranty is W. B. McGuire's exclusive expressed warranty. Warranty is limited to value of
components only. W. B. 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/one year period described above.
Represented in This Area By:
A Division of
One Hudson Ave.
Hudson, NY 12534
1-800-624-8473
518-828-7652 • Fax: 518-828-1262
www.wbmcguire.com
P/N 501-151
Form #: M900-520
5/04
2,500
PP