McGuire Dock Leveler User Manual

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Page 1

MP Series

A Division of Systems, LLC

Dock Leveler

Owner’s/User’s Manual

McGuire • Division of Systems, LLC • W194 N11481 McCormick Drive • Germantown, WI 53022

800.624.8473 • fax: 262.255.5917 • www.wbmcguire.com • [email protected]

Manual No. 4111-0019

June 2019

Page 2

Table of Contents

Page

Precautions

Recognize Precautionary Information ................................................ 1

General Operational Precautions ........................................................ 1

Operational Precautions ...................................................................... 2

Safety Decals ......................................................................................... 4

Placard ................................................................................................... 5

Owner’s/User’s Responsibilities ......................................................... 6

Introduction

General Information .............................................................................. 8

Component Identication ..................................................................... 9

Installation

Installation Precautions ...................................................................... 10

Prepare Pit ............................................................................................ 12

Prepare Dock Leveler .......................................................................... 13

Install Dock Leveler ............................................................................. 14

Placard Installation Instructions ........................................................ 20

Operation

Operational Precautions ..................................................................... 21

Operating Instructions ........................................................................ 22

Maintenance

Maintenance Precautions .................................................................... 24

Periodic Maintenance .......................................................................... 25

Adjustments

Adjust Main Spring & Lip Assist Spring Tension ............................. 26

Adjust Lip Stop Bolt ............................................................................ 28

Troubleshooting

Troubleshooting ................................................................................... 30

Parts

Hold-Down Components ..................................................................... 32

Main Lift Springs .................................................................................. 33

Frame Components ............................................................................. 34

Platform Components ......................................................................... 36

Weather Seals....................................................................................... 38

Toe Guards ........................................................................................... 39

Miscellaneous

Customer Information ......................................................................... 41

Warranty ................................................................................ Back Cover

Page 3

PRECAUTIONS

Recognize Precautionary Information

Safety-Alert Symbol

The Safety-Alert Symbol is a graphic representation intended to convey a safety message without the use of words. When you see this symbol, be alert to the possibility of death or serious injury. Follow the instructions in the safety message panel.

The use of the word DANGER signies the presence of an extreme hazard or unsafe practice which will most likely result in death or severe injury.

General Operational Precautions

Read and understand the Owner’s/User’s Manual 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, Placards or Decals on the equipment unless replacing them.

The use of the word WARNING signies the presence of a serious hazard or unsafe practice which could result in death or serious injury.

The use of the word CAUTION signies possible hazard or unsafe practice which could result in minor or moderate injury.

The use of the word NOTICE indicates information considered important, but not hazard-related, to prevent machine or property damage.

Indicates a type of safety sign, or separate panel on a safety sign, where safety-related instructions or procedures are described.

Figure 1

Do not start the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone (see Figure 1).

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.

WARNING: This product can expose you to chemicals including lead, which are known to the State of California to cause cancer or birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov

Page 4

PRECAUTIONS

Operational 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 transport vehicle is entering or leaving area.

Do not move or use the dock leveling device if anyone is under or in front of it.

Keep hands and feet clear of pinch points. Avoid putting any part of your body near moving parts.

Chock/restrain all transport vehicles. Never remove the wheel chocks or release the restraining device until loading or unloading is

nished, and transport driver has been given

permission to drive away.

Do not use a broken or damaged dock leveling device or restraining device. Make sure proper service and maintenance procedures have been performed before using.

Make sure lip overlaps onto transport vehicle bed at least 4 in. (102 mm).

Keep a safe distance from both side edges.

4111-0019 — June 2019

Page 5

Operational Precautions

Do not use dock leveling device if transport vehicle is too high or too low.

PRECAUTIONS

Do not overload the dock leveling device.

Do not operate any equipment while under the

inuence of alcohol or drugs.

Do not leave equipment or material unattended on dock leveling device.

Page 6

2.43"

FORK HERE

5.05"

5.93"

PRECAUTIONS

Safety Decals

FORK THIS SIDE

1751-0329

1751-0330 Rev C

1751-0330

Two positions one on top of each fork pocket.

CRUSH HAZARD

DO NOT ENTER P IT unless dock le veler is secure ly supported by maintenan ce prop. Plac e barrie rs on driveway and do ck floo r to i ndicate servic e work being perfo rmed. Failur e to comply will resul t i n d eath or serious inju ry. R efer to owner ‘s/user‘s manual for proper maintenanc e proced ures.

1751-0726

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

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

CRUSH HAZARD

Do not work under dock leveler unless this maintenance prop has been secured in the upright position. Failure to comply will result in death or serious injury. See owner’s/user’s manual for proper procedures

1751-0729

1751-0330 Rev C

1751-0731 Rev A

DO NOT

1751-0726 Rev B

CRUSH HAZARD

Do not remove main springs until leveler is securely supported by a suitable lifting device. Main springs contain stored energy. Be sure springs

are fully unloaded and ends are loose before removal. Failure to comply will result in death or serious injury. Refer to owner’s/user’s manual for

1751-0728

proper maintenance procedure.

1751-0729 Rev A

1751-0727 Rev B

1751-0329 Rev A

Unsupported dock leveler ramps can lower unexpectedly.

Before allowing vehicle to leave

Failure to follow posted instructions will result in death or serious injury.

the dock always:

••Ensure no equipment, material or people are on dock leveler.

Return dock leveler to its stored position at dock level.

Unsupported dock leveler ramps can lower unexpectedly.

Before allowing vehicle to leave the dock always:

••Ensure no equipment, material or people are on dock leveler.

Return dock leveler to its stored position at dock level.

1751-0730

1.800.643.5424

1751-0728 Rev B

1.800.643.5424

1751-0651

MP SERIES

www.DockSystemsInc.com 1.800.643.5424

1751-0643

PROUDLY

MADE

USA

SYSTEMS, INC.

GERMANTOWN,WI

MALVERN,AR

1751-0735

OPERATION

1. Read and follow all instructions and warnings in owner’s/user’s manual.

2. Use of dock leveler restricted to trained operators

3. Always chock traile r whe els or enga ge truc k r estr ain t b efor e operating dock leveler or beginning to load or unload.

4. Never use hands or equipment to move 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 truck bed supports extended lip or leveler frame supports the ramp before driving on ramp.

Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.

OPERATION

1. Read and follow all instructions and warnings in owner’s/user’s manual.

2. Use of dock leveler restricted to trained operators

3. Always chock traile r whe els or enga ge truc k r estr ain t b efor e operating dock leveler or beginning to load or unload.

4. Never use hands or equipment to move 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 truck bed supports extended lip or leveler frame supports the ramp before driving on ramp.

Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.

7. Stay clear of hinges and front and sides of moving dock leveler.

8. N e v e r us e d a m a g e d o r malfunctioning dock leveler. Report problems immediately to supervisor.

MAINTENANCE/SERVICE

1. Read and follow all instructions, wa rn in gs an d ma in te na n ce schedules in t he own er‘s/user ‘s manual.

2. Maintenance/Service of dock leveler restricted to trained personnel.

3. Place barriers on the driveway and 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.

7. Stay clear of hinges and front and sides of moving dock leveler.

8. N e v e r us e d a m a g e d o r malfunctioning dock leveler. Report problems immediately to supervisor.

MAINTENANCE/SERVICE

1. Read and follow all instructions, wa rn in gs an d ma in te na n ce schedules in t he own er‘s/user ‘s manual.

2. Maintenance/Service of dock leveler restricted to trained personnel.

3. Place barriers on the driveway and 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.

1751-0730 Rev B

www. .comDockSystemsInc

Device may contain stored energy. Decice is not adjustable.

Do not attempt to service. Failure to comply could result in serious injury or death. Refer to owner’s/user’s manual for proper replacement procedures.

Device may contain stored energy. Decice is not adjustable. Do not attempt to service.

Failure to comply could result in serious injury or death. Refer to owner’s/user’s manual for proper replacement procedures.

1751-0043

Right Platform Side

Serial Tag

Left Platform Side

Figure 2

Decal Placement

for MP Series

4111-0019 — June 2019

Page 7

Placard

OPERATING

PRECAUTIONS

DANGER

• Read and follow all instructions, warnings, and maintenance schedules in the manual and on placards.

• Operation and servicing of dock leveler is restricted to authorized personnel.

• Always chock transport vehicle wheels or engage vehicle restraint and set parking brakes before operating dock leveler or beginning to load or unload.

• Before activating dock leveler, check to make sure the transport vehicle is positioned squarely against dock bumpers. Ensure lip will avoid contact with transport vehicle frame, sides and cargo during dock leveler activation. If contact is likely or observed, reposition transport vehicle.

• Ensure the transport vehicle oor supports extended lip or the leveler frame (lip keepers or below dock endload supports) supports the ramp before driving on ramp.

• Stay clear of hinges and front and sides of moving dock leveler.

• Never use hands or equipment to move the ramp or lip.

• Never use damaged or malfunctioning dock leveler. Report problems immediately to supervisor.

• Always store dock leveler and remove people, material, and equipment from ramp before vehicle leaves the dock.

• DO NOT ENTER PIT unless dock leveler is securely supported and proper lockout/tagout procedures have been completed. See “Maintenance Precautions” in Owner’s/User’s Manual.

FAILURE TO FOLLOW THESE INSTRUCTIONS WILL RESULT IN DEATH OR OTHER SERIOUS INJURY.

Scan to view our owner’s/user’s manuals online. www.LoadingDockSystems.com

1.800.643.5424

Call for additional placards, or manuals, or with questions regarding proper use, maintenance, and repair of dock leveler.

1751-0875

WARNING: CANCER AND REPRODUCTIVE HARM www.P65Warnings.ca.gov

1751-0875 Rev D

INSTRUCTIONS

MECHANICAL DOCK LEVELERS

NORMAL OPERATION

1. Raise the platform by pulling and holding the platform release ring.

2. Hold the platform release ring until the lip is fully extended, then release the platform release ring. Walk out onto the platform. The platform will lower until lip is resting on the transport vehicle.

STORING LEVELER

1. Pull the platform release ring. Slowly walk the platform down allowing enough time for the lip to fold, clearing the transport vehicle. Once lip clears transport vehicle,

continue to walk leveler to the cross-trafc

position.

BELOW DOCK ENDLOADING

• Pull and hold the platform release ring until the platform is at the fully-raised position. Slowly walk the platform down allowing enough time for the lip to fold. Just before

the platform reaches the cross-trafc

position, pull and hold the safety leg retract pull ring located in a recess at front of the platform. The platform will continue lowering to the full below dock position.

Page 8

OWNER’S/USER’S RESPONSIBILITIES

1) The manufacturer shall provide to the initial purchaser and make the following information readily available to the owners/users and their agents, all necessary information regarding Safety Information, Operation, Installation and Safety Precautions, Recommended Initial and Periodic Inspections Procedures, Planned

Maintenance Schedule, Product Specications,

Troubleshooting Guide, Parts Break Down, Warranty Information, and Manufacturers Contact Information, as well as tables to identify the grade(slope) for all variations of length or

conguration of the dock leveling device and

information identifying the maximum uncontrolled drop encountered when sudden removal of support while in the working range of the equipment.

2) When selecting loading dock safety equipment, it is important to consider not only present requirements but also future plans and any possible adverse conditions, environmental factors or usage. The owners/users shall provide application information to the manufacturer to receive recommendations on appropriate equipment specications and capacity.

3) The owner/user must see all nameplates, placards, decals, instructions and posted warnings are in place and legible and shall not be obscured from the view of the operator or maintenance personnel for whom such warnings are intended for. Contact manufacturer for any replacements.

4) Dock leveling devices may become hazardous if the manufacturer’s instructions regarding

modications or adjustments are not followed. Modications or alterations of dock leveling

devices shall only be made with prior written approval from the original manufacturer. These changes shall be in conformance with all applicable provisions of the MH30.1 standard and shall also satisfy all safety recommendations of the original equipment manufacturer of the particular application.

5) The owner/user should recognize the inherent dangers of the interface between the loading dock and the transport vehicle. The owner/ user should, therefore, train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer’s recommendations and industry standards.

E󰀨ective operator training should also focus on

the owner’s/user’s company policies, operating

conditions and the manufacturer’s specic

instructions provided with the dock leveling device. Maintaining, updating and retraining all operators on safe working habits and operation of the equipment, regardless of previous experience, should be done on a regular basis and should include an understanding and familiarity with all functions of the equipment. Owners/users shall actively maintain, update and retrain all operators on safe working habits and operations of the equipment.

6) An operator training program should consist of, but not necessarily be limited to, the following:

a) Select the operator carefully. Consider the physical qualications, job attitude and aptitude.

b) Assure that the operator reads and fully understands the complete manufacturer’s owners/ users manual.

c) Emphasize the impact of proper operation upon the operator, other personnel, material being handled, and equipment. Cite all rules and why they are formulated.

d) Describe the basic fundamentals of the dock leveling device and components design as related to safety, e.g., mechanical limitation, stability, functionality, etc.

e) Introduce the equipment. Show the control locations and demonstrate its functions. Explain how they work when used properly and maintained as well as problems when they are used improperly.

f) Assure that the operator understands the capacity rating, nameplate data, placards and all precautionary information appearing on the dock leveling device.

g) Supervise operator practice of equipment.

h) Develop and administer written and practical performance tests. Evaluate progress during and at completion of the course.

i) Administer periodic refresher courses. These may be condensed versions of the primary course and include on-the-job operator evaluation.

4111-0019 — June 2019

Page 9

OWNER’S/USER’S RESPONSIBILITIES

7) Loading dock safety equipment should never be used outside of its vertical working range, or outside the manufacturer’s rated capacity. It shall also be compatible with the loading equipment and other conditions related to dock activity. Please consult the manufacturer if you have any questions as to the use, vertical working range or capacity of the equipment. Only properly trained and authorized personnel should operate the equipment.

8) It is recommended that the transport vehicle is positioned as close as practical to the dock leveling device and in contact with both bumpers.

When an industrial vehicle is driven on or o󰀨 a

transport vehicle during loading and unloading operations, the transport vehicle parking brakes shall be applied and wheel chocks or a restraining device that provides equal or better protection of wheel chocks shall be engaged. Also, whenever possible, air-ride suspension systems should have the air exhausted prior to performing said loading and unloading operations.

9) When goods are transferred between the loading dock and a trailer resting on its support legs/

landing gear instead of a tractor fth wheel

or converter dolly, it is recommended that an adequate stabilizing device or devices shall be utilized at the front of the trailer.

instructions, labels, decals and placards or their equivalent. Written documentation of maintenance, replacement parts or damage should be kept. In the event of damage, notication to the manufacturer is required.

12) Loading dock devices that are structurally damaged or have experienced a sudden loss of support while under load, such as might occur when a transport vehicle is pulled out from under the dock leveling device, shall be removed from service, inspected by a manufacturer’s authorized representative, and repaired or replaced as needed or recommended by the manufacturer before being placed back in service.

10) In order to be entitled to the benets of the standard product warranty, the dock safety equipment must have been properly installed, maintained and operated in accordance with all manufacturer’s recommendations and/

or specied design parameters and not

otherwise have been subject to abuse, misuse, misapplication, acts of nature, overloading,

unauthorized repair or modication, application in

a corrosive environment or lack of maintenance. Periodic lubrication, adjustment and inspection in accordance with all manufacturers’ recommendations are the sole responsibility of the owner/user.

11) Manufacturer’s recommended maintenance and inspection of all dock leveling devices shall be performed in conformance with the following practices: A planned maintenance schedule program must be followed, only trained and authorized personnel shall be permitted to maintain, repair, adjust and inspect dock leveling devices, and only the use of original equipment manufacturer parts, manuals, maintenance

Page 10

INTRODUCTION

General Information

Figure 3

This manual provides current information on the MP-series dock leveler. Due to ongoing product improvement, some parts may have changed, along with operation and troubleshooting methods. This manual describes these changes where applicable.

The MP-series mechanical dock leveler design allows

nger tip release pull chain activation with smooth

reliable operation via a cam and roller counterbalance to assure smooth dependable walk down to trailer bed with below dock capability included.

The hold down design oats with air ride trailers and

the full width rear compression hinge is designed for superior strength.

Each MP-series dock leveler has been factory tested to ensure satisfactory operation.

MP dock levelers are available in the following sizes, weight capacities, and options:

Width

6 ft (1829 mm) 6-1/2 ft (1981 mm) 7 ft (2134 mm)

Length

6 ft (1829 mm) 8 ft (2438 mm) 10 ft (3048 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 (22 680 kg)

* CIR (Comparative Industry Rating)

Call McGuire to discuss available options to meet your

specic needs.

Technical Service at 800-643-5424 or [email protected]

4111-0019 — June 2019

Page 11

INTRODUCTION

Component Identication

Inspect package and all components. Report any missing or damaged items immediately and note on the shipping Bill Of Lading (BOL).

1 — Lip 2 — Lip Maintenance Prop 3 — Platform 4 — Bell Crank 5 — Lip Assist Spring

Figure 4

6 — Hold Down Release Ring 7 — Ratchet Pawl & Bar 9 — Hold Down 10 — Platform Maintenance Prop

11 — Main Base Frame 12 — Safety Leg Assy. 13 — Lip (Snubber) Spring 14 — Lip Shock Absorber

15 — Safety Leg Pull Chain 16 — Lift Arm Assembly 17 — Lift (Main) Spring 18 — Prop. Pin and Clip 19 — Working Range Toe Guards

Page 12

INSTALLATION

Installation Precautions

It is recommended and good safety practice to use an additional means to support the dock platform and lip anytime when physically working in front of or under the dock leveler. This additional means may include, but is not limited to a boom truck, fork truck, stabilizing bar or equivalent.

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.

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.

A hard hat or other applicable head protection should always be worn when working under or around a dock leveler.

Always stand clear of platform lip when working in front of the dock leveler.

Only trained installation professionals with the proper equipment should install this product.

4111-0019 — June 2019

Page 13

Leveler Forklift Pick-Up*

INSTALLATION

Rear Pick-Up (recommended)

To pick up the dock leveler from the rear, slide forks

into the fork slots and under the cross member as shown in Figure 5.

Figure 5

Front Pick-Up

To pick up the dock leveler from the front, move forks

closer together and slide over the frame and under the crossmember as shown in Figure 6. It may be necessary to remove the shipping bands from the unit to gain access to the front, by lifting the lip up then sliding the forks under the cross member.

Figure 6

Dock leveler platform not shown for clarity.

Page 14

INSTALLATION

Prepare Pit

10”

14”

A—Pit Width (Front and Rear)

B— Dock Floor-to-Pit Floor (All Four Corners)

Before lowering the dock leveler into the pit, the following must be performed:

Figure 7

C— Pit Length (Both Sides of Pit)

D— Pit Corner-to-Corner (Top, Bottom, and Both Sides)

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/certied pit

drawings. Make sure pit is square by making the following measurements (see Figure 7):

• 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 (diagonal) distance (D)

at both sides. Take measurements at dock oor level and at pit oor level.

If any measurement is o󰀨 by more than 1/8 in. (3.2

mm), contact Systems, LLC Technical Services before proceeding.

Note: If a junction box is required for electrical components (such as interlock switches), locate it 10”

o󰀨 center and 14” down from the curb as shown.

4111-0019 — June 2019

Page 15

Prepare Dock Leveler

INSTALLATION

A— Lifting Bracket (2 used) B — Shipping Bands

McGuire dock levelers are shipped with lifting brackets (A) fastened to the platform side joists, and shipping bands (B) around the platform lip and leveler frame (see Figure 8).

1. Remove any bumpers and/or control panels 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. The shipping bands are needed to hold the leveler together during the installation process.

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 without binding on the mounting cap screw.

Figure 8

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 wood blocks that are attached to the leveler frame before putting the dock leveler into the pit.

5. Proceed to “Install Dock Leveler” on Page 14.

DO NOT over-tighten the lifting bracket hardware.

Over-tightening can damage the weather seal, if equipped.

Page 16

INSTALLATION

TOLERANCES

(UNLESS OTHERWISE NOTED)

DRAWN BY

CHECKED BY

DRAWING NO.

DATE

BDK 7/18/2018

S Y S T E M S

L o a d i n g D o c k E q u i p m e n t

P O W E R A M P

M C G U I R E

D L M

MATERIAL

STOCK NO.

GOOD

BAD

Install Dock Leveler

F G

D E F

A— Distance (Leveler Frame

Height)

B— Shim Locations (Under

Rear Vertical Supports)

C— Shim Location (Under

Maintenance Prop)

Figure 10

D— Shim Locations (Under

Lip Keepers) E— Dock Floor F— Rear Pit Curb Angle G— String

Figure 9

H— Rear Hinge Frame Angle J— Shims Location (Under

Lift Arm)

K— Distance (Dock Floor-to-

Pit Floor)

Figure 11

L— Distance (Top of Shim

M— Shim Stack N— Dock Leveler Frame P— Lip Keeper Shim (as

Stack-to-Dock Floor)

required)

4111-0019 — June 2019

Page 17

INSTALLATION

Install Dock Leveler (continued)

Note: McGuire dock levelers are designed with a

nominal 1/2” (12.7 mm) shimming distance to allow for pit inconsistencies.

1. Determine height of shim stack (M) for each shim location (B) by performing the following:

a. Measure leveler frame height distance (A).

b. Measure dock oor-to-pit oor distance

(K) at each shim location (B). Write down the dimensions obtained at each location.

c. Subtract distance (A) from distance (K) to obtain the shim height. Repeat for each shim location.

2. Using the results obtained in step 1, create the individual shim stacks on the pit oor at location (B). Build each shim stack (M) with the top shim having a minimum size of 4-1/2” x 4-1/2” (114.3 mm x 114.3 mm) and each successive lower shim being larger so

the shims can be welded together using a llet weld. If using o󰀨set method, make sure load is over center

of shim stack, NOT over the edge. DO NOT use straight method. See Figure 12.

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” (114.3 mm x 114.3 mm) to support the full width of the frame rail and to

provide a shelf for a llet weld.

Use the thickest shim stock possible for stability and weld penetration purposes. DO NOT use multiple layers of 1/8 in. (3.2 mm) or thinner shim stock.

Shim Stacking Methods

Pyramid

(Preferred)

O󰀨set w/Load Over Center

(Acceptable)

O󰀨set w/Load Over Edge

(Not Acceptable)

Stepped

(Acceptable)

Straight

(Not Acceptable)

Figure 12

Note: A 1/4” (6.4 mm) thick shim at locations (C and D) are used only as a starting point. The nal shim

stack height will be determined after dock leveler is lowered into the pit.

5. Using an appropriate lifting device connected to the lifting brackets, lower dock leveler into the pit so rear hinge frame angle (H) is tight against rear pit curb angle (F) across full width of the leveler frame.

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.

Note: To assist in obtaining an accurate measurement of distance (L), use a string (G) 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 (L) [top of shim stack (M) to dock oor]. Distance (L) must equal the dock leveler height (A).

4. Put a 1/4 in. (6.4 mm) thick shim at locations (C and D).

6. Allow rear of dock leveler to rest on the rear shims while keeping the front of the dock leveler level with the dock oor.

7. Add shims at front shim locations (C and D) so

front of dock leveler will stay level with dock oor

when leveler is resting fully on shims.

Page 18

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.

Figure 13

E— Pry Locations F— Rear Hinge Frame

Angle

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 oor 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, LLC Technical Services.

G— Rear Pit Curb Angle H— Flare Bevel Weld, Typical

(To Fit Spacing)

4111-0019 — June 2019

Page 19

Install Dock Leveler (continued)

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 a󰀨ected components.

INSTALLATION

12. 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) are 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.

Note: Figure 13 shows a typical weld pattern. The weld pattern will vary slightly depending on size of dock leveler.

13. Prior to welding front of frame to curb steel,

remove the shipping bands from around lip and leveler frame. Operate leveler through full cycle 4-6 times and walk the platform into stored position.

14. Allow platform and lip to oat out of lip keepers,

and shim under front of frame as required to level top of platform with dock oor.

15. Weld front of dock leveler frame (B) to shims

located under the keepers, then weld the shims to the front pit curb steel.

16. Disconnect lifting device and chains from the

lifting brackets.

17. Pull and hold the release ring (located in recess

at rear of platform) until the platform is fully raised. Check for binding as platform rises.

18. Slowly walk out onto the platform to lower the

platform. Allow the platform to lower to the crosstraffic position. Check for binding as platform lowers.

19. If binding occurs, reposition leveler and/or

add or remove shims as necessary. Raise and lower platform again. If platform still binds, contact Technical Services for further instructions.

20. Check that the leveler is flush with the dock floor

and that the platform lip contacts both lip keepers evenly.

Page 20

INSTALLATION

Figure 14

A— Hold-Down Release Ring B— Maintenance Prop

C— Lip Maintenance Prop D— Prop Pin and Clip

21. Pull the release ring (A) to raise the platform. Engage lip maintenance prop (C).

22. Shim and weld the maintenance prop (Figure 14):

a. Install shims under maintenance prop (B) where prop attaches to leveler frame. Make sure prop is solidly shimmed.

b. Raise maintenance prop (B) to the service (upright) position and lock prop in this position using an OSHA approved locking device.

c. Proceed to step 23.

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, and also to the leveler frame.

E— Safety Leg Chain

23. Install shims under lift arm (J, Figure 9 on page

14) at locations using an acceptable shimming method (see Figure 15). The lift arm pivot must be solidly shimmed the entire length of the lift arm pivot. Make sure the lift arm pivot is level from side-to-side.

24. Finish weld all shims using a llet 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.

Make sure the platform is properly supported in the raised position before entering the pit to finish weld the shims.

25. Remove the lifting brackets from the platform side joists.

26. Disengage the platform maintenance prop.

4111-0019 — June 2019

Page 21

Install Dock Leveler (continued)

27. Slowly walk out onto the platform to lower the platform until it is at the cross-traffic (stored) position.

28. Check operation of dock leveler by cycling the leveler at least four times:

• When the platform is at full height, lip will be fully extended.

• Lip will begin to drop after the unit begins to lower to truck bed.

29. Check below-dock position by walking platform

down before lip folds completely:

• Lip will be over lip keepers.

INSTALLATION

Shim Stacking Methods

Pyramid

(Preferred)

O󰀨set w/Load Over Center

(Acceptable)

Stepped

(Acceptable)

• Platform safety legs will be resting on frame.

30. Check full below-dock position by walking the

platform down. Pull and hold safety leg chain (E) before lip folds completely.

Note: If the lip does not extend fully or lip folds too quickly, see appropriate symptom in the Troubleshooting section.

31. When all welding has been completed, paint all

the welds and shims.

32. Install the dock bumpers as required.

33. Install placard (see page 20).

O󰀨set w/Load Over Edge

(Not Acceptable)

Figure 15

Straight

(Not Acceptable)

Page 22

Placard Installation Instructions

Owner/Users are responsible for the installation and placement of product

Make sure placard is in plain view of dock leveler and/or vehicle restraint

Suggested placement of placard is near control box attached to electrical conduit by using nylon tie. If there is no control box present, mount placard

INSTALLATION

Placard Installation Instructions

• Owner/Users are responsible for the installation and placement of product placards.

placards.

• Make sure placard is in plain view of dock leveler and/or vehicle restraint operations.

operations.

• Suggested placement of placard is near control box attached to electrical conduit by using nylon cable tie. If there is no control box present, mount placard on wall to the immediate left of leveler at eye level.

on wall to the immediate left of leveler at eye level.

Control Box

(Placard placement shown

Placard

as example only.)

Nylon Tie

Conduit

(Placard placement shown as reference only.)

A - Control Box B - Placard C - Nylon Cable Tie D - Conduit

Figure 16

4111-0019 — June 2019

Page 23

Operational Precautions

OPERATION

Stay clear of dock leveler and vehicle restraint when transport vehicle is entering or leaving dock area.

DO NOT move or use the dock leveler or restraint 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.

Only trained personnel should operate the dock leveler.

DO NOT use a broken or damaged dock leveler. Make sure proper service and maintenance procedures have been performed on leveler before using.

Transport vehicle wheels must be chocked unless a vehicle restraint is used. Never remove the wheel

chocks until loading/unloading is nished and

transport driver has been given permission to leave.

12 in. (305 mm)

The MP mechanical dock leveler is designed to compensate for a maximum ± 12 in.* (305 mm) of

height di󰀨erence between the loading dock and the

transport vehicle’s bed. DO NOT use the dock leveler if the transport vehicle’s bed is more than 12

in. (305 mm) higher or lower than the dock oor.

*Service height may vary with design specications.

DO NOT overload the dock leveler.

DO NOT operate any equipment while under the

inuence of alcohol or drugs.

DO NOT leave equipment or material unattended on the dock leveler.

Make sure platform lip rests on the transport vehicle bed with at least 4 in. (102 mm) of overlap.

Maintain a safe distance from side edges of leveler during the loading/unloading process.

When activating the leveler, always pull swiftly AND hold the platform release ring until the platform is at the full raised position. Releasing the ring while the platform is still raising may result in damage to the equipment.

Page 24

OPERATION

Operating Instructions

Ramp Loading/Unloading

1. Before activating dock leveler, check to make sure the transport vehicle is positioned squarely against dock bumpers. Ensure lip will avoid contact with transport vehicle frame, sides and cargo during dock leveler activation. If contact is likely or observed, reposition transport vehicle.

2. Instruct driver to remain at the dock until the loading or unloading process has been completed.

Figure 17

3. Chock the transport vehicle wheels, or use a vehicle restraint if available.

Figure 15

4. Raise the platform by pulling and holding the platform release ring (A).

5. Hold the release ring until the platform is at the fully-raised position and lip is fully extended.

8. Proceed with loading or unloading the transport vehicle.

Figure 18

9. When the loading or unloading process has been completed, return platform to cross-traffic (stored) position as follows:

a. Raise the platform to the full-raised position by pulling and holding the platform release ring (A).

b. Lower platform by slowly walking out onto the platform allowing time for the lip to fully fold and clear the transport vehicle. Continue walking out on platform until platform lowers to the crosstraffic position (lip engages in the lip keepers).

Figure 16

6. Walk out onto the platform. The platform will lower until the lip rests on the transport vehicle bed.

7. Make sure that the lip is fully extended and supported on the transport vehicle along the entire width of the platform with at least 4 in. (102 mm) of lip contacting the transport vehicle bed.

10. Remove chocks from transport vehicle wheels, or release the vehicle restraint if used.

11. Indicate to driver that the transport vehicle may leave the dock.

4111-0019 — June 2019

Page 25

Operating Instructions (continued)

End Loading/Unloading

2. Instruct driver to remain at the dock until the loading or unloading process has been completed.

3. Chock the transport vehicle wheels, or use a vehicle restraint if available.

Figure 19

OPERATION

Figure 21

6. Slowly walk the platform down allowing enough time for the lip to fold. Just before the platform reaches the cross-traffic position, pull and hold the safety leg retract pull ring (B, located in a recess at front of the platform). The platform will continue lowering to the full below dock position.

7. Proceed with loading or unloading.

Note: When end unloading is nished and access

to the rest of the transport vehicle is still required, the platform lip will need to be extended. See Ramp Loading/Unloading Instructions on page 22 for further instructions.

4. If transport vehicle bed is at or above dock oor

level, leave leveler at the cross-tra󰀩c position and

proceed with loading or unloading. If transport vehicle bed is below the dock level, continue with Step 5.

Figure 20

5. Pull and hold the platform release ring (A) until the platform is at the fully-raised position.

8. When loading or unloading is finished, raise the platform to the full-raised position by pulling and holding the platform release ring. Slowly walk the platform down, allowing enough time for the lip to fold. The platform will lower to the cross-traffic position (lip engages in the lip keepers).

9. Remove chocks from transport vehicle wheels, or release the vehicle restraint if used.

10. Indicate to driver that the transport vehicle may leave the dock.

Page 26

MAINTENANCE

Maintenance Precautions

Figure 25

A - Platform Release Ring B - Maintenance Prop

C - Lip Maintenance Prop D - Platform Header

Figure 24

E - Safety Leg Pull Chain F - Lock Out Device

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* (F) and tag out device* (G). See Figures 24 and 25.

Only the person servicing the equipment should have the capability to remove the lockout devices. The tag out devices* must inform that repairs are in process and clearly state who is responsible for the lockout condition.

G - Tag Out 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.

* Refer to OSHA regulations 1910.146. Conned Space and 1910.147. Lockout/Tagout

A hard hat or other applicable head protection should always be worn when working under or around a dock leveler.

Always stand clear of platform lip when working in front of the dock leveler.

4111-0019 — June 2019

Page 27

Periodic Maintenance

Grease

MAINTENANCE

1 — Lip Hinge Grease Fittings 2 — Lip Maintenance Prop Pivot 3 — Lift Arm Roller Bushing

4 — Lift Arm Pivot 5 — Hold-Down Pivot/Pulley 6 — Safety Leg Linkage Pivots

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.

• Inspect warning decals and placards. Replace if damaged or missing.

Quarterly Maintenance

• Complete Weekly Maintenance.

• Inspect the following for damage/abnormal wear:

• Check welds for cracks.

• Lift arm pins and mounting holes.

• Lip hinge pins and rear hinge pins.

• Check toe guards for free movement.

• Bumpers for more than 1” of wear. Replace worn, loose, damaged or missing bumpers.

• Side and rear weather seals.

Figure 26

7 — Lip Lift Assist Pin 8 — Hold Down-to-Platform Pin

• Lubricate the following areas with light weight machine oil (see Figure 26):

(2) — Lip maintenance prop pivot (5) — Hold-down pivot/pulley (6) — Safety leg linkage pivots (8) — Hold-down to platform pin

• Lubricate the following areas with white lithium grease:

(1) — Lip hinge area (3) — Lift arm roller bushing (4) — Lift arm pivot (7) — Lip assist pin

Note: Apply grease to lip hinge grease ttings if equipped. Do not put grease or oil on the ratchet bar or cam!

Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler.

Page 28

ADJUSTMENTS

Adjust Main Spring & Lip Assist Spring Tension

1 — Jam Nut 2 — Adjustable Nut

3 — Lip Assist Spring 4— Lift Springs

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.

Figure 27

5 — Lift Spring Bolt 6 — Hold-Down Mechanism

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.

A hard hat or other applicable head protection should always be worn when working under or around a dock leveler.

Always stand clear of platform lip when working in front of the dock leveler.

4111-0019 — June 2019

Page 29

Adjust Main Spring & Lip Assist Spring Tension (continued)

3. After lift spring adjustment is completed, check operation of the lip:

If the platform does not rise fully on its own, it may be necessary to use an external lifting device. Use a lifting device with the appropriate lifting capacity to safely raise the platform. Make sure to engage and pin the platform maintenance prop after raising the platform.

When using an external lifting device to raise the platform, make sure hold-down mechanism (6) is disengaged. Pull and hold platform release ring during the lifting process to avoid shearing the ratchet pawl and ratchet bar teeth.

• If the lip folds before the platform can be walked down, tension of lip assist spring (3) may be set too low.

• If the lip does not fold fully or takes too long to fold, tension of lip assist spring (3) may be set too high.

4. Adjust lip assist spring tension as follows:

Note: Use two-turn increments when adjusting lip assist spring (3). Check lip operation after each adjustment. Repeat until proper operation is obtained.

ADJUSTMENTS

If the platform does not rise fully and/or lip does not extend fully, the main lift spring tension may be set too low.

If the platform cannot be walked down or is difficult to walk down, the main lift spring tension may be set too high.

Note: Adjusting the tension of lift springs (4) usually requires that the lip assist spring (3) also be adjusted.

1. Raise the platform and engage the platform maintenance prop. Pin the maintenance prop in the service position using attached pin device.

2. Adjust tension of lift springs (4) as follows:

Note: Use 1/2 turn increments when adjusting lift spring bolt (5).Turn clockwise to increase tension and counterclockwise to decrease tension. Check platform operation after each adjustment. Repeat until proper operation is obtained.

• To increase lift spring tension, turn lift spring bolt (5) clockwise.

a. Loosen jam nut (1).

b. To increase spring compression, turn nut (2) clockwise.

c. To decrease spring compression, turn nut (2) counterclockwise.

d. Tighten jam nut.

5. Recheck operation of platform and lip. Readjust lift spring tension and lip assist spring tension until proper operation is obtained.

• To decrease lift spring tension, turn lift spring bolt (5) counterclockwise.

Page 30

ADJUSTMENTS

Adjust Lip Stop Bolt

When at rest, lip (E) should be fully resting on the lip keepers (D) and at the lowest part of the lip keepers. If lip is not resting properly in the lip keepers, perform the following adjustment:

1. Fully raise the platform and engage the maintenance prop in the service position. Manually raise the lip and engage lip maintenance prop (not shown).

2. Loosen jam nut (B).

3. Adjust stop bolt (C) as necessary.

• Turn stop bolt “in” (clockwise) to allow lip to fold closer to platform (A).

• Turn stop bolt “out” (counterclockwise) to hold lip further away from platform (A).

4. Tighten jam nut (B).

5. Disengage lip maintenance prop.

6. Walk platform down to cross-traffic (stored)

position.

7. Check lip position in both keepers. Repeat

procedure if necessary.

A— Platform B— Jam Nut C— Stop Bolt

Figure 28

D — Lip Keeper E — Lip

4111-0019 — June 2019

Page 31

ADJUSTMENTS

This page intentionally left blank.

Page 32

TROUBLESHOOTING

Symptom Possible Cause Solution

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.

A hard hat or other applicable head protection should always be worn when working under or around a dock leveler.

Always stand clear of platform lip when working in front of the dock leveler.

Remove object(s) from platform.

Platform does not rise.

Platform rises slowly or does not rise to the full raised position.

Heavy object(s) on platform.

Disconnected or broken release chain.

Dock leveler binds.

Heavy object(s) on platform.

Dock leveler binds.

Insu󰀩cient main spring

tension.

Note: For safety reasons, the dock leveler is designed to lift only the platform’s own weight.

Connect or replace release chain.

Check for visible obstructions that could cause binding. Remove obstructions. If no obstructions found, contact Systems, LLC Technical Services.

Remove object(s) from platform.

Note: For safety reasons, the dock leveler is designed to lift only the platform’s own weight.

Check for visible obstructions that could cause binding. Remove obstructions. If no obstructions found, contact Systems, LLC Technical Services.

Increase tension on main springs. See pages 26-27 for instructions.

Damaged or worn hold-down mechanism.

Inspect and clean hold-down mechanism. Replace if damaged or faulty.

4111-0019 — June 2019

Page 33

TROUBLESHOOTING

Symptom Possible Cause Solution

Platform rises to full height, but lip does not fully extend.

Platform does not lower when operator walks out onto the platform.

Lip folds too fast during normal walk-down.

Lip assist chain disconnected or broken.

Insufficient main spring tension.

Insufficient lip assist force.

Excessive main spring tension.

Damaged or worn holddown mechanism.

Insufficient lip assist force.

Disconnected, worn, or broken gas shock.

Connect or replace lip assist chain.

Increase tension on main springs. See pages 26-27 for instructions.

Increase tension on lip assist spring. See pages 26-27 for instructions.

Reduce main spring tension. See pages 26-27 for instructions.

Inspect and clean hold-down mechanism. Replace if damaged or faulty.

Increase tension on lip assist spring. See pages 26-27 for instructions.

Inspect gas shock. Replace if damaged or faulty.

Platform does not stay down.

Lip does not fold after truck departs.

Binding or stuck release chain.

Dirt impacted in ratchet bar teeth.

Broken or damaged ratchet assembly teeth.

Disconnected or broken hold-down pivot pins.

Damaged or worn holddown mechanism.

Lip hinge binding due to lack of lubrication

Excessive lip assist force.

Check for visible obstructions that could cause binding. Remove obstructions.

Inspect and clean ratchet bar and ratchet pawl teeth. DO NOT lubricate the ratchet assembly.

Replace ratchet assembly. DO NOT lubricate the

ratchet assembly.

Connect or replace hold-down pivot pins.

Inspect and clean hold-down mechanism. Replace if damaged or faulty.

Grease lip hinge. See page 25 for instructions.

Decrease tension on lip assist spring. See pages 26-27 for instructions.

If additional troubleshooting assistance is required, contact Systems, LLC

Technical Services with equipment serial number or customer order number (CO#).

Technical Service at 800-643-5424 or [email protected]

Page 34

NOTES

REVISIONS

EN REV

DESCRIPTION DATE

XX-XXX

ORIGINAL ISSUE

PARTS

Hold-Down Components

Item Quantity Part Number Description

A 1 M502.089 Hold Down, Complete (ts 1990-present)

B 1 M512.986 Ratchet and Pawl Kit (for M502.089)

NS* 1 M512.988 Release Arm Spring (for M502.089)

NS = Not Shown

4111-0019 — June 2019

Page 35

Main Lift Springs

PARTS

Length

Coils

Wire Diameter

Outer Diameter

Part Number* Description Length (A) O.D. (B) Wire Dia. (C) Coils (D)

DOTH-2570 Main Lift Spring - Blue 20” (508mm) 3.468” (88mm) .406” (10mm) 38 DOTH-2574 Main Lift Spring - Red 21” (533mm) 4.750” (121mm) .531” (13mm) 26 DOTH-2576 Main Lift Spring - Black 23” (584mm) 3.875” (98mm) .500” (12mm) 37 DOTH-2578 Main Lift Spring - Yellow 23” (584mm) 4.700” (119mm) .594” (15mm) 30

Provide dock leveler serial number, platform size, lip size and capacity when e-mailing, calling or faxing orders.

Page 36

PARTS

Frame Components

See Page 33

4111-0019 — June 2019

Page 37

Frame Components

Item Quantity Part Number Description

1 1 8435-____

2 1 M502.089 Hold Down, Complete (ts 1990-present)

1 DOTP-6424

1 DOTP-6423

4 1 9224-____

5 1 9221-____

6 1 DOTH-2555 Spring, Snubber

2101-0361 Bolt, Shoulder, 1/2 x 2-1/4, 3/8-16

DFRA-0350 Roller, Release Chain

7 1

DOTH-2210 Washer, Flat, 1/2”

2101-0060 Washer, Flat, 3/8” SAE

DOTH-2131 Lock Nut, Nylon, 3/8-16

9 1 DOTH-2416 Lap Link, 3/16” x 1”

10 1

DFRA-0326

DFRA-0327

13 2 DOTH-2218 Washer, Flat,1-1/16” ID x 2” OD

14 2 DOTH-2222 Washer, Flat, 1-1/16 ID x 1-1/2 OD

15 4 DOTH-2374 Pin, Cotter, 1/8 x 1

16 1 DFRA-1205 Pin, Lift Arm, 1” x 9-1/8”

5265-0012

17 1

5265-0013

5265-0014

18 2 8432-____

19 1 9201-0006 Prop Pin & Clip

20 1 DOTH-2401 Caster Assembly, 4” OD

21 1 DPLA-2128 Chain, Lip Assist Link

Frame, Welded Assembly

Lift Arm, Short, 25” (Includes Caster Assembly)

Lift Arm, Long, 27” (Includes Caster Assembly)

Prop, Maintenance

Housing, Maintenance Prop

T-Bar and Adjusting Rod, 6’

T-Bar and Adjusting Rod, 8’/10’

Chain, Hold-Down Release, 6’

Chain, Hold-Down Release, 8’

Chain, Hold-Down Release, 10’

Keeper, Lip

PARTS

Provide dock leveler serial number, platform size, lip size and capacity when e-mailing, calling or faxing orders.

Page 38

PARTS

Platform Components

See Page 33

4111-0019 — June 2019

Page 39

Platform Components

Item Quantity Part Number Description

1 1 9515-____

2 1 DPLA-0338 Lip Banger Assembly, Neutron (Includes Item 3)

3 1 DPLA-0341 Bar, 5/8 x 1 x 11-5/8

4 1 DPLA-0353 Below Dock Chain Assembly

9 1

DPLA-0343 Below Dock Control Assembly

DPLA-0401 Below Dock Control Assembly (6' Long Units Only)

10 2 DOTH-2382 Pin, Cotter, 1/4 x 2

11 1 DOTH-2074 Bolt, Hex, 5/8-11 UNC x 2

12 1 DOTH-2160 Nut, Hex, 5/8-11

17 1 DPLA-0360 Below Dock Control Push Rod Assembly

18 1 DOTH-2060 Bolt, Shoulder, 1/2 x 1, 3/8”-16 UNC

19 1 DOTH-2131 Lock Nut, Nylon, 3/8-16

20 1 DOTH-6406 Lip Assist Rod

23 1

DOTH-2550

DOTH-2546

25 1 9513-0091 Assembly, Lip Prop

30 1 DKIT-6465 Kit, Gas Shock w/Hardware

DPLA-2101

35 2

DPLA-2102

DPLA-2103

36 2 DOTH-2355 Pin, Clevis, 1/2 x 2-1/4 w/Hole

37 2 DOTH-2373 Cotter Pin, 1/8 x 1-1/2

38 1 0595-____

39 2 2101-0079 Washer, Flat, 1/2” SAE

Platform, Welded Assembly

Spring, Lip Assist, Standard Orange)

Spring, Lip Assist, Heavy Duty (Green)

Pin, Lip Hinge, 1” OD x 35.25

Pin, Lip Hinge, 1” OD x 38.25

Pin, Lip Hinge, 1” OD x 40.5

Lip, Welded Assembly

PARTS

Provide dock leveler serial number, platform size, lip size and capacity when e-mailing, calling or faxing orders.

Page 40

PARTS

Weather Seals

Weather Seal Kits

Item Quantity Part Number Description

Individual Replacement Seals

Item Quantity Part Number Description

B 1 DOTH-2822 Brush Rell, 1-1/2 in. 84" Lg. C 1 DOTH-2824 Rubber Rell, 1-1/2 in. 84" Lg. D 1 DOTH-2840 Replacement Channel

1 DKIT-9293 Brush Kit (Includes Seal and Track), 1-1/2 in. 84" Lg. (Both Sides) 1 DKIT-9292 Rubber Kit (Includes Seal and Track), 1-1/2 in. 84" Lg. (Both Sides)

4111-0019 — June 2019

Page 41

Toe Guards

PARTS

Item Quantity Part Number Description

DKIT-9183* Toe Guard Kit, Sliding 6’ (Includes Both Sides)

A 1

DKIT-9184* Toe Guard Kit, Sliding 8’ (Includes Both Sides)

DKIT-9185* Toe Guard Kit, Sliding 10’ (Includes Both Sides) B 2 DOTH-2043 Cap Screw C 6 DOTH-2207 Washer D 2 DOTH-2131 Lock Nut E 2 0011-0010 Platform Mounting Tab

Provide dock leveler serial number and size of platform when e-mailing, calling or faxing orders.

Page 42

MISCELLANEOUS

This page intentionally left blank.

4111-0019 — June 2019

Page 43

Customer Information

MISCELLANEOUS

Figure 29

NOTE: Refer to Figure 29 for left/right orientation of dock

leveler and Figure 30 for example of decal.

The LEVELER model/serial number decal is

located on the left platform joist near the front (lip) of dock leveler (A).

Figure 30

Dock Leveler Information

Model ___________________________________

Serial No. ________________________________

When you receive your new equipment, write down the 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, B) becomes lost or damaged.

Also, write down Systems, LLC’s order 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, LLC P.O. Box 309 Germantown, WI 53022

Phone: (800) 643-5424 Fax: (262) 255-5917

Systems, LLC, Job No. ______________________

Vehicle Restraint Information

Model ___________________________________

Serial No. ________________________________

Systems, LLC Order No. ______________________

Original Owner Information

Name ___________________________________

Address _________________________________

________________________________

Installer Information

Name ___________________________________

Address _________________________________

_________________________________

www.loadingdocksystems.com

Date of Installation ________________________

Page 44

STANDARD PRODUCT WARRANTY

SYSTEMS, LLC warrants that its products will be free from defects in design, materials and workmanship for a period of one (1) year from the date of shipment. All claims for breach of this warranty must be made within 30 days after the defect is or can with reasonable care, be detected. In no event shall any claim

be made more than 30 days after this warranty has expired. In order to be entitled to the benets of this

warranty, the product must have been properly installed, maintained and operated in accordance with all

manufacturer’s recommendations and/or specied design parameters and not otherwise have been subject to abuse, misuse, misapplication, acts of nature, overloading, unauthorized repair or modication, application in a corrosive environment or lack of maintenance. Periodic lubrication, adjustment and inspection in

accordance with all manufacturers’ recommendations are the sole responsibility of the Owner/User.

In the event of a defect, as determined by SYSTEMS LLC, covered by this warranty, SYSTEMS LLC shall remedy such defect by repairing or replacing any defective equipment or parts, bearing the cost for the parts, labor and transportation. This shall be exclusive remedy for all claims whether based on contract,

negligence or strict liability.

WARRANTY LIMITATIONS

THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. SYSTEMS LLC AND ITS SUBSIDIARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE, INCLUDING THIRD PARTIES, FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO, BREACH OF WARRANTY, LOSS OF USE, LOSS OF PROFIT, INTERRUPTION OF BUSINESS OR LOSS OF GOODWILL.

PRODUCT SPECIFIC WARRANTY

“MP” SERIES LEVELER

In addition to the “Standard Product Warranty” provided with all McGuire® products, Systems LLC, guarantees materials, components and workmanship to be free of defects for the following extended periods:

• Structural Warranty – For an additional period of four (4) years, for parts, labor and freight, product will carry a prorated structural warranty. This warranty specically applies to; the deck section, lip section, frame, rear hinge assembly and front hinge assembly only. This warranty covers structural repairs to or replacement of dock leveler in Systems LLC sole discretion and expense including reasonable labor, materials, freight and travel. If Systems LLC determines replacement is necessary, it will provide the original purchaser with a credit toward the purchase of the new replacement Systems LLC product in the amount equal to the original purchase price

of the warranted product F.O.B. point of manufacture, discounted on a ve year straight line

basis by the number of years of use prior to replacement.