Mechanical Dock Leveler MKA 1000LB MKA 1000HDMKA 1300M-Series

W.B. McGuire Company, Inc.One Hudson Ave.

Hudson, NY 125341-800-624-8473

Owner's Manual & Installation Instructions

Important: Thoroughly read and understand entirecontents of this manual prior to installation and/oroperation of this equipment.

Caution: Be sure that installation and maintenanceare performed by qualified personnel.

INTRODUCTION....

Congratulations! You have purchased the industry's finest mechanically operated dock leveler. Being dynamicallyengineered, it will provide many years of service for you. As with all equipment using some mechanical function, a simplemaintenance program will insure proper operation. On-site maintenance personnel can follow the enclosed serviceinstructions 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 ContentsOverview of Potential HazardsInstallation Instructions & Shim LocationsPit DimensionsBumper Mounting DetailsOperating SequenceMaintenance & Required AdjustmentsComponent IdentificationParts ListTrouble Shooting ProceduresDock Leveler Warranty

NOTE: All information contained in this manual is applicable for all mechanical dock leveler models mentioned on thecover. In specific instances, the difference between models is noted. Only structural differences and capacity ratingsoccur 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 consequentialinjuries or damages of any kind as a result of misuse or improper operation of this product.

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Back Cover

WARNING!

SAFETY INSTRUCTIONS

OVERVIEW OF POTENTIAL HAZARDS...

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.

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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.

Dock levelers are large, heavy objects that move with the help of springs under high tension. Since moving objectsand springs under tension can cause injuries, your safety and the safety of others depend on you reading the infor-mation in this manual. If you have questions or do not understand the information presented, call the McGuireTechnical Support team at 1-800-624-8473.

WARNING: can cause seriousinjury or death.

WARNING: can cause seriousinjury or death.

Moving Leveler

Moving Truck

Moving Ramp can cause seriousinjury or death.

Stay Clear when ramp is in motion.

Do Not enter pit area until ramphas been braced open and poweris turned off and locked out.

Moving Truck can cause seriousinjury or death.

Stay Clear when truck is in motion.

Do Not stand between truck andramp when truck is entering orleaving.

!

!

INSTALLATION INSTRUCTIONS...

1. On arrival, the platform will be banded to the base. DO NOT UNBAND. Check unit for anydamage that may have occurred during transit. If any damage is detected, file a claim with thetransportation company delivering carrier immediately. DO NOT INSTALL ANY UNIT THATAPPEARS 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 levelerfor 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 curbangle. Center the leveler in front so that there is I" clearance on both sides. Raise the rear ofthe leveler until rear top angle and curb angle are flush and tight together. Check to see thatthe 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 platformand 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.

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CAUTION: Do Not Unband. Check unitfor damage, If damaged, do not install.Contact factory immediately.

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 additionalcost. (Note: Part #4 may not be required. Consult factory or contractor.)

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BUMPER MOUNTING DETAILS...

Drawings not to scale.

Two-holed, molded bumpers are available. Thesebumpers are used mainly for edge-of-dock units. Certainapplications may call for this size bumper.

4" thick, 4-holed bumpers are standard. Twoincluded with each leveler.

Bumpers are to bemounted flush and tightagainst the side and topof the pit wall, on eachside of the leveler.

4” thick, “AD” bumpers are standard on the M-SeriesMechanical leveler.

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OPERATING SEQUENCE...

IMPORTANT Pull-chain controls operated from above the leveler deck require only moderate effort to functionproperly. Excessive, forceful jerking or straining on these controls can prevent proper operation or even damage the lev-eler mechanism. Damage resulting from such forceful operation of the controls is considered abuse and can VOID thewarranty. The pull-chain activation is designed to be pulled straight up, out of the cup, at the rear of the levelerPulling 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 dockattendant 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 pullaway from the dock. BE SURE THAT NO GOODS OR PEOPLE ARE STANDING ON THELEVELER PLATFORM AT THIS TIME. The hinged lip will automatically lower to its storedposition.

5. End Loading: For end loads below dock level, perform steps 1, 2 & 3 first, then pull thering recessed in the deck near the front of the leveler. The deck can be lowered to either oftwo supported positions below dock level.

6. Store - Above Dock Level: When the deck is above dock level, the attendant walking ontothe 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 anupright position for qualified personnel to perform maintenance or service. Setting the service leg requires twopeople. 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.

6

WARNING: Stay Clear when leveler or truck is in motion. Do Not stand between truck andleveler when truck is entering or leaving.

WARNING: Do Not enter pit area until levelerhas been braced open with jack stands.

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 mem-bers. If any members are damaged, DO NOT USE THIS UNIT UNTIL IT IS REPAIRED.

1. Keep the area around and under the leveler clean and free of debris.2. Keep lip hinge clean and free of debris that would restrict free lip movement.3. Every 3 months, lubricate points as indicated below.4. 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 thecenter depending on model.

THE McGUIRE MECHANICAL DOCK LEVELER MECHANISMFunction - As the platform rises, snubber chain is drawn tight to pull lip lug down and out with assist of momen-

tum and counterbalance.

Lip Counterbalance - serves two functions: It spring pre-loads the lip so that a minimum force is required toextend it. With the lip in the pendent position, it exerts pressure to hold it there. As the lip extends, the counterbalancecrosses the center line of the pivot point applying pressure to the lip. When properly adjusted, the lip becomes nearlyweightless as it approaches the pivot cross-over point. Adjustment is made with the nut on the clevis spring rod.

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Light Oil

Grease

Penetrating Oil

GreasePenetrating Oil

COMPONENT IDENTIFICATION...

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 adjustedby 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 supportingmembers that stop the deck from downward travel at dock level, and permit lowering of the deck ontotwo safe, supported stops below dock level. The cross traffic legs support the deck when it is in across traffic position.

6. Cross Traffic Leg Pedestals.

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WARNING: Do Not enter pit area untilleveler has been braced open with jackstands.

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2

3

5

4

6

ITEM1

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PART NO.

1 13-0999999991

1 13-073

1 13-061

1 13-0551 13-058

512-942

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812-032121-071

121-021

812-086

512-949512-950

822-024

PART NAME

HOLDDOWNROLL PIN

COTTER PIN

SPRING 6 '

SPRING 8 '

SNUBBER SPRING

CHAINLIFT.ARM 6'

LIFT.ARM 8'

WASHERHEX.NUT

SPRING PADDLE

CHAIN 6'

CHAIN 8'

LIFT.ARM PIN

QTY22

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ONLY ONE WEATHERSEAL SHOWN.ONLY ONE SET OF TOE GUARDS SHOWN.

PART NAMELIP ASSY 6FT X 16''LIP ASSY 6 FT X 18''LIP ASSY 6 FT X 20"LIP ASSY 6.5 FT X 16' 'LIP ASSY 6.5 FT X 1B' 'LIP ASSY 6.5 FT X 20"LIP ASSY 7 FT X 16''LIP ASSY 7 FT X 18' 'LIP ASSY 7 FT X 20"LIP SHAFT 6 FTLIP SHAFT 6.5 FTLIP SHAFT 7 FTWEATHERSEAL SET 6'WEATHERSEAL SET 8'WEATHERSEAL SET 1O'

CAPACITY IPART

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25K812-095812-096812-097812-098812-099812-1008 1 2 - 1 0 1812-102812-103

30K812-104812-105812-106812-107812-108812-1098 1 2 - 1 1 0812-111812-112821-006821-013821-014531-452531-453531-454

NUMBER35K812-1288 1 2 - 1 3 1812-134812-129812-132812-135812-130812-135812-136

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PART NAME1ST STAGE TOEGUARD 6' LG. (RH)1ST STAGE TOEGUARD 6', LG. (LH)2ND STAGE TOEGUARD 6' LG. (RH)zND STAGE TOEGUARD 6' LG. (LH)3RD STAGE TOEGUARD 6' LG. (RH)3RD STAGE TOEGUARD 6' LG. (LH)1ST STAGE TOEGUARD 8' LG. (RH)1ST STAGE TOEGUARD 8' LG. (LH)2ND STAGE TOEGUARD 8' LG. (RH)2ND STAGE TOEGUARD I' LG. (LH)3RD STAGE TOEGUARD 8', LG. (RH)sRD STAGE TOEGUARD B' LG. (LH)1ST STAGE TOEGUARD 10' LG. (RH)1ST STAGE TOEGUARD 1o', LG. (LH)2ND STAGE TOEGUARD 1o'LG. (RH)2ND STAGE TOEGUARD 1o' LG. (LH)3RD STAGE TOEGUARD 1o', LG. (RH)3RD STAGE TOEGUARD 10'LG. (LH)SHOCKS, MECH. LEVELERPIN, ROLL SST .25 X 1 .50cLEVlS, PIN 112" X 1 314"cLEVls PlN, 5/8" X 1 518"PIN, COTTER .125 X 1 .50 LBUSHING 14GA 518" X 1"TOGGLE ARMSHOCK SPACERCLEVIS PlN, 112" X 5 718"COUNTER BALANCE ROD ASSYBOLT, HEX .375 - 16 X .75NUT, HEX .375 - 16 X 1"WASH/FL 1''OD X .375 IDTEK SCREWSPRING COUNTER BALANCEX.TRAFFIC LEG ASSYBELL CRANK ASSYBELOW DOCK CHAINSPRING, EXTENSION

FOLLOWING ITEMS NOT SHOWNLABEL, PRODUCTLABEL, LEVELER WARNINGLABEL, LOGO MADE IN USALABEL, WARNING DO NOT . . .TAPE, HAZARDLABEL, MCGUIRE CERTIFIED . . .LABEL, STAY CLEAR . . .LABEL. TOE GUARD

PART NO.81 1-07581 1-076811-07781 1-078821-027821-02981 1-07981 1-08081 1-08181 1-082821-082821-034XXX-XXXXXX.XXXXXX.XXXXXX.XXXXXX-XXXXXX-XXX1 13 -140113-2711 13-0711 13-3501 13-0731 13-351721-020822-0971 13-296512-545122-021121-022121-062122-1881 13 -3167 1 1 - 1 1 0512-960512-9551 13-268

FOR CLARITY131-0051 3 1 - 1 1 6131-122131-1321 3 1 - 1 5 4131-167'131 -169

1 3 1 - 0 1 3

1 1

PARTS LIST...

PART NUMBER DESCRIPTION COMMENTS

502-058 HOLD DOWN ASSEMBLY

HOLD DOWN KIT For levelers prior to 1990

Specify model & pit depth

502-085

113-219

512-545

113-316

522-240

522-251

113-058

113-122

512-566

113-052

113-056

113-061

113-055

113-096

121-024

121-071

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.

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SELF-RELEASING HOLD DOWN

LIP SHOCK

LIP COUNTERBALANCE ROD ASSEMBLY

LIP COUNTERBALANCE SPRING

SHOCK MOUNTING PIN

SHOCK SPACER

SNUBBER SPRING

SNUBBER CHAIN Specify length required

BELOW DOCK RELEASE CHAIN

CROSS TRAFFIC LEG RETURN SPRING

S-HOOK

MAIN SPRING - RED 19.5" OVERALL LENGTH

MAIN SPRING - PURPLE 23.5" OVERALL LENGTH

LIFT ARM ASSEMBLY Specify model & pit depth

SPRING PULL PADDLE Specify model & pit depth

LIFT ARM CASTER

COUPLING NUT (For spring paddle)

WASHER (For spring paddle)

TROUBLE SHOOTING PROCEDURES...

If the corrective action does not solve the problem, or you encounter a problem that is not covered in this section, consultthe McGuire Technical Support Team immediately. DO NOT USE THE LEVELER.

1. Leveler will not rise or rises slowly.

2. Leveler will not lower.

3. Leveler not level in pit.

4. Lip will not extend.

5. Leveler will not go below dock.

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A. Sides of pit causing binding against weatherseals.

A. Physical obstruction.B. Pit bowed up in center.C. Spring tension too high.

A. Pit is sloped.

B. Improper installation.

C. Frame damaged.

A. Obstruction in hinge area.B. Hold down not fully released.

C. Springs not working.

A. Cross traffic legs not fully retracted.

B. Chain caught.

A. Check clearances.

A. Remove obstruction.B. Reshim unit.C. Adjust tension by:

A. Check pit with level gauge in length and width. Relevel unit.

B. Relevel unit.

C. File claim with shipper.

A. Remove obstruction.B. Walk leveler to stored position.

Repeat operate procedure.C. Check and replace if necessary.

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.

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

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 defectsin 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 byMcGuire to be defective, and is conditioned upon the buyer giving written notice of any such defect within the warrantyperiod. 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 toabuse, neglect, misuse or by accident. Warranty will be VOID if any repairs are made or attempted to be made by anyperson 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. McGuireassumes 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.

MECHLEV/31-5-2 PRINTED IN U.S.A.

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Models covered by this warranty:M-Series (5 years)MKA 1300 (1 year)

MKA 1000HD & MKA 1000LB (1 year)

One Hudson Ave.Hudson, NY 125341-800-624-8473518-828-7652 • Fax: 518-828-1262www.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.

Represented in This Area By: