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Blue Giant M Service Manual

Mechanical dock leveler
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SERVICE MANUAL
Mechanical Dock Leveler
Issue Date: 10/01/01, Rev. 0 (Part #038-550E)

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  • Page 1 SERVICE MANUAL Mechanical Dock Leveler Issue Date: 10/01/01, Rev. 0 (Part #038-550E)
  • Page 2 Mechanical Dock Leveler – M and FMC Group 01, Section 01, Page 1 MECHANICAL DOCK LEVELER Models M and FMC Serial Number 9840001 and Up IMPORTANT Read and understand Pages 1 through 4 at the beginning of this binder before proceeding with any repair or maintenance work.
  • Page 3 Group 02, Section 01, Page 1 INTRODUCTION Mechanical Dock Leveler Blue Giant dock levelers are identified by information located on an I.D. plate mounted on the upper, front, right hand side of the unit. Model number, Serial number and Capacity information is included for use when requesting information or ordering service parts.

  • Page 4: Component Identification

    Mechanical Dock Leveler – M and FMC Group 02, Section 01, Page 2 COMPONENT IDENTIFICATION Issue Date: 10/01/01, Rev, 0 (Part #038-550E)
  • Page 5 Mechanical Dock Leveler – M and FMC Group 02, Section 01, Page 3 INTRODUCTION and COMPONENT IDENTIFICATION Right & Left Side The right side is identified by standing on the dock leveler while facing the dock door and lip. Base Frame The angle iron mounting frame that is the base platform for the entire dock leveler.
  • Page 6 Mechanical Dock Leveler – M and FMC Group 02, Section 01, Page 4 INTRODUCTION and COMPONENT IDENTIFICATION Lip Keepers These are the retainers for the Lip when it is in the park position. Lip Stops Prevent the Lip from traveling too far when parking the dock leveler.
  • Page 7 NOTICE The description and specifications included in this manual were in effect at the time of printing. Blue Giant reserves the right to discontinue models at any time, or make improvements and changes in specifications or design without notice and without incurring obligation.
  • Page 8 Always engage maintenance strut attempting to do any repair work. and place traffic barriers before entering pit area. When in doubt of any procedure, contact your Blue Giant distributor • There are numerous variations in for assistance. procedures, techniques, tools and...
  • Page 9 Damage to the dock equipment, death, or serious injury to you or other persons may result if these messages are not followed. If warning decals are damaged, they must be replaced. Contact your Blue Giant Distributor for replacements. NOTICE This message is used when special information, instructions or identification are required relating to procedures, equipment, tools, capacities and other special data.
  • Page 10 NOTICE Contact your Blue Giant Distributor for more information on Maintenance and Repair of your Dock Equipment. Page 4 Issue Date: 10/01/01, Rev, 0...

  • Page 11: How To Use This Manual

    BLUE GIANT SERVICE MANUAL PRODUCTS COVERED BY THIS MANUAL PRODUCT MODEL CODE Dock Leveler – Mechanical – Pit Mounted Dock Leveler – Hydraulic – Pit Mounted Dock Leveler – Hydraulic – Vertical Storing E.O.D. Dock Leveler – Mechanical – Edge of Dock MD-M E.O.D.

  • Page 12: Theory Of Operation

    Mechanical Dock Leveler – M and FMC Group 03, Section 01, Page 1 Theory of Operation Mechanical Dock Leveler Index SUBJECT GROUP SECTION PAGE Description of Operation Walking the Dock into Working Position 2 –3 Return to Stored Position Diagonal Float Ability...

  • Page 13: Description Of Operation

    Mechanical Dock Leveler – M and FMC Group 03, Section 01, Page 2 DESCRIPTION OF OPERATION Before moving the dock leveler from the stored position, it is most important to chock the vehicle wheels or otherwise secure the vehicle to prevent its movement away from the dock, before operating the Dock Leveler.

  • Page 14: Return To Stored Position

    Irregularities in left to right corner height of the truck floor are sometimes caused by uneven paving or lop sided loads. The design of the Blue Giant Dock Leveler incorporates the use of "Tilt Bars and Pockets". These are floating hinge and mount points located at the rear of the deck that allow the deck to float diagonally and compensate for irregularities in left to right corner height of the truck floor.
  • Page 15 Mechanical Dock Leveler – M and FMC Group 03, Section 01, Page 4 FALL SAFE FEATURES A fall safe device is included on all U.S. dock levelers and is available as an option in all other countries. Its purpose is to limit the free fall of the deck to 1-1/2” below dock height if a trailer pulls away when a fork truck is on the dock leveler.
  • Page 16 Mechanical Dock Leveler – M and FMC Group 03, Section 01, Page 5 DETAIL OF COMPONENT FUNCTIONS In the previous descriptions outlined in this section we explained the general operation of the Mechanical Dock Leveler. In this part of the operation...
  • Page 17 Mechanical Dock Leveler – M and FMC Group 03, Section 01, Page 6 DETAIL OF COMPONENT FUNCTIONS – cont’d In this view the deck has been allowed to raise to the point where the actuator extended the lip. Notice that as the actuator assembly moved forward –...
  • Page 18 Mechanical Dock Leveler – M and FMC Group 03, Section 01, Page 7 DETAIL OF COMPONENT FUNCTIONS – cont’d As you can see here, the rewind spring is always trying to pull the cable towards the hold down box. The rewind spring only has enough power to rewind the cable as the deck moves downward.

  • Page 19: Hold Down In Locked Position

    Mechanical Dock Leveler – M and FMC Group 03, Section 01, Page 8 HOLD DOWN IN LOCKED POSITION: The “one-way direction check” is created by the action of the lower “Lock Roller” which is held downward by the upper “Counter Weight”...

  • Page 20: Below Level Feature

    Mechanical Dock Leveler – M and FMC Group 03, Section 01, Page 9 BELOW LEVEL FEATURE A vehicle loadbed that is lower than dock height may be serviced by using the below level feature. Fall Safe support legs prevent service of below dock height truck bed and / or end load.
  • Page 21 Mechanical Dock Leveler – M and FMC Group 03, Section 01, Page 10 DETAIL OF COMPONENT FUNCTIONS – cont’d MAINTENANCE STRUT This illustration shows a typical dock leveler being supported by the maintenance strut. The angle bracket, that forms the upper end of the strut,...

  • Page 22: Troubleshooting

    Mechanical Dock Leveler – M and FMC Group 04, Section 01, Page 1 TROUBLESHOOTING DO NOT attempt to make repairs or adjustments yourself, only Trained and Authorized Personnel should perform repairs or adjustments. Contact your local Blue Giant Distributor for assistance...
  • Page 23 Mechanical Dock Leveler – M and FMC Group 04, Section 01, Page 2 PROBLEM PROBABLE CAUSE LIP DOES NOT RELEASE 1. Lip lock seized. Does not swing down from locked position. AND SWING DOWN - Lack of lubrication. - Damaged by foreign material in pit.
  • Page 24 Mechanical Dock Leveler – M and FMC Group 06, Section 01, Page 1 Service Adjustments Mechanical Dock Leveler Index SUBJECT GROUP SECTION PAGE Index Preparation Instructions Sequence and Detailed Instructions 1 - 3 Special Application Instructions: Light Weight Dock Operator...
  • Page 26 Mechanical Dock Leveler – M and FMC Group 06, Section 02, Page 1 ADJUSTMENT PREPARATION Before performing any adjustments, read the Trouble Shooting Section of this manual for possible mechanical interference problems that must be corrected before adjustments are made.
  • Page 27 Mechanical Dock Leveler – M and FMC Group 06, Section 02, Page 2 ADJUSTMENT SEQUENCE and INSTRUCTIONS – cont’d Step Number 2: Place a straight edge on the top surface of the deck, extending out over the lip area an amount equal to the length of the lip.
  • Page 28 Mechanical Dock Leveler – M and FMC Group 06, Section 02, Page 3 ADJUSTMENT SEQUENCE AND INSTRUCTIONS – con’d Step Number 4: Observe the lip- lock spring assembly, Figure 4 and item ‘D’, Figure 2. The spring body should measure 3-1/4” to 3-3/4”...
  • Page 29 Mechanical Dock Leveler – M and FMC Group 06, Section 03, Page 1 SPECIAL APPLICATION ADJUSTMENT INSTRUCTIONS Light Weight Dock Attendant has difficulty lowering the Dock Leveler from the fully raised position. Figure 6 The main lift spring tension may be decreased to provide easier lowering, but is not recommended for normal applications because the setting will cause the lip to be borderline non-operational.
  • Page 30 Mechanical Dock Leveler – M and FMC Group 06, Section 03, Page 2 LIP STRIKES REAR OF PARKED VEHICLE AS DECK RAISES – cont’d The aim of this adjustment is to have the lip begin to extend as late as possible in the deck-upward...

  • Page 31: Service And Repair

    Mechanical Dock Leveler – M and FMC Group 08, Section 01, Page 1 Service and Repair Mechanical Dock Leveler Index SUBJECT GROUP SECTION PAGE Index Hold Down Box and Components: Lock Roller and Wear Strip Replacement 1 – 2 Hold Down Box Assembly Replacement 1 –...
  • Page 32 Mechanical Dock Leveler – M and FMC Group 08, Section 02, Page 1 HOLD DOWN BOX SERVICE and REPAIR LOCK ROLLER and WEAR STRIP REPLACEMENT 1) Raise dock leveler and position maintenance strut and traffic barriers as required for safety. Place a safety stand between the deck assembly and the lower frame to assure the deck cannot lower.
  • Page 33 Mechanical Dock Leveler – M and FMC Group 08, Section 02, Page 2 LOCK ROLLER and WEAR STRIP REPLACEMENT – cont’d 9) Place the hold down box cover, two bolts, positioning the cover 1/16” maximum above the rewind wheel top surface. The box cover acts as...
  • Page 34 Mechanical Dock Leveler – M and FMC Group 08, Section 03, Page 1 HOLD DOWN BOX REPLACEMENT 1) Raise the dock leveler and position maintenance strut and traffic barriers as required for safety. Place a safety stand between the deck assembly and the lower frame to assure the deck cannot be lowered.
  • Page 35 Mechanical Dock Leveler – M and FMC Group 08, Section 03, Page 2 HOLD DOWN BOX REPLACEMENT - cont’d The rewind spring in the new hold down box is under tension and is locked in position with a cable clamp positioned on the cable at the point the cable exists the hold down box.
  • Page 36 Mechanical Dock Leveler – M and FMC Group 08, Section 03, Page 3 HOLD DOWN BOX REPLACEMENT - cont’d 14) Carefully remove the cable clamp lock that is positioned on the cable at the point the cable exits the hold down box.
  • Page 37 Mechanical Dock Leveler – M and FMC Group 08, Section 04, Page 1 HOLD DOWN CABLE REPLACEMENT (Broken Cable) Note: A broken hold down cable often indicates long time use or severe working conditions and may be indicative of the general condition of the entire hold down system.
  • Page 38 Mechanical Dock Leveler – M and FMC Group 08, Section 04, Page 2 HOLD DOWN CABLE REPLACEMENT (Broken Cable) – cont’d The broken portion of the cable may be wedged under the rewind wheel, maintaining pressure on the rewind spring. Lock the rewind wheel in its present position with vice-grips or other suitable clamping device.
  • Page 39 Mechanical Dock Leveler – M and FMC Group 08, Section 04, Page 3 HOLD DOWN CABLE REPLACEMENT (Broken Cable) – cont’d Do not proceed with the next step without adequate personal protection from spring and cable. Eg: leather gloves, safety glasses, etc.
  • Page 40 Mechanical Dock Leveler – M and FMC Group 08, Section 04, Page 4 HOLD DOWN CABLE REPLACEMENT (Broken Cable) – cont’d 14) Feed loose cable end through lower and upper cable rollers and through float spring eye. Loop cable back and install cable clamp loosely.
  • Page 41 Mechanical Dock Leveler – M and FMC Group 08, Section 05, Page 1 HOLD DOWN REWIND SPRING The replacement rewind spring is under tension in its shipping container and will unwind when the shipping straps, etc. are removed. Use appropriate caution.
  • Page 42 Mechanical Dock Leveler – M and FMC Group 08, Section 05, Page 2 REWIND SPRING REPLACEMENT – cont’d 7) Remove the rewind cable clamp that retains the cable at the float spring. Pull the cable down through the upper cable roller and back through the lower roller to free full length of cable.
  • Page 43 Mechanical Dock Leveler – M and FMC Group 08, Section 05, Page 3 REWIND SPRING REPLACEMENT – cont’d 11) Pull cable slowly out of the box to rotate rewind wheel and wind the rewind spring onto the wheel hub. As...
  • Page 44 Mechanical Dock Leveler – M and FMC Group 08, Section 05, Page 4 REWIND SPRING REPLACEMENT – cont’d 16) Raise and lower the release handle to assure free movement of the lock roller and counter weight. IMPORTANT: Do not lubricate anything in the interior of the hold down box.
  • Page 45 A worn out rewind wheel often indicates long-time use or severe working conditions and may be indicative of the general condition of the entire hold down system. When investigation shows this to be the case, Blue Giant recommends installing a complete, new, hold down box assembly to assure trouble free use of the dock leveler.
  • Page 46 Mechanical Dock Leveler – M and FMC Group 08, Section 07, Page 1 FLOAT SPRING and CABLE ROLLER REPLACEMENT 1) Raise dock leveler and position maintenance strut and traffic barriers as required for safety. The hold down cable will now be handled.
  • Page 47 Mechanical Dock Leveler – M and FMC Group 08, Section 07, Page 2 FLOAT SPRING and CABLE ROLLER REPLACEMENT – cont’d 6) Grasp the cable firmly, approximately 12" from the front of the hold down box, and slowly release the vice-grip clamp.
  • Page 48 Mechanical Dock Leveler – M and FMC Group 08, Section 08, Page 1 LIP LOCK and SPRING ASSEMBLY REPLACEMENT 1) Raise dock leveler and position maintenance strut and traffic barriers as required for safety. 2) Manually lift lip to its fully raised height.
  • Page 49 Mechanical Dock Leveler – M and FMC Group 08, Section 08, Page 2 LIP LOCK and SPRING ASSEMBLY REPLACEMENT – cont’d 10) Enter the apron area and lower the lip by lifting approximately 2" to release the lip lock and lowering to the hanging position.
  • Page 50 Mechanical Dock Leveler – M and FMC Group 08, Section 09, Page 1 LIP ACTUATOR REPLACEMENT This procedure requires the dock leveler deck to be maintained in the fully raised position without the aid of the main lift springs or lifting arm. Block as described below or otherwise assure the deck will not lower before attempting repairs.
  • Page 51 Mechanical Dock Leveler – M and FMC Group 08, Section 09, Page 2 LIP ACTUATOR REPLACEMENT – Cont’d 3) Measure and record the length of 'U' bolt thread showing between end of 'U' bolt and face of adjusting nuts, Figure 38.
  • Page 52 Mechanical Dock Leveler – M and FMC Group 08, Section 09, Page 3 LIP ACTUATOR REPLACEMENT – Cont’d 9) Remove the lip clevis and lock nut from the old assembly and install onto the new shock assembly to the dimension recorded as Dimension 'A', Figure 40.
  • Page 53 Mechanical Dock Leveler – M and FMC Group 08, Section 09, Page 4 LIP ACTUATOR REPLACEMENT – Cont’d 12) Remove the 2" x 4" blocks that are holding the lip up, and allow the lip to lower until its weight is supported by the lip lock.
  • Page 54 Mechanical Dock Leveler – M and FMC Group 08, Section 10, Page 1 CAM ROLLER REPLACEMENT This procedure requires the dock leveler deck to be maintained in the fully raised position without the aid of the main lift springs or lifting arm. Block as described below or otherwise assure the deck will not lower before attempting repairs.
  • Page 55 Mechanical Dock Leveler – M and FMC Group 08, Section 10, Page 2 CAM ROLLER REPLACEMENT – cont’d When other than recommended method of raising and / or blocking the deck is used, Eg: fork lift trucks, overhead crane, mechanical jack, short jack with blocks, etc.
  • Page 56 Mechanical Dock Leveler – M and FMC Group 08, Section 11, Page 1 REPLACEMENT PROCEDURES FOR: Lifting Arm Adjusting ‘U’ Bolts Adjusting Blocks Main Springs This procedure requires the dock leveler deck to be maintained in the fully raised position without the aid of the main lift springs or lifting arm.
  • Page 57 Mechanical Dock Leveler – M and FMC Group 08, Section 11, Page 2 REPLACEMENT PROCEDURES - cont’d 3) Measure and record the length of 'U' bolt thread showing between end of 'U' bolt and face of adjusting nuts, Figure 50. This will be used as an initial...
  • Page 58 Mechanical Dock Leveler – M and FMC Group 08, Section 11, Page 3 REPLACEMENT PROCEDURES - cont’d 9) Inspect all work performed to assure retainers are in place, etc. and lubricate the entire unit. 10) Pull the hold down release ring up...
  • Page 59 Mechanical Dock Leveler – M and FMC Group 08, Section 12, Page 1 LIP and LIP HINGE – REPLACEMENT and REPAIR Figure 53 History has shown that when a dock leveler is properly maintained and used within its capacity rating, the only service required on the lip and lip hinge is lubrication of the hinge pin and spools, and cleaning of the upper hinge area where the lip plate makes contact with the headboard, Figure 53.
  • Page 60 Mechanical Dock Leveler – M and FMC Group 08, Section 12, Page 2 PROBABLE CAUSE OF DAMAGED COMPONENTS – cont’d Figure 54 A build-up of foreign material at one location along the hinge, between the lip and the headboard, causing that area to take the full load of stopping the hinging action.
  • Page 61 Mechanical Dock Leveler – M and FMC Group 08, Section 13, Page 1 LIP REPLACEMENT NOTE: This section is to be used only for the purpose of replacing or repairing damaged or worn-out lip and hinge components using same size and capacity parts.
  • Page 62 Mechanical Dock Leveler – M and FMC Group 08, Section 13, Page 2 LIP REPLACEMENT – cont’d METHOD N – No Interference to Pin Removal Raise dock leveler and position maintenance strut and traffic barriers as required for safety. Place a safety...
  • Page 63 Mechanical Dock Leveler – M and FMC Group 08, Section 13, Page 3 LIP REPLACEMENT – cont’d METHOD N – Door Frame or other Interference to Pin Removal Raise dock leveler and position maintenance strut and traffic barriers as required for safety. Place a safety...
  • Page 64 Mechanical Dock Leveler – M and FMC Group 08, Section 13, Page 4 LIP REPLACEMENT – cont’d METHOD N . 2 - cont’d – Door Frame or other Interference to Pin Removal The complete deck and lip assembly is now free to be removed from the lower frame and pit area.
  • Page 65 Mechanical Dock Leveler – M and FMC Group 08, Section 13, Page 5 LIP REPLACEMENT – cont’d METHOD N – Door Frame or other Interference to Pin Removal Figure 64 This method is recommended when there is sufficient floor space immediately behind the dock leveler to allow the deck to be hinged up and over to place it up-side-down behind the pit.
  • Page 66 Mechanical Dock Leveler – M and FMC Group 08, Section 13, Page 6 LIP REPLACEMENT – cont’d METHOD N – Door Frame or other Interference to Pin Removal Use this method when it is determined that the headboard hinge spools must...
  • Page 67 Mechanical Dock Leveler – M and FMC Group 08, Section 13, Page 7 LIP REPLACEMENT – cont’d METHOD N . 4 – cont’d – Door Frame or other Interference to Pin Removal Rotate the lip lock down to its unlocked...
  • Page 68 Mechanical Dock Leveler – M and FMC Group 08, Section 13, Page 8 LIP REPLACEMENT – cont’d METHOD N . 4 – cont’d – Door Frame or other Interference to Pin Removal Completely assemble the new lip, headboard hinge spools and hinge pin.
  • Page 69 Mechanical Dock Leveler – M and FMC Group 08, Section 13, Page 9 LIP REPLACEMENT – cont’d METHOD N . 4 – cont’d – Door Frame or other Interference to Pin Removal At the center point of each headboard spool, while holding the spool up towards...
  • Page 70 Mechanical Dock Leveler – M and FMC Group 08, Section 13, Page 10 LIP REPLACEMENT – cont’d METHOD N . 4 – cont’d – Door Frame or other Interference to Pin Removal Using a hand grinder or other suitable tool, clean off the remains of the three tack-welds from the deck plate and the lip.
  • Page 71 Mechanical Dock Leveler – M and FMC Group 08, Section 13, Page 11 LIP REPLACEMENT – cont’d METHOD N . 4 – cont’d – Door Frame or other Interference to Pin Removal Remove all blocking and lower the hoisting equipment to allow the lip to lower until the lip lock supports the lip in its normal extended position, Figure 78.
  • Page 72 Mechanical Dock Leveler – M and FMC Group 08, Section 14, Page 1 LIP CROWN MODIFICATION – Special Application Note: Measuring Lip Crown is described in the Lip Replacement Section, Group 08, Section 13, Pages 7 and 8. Decreasing Lip Crown...
  • Page 73 Mechanical Dock Leveler – M and FMC Group 08, Section 14, Page 2 LIP CROWN MODIFICATION – cont’d Decreasing Lip Crown – cont’d To determine the amount of material that must be removed, select the highest vehicle that will be encountered and park it in place against the bumpers of the dock.
  • Page 74 Mechanical Dock Leveler – M and FMC Group 08, Section 14, Page 3 LIP CROWN MODIFICATION – cont’d Decreasing Lip Crown – cont’d Scribe a mark across the full face of the lip that indicates the estimated maximum amount of material that is to be removed.
  • Page 75 Mechanical Dock Leveler – M and FMC Group 08, Section 15, Page 1 LIP CROWN MODIFICATION – Special Application Increasing Lip Crown NOTE: The following instructions and information are to be used only after a thorough inspection has been performed to verify that damage or excessive wear are not evident in any of the associated components.
  • Page 76 Mechanical Dock Leveler – M and FMC Group 08, Section 15, Page 2 LIP CROWN MODIFICATION Increasing Lip Crown – cont’d Figure 91, illustrates the same situation as Figure 90 with the lip modified for additional crown. Note that the tip of...
  • Page 77 Mechanical Dock Leveler – M and FMC Group 08, Section 16, Page 1 INCREASING LIP LENGTH and / or THICKNESS Not Recommended: Field modifications that increase the weight of a lip assembly are not recommended on Mechanical Dock Levelers. Do not attempt to install a longer or thicker lip and do not add material in an attempt to strengthen or lengthen a lip.
  • Page 78 Mechanical Dock Leveler – M and FMC Group 08, Section 17, Page 1 LONGER LIP REQUIREMENT – Move Dock Leveler Forward Figure 93 Changes made to a dock area, such as the addition of Door Seals or Shelters around a shipping door, may necessitate preventing vehicles form backing fully into their normal position at the dock leveler.
  • Page 79 Mechanical Dock Leveler – M and FMC Group 08, Section 17, Page 2 LONGER LIP REQUIREMENT – cont’d Move Dock Leveler Forward Figure 94, shows a side view of a typical dock leveler installed in a standard pit. Deck and lip are not shown.
  • Page 80 Mechanical Dock Leveler – M and FMC Group 08, Section 17, Page 3 LONGER LIP REQUIREMENT – cont’d Move Dock Leveler Forward Inspect the lifting arm cam mounting plate to determine if shims are located between it and the pit floor. If shims are present, move forward with the unit.
  • Page 81 Mechanical Dock Leveler – M and FMC Group 08, Section 17, Page 4 LONGER LIP REQUIREMENT – cont’d Move Dock Leveler Forward Fit and assemble the filler beam, support posts and shims into the rear pit area as shown in Figure 98. Assure the top...
  • Page 82 Mechanical Dock Leveler – M and FMC Group 08, Section 17, Page 5 LONGER LIP REQUIREMENT – cont’d Move Dock Leveler Forward Square the dock leveler in the pit and shim under each side frame, at the front corners of the pit, to locate...
  • Page 83 Mechanical Dock Leveler – M and FMC Group 08, Section 17, Page 6 LONGER LIP REQUIREMENT – cont’d Move Dock Leveler Forward Figure 102 is a side view of the front beam of the dock leveler extended out of the pit and supported with a full width...
  • Page 84 Mechanical Dock Leveler – M and FMC Group 08, Section 17, Page 7 LONGER LIP REQUIREMENT – cont’d Move Dock Leveler Forward Finish weld the ends of the filler beam to the side curb angles, 1/4" x 4" long weld, both ends.
  • Page 85 Mechanical Dock Leveler – M and FMC Group 12, Section 01, Page 1 Replacement Parts Listing Mechanical Dock Leveler Index Subject Group Section Page Index Hold Down System Parts Illustration Hold Down System Parts Listing General Assembly Parts Illustration General Assembly Parts Listing...
  • Page 86 Mechanical Dock Leveler – M and FMC Group 12, Section 02, Page 1 HOLD DOWN SYSTEM ILLUSTRATION & PARTS LIST ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION 788-037 Complete Assy 010-123 Hex Head Bolt 788-111 Rewind Wheel 113-089 Wear Strip...
  • Page 87 Mechanical Dock Leveler – M and FMC Group 12, Section 03, Page 1 REPLACEMENT PARTS ILLUSTRATION Issue Date: 10/01/01, Rev. 0 (Part #038-550E)
  • Page 89 Mechanical Dock Leveler – M and FMC Group 12, Section 03, Page 1 PARTS LISTING ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION Safety Skirt Assy 109-107 Spring – Lip Lock SEE PAGE (Right) 013-134 Ring - Split Safety Skirt Assy (Left)
  • Page 91 Mechanical Dock Leveler – M and FMC Group 12, Section 04, Page 1 SAFETY SIDE SKIRTS Illustration and Parts List Used From Serial Number 0043500 Onward NOMINAL DECK LENGTH ITEM PART NO. DESCRIPTION 202-0015 Lower Section - Left & Right Sides...
  • Page 93 Mechanical Dock Leveler – M and FMC Group 12, Section 04, Page 1 SAFETY SIDE SKIRTS Illustration and Parts List Used Prior to Serial Number 0043500 3, 4 5, 6, 7 8, 9, 10 1, 2 NOMINAL DECK LENGTH ITEM PART NO.

  • Page 95: Parts Lists

    Mechanical Dock Leveler – M and FMC Group 12, Section 04, Page 1 BACK FRAME WELDMENT Parts Lists Standard 19” Height Frame Deck Assembly Width Capacity Part No. 5’ 781-577 30,000 lbs. 6’ 781-577-1 6’ – 6” 781-577-2 35,000 lbs 7’...

  • Page 96: Installation Instructions

    This manual may not be copied, quoted or transferred in any form or medium to any WARNING: individual or company, in whole or in part, without written consent from Blue Giant Limited 85 Heart Lake Road South, Brampton, Ontario L6W 3K2, Canada...
  • Page 97 Mechanical Dock Leveler – M and FMC Group 14, Section 01, Page 2 INSTALLATION INSTRUCTIONS Mechanical Dock Leveler Index Subject Group Section Page Index Responsibilites and Assumption Safety Signs and Messages Typical Mechanical Dock Leveler Pit Layout Installation Instructions - Detailed 1 –...
  • Page 98 Damage to the Dock Leveler, death or serious injury to you or other persons may result if these messages are not followed. If warning decals are damaged, they must be replaced. Contact your Blue Giant Distributor for replacements. NOTICE...
  • Page 99 Mechanical Dock Leveler – M and FMC Group 14, Section 03, Page 1 PIT LAYOUT - TYPICAL IMPORTANT PIT CURB ANGLES: 1. Must be level side-to-side and front-to-back. 2. Must be square at both rear corners. 3. Side curb angles must be parallel to each other.
  • Page 100 Mechanical Dock Leveler – M and FMC Group 14, Section 04, Page 1 INSTALLATION INSTRUCTIONS Mechanical Dock Leveler 1. Prior to installation of Dock Leveler, remove all debris from pit and clean pit thoroughly. 2. Measure the overall height of the rear corners of the Dock Leveler (19”...
  • Page 101 Mechanical Dock Leveler – M and FMC Group 14, Section 04, Page 2 INSTALLATION INSTRUCTIONS - cont’d 5. If rear beam does not line up squarely with rear curb angle, use 3” x 6” (76mm x 153mm) shims of suitable thickness to fully support the top rear and bottom rear of the rear beam to weld areas.
  • Page 102 Mechanical Dock Leveler – M and FMC Group 14, Section 04, Page 3 DO NOT work beneath Dock Leveler without engaging maintenance strut 8. Operate the Dock Leveler to raise the deck and extend the lip. Raise the maintenance strut to its vertical position. "Pull' the deck down to engage the maintenance strut.
  • Page 103 Mechanical Dock Leveler – M and FMC Group 14, Section 05, Page 1 INSTALLATION INSTRUCTIONS PICTORIAL Issue Date: 10/01/01, Rev. 0 (Part #038-550E)
  • Page 104 Mechanical Dock Leveler – M and FMC Group 14, Section 06, Page 1 OUTLINE DRAWING and DIMENSION Issue Date: 1/01/01, Rev, 0 (Part #038-550E)
  • Page 105 Mechanical Dock Leveler – M and FMC Group 14, Section 07, Page 1 PIT LAYOUT - TYPICAL Dock Face Flush to Building Issue Date: 10/01/01, Rev, 0 (Part #038-550E)
  • Page 106 Mechanical Dock Leveler – M and FMC Group 14, Section 08, Page 1 PIT LAYOUT - TYPICAL Dock Face Projected from Building Issue Date: 10/01/01, Rev, 0 (Part #038-550E)
  • Page 107 Mechanical Dock Leveler – M and FMC Group 14, Section 09, Page 1 RECOMMENDED DOCK DESIGN For Declined Driveways Issue Date: 10/01/01, Rev, 0 (Part #038-550E)
  • Page 108 Mechanical Dock Leveler – M and FMC Group 14, Section 10, Page 1 PIT FORMING KIT DOCK LEVELERS PIT KIT INSTALLATION INSTRUCTIONS Includes: Three piece all steel construction pit walls, curb angles welded to steel panels, front curb angle. Provides:...
  • Page 109 Mechanical Dock Leveler – M and FMC Group 14, Section 11, Page 1 POUR-IN-PLACE DOCK LEVELER c/w Pit Forming Walls - Details IMPORTANT Pit Perimeter Curb Angles Must be level side-to-side and front-to-back. Must be square and parallel to each other.
  • Page 111 Mechanical Dock Leveler – M and FMC Group 14, Section 12, Page 1 TROUBLESHOOTING DO NOT attempt to make repairs or adjustments yourself, only Trained and Authorized Personnel should perform repairs or adjustments. Contact your local Blue Giant Distributor for assistance.
  • Page 112 Mechanical Dock Leveler – M and FMC Group 14, Section 12, Page 2 PROBLEM PROBABLE CAUSE DECK WILL NOT 1. Foreign material in pit, blocking mechanism. 'WALK' DOWN 2. Side safety skirts badly damaged and jammed against pit wall (when used).
  • Page 113 Mechanical Dock Leveler – M and FMC Group 14, Section 12, Page 3 PROBLEM PROBABLE CAUSE LIP STRIKES REAR OF 1. Damaged or missing dock bumpers allow the vehicle to TRUCK AS DECK be parked to close to the dock leveler.
  • Page 114 Mechanical Dock Leveler – M and FMC Group 16, Section 01, Page 1 MAINTENANCE and LUBRICATION Blue Giant Dock Levelers are designed and manufactured to be as Maintenance-Free as possible. Designed specifically with a minimum number of moving parts and lifetime lubricated pivot points to assure maximum maintenance-free life expectancy.
  • Page 115 Mechanical Dock Leveler – M and FMC Group 16, Section 01, Page 2 MAINTENANCE Figure 105 A Typical Planned Maintenance Inspection will include the following: Cleaning: Pit Area Lip Hinge Visual Inspection: Structural Damage Curb Angle Damage Dock Bumper and Door Seal Damage...
  • Page 116 Mechanical Dock Leveler – M and FMC Group 16, Section 01, Page 3 LUBRICATION Figure 106 Note: Do not lubricate any of the components in the interior of the hold down box or any potion of the hold down cable that may enter into the hold down box.

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