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McGuire RRH SERIES Owner's Manual

Dock leveler
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RRH SERIES
Dock Leveler
Owner's/User's Manual
MCCGUIRE • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022
800.643.5424 • fax: 262.257.7399 • www.wbmcguire.com • techservices@wbmcguire.com
Printed in U.S.A.
Manual No. 4111-0070
Copyright
2017
May 2017
©
June 2017

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  • Page 1 RRH SERIES Dock Leveler Owner’s/User’s Manual MCCGUIRE • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022 800.643.5424 • fax: 262.257.7399 • www.wbmcguire.com • techservices@wbmcguire.com Printed in U.S.A. Manual No. 4111-0070 Copyright 2017 May 2017 ©...

  • Page 2: Table Of Contents

    Table of Contents Page Precautions Recognize Precautionary Information ..........1 General Operational Precautions ............1 Operational Precautions ..............2 Maintenance Precautions ..............4 Precaution Decal’s ................5 Owners/Users Responsibility .............. 6-7 Introduction General Information ................7 Dock Leveler Stock Specifications ............. 7 Component Identification ..............

  • Page 3: Precautions

    PRECAUTIONS Recognize Precautionary Information General Operational Precautions 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 Read and understand the Owner’s/User’s Manual instructions in the safety message panel.

  • Page 4: Operational Precautions

    PRECAUTIONS Operational Safety 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. Chock/restrain all transport vehicles, Never Stay clear of dock leveling device when transport Stay clear of dock leveling device when transport remove the wheel chocks until loading or vehicle is entering or leaving area.
  • Page 5 PRECAUTIONS Operational Precautions Do not use dock leveling device if transport vehicle is too high or too low. Do not overload the dock leveling device. Do not operate any equipment while under the influence of alcohol or drugs. Do not leave equipment or material unattended on dock leveling device.

  • Page 6: Maintenance Precautions

    PRECAUTIONS Maintenance Safety Precautions 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.

  • Page 7: Precaution Decal's

    PRECAUTIONS Precaution Decal’s CRUSH HAZARD DO NOT WALK IN FRONT OF DOCK LEVELER until you: Restore the dock  leveler to its safe sto red ver t ical position with lip extended. Unsupported dock levelers can lower unexpectedly. Before allowing CRUSH HAZARD vehicle to leave Prior to any maintenance, repair or adjustments to dock...

  • Page 8: Owners/Users Responsibility

    OWNER’S/USER’S RESPONSIBILITIES 1) The manufacturer shall provide to the initial should be done on a regular basis and should include purchaser and make the following information an understanding and familiarity with all functions of readily available to the owners/users and their the equipment.

  • Page 9: Introduction

    Ramp Hydraulic) series hydraulic dock leveler. Capacity (CIR*) 40,000 lb (18 144 kg) Designed by McGuire to be a marvel of simplicity and 45,000 lb (20 412 kg) efficiency, your dock leveler, when properly installed, 50,000 lb (22 680 kg will provide many years of trouble-free performance with an absolute minimum of maintenance.

  • Page 10: Component Identification

    INTRODUCTION Component Identification RRH Fixed E Hoist Cylinder* Side End Load Support Platform F Hinge Pin, Lip PowerPac** C Lip Cylinder G Maintenance Props K Hinge Pin, Platform D Flow Control Valve H Embed P Lifting Bracket * Models may be equipped with 1 or 2 cylinders. **Powerpac may be mounted on underside of leveler or remotely.

  • Page 11: Installation

    INSTALLATION Component Identification RRH Manual Side Shift Hinge Pin, Lip Maintenance Props Platform G Hinge Pin, Platform M Stops, Roller Track Lip Cylinder* H Carriage N PowerPac (remote mount) Flow Control Valve Cam Followers (Bearings) O Side End Load Support Hoist Cylinder* Roller Track * Models may be equipped with 1 or 2 cylinders.
  • Page 12 INTRODUCTION Component Identification RRH Hydraulic Side Shift F Hinge Pin, Lip K Carriage Platform G Hinge Pin, Platform PowerPac (remote mounted) C Lip Cylinder* H Maintenance Props M Side End Load Support D Flow Control Valve Cam Followers (bearings) N Side Shift Cylinder Hoist Cylinder* Roller Track O Side Shift Cylinder Mount...

  • Page 13: Fixed Leveler

    INSTALLATION RRH Fixed installation 4. Attach lifting chain to lifting bracket(s) (A) and to a lifting device (i.e., hoist or fork truck) having the appropriate lifting capacity and reach. Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized 5.

  • Page 14: Manual Side Shift Leveler

    INSTALLATION RRH Side Shift Installation 6-1/2” 10” Channel Roller Track Installation of Carriage and Platform (if separated). 1. Check the roller track (A) for proper construction according to approved/certified pit drawings. Make sure roller track is level. Inspect track to be free from damage and clear of foreign material.
  • Page 15 INSTALLATION ALWAYS disconnect electrical power source and ground wire before welding on dock leveler. DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler. Always ground to the dock leveler frame. 8. Installation of platform to carriage. A.
  • Page 16 INSTALLATION Install Dock Leveler CRUSH HAZARD DO NOT WORK UNDER OR IN FRONT OF RAIL RAMP unless ALL maintenance props have been properly positioned secured. Side maintenance props must be positioned and secured with screw and nut as shown in figure “A” below.

  • Page 17: Hydraulic Side Shift Leveler

    INSTALLATION Optional Hydraulic Side Shift 1. Install side travel mount (see drawings for mounting locations). 2. Install side shift cylinder. 3. Connect hydraulic hoses. Note: Do not connect hoist cylinder(s) at this time. System must be bled before connected (see page 19).

  • Page 18: Install Control Panel And Wiring

    INSTALLATION Install Control Panel and Wiring The electrical power must be OFF prior to electrical installation. For maximum protection, use an OSHA approved locking device to lock out all power sources. Only the person installing the equipment should have the key to unlock the power source. DO NOT make any final electrical connections until all welding has been completed.
  • Page 19 INSTALLATION Placard Installation Instructions • Owner/Users are responsible for the installation and placement of product placards. • Make sure placard is in plain view of dock leveler and/or vehicle restraint operations. • Suggested placement of placard is near control box attached to electrical conduit by using nylon tie.

  • Page 20: New Leveler Into Service

    INSTALLATION Put New Dock Leveler Into Service 1. Purge system (see page 19). DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be 2. Connect hoist cylinder (see page 19) ground or welded. 3.
  • Page 21 INSTALLATION Purging Air from the RRH Hydraulic System. 1. Begin by supporting the RRH leveler in the stored CRUSH HAZARD position with securing the maintenance props in DO NOT WORK UNDER OR IN FRONT OF RAIL RAMP unless ALL maintenance props have been the maintenance position.

  • Page 22: Operation

    OPERATION Theory Control Box Hoist Cylinder (s) Side End Load Supports Lip Button Platform Lip Cylinder (s) Roller Track Lower Button PowerPack Raise Button Left Button When the RRH dock leveler is operated, an electric time and the motor will shut off and the lip will lower. motor(C) is activated, which, drives a hydraulic pump.

  • Page 23: Operating Instructions

    OPERATION Stay clear of dock leveler when transport vehicle Only trained personnel should operate the dock carrier is entering or leaving dock area. leveler. DO NOT move or use the dock leveler if anyone is DO NOT use a broken or damaged dock leveler. under or in front of leveler.

  • Page 24: Ramp Loading/Unloading Instructions

    OPERATION Operating Instruction Ramp Loading/Unloading Instructions NOTE: If end unloading is required, see End Loading/Unloading Instructions on page 23. 4. Proceed with loading or unloading the transport vehicle. 1. Check to make sure RRH dock leveler is positioned squarely on transport vehicle. 5.

  • Page 25: End Loading/Unloading Instructions

    OPERATION Operating Instructions—Continued Below Dock End Loading/Unloading Instructions Optional Side Shift Instructions 1. Check to make sure the RRH dock leveler is 1. Instruct transport vehicle to remain at the dock positioned squarely on transport vehicle. until the loading or unloading process has been completed.

  • Page 26: Maintenance

    MAINTENANCE Service Dock Leveler 1.50" Arc Flash and Shock Hazard PPE [Personal Protection Equipment] Required De-energize equipment before working on or inside. Do not open cover without appropriate PPE. Refer to NFPA 70E for PPE requirements. This panel may contain more than one power source.
  • Page 27 MAINTENANCE To ensure normal operation of the RRH dock leveler, use only Aircraft Hydraulic Fluid designed to meet or exceed military specification MIL-H-5606-G. It is When service under the dock leveler is required, recommended that the following hydraulic fluids be always lock all electrical disconnects in the OFF used: position after raising the platform and engaging the...

  • Page 28: Periodic Maintenance

    MAINTENANCE Lip Hinge Area Hoist Cylinder Lip Cylinder pins Platform Pins Cam Rollers Hoist Cylinder rod eye Regular maintenance must be performed on a weekly Quarterly Maintenance and quarterly schedule. Follow all safety precautions. • Weekly Maintenance Weekly Maintenance • Lubricate the following areas with light weight machine oil: •...
  • Page 29 MAINTENANCE • Rue clip is in manual lock position. • J box for water damage. • Inspect hoses,cylinders, fittings and power pack. • Control box and conduit for damage • Check fluid level when the unit is in the stored position.

  • Page 30: Adjustments

    ADJUSTMENTS Main Pressure Relief The pressure relief on the remote PPACs are factory adjusted. Consult Factory. When service under the dock leveler is required, always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop.

  • Page 31: Leveler Pressure Relief

    ADJUSTMENTS Leveler Pressure Relief Slotted Adjusting Screw Jam Nut 1. The leveler must be in the stored position and the maintenance prop in the service position. Pressure Relief 2. Turn OFF all electrical power to the dock leveler. Attach safety lockout and tagout devices. 3.

  • Page 32: Troubleshooting

    TROUBLESHOOTING Troubleshooting Before performing the detailed troubleshooting procedures, check the following items first: • Check all fuses inside the control panel(s). Replace • Make sure the correct voltages are present at the any blown fuse(s) with a fuse of equal specification. proper locations inside the control panel(s).
  • Page 33 TROUBLESHOOTING Symptom Possible Cause Solution Motor overload device Reset overload relay (three-phase) or replace tripped or fuse blown. fuse(s) (single-phase). Determine cause of overload. NOTE: When replacing fuse(s), the new fuse must have the same specification as the old fuse. Platform does not rise or lower.
  • Page 34 TROUBLESHOOTING Symptom Possible Cause Solution Heavy object(s) on platform. Remove object(s) from platform. NOTE: For safety reasons, the dock leveler is designed to lift only the platform’s own weight. Dock leveler binds. Check for visible obstructions that could cause binding. Remove obstructions. If no obstructions found, call Poweramp Technical Services.
  • Page 35 TROUBLESHOOTING Symptom Possible Cause Solution Low hydraulic fluid. Add fluid as needed. See Periodic Maintenance in Platform does not rise to the Maintenance section. full height. Float coil energized. Remove the wire of terminal strip to the float coil, If leveler raises possible bad relay.

  • Page 36: Parts

    PARTS PARTS J -Box Item Quantity Part Number Description 2751-0042 J Box Fiber Glass 5” x 5“ (Includes Cover) 0961-0054 Mercury Switch Click for manuals and videos http://www.docksystemsinc.com/Parts-Service 4111-0070 — May 2017 June 2017...

  • Page 37: Hose Routing

    PARTS Platform Hose Routing Item Quantity Part Number Description 9301-0192 Fitting, Tee #6 JIC As Req. 9904-____ Hose, Lip Cylinder As Req. 9904-____ Hose, Hoist Cylinder Blind End As Req. 9904-____ Hose, Hoist Cylinder Rod End 9904-____ Hose, Hoist Cylinder Bind End Tee To Valve Block As Req.

  • Page 38: Platforms

    PARTS Carriage Lip and Platform 4111-0070 — May 2017 June 2017...
  • Page 39 PARTS Item Quantity Part Number Description Lip and Platform 0595-____ Lip, Weldment 0595-____ Platform, Welded Assembly 9202-____ Pin, Lip Hinge 9202-0040 Rear Hinge Pin 9202-0041 Rear Hinge Pin Stainless Steel 2101-0245 Cotter Pin 9515-____ Trolley 9222-0221 Maintenance Prop 2101-0262 Bolt 5/8-11 UNC X 1.75 Grade 8 2101-0042 Nut 5/8-11 UNC Grade 5 As Req.

  • Page 40: Side Shift Cylinder

    PARTS Optional Hydraulic Side Shift Item Quantity Part Number Description 0525-0071 Cylinder 0000-____ Cylinder Mount 2101-0237 Cap Screw 3/4-10 x 5-1/2 Lg. Cylinder Pin Short 2101-0148 Nut 3/4-10 2101-0093 Washer, Flat 3/4 Provide dock leveler serial number, platform size, and lip size when calling or faxing orders 4111-0070 —...

  • Page 41: Carriage

    PARTS Carriage A B C Torque Specifications: 1-7/8” or 2” Roller 65-75 ft/lbs. 3” Roller 170 ft/lbs. Item Quantity Part Number Description 9461-0004 Cam Roller 1-7/8” Dia. (before 2004) 9461-0007 Cam Roller 2” Dia. (after 2004) 2101-0199 Nut, Hex 7/8”-14 (One Per 9461-0007 Cam Roller) 2101-0200 Washer, Lock 7/8”...

  • Page 42: Hydraulic Components

    PARTS RRH Manifold Pressure Relief Hoist Cyl Rod End Return To Tank Pump Psi “C” Lip Valve “E” Lower Platform “D” Lower Platform Lip Cyl Hoist Cyl Blind End “B” Float Valve Item Quantity Part Number Description 8585-0089 Vertical Valve Assembly 8581-0005 Valve Cartridge 3-Way Delta 8581-0102...
  • Page 43 PARTS RRH Manifold Remote Mounted Pressure Relief Hoist Cyl Rod End Return To Tank Pump Psi “C” Lip Valve “E” Lower Platform Lip Cyl “D” Lower Platform Hoist Cyl Blind End “B” Float Valve Item Quantity Part Number Description 8585-0088 Valve Assembly - Complete 8581-0005 Valve Cartridge 3-Way...
  • Page 44 PARTS RRH Side Shift Diverter Valve Manifold To Side Shift Valve Pressure From Pump To Leveler Manifold Item Quantity Part Number Description 8583-0013 Valve, RRH, Leveler/Side-Shift Direct - Complete 8581-0005 Valve Cartridge 3-Way 9301-0113 Fitting 90 Deg #6 ORB X #6 JIC 9301-0115 Fitting 90 Deg #6 ORB X #8 JIC 9301-0116...
  • Page 45 PARTS RRH Side Shift Directional Valve Manifold To Rod End of Cylinder To Blind end of Cylinder Pressure To Side Shift Manifold Return To Tank Item Quantity Part Number Description 8583-0014 Valve, RRH, Side-Shift - Complete 8581-0011 Valve Cartridge 4-Way 9301-0113 Fitting 90 Deg #6 ORB X #6 JIC 9301-0115...
  • Page 46 PARTS RRH Remote Manifold W/ Side Shift HB Hoist Cylinder (Blind End) Side Shift Cylinder (Blind End) HR Hoist Cylinder (Rod End) Side Shift Cylinder (Rod End) LC Lip Cylinder 4111-0070 — May 2017 June 2017...
  • Page 47 PARTS RRH Remote Manifold W/ Side Shift Hydraulic Schematic Item Quantity Part Number Description 0521-0022 Fitting, Tee, Run Swivel #8 JICF #8 JICM 2101-0011 Hex Head Cap Screw 5/16-18 x 1” 2101-0039 Nylon Lock Nut 5/16-18 2101-0077 Hex Head Cap Screw 5/16-18 x 3 2751-0080 J-Box, Fiberglass 2101-0102...

  • Page 48: Hoist Cylinder Repair Parts

    PARTS Platform Cylinder Repair Parts Barrel Lg. Item Quantity Part Number Description 9301-0109 Fitting Connection Str Thread 90 DEG Male 1751-0138 Decal 0521-0073 Grease Zerk 2101-0159 Hex Nut 9461-0002 Rod End 0525-0125* Hoist Cylinder 8’Lg, 10” or 12” Pits 0525-0126* Hoist Cylinder 8’Lg, 15”...

  • Page 49: Lip Cylinder Repair Parts

    PARTS Lip Cylinder Repair Parts SECTION A-A 13.75” Item Quantity Part Number Description 0522-0191 Yoke (included in 0525-0085) 0521-0005 Roll pin (included in 0525-0085) 0525-0059 Seal Kit 1992 and newer 0525-0085 Lip Cylinder Without Fittings E-F 0526-0016 Lip Cylinder With Fittings E-F 9301-0109 Fitting, Connector Str.

  • Page 50: Power Pack Assembly

    PARTS Power Pack Assembly Return Line Pressure Line Item Quantity Part Number Description 9395-____ 1 Reservoir, Pump and Motor 0521-0007 Elbow, 1/4 NPT Male x 1/4 Tube 9301-0218 Breather Cap,Push In 9301-0159 Breather Cap, Threaded 9301-0120 Fitting 45 Degree, #8 ORB x #8-JIC Male 3411-____ 1 Motor Only 2101-0225...
  • Page 51 PARTS This page was left intentional left blank 4111-0070 — May 2017 June 2017...

  • Page 52: Remote Power Unit

    PARTS Remote Mount Power Pack Assembly Pressure Return 4111-0070 — May 2017 June 2017...
  • Page 53 PARTS Power Pack Assembly Item Quantity Part Number Description 2101-0039 Nylon Lock Nut, 5/16-18 UNC 9301-0029 Seal, Thread 9302-0014 Reservoir 9301-0199 Breather Cap, 3/8 NPT Male 9301-0027 O-Ring (Reservoir) 9302-0012 Tie Rod (Reservoir) 9301-____ Pump Only 2101-0039 Cap Screw, 5/16-18 UNC x 3-1/2 in., Grade 5 9301-0028 Gasket, Pump 9303-0002...
  • Page 54 NOTES This page was left intentional left blank 4111-0070 — May 2017 June 2017...

  • Page 55: Miscellaneous

    MISCELLANEOUS Customer Information NOTE: Refer to illustration for left/right orientation of Dock Leveler Information dock leveler. Model ___________________________________ The model/serial number decal (A) is located on the left platform joist near the front (lip) of Serial No. ________________________________ dock leveler. Systems, Inc., Job No.

  • Page 56: Warranty

    STANDARD PRODUCT WARRANTY SYSTEMS, INC. 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.

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