Blue Giant M Bedienungsanleitung

Issue Date: 10/01/01, Rev. 0 (Part #038-550E)

SERVICE MANUAL

Mechanical Dock Leveler

Mechanical Dock Leveler – M and FMC Group 01, Section 01, Page 1

Issue Date: 10/01/01, Rev. 0 (Part #038-550E)

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.

The technician is cautioned and expected to take time to completely

read and understand the first four pages of this binder, including any

special instructions contained in this Mechanical Dock Leveler

portion, to be better prepared to safely perform the necessary work

before beginning any work.

Do not work under or around the Dock Leveler without first placing

adequate barriers to positively prevent vehicle traffic from entering

the work area.

INDEX

Subject Group Section Page

Master Index 01 01 1

Introduction & Component I.D. 02 01 1 - 4

Theory of Operation – Index 03 01 1

Troubleshooting 04 01 1 - 2

Service Adjustments – Index 06 01 1

Service and Repairs – Index 08 01 1

Replacement Parts - Index 12 01 1

Installation Instructions - Index 14 01 2

Maintenance Lubrication 16 01 1 - 3

Mechanical Dock Leveler – M and FMC Group 02, Section 01, Page 1

Issue Date: 10/01/01, Rev. 0 (Part #038-550E)

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.

The capacity listed must not be exceeded and includes total

weight of fork truck plus total weight of load being transported.

Group 02, Section 01, Page 2 Mechanical Dock Leveler – M and FMC

Issue Date: 10/01/01, Rev, 0 (Part #038-550E)

COMPONENT IDENTIFICATION

Mechanical Dock Leveler – M and FMC Group 02, Section 01, Page 3

Issue Date: 10/01/01, Rev. 0 (Part #038-550E)

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. It sits firmly on the bottom of

the dock pit and is the base that supports for the entire

leveler

Rear Frame Assembly

The rear portion of the Base Frame that contain the tilt

bar pockets.

Front Beam Assembly Front of Base Frame that contains the Lip Keepers and

provides mounting points for other components.

Cam The curved track that provides a ramp action. This ramp

action works in conjunction with the lifting arm, roller and

Main Lift Springs to elevate the deck.

Lifting Arm Roller

Attached to the lower end of the Lifting Arm, the Cam

Roller travels the contour of the Cam and allows smooth

low resistance movement while raising or lowering the

dock leveler deck.

Lifting Arm When pulled rearward by the Main Lifting Springs this

arm rotates around it's pivot point and by so doing,

transfers motion to the appropriate components of the

deck leveler.

Main Lift Springs Create the potential energy necessary to raise and

suspend the entire weight of the deck and lip.

Deck & Lip

The plates that become the bridge from the dock to the

truck floor

Tilt Bars & Pockets Floating hinge points located at the rear of the deck that

allow the deck to float diagonally and compensate for

irregularities in lateral truck positioning.

Lip This is the hinged plate on the outside edge of the deck.

It rests on the truck floor when the deck is in working

position.

Group 02, Section 01, Page 4 Mechanical Dock Leveler – M and FMC

Issue Date: 10/01/01, Rev, 0 (Part #038-550E)

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.

Lip Actuator Assembly

(Shock Assembly)

Works in conjunction with the forward motion of Lifting

Arm to extend and position the lip.

Actuator Spring

Provides cushioned thrust action when extending the Lip.

Actuator Bar

As part of the Lip Actuator Assembly it provides for

positively extending the lip.

Lip Lock Engages the Actuator Bar and locks it in the extended

position.

Lip Lock Spring

Transfers motion from the Lifting Arm to engage the Lip

Lock, with the Actuator Bar Lock Block.

Release Chain

Releases the Braking action of the Hold Down Box and

it's components.

Hold Down Box

(Load Roller & Wear Strip)

Provides a braking action through a cable to maintain

deck positioning by opposing the upward action of the

Main Lift Spring.

Float Spring

Located on the upper end of the Hold Down Cable it

allows for over-ride of brake action as the cargo or load is

removed from a truck.

Safety Skirt

The plates located on the sides of the deck commonly

referred to as "Toe Guards".

Maintenance Strut

As a maintenance device the adjustable strut is stowed in

the frame and is used to lock the dock leveler deck in the

up position while personnel are performing maintenance

or repairs on the underside of the dock leveler.

Building Bumpers

Molded rubber blocks mounted outside of the building

protruding from the outer sides of the dock leveler. They

protect the dock and leveler from shock from reversing

trucks (laminated type also available).

BLUE GIANT SERVICE MANUAL

Issue Date: 10/01/01, Rev. 0 Page 1

FORWARD

Each product section is identified by

description and Model Identification

and includes a pictorial listing of

components. A contents index is

placed at the beginning of each

section.

Procedures have been made easier

to use by providing specific steps only

when necessary and general

instructions required to explain the

activity, components, assembly, or

process being worked on. The

technician is expected to include

obvious additional steps of standard

procedures for removal, disassembly,

cleaning, inspection, reassembly,

installation, etc., as needed.

The technician is cautioned and

expected to take time to completely

read and understand the entire

procedure, including any special

instructions, to be better prepared to

do the necessary work before

beginning any work.

This Service Publication provides

information covering normal service,

maintenance and repair of Blue Giant

loading dock equipment listed on

Page 5. It has been specifically

prepared to help owners and service

personnel maintain this equipment in

safe and efficient operating condition.

This manual is intended for use by

persons who are trained and

authorized to perform loading dock

equipment maintenance. It is

designed to provide essential

information about the correct and

safe service, maintenance and repair

of the equipment by trained service

technicians.

General and detailed service and

repair procedures are outlined (as

required) for each product. Some

procedures include explanations that

are common to several components

or sub-systems.

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. Specifications, pressures, measurements,

adjustments, illustrations, and other items may change at any time.

Contact your Blue Giant distributor for information on possible

updates or revisions.

SERVICE MANUAL BLUE GIANT

Page 2 Issue Date: 10/01/01, Rev, 0

SAFE MAINTENANCE PRACTICES

The following instructions have been

prepared from current industry and

government safety standards

applicable to dock equipment

operation and maintenance. These

recommended procedures specify

conditions, methods, and accepted

practices that aid in the safe

maintenance of dock equipment.

They are listed here for the reference

and safely of all workers during

maintenance and repair operations.

Carefully read and understand these

instructions and the specific

maintenance procedure before

attempting to do any repair work.

When in doubt of any procedure,

contact your Blue Giant distributor

for assistance.

•Dock equipment can become

hazardous if maintenance is

neglected. Therefore, trained

personnel and procedures must

be provided.

•Maintenance and inspection of all

dock equipment shall be done in

conformance with the

manufacturers recommendations.

•A scheduled planned

maintenance, lubrication and

inspection program shall be

followed.

•Avoid fire hazards and have fire

protection equipment present in

the work area.

•Only trained and authorized

personnel shall be permitted to

maintain, repair, adjust and

inspect dock equipment. Work

should be performed in

accordance with the

manufacturers specifications.

•Do not use open pans of fuel or

flammable cleaning fluids for

cleaning parts.

•Before starting work, wear eye

protection and remove all jewelry.

•Always engage maintenance strut

and place traffic barriers before

entering pit area.

•There are numerous variations in

procedures, techniques, tools and

parts for servicing dock

equipment, as well as in the skill

of the individual doing the work.

This manual can not possibly

anticipate all such variations and

provide advice or precautions as

to each. Accordingly, anyone

departing from the instructions

provided in this manual through

procedures used or choice of

tools, materials and parts, may

jeopardize his or her personal

safety and / or the safety of the

equipment operator.

•Improper or careless techniques

cause accidents. Read and

understand the procedures for

safe maintenance outlined in this

manual.

•Work safely and follow the safety

signs and their messages

displayed in the work area and in

this manual.

BLUE GIANT SERVICE MANUAL

Issue Date: 10/01/01, Rev. 0 Page 3

SAFETY SIGNS and SAFETY MESSAGES

Improper operation can cause accidents. Don’t take chances with incorrect or damaged

equipment. Read and understand the procedures for safe operation and maintenance

outlined in this manual. Don’t hesitate to ask for help.

Stay alert! Follow safety rules, regulations, and procedures. Avoid accidents by

recognizing dangerous procedures or situations before they occur.

Safety signs and messages are placed in this manual to provide instructions and

identify specific areas where potential hazards exist and special precautions should be

taken. Know and understand the meaning of these instructions, signs, and messages.

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.

IMPORTANT

This message is used when special precautions should be taken to

ensure a correct action or to avoid damage to or malfunction of the

dock equipment or a component.

This message indicates a potentially hazardous situation which,

if not avoided, may result in minor or moderate injury

This message indicates a potentially hazardous situation which, if

not avoided, could result in death or serious injury.

This message indicates an imminently hazardous situation which,

if not avoided, will result in death or serious injury.

SERVICE MANUAL BLUE GIANT

Page 4 Issue Date: 10/01/01, Rev, 0

PLANNED MAINTENANCE

The importance of proper

maintenance through planned

service, inspection, and qualified

repairs can not be emphasized too

strongly. Planned maintenance

instructions are provided for

reference in setting up and

conducting a recommended periodic

Planned Maintenance (PM) program.

Planned maintenance is a program in

which inspections, cleaning, minor

adjustments, are performed on a

scheduled and systematic basis. A

solid PM program should incorporate

a method of record keeping which

enables you to better determine PM

schedules and enables you to track

the maintenance costs.

An effective PM program should

incorporate two basic phases:

•An inspection performed by

operator or maintenance man at

the beginning of each shift. This

is a quick visual check for obvious

damage.

•A planned maintenance routine

performed every three months

based on a single shift operation

or monthly for multi-shift

operations.

Minimum work to be performed at

each planned maintenance interval:

•Cleaning, including surrounding

area.

•Visual inspection of all

components.

•Test operate all functions.

•Lubricate as required.

•Adjustment and retest if required.

•Check for damaged dock

bumpers.

•Record inspection details and

findings for owners files.

If the PM is routinely followed, need

for repair, major adjustment, and

component replacement will be

discovered automatically and such

work can be scheduled, eliminating

unnecessary down-time and cost.

The objectives of PM are:

•To reduce costly unscheduled

down-time.

•Reduce maintenance costs.

•Increase loading dock

productivity.

•Increase personal safety of

operators and other personnel.

Refer to the Operators Manual,

located with the dock equipment, for

additional information on care and

maintenance of your equipment.

NOTICE

Contact your Blue Giant Distributor for more information on

Maintenance and Re

air of

our Dock E

ment.

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