Edge-of-Dock Leveler 'BA' - 'BX' Series. Owner s Manual and Installation Instructions

Transcription

1 Edge-of-Dock Leveler 'BA' - 'BX' Series Owner s Manual and Installation Instructions

2 A Message to Aaron-Bradley Edge-of-Dock Owners and Operators Edge-of-Docks are specialized equipment with unique operating characteristics, designed to perform a specific job. Their function and operation is not like any other piece of equipment. They require specific instructions and rules for safe operation and maintenance. Safe operation of your Edge-of-Dock is of primary importance to Aaron-Bradley. In general, dock equipment accidents that result in injury or death can be the result of: Operator not properly trained Operator not experienced with Edge-of-Dock operation Basic safety rules not followed Edge-of-Dock not maintained in safe operating condition For these reasons, Aaron-Bradley wants you to know about the safe operation and correct maintenance of your Edge-of-Dock. This manual is designed to help you operate your Edge-of-Dock safely and efficiently. Included are general safety rules, recommended safety and maintenance inspections, Planned Maintenance Programs (PM) and correct operating procedures. Special components and features of the Edge-of-Dock are described and their respective functions explained. Illustrations and important safety / warning messages are included for clear understanding. The Operator s Manual is not to be confused with a training manual. It is merely a guide to assist already trained and authorized operators to safely operate and maintain their Edge-of-Dock by emphasizing and illustrating the correct procedures. This manual cannot cover every possible situation that may result in an accident; therefore you should continuously watch for potential or existing hazards in your work area(s) and avoid or correct them as soon as possible. It is important that your equipment is maintained in a safe condition. Do not operate a damaged or malfunctioning Edge-of-Dock. This manual is intended to be readily available for operations and maintenance personnel. Your Aaron-Bradley distributor is pleased to answer questions about the operation and maintenance of your Edge-of-Dock and provide you with additional information should it become necessary. Note: Pictures and drawings used throughout this manual are for representation only.

3 Installation Instructions Mechanical Edge-of-Dock WARNING Do not work under or around the Edge-of-Dock being installed without first placing adequate barriers to positively prevent vehicle traffic from entering the work area. 1. Inspect the loading dock curb angle and verify that it is firmly embedded and anchored in the concrete and is minimum 3" x 3" x 1/4" (75 x 75 x 6mm) steel. If there is no curb angle, if anchoring or embedding is questionable, or is not of minimum size specified, install an approach plate and / or face plate before proceeding with the installation. WARNING Edge-of-Dock failure hazard. The Edge-of-Dock must be welded to firmly embedded curb angle or other dock steel as described in the Installation Instructions. Do not attempt to use only bolts or lags to attach the Edge-of- Dock to the concrete. 2. Un-band the Edge-of-Dock and discard all shipping material. WARNING Cut, pinch or eye injury hazard. Use caution when un-banding the Edge-of- Dock. 3. Using appropriate hoisting equipment, use the lifting hole located in the lip to sling the Edge-of- Dock into position against the curb angle.

4 Mechanical Edge-of-Dock cont d. WARNING Use caution when lifting or moving the Edge-of-Dock. Do not attempt to lift without suitable hoisting equipment. 4. Position the base plate so that the top edge of the base plate is 1/8 below the level of the top of the curb angle. Ensure top of base plate is parallel with the top of the curb angle. Tack weld top of back base plate securely to curb angle. 5. Assure base plate is firmly against curb angle or dock face concrete and plug-weld the base plate to the curb angle at the pre-punched holes in the base plate. If curb angle does not overlap these holes, use the back plate as a template and drill four holes 5/8 dia. x 6 deep, in the dock face concrete. Clean out holes and insert, and permanently install appropriate concrete anchors. Tighten enough to secure base plate. 6. Finish-weld the top of the base plate to the curb angle. Factory recommends a continuous ¼ weld. Note: IMPORTANT If not continuous, welds must be behind hinge tubes that are welded to the base plate. 7. Vertical-weld both ends of base plate to curb angle, full length of vertical contact. Tighten lag bolts at this time securely. 8. Bump Block Assemblies: a) Position the left-hand bump block assembly (as viewed when standing on the driveway in front of the Edge-of-Dock) so that there is ½ clearance between the bump block side and the control handle pocket, and the bump block is level with the top of the curb angle. Weld all horizontal and vertical contact areas between the bump block and curb angle and plug weld mounting holes that overlap curb angle. Install concrete lag bolts 5/8 x 6 in mounting holes that are not welded. b) Position the right-hand bump block assembly bracket so that there is a ½ clearance between the bump block and the Edge-of-Dock base plate. 9. Install the control handle in the pocket on the left side of the deck. To do so, remove the bolt from the bottom of the handle, insert handle through pocket, then re-install bolt through hole in handle. 10. Lubricate all pivot points using SAE10 motor oil or equivalent. 11. Final Inspection: a) Clean up the entire work area, remove slag from all welds and apply touch-up paint to all welds, scratches and burns. b) Ensure all fasteners have been securely tightened and locked and / or tack-welded. c) Test-operate the unit through several full cycles of operation. If problems are noted, see the Troubleshooting section of this manual. d) Leave these instructions with the owner. Note: Drawings are for representation only and do not necessarily portray the actual product

5 Installation Instructions, cont. Weld-on - New Construction Use when dock edge vertical steel is 8 or wider. At dock edge, mark the center of chosen leveler location. Mark dock edge 33 either side of center (36 for 72 models; 39 for 78 models; 42 for 84 models). Locate leveler with top of rear hinge flush with top of dock. This will place top of base plate approx. ¼ below dock surface. Tack-weld ends of base plate to dock face steel, the top edge of base plate being ¼ below dock. Tack-weld both bump blocks at left and right ends of leveler allowing ¼ space for weld between base plate ends and bump block. Continuous-weld bump blocks and base plate along top and all vertical edges while holding leveler firmly against dock. Disregard pre-punched holes. Weld-on / Bolt On Existing Construction Use when dock edge steel is securely anchored, but not adequate for weld-on method. Complete all steps of instruction under WELD-ON NEW CONSTRUCTION as noted above. Bolt leveler and bump blocks to dock face using all pre-furnished 13/16 prepunched holes.

6 Installation Instructions, cont. Bolt-on + Approach Plate Existing Construction Use when dock edge has no steel or steel is poorly anchored, and dock face is adequate for bolting. Mark and drill holes for dock leveler centered 6-1/4 below dock edge; base plate to be raised 1/8 above dock edge for welding to approach plate. Install two (2) anchor bolts in end holes; position leveler on bolts and partially tighten nuts to hold leveler secure. Place approach plate in position, on the floor, with front edge being 1/8 behind base plate. Mark floor along rear edge of approach plate. Slide plate forward 2 and tack-weld to leveler. Use as a guide for cutting a groove in the floor along the entire width (long dimension) of the approach plate. Groove to be 2 wide and 1/8 deeper than the thickness of the approach plate. Break the plate loose from the leveler. Position the approach plate in the groove and tack-weld to the leveler base plate. Drill holes in the floor using the plate holes as a guide. Install anchor bolts in the plate. Weld and grind the bolt-heads at the approach plate to a smooth dome shape. Continuous-weld the approach plate to the top of the base plate. Complete the bolting phase of the unit.

7 Installation Instructions, cont. Weld-on & Raise Approach Plate Use when dock edge is sound but height is less than adequate (bolting may also be required). At dock edge, mark the center of chosen leveler location. Mark dock edge 33 either side of center (36 for 72 models; 39 for 78 models; 42 for 84 models). Raise leveler and bump blocks to desired height (3 max.) and weld back of base plate to dock edge steel. Tackweld both bump blocks at left and right ends of leveler allowing ¼ space for weld between base plate ends and bump block. Cut groove in floor; position approach plate at top edge of base plate and tack-weld to unit and bump blocks. (See Illustration on page 6 for further details). Complete bolting phase of installation, then Continuous-weld all points of contact between leveler, dock steel and approach plate. Formed Angle Weld-on Raised Approach Plate Use when dock edge steel is badly crumbled and dock edge is slightly low. Unit must be raised approximately 2 in this application! Position formed angle at desired location, mark holes, remove angle, drill holes and install angle. Install unit and approach plate according to methods described for Existing Construction.

8 OPERATION OF EDGE-OF-DOCK LEVELER Note: Drawings for Concept Only

9 Routine Servicing and Maintenance Regular maintenance and care of your Edge-of-Dock is not only important for economy and utilization reasons, it is essential for your safety. A faulty Edge-of- Dock is a potential source of danger to the operator, and to other personnel working near it. As with all quality equipment, keep your Edge-of-Dock in good operating condition by following the recommended schedule of maintenance. Planned Maintenance Aaron-Bradley recommends, and local government regulations may require that a planned maintenance and safety inspection program (PM) be performed by a trained and authorized mechanic on a regular basis to maintain your equipment in safe operating condition. The PM will provide an opportunity to make a thorough inspection of the safety and operating conditions of your Edge-of-Dock. Necessary adjustments and repairs can be done during the PM, which will increase the life of components and reduce unscheduled downtime as well as maximizing safety. The PM can be scheduled to meet your particular application and Edge-of-Dock usage. A periodic planned maintenance program (PM) that covers inspections, operational checks, cleaning, lubrication, and minor adjustments are available through your Aaron-Bradley distributor. They are prepared to assist you with a planned maintenance program (PM) using trained service personnel who know your Edge-of-Dock and can keep it operating safely and efficiently.

10 Trouble Shooting Mechanical Edge-of-Dock WARNING DO NOT attempt to make repairs or adjustments yourself. Only trained and authorized personnel should perform repairs or adjustments. Contact your Aaron-Bradley distributor for assistance. PROBLEM Edge-of-Dock requires more effort than usual when pulling it up to raised position. After pulling Edge-of-Dock up to raised position, lip does not remain horizontal as deck is pushed forward. Lip does not deploy onto truck bed. Lip Lock Bar does not swing down to release position when unit is lowered onto truck bed. Lip remains partially extended after truck drives away. Lip hits back of truck while rotating up to raised position. PROBABLE CAUSE Adjustment of lift springs required. - Increase tension of both springs equally. (Note: Increase spring tension only enough to provide usual lifting effort.) - Center plate should float approx. 1 above gussets at proper adjustment. Lip Lock Bar did not swing into position over fixed block. - Adjust lip stop bolt outward to raise lip and allow lock bar to swing into position over block. - Lip lock bar binding at mounting bracket. Bar must swing freely. Lubricate or straighten. Lock bar is binding in its mounting bracket. - Lubricate or straighten. Bar must swing freely. 1. Adjust the lip stop bolt to provide clearance. 2. Replace worn out bumper.

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12 AARON-BRADLEY BX Series Edge-of Dock (EOD) Leveler- Parts List PART NUMBERS ITEM NO. DESCRIPTION BX6620 BX6625 BX7220 BX BASE PLATE ASSEMBLY CENTER PLATE ASSEMBLY LIP PLATE ASSEMBLY LIP LINKAGE SPRING ATTACHMENT BAR CLEVIS PIN, 1/2 X 2 A37 A37 A37 A37 7 SPRING LIFT ASSIST SPRING ADJUSTMENT HARDWARE SET SLOTTED SPRING PIN, 3/16 X 1-1/ COTTER KEY, 1/8 X HINGE PIN BAR LIFT HOLDER ASSEMBLY BUMP BLOCK ASSEMBLY BUMP BLOCK HARDWARE SET MOLDED BUMPER (9243), 4 X 10 X 13 R2 R2 R2 R2 16 STEEL BUMP BLOCK W/ COVER HANDLE ASSEMBLY GUSSET END TUBE PLUG LIP STOP TAB LIP RELEASE TAB LIP KICKOUT BAR LIP LINKAGE TABS LIP KICKOUT PIN Descriptions and specifications subject to change without notice

13 BL Edge-Of-Dock Exploded Linkage arms CctnaCCl tab... Bar Lift Conversion Kit wlpush @

14 'BA' Series Edge-of-Dock Leveler Parts List Illus# Part # Description Illus# Part # Description Lip Plate Ass'y - BA Gusset w/ Bearing Lip Plate Ass'y - BA6620-L Bearing, Torsion Arm Lip Plate Ass'y - BA Gusset w/ Retainer Lip Plate Ass'y - BA Gusset Lip Plate Ass'y - BA7220-L Lip Tab Lip Plate Ass'y - BA Lip Linkage Arms (2 ea required) Lip Plate Ass'y - BA Linkage Pins ( 2 ea required) Lip Plate Ass'y - BA Linkage Pin Keys (3 ea required) Lip Hinge Pin - 66" Units Molded Cord Rubber Bumper (2 hole) 18 R Lip Hinge Pin - 72" Units 4" x 10" x 12" Lip Hinge Pin - 78" Units Molded Cord Rubber Bumper (4 hole) 18 R Lip Hinge Pin - 84" Units 4" x 12" x 13" Rivet (2 ea required for 3ach pin) Molded Cord Rubber Bumper (18" Tall) 18 M Center Plate Ass'y - BA6620 & BA6620-L17 4" x 10" x 18" Center Plate Ass'y - BA Bump Block Steel w/ Cover (4 hole) Center Plate Ass'y - BA7220 & BA7220-L Bump Block Steel w/ Cover (2 hole) Center Plate Ass'y - BA Bump Block Ass'y (4 hole - Optional) Center Plate Ass'y - BA Bump Block Ass'y (2 hole - Optional) Center Plate Ass'y - BA Bump Block Ass'y (18" - Optional) Base Plate Ass'y - 66" Units Bar Lift Handle Ass'y Base Plate Ass'y - 72" Units Bar Lift Holder Ass'y Base Plate Ass'y - 78" Units Lip Linkage Tabs (2 ea required) Base Plate Ass'y - 84" Units R2 Lip Kickout Bar Base Hinge Pin - BA6620 & BA Lip Release Tab Base Hinge Pin - BA7220 & BA Lip Stop Tab Base Hinge Pin - BA7820 & BA Lip Kickout Pin Base Hinge Pin - BA8420 & BA Kick Out Bar Guide 7, 8 111A Torsion Spring Winding Ass'y Bar Lift Conversion Kit w/ Push-over Torsion Arm & Linkage Ass'y

15 ABC Docks, LLC Warranty Edge-of-Dock Levelers (EOD) ABC Docks, LLC warrants Edge-of-Dock Levelers against defective parts and faulty workmanship for a period of two (2) years for structural assembly and one (1) year for motor, pump (hydraulic units only) and miscellaneous parts commencing at the time of shipment from our plant. All replacement parts will be F.O.B. our plant and will be issued upon return of defective parts or as designated by ABC Docks, LLC. All purchased items, such as components not manufactured in our plant, will carry the warranty of the original manufacturer. This warranty shall not cover failure or defective operation in excess of the recommended capacities, misuse, negligence, accident, alteration or repair not authorized by ABC Docks, LLC. All applicable and incurred labor and / or freight charges are the customer s responsibility. No other warranty exists except as stated herein. ABC Docks, LLC has no liability for general, consequential, incidental or special damages; is not responsible for loss of use of any equipment, and expressly disclaims any and all implied warranties. In the United States, some states do not allow exclusion or limitation of incidental or consequential damages, so the limitations above may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. IMPROVEMENTS ABC Docks, LLC is constantly striving to improve its products. Change in design and improvement will be made whenever the manufacturer believes the performance or operation of the equipment will be improved with no obligation to incorporate any such improvement in any equipment, which has been shipped or is in service.