Beacon BM5 Series User manual

BM5 SERIES
MANUAL LOADING
LEVELER
OWNER’S MANUAL
INSTALLATION Ɣ23(5$7,21
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BEACON INDUSTRIES, INC.
12300 Old Tesson Rd. St. Louis, MO 63128-2247 USA
OFFICE: 314-487-7600 FAX: [phone]
www.beacontechnology.com
E-Mail: [e-mail]

SECTION 1 INSTALLATION INSTRUCTIONS
RECEIVING:
HANDLING:
FIGURE A
. .·· ~ RECEIVING AND HANDLING
Check for possible damage or missing parts immediately upon receipt of
unit. Note any damage on receiving papers.
Prepare any claims against carrier if necessary.
NOTE: Damage noticed after receipt must be reported to carrier within 15
days.
Notify
.Beacon .:>f any damage or missing parts. Failure to do so within 15
days may result in loss of warranty coverage.
Move leveler into position
by using:
• chain sling inserted into upper side plate holes. (See FigureA) or
• fork lift, inserted into front fork slots;
• fork lift. inserted into rear fork slots
just below the deck.
NOTE:
Two bumpers, and weather seals, if applicable, are strapped under leveler.
Handle with care to avoid damage to these components. Contact
for chain sling assembly (Part #1700)
SECTION 1 . INSTALLATION INSTRUCTIONS
INSTALLATION
INSTALLATION: (Consists of 3 phases) Pit preparation
Leveler Preparation
Leveler Installation
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1-1

FIGURE B - PLAN VIEW BM-5 SERIES .PIT DETAIL
&m
DIM."A
"'[i:..:.==.oc.:.:·····=···············~
,,., ...
PLAN
DIM. "9" MA1"L: A·5' C S'l1lllL
.. ... ......... ....................... -·- ··············---- .......... .
... .
A
FRONT ELEVATION
DIM. ""lrMA'M.: A~ C snEL
NOTTO SCALE I
NOTES
PrrCUUANCLB
'8"T050'
0
(RECOMMENDED
DOCK HEICHTl
'
J
VARIABLE DIMENSIONS
MODEL SIZE
"A"
"B"
"C' "D"
6'Wx6'L
63" 74"
19%''
20"
6'Wx8'L
87" 74"
19%"
20"
6'-6"Wx6'L
63" 80"
19%"
20"
6'-6"Wx8'L 87" 80"
19%"
20"
7'Wx6'L
63" 85" .
19%"
20"
7'Wx8'L
.87" 85"
19%'°
20"
6'Wx10'L
111" 74" 23W' .24"
6'-6"Wx lO'L
111"
80"
23%''
24
7'Wx lO'L
111"
85''
231/t
24"
.. ". . ..... ..
Rl!All m WALL TO BE SQUARE
wmt DOCK FLOOR (REVERSE SLOPE
UPTO'!tr' AS SHOWN IS ACCEPTABLE)
SECTION "A-A"
MAT'L: A-36C STEEL
D.RAWN1 SCALE: DATE: DRAWING NUMll!R:
D.l!.A. AS NO'Jl!D ~
TOLERANCES:
lDch Dlmeulm • Dedlm1DtmeM.lon• Altgla ..
. tlll•· . '!'.DDS t1°

SECTION 1 INSTALLATION INSTRUCTIONS
PITPREPARATION
l. Examine pit
2. Measure pit dimensions. (See "Variable Dimensions" Figure B, Page 1~2)
PRE-PLACEMENT OF SHIMS:
1. Place ~hi~s in correct locations on pit floor before lowering leveler into
place mpit.
PIT PREPARATION
Pit walls should be square and plumb. Clean all debris from pit.
Verify that walJs are square and plumb.
Proper shim thickness will assure that deck
of leveler is level with dock floor.
NOTE 1: Shims are
to be placed directly under each rear frame upright, and
under lip keepers. (See Figure C, Page 1-3) and (See Plan
View, Page 1-2).
NOTE 2: Forunits with a 20" lip the lip keepers are separate. Prior to shimming,
weld the angle with the lip keeper under the front base frame. (See Figure C,
Page 1-3) (SeeFigure E, Page 1-4)
, SECTION 1 INSTALLATION INSTRUCTIONS
LEVELER PREPARATION
1. Position leveler directly infront of pit
2. Cutrestraining band on lip.
FIGUREC
$11 1 1.1 UN D Ell
EACH UPl\IO>ll
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LEVELER PREPARATION
Remove band completely from leveler ..
FIGURED
1-3

SECTION 1 INSTALLATION INSTRUCTIONS
LEVELER INSTALLATION
LEVELER INSTALLATION:
I.
Place leveler into pitopening. Allow one inch
(1 ") equal clearance between leveler sides and pit walls. Rear
frame angle of leveler should be tight against and flush with rear curb angle for
proper welding.
2. Recheck shim packs
to ensure leveler isat proper height. flush with floor Shims must beplaced properly undereach rear frame upright. and front lip
level, front and rear, after restraining band has been cut. keepers. (See Figure C, Page
1-3, for close up view and Plan View B, Page.1-2,
for shim locations.)
For leveler with a 20" lip-with leveler flush with dock floor locate lip
keepers on frame I embedded curb angle
and move upwards until Jip
Skip weld Rm: of leveler to curbangle (weld center first then ends) and front
touches bottom
of keeper. Lip keeper should be located 12" toward center · shims
to leveler and curb angle. (See Figure D, Page 1-3)
from each side.
3.
Bring decksection of leveler to fully raised position.
To operate, pull and hold the ratchetrelease chain located at rear of leveler.
4. Place maintenance strut securely under leveler. Place strut in tubes located on base & under lip.
5. Weld all shims securely in place. Front shims must be welded securely to frame and steel curb angle.
6.
Storemaintenance strut. Walk forward onto leveler, returning it to dock level with lip in keepers.
7. Install bumpers
on dock face. Securely boltbumpers to dockface as close to pit opening as possible. Bumpers
should be flush with dock floor
or 48" off ground. Raised bumpers should be
supported to floor from behind.
8. Complete weld at rear
of leveler. Weld to cover approximately 50% of the length of the rear angle. Ensure welds
are placed directly behind frame uprights and at ends
of angle. (See Figure D,
Page 1-3)
6/00
1-4

SECTION 1. INSTALLATION INSTRUCTIONS
20" LIP KEEPER INSTALLATION INSTRUCTIONS
Two separate lip ke~per angles are provided with every
unit that has a 20" lip. These angles are tack welded
to
the leveler base frame just behind the lip.
Break each one loose
and set the leveler into the pit per
the inst&llation instructions in the owner's manual.
Prior to angle installation or shimming make sure that
the unit is snug against the embedded curb angle
at the
back
of the pit.
Place the lip keepers under the front base angle
on
eitherside of tbe unit with the top of the angle protrud-
ing out past the base 1/4"
in the front and on the leftfor
the left hand keeper and on the right for the right hand
keeper. This
will facilitate welding.
Fully weld the keeper angle to the base angle.
Proceed with shimming
per the owner's manual.
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TOP VIE\./
FRONT VIE\./
114•
FILLET 'JELD
LEVELER PREPARATION
PICTORIAL VIEV
SIDE VIE\./
1-5

SECTION 2 OPERATING INSTRUCTIONS
ABOVEDOCKUSE:
1. Pull firmly and hold the release ring located in rear of deck.
2. Walk forward onto deck to lower unit onto buckbed. (Truck should be
secured firmly against bumpers with "Truck Restraint" or wheel chocks.)
3. When truck departS. lip will close to pendant (not stored) position.
4. Walk forward onto deck until unit is returned
to stored position.
5. Leveler may be recycled with truck at dock.
ABOVE DOCK OPERATION
When deck raises and lip extends. release the ring. DO NOT release the ring
until the lip is fully extended.
With standard locking typelip mechanism, lock will release once lip makes
firm contact with truck bed.
This action applies when truck is above dock height.
In this position, lip is secure in lip keepers, and ready to receive the next truck.
Pu11 the rear releasering inshort, rapid pullsallowing decktoraise 2" - 3" above
dock with lipdown. This allowsoperatorto close the truck and/or building door
prior to truck departure. ·
Walk forward onto leveler, returning it to dock level with lip in keepers.

SECTION 2 OPERATING INSTRUCTI S
BELOWDOCKUSE: (WITH LIP EXTENDED)
. I. Repeatsteps 1 & 2 for above dock use.
2. As you walkforward on the leveler, pull the safety leg release ring located
in the front
of deck plate.
3. When truck departs, lip will return to
pen~ant (not stored) position.
4. To recycle unit after truck departure, pull release ring in short, rapid pulls.
5. Leveler may be recycled with truck at dock.
6. Following Step #4, walk forward onto deck until unit is returned
to stored
position.
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BELOW DOCK OPERATION
This will pull safety legs away from the pads they would normally contact
allowing unit to go below dock.
When lip makes firm contact with the truck bed, release the front ring.
Lip will
be in front of lip keepers, and deck will remain below floor level.
Thisaction will allow thedeck to raise 2"-3" abovedockfloor whilethe lip
will
remain in a pendant position.
Follow Step #4 to recycle.
Lip should be completely closed and resting in lip keepers which provide
overnight security.
2·2

SECTION 2 OPERATING INSTRUCTIONS
BELOW DOCK USE: (LIP RETRACTED FOR END LOADS)
BELOW DOCK CONTROL OPTION IS RECOMMENDED FOR nns
OPERATION:
I. Pull release ring in short rapid pulls.
2. As you walk forward
on the leveler, pull the safety leg release ring located
in the front
of deck plate.
3. When truck departs, lip will close to pendant (not stored) position.
4. To recycle unit after truck departs, pull release ring in short, rapid pulls.
5. Leveler may be recycled with truck at dock.
6. Following Step #4, walk forward onto deck until unit is returned to stored
position.
BELOW DOCK OPERATION
Allow deck Jo raise 2" - 3" above dock floor. (This will raise lip out of lip
keepers, without extending lip.)
With Below Dock Control o.ptjon, lip will be pushed out in front of keepers
while safety legs are being pulled away from pads.
Lip will
be in front of keepers, and deck will remain below dock.
Continue this until unit is 2" -3" above dock floor.
Follow Step#4 to recycle.
Lip should becompletely closed
and resting in lip keepers whic~ also provide
overnight security.

SECTION 3 TROUBLESHOOTING
LEVELERS ARE TFSfED AND ADJUSTED AT THE FACTORY. HOWEVER, MINOR ADJUSTMENTS TO THE MAIN
SPRINGS MAY BE REQUIRED ONCE THE UNIT IS INSTALLED. (UNITS WITH WEATHER SEALS NORMALLY REQUIRE MAIN SPRING
ADJUSTMENT
TO INSURE PROPER LIP EXTENSION.
NOTE: ALWAYS SECURE LEVELER WITH MAINTENANCE STRUf BEFORESERVICING.
SYMPTOM: PROBABLE CAUSE:
WHEN RELEASE RING IS PULLED,. DECK
1.
Improper main spring adjustment·
RAISES
BUT LIP DOES NOT FULLY EXTEND NOTE:
On units with either lip assist or hydra lip,
AND LOCK. proper adjustment will entail a combinatioi;t
of
adjusting the lip assist spring and possibly the main
springs. (See#3 below)
2. Lip lock spring is stretched.
Note: 3. Improper adjustment
of lip assist . spring
With Hydra-Lip lip is designed to begin
(f umished as standard equipment with 18" and 20"
closing once ex.tended,
or when truck departs.
No adjustment is required. Assem.
#30
lip lengths)
4. Liplock spring is broken
or disconnected.
Leveler may be servicing trucks that are above the
factory setservice range (8'
models- 12", 6' models
-8") causing lip to impact truck during upward
movement.
6/00
CORRECTION:
0Tighten both mainspringadjustment nuts one or tw
rotation cJ~kwise and re-test.
Item
#7 (1 1/2" socket or wrench)
Replace spring or lower spring one or two links i
n
snubberchain. Item #22 ;Assem. #6
Tighten both hex nulS , on the lip wist rods, two (2) cloclcwi se
rotations and re-test. Item# 27 .
Note: The back nut, ioward the rear ofthe levcrler, is the adjust
ment nuL After attaining proper adjustment, hold the back nut
and
securely lighten the front or lock nut against the adjuslmcnt nut.
Replace broken spring and/or reconnect spring
to
properchain link with "S" hook.
Item#22,Assem. #6
Minoradjustments to service rangeabovedock ma
y
NEER
be made in the field. Consult the local
PIO
representative or call.the factory for assistance.
3-1.

SECTION 3 TROUBLESHOOTING
•' • .
SYMPTOM: PROBABLECAUSE: CORRECTION:
'HYDRA-LIP Lip assist spring is overcompressed. ·Loosen both hex nuts on the lip assist rod two (2)
rotations
COQnter=clockwise and re-test
Lip will· not close comepletely when truck departs.
Item#27
HYDRA-LIP Lip assist spring is under compressed. Tighten both hex nuts on the lip assist rod two (2)
clockwise rotations and re-test. Item #
27
Lip closes too fast when extended.
Shocks are failing afteryears
of use. Replace with new shocks. Item # 29
(Covered by 1 year warranty)

SECTION 3 TROUBLESHOOTING
PARTS LIST
ITEM DESCRIPTION
1
LIP PLATE ASSEMBLY 16"
2
HINGE PIN-LIP
4
MAIN SPRING
5
RATCHET PULL CHAIN ASSEMBLY
18
RATCHET MOUNTING ASSEMBLY UPPER
23
SAFETY LEG & MOUNTING ASSEMBLY
24
SAFETY LEG CHAIN ASSEMBLY
25
LIP LOCK ASSEMBLY
26 ROLL
PINS
27
LIP ASSIST ASSEM. (STANDARD ON 18" & 20" LIP)
.OPTIONAL KITS
(FIELD INSTALLED
ITEM DESCRIPTION
27 LIPP
ASSIST ASSEM. (OPTIONAL ON 16" LIP)
29 SHOCK
ABSORBER
30
HYDRA LIP KIT· {S1"ANOAR.O ""°'
&MS)
31 FULL
RANGE TOES GUARDS (SET)
WEATHER SEAL KIT 6'
WEATHER SEAL KIT 8'
6/00
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SECTION 3 TROUBLESHOOTING
PARTS LIST
ITEM DESCRIPTION
3 DECK REAR HINGE KIT (SEl)
6 SNUBBER CHAIN ASSEMBLY (For standard 16n Lip)
7 ADJUSTING
ROD ASSEMBLY
8 WING NUT ASSEMBLY
9 RATCHET ASSEMBLY
10
UPPER BAR
11 PAWL
12 PAWL SPRING
13
RELEASE LEVER SPRING
14
RATCHET HOUSING
15
UPPER PIN KIT
16 LOWER PIN KIT
19
RATCHET MOUNTING ASSEMBLY LOWER
20
SNUBBER SPRING
21
SNUBBER CHAIN TENSION SRPING
22 LIP LOCK SPRING
28 "$"HOOK
32 AUXILIARY RACHET RELEASE CHAIN
6/00