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BM5 SERIES
MANUAL LOADING
LEVELER
OWNER’S MANUAL
INSTALLATION Ɣ23(5$7,21
6(59,&(Ɣ5(3$5,3$576
BEACON INDUSTRIES, INC.
12300 Old Tesson Rd. St. Louis, MO 63128-2247 USA
OFFICE: 314-487-7600 FAX: 314-487-0100
www.beacontechnology.com
E-Mail: sales@beacontechnology.com
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
6/00
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
6/00
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.
6/00
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.
6/00
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.