Perma Tech PermaDOCK-MD User manual

Perma Tech, Inc.
“Your Single Source for ALL Your Loading Dock Needs”
TF: [phone] | P: [phone]
[e-mail] | www.permatechinc.com
PermaDOCK-MD
WARNING : Do not install this product unless you have read and understand the
warnings and installation instructions contained in the manual.
IMPORTANT TO CHECK SHIPPING CONTAINERS BEFORE RELEASING CARRIER.
NOTIFY CARRIER IMMEDIATELY UPON DISCOVERING ANY CONCEALED DAMAGE.
Mechanical Dock Leveler
OWNER’S MANUAL

TABLE OF CONTENTS
Page
Safety Information 1
Installation Instructions 3
Shimming Details 4
Preliminary Operations 5
Operating Instructions 6
Mechanical Dock Leveler Diagram 7
Parts List for Mechanical Dock Levelers 8
Schematic Drawing & Parts List for Lifting Arm 9
Schematic Drawing & Parts List for Ratchet Hold Down 10
Schematic Drawing & Parts List for Lip Assist Assembly 11
Schematic Drawing & Parts List for Lip Latch Assembly 12
Trouble Shooting 13
Maintenance & Lubrication 14
Warranty 15
Manufacture Date:
Model:
Serial #:
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Perma Tech Inc.

SAFETY INFORMATION
WARNING
Failure to read and understand the entire contents of this manual may result in damage
to the equipment, bodily injury and/or death. Never install, maintain or operate this
equipment under the influence of drugs or alcohol.
INSTALLATION
• Personnel installing this equipment must be fully qualified and experienced in safe
working procedures.
• All lifting and slinging devices must be in good working order and used in the correct
manner.
• Concrete must be in good repair with no cracks in pit or around the dock leveler.
• Never go beneath the dock leveler unless the dock is barricaded in front of the dock
leveler on the loading dock floor and driveway.
• Never go beneath the dock leveler unless the maintenance strut is in position.
• Do not alter the equipment.
MAINTENANCE
1. When replacing parts use only genuine PermaDOCK Levelers parts.
2. Never go beneath the dock leveler unless the dock is barricaded in front of the dock
leveler on the loading dock floor and driveway.
3. Never go beneath the dock leveler unless the maintenance strut is in position.
4. Do not alter the equipment.
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SAFETY INFORMATION
OPERATION
NOTE: ALWAYS RESTRAIN THE TRUCK/TRAILER BEING LOADED/UNLOADED, I.E. BY USE OF WHEEL
CHOCKS OR A TRUCK RESTRAINT DEVICE.
1. Keep clear of the equipment’s operating path when positioning or storing the dock
leveler.
2. Never lower the dock leveler with a lift truck.
3. Do not wear loose clothing or jewelry while operating this equipment.
4. Keep hands, limbs and loose hair clear of equipment during positioning or storing of
the dock leveler.
5. Never go beneath the dock leveler unless the maintenance strut is in position.
6. Never continue to use the equipment if you believe it is unsafe because of bent
structural members, broken welds, oil leaks, etc. Have the unit inspected by your
nearest Perma Tech Dock Leveler representative.
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Perma Tech Inc.

INSTALLATION INSTRUCTIONS
Prior to installation, check pit for correct depth and square-ness of pit across corners.
If pit is not correct in size and square-ness, make corrections before installation dock
board.
IMPORTANT
Do not break bands on dock board until called for in Step 4, otherwise damage may
occur which would not be covered by the warranty.
1. Place board in pit by means of crane or forklift, level back end of board with rear pit
angle, weld angles as shown on Drawing.
2. Shim front end of board so as top deck of board is level with the rear angle.
3. Weld front base and shims to front curb angle.
4. With the board welded in the pit, remove bands; elevate deck by pulling release
chain at rear of dock.
5. Block the board securely in the up position before working underneath the dock
board.
6. Shim under back frame of the board and under the centre angle as shown on
drawing. Weld shims to the angles.
7. Read operating instructions. Operate the board several times, pausing between
operation to expel the air in system.
NOTE: WHILE THE DOCK BOARD IS FACTORY AD USTED, THEY MAY REQUIRE SLIGHT AD USTMENT ON
SITE DUE TO THE MOVEMENT IN SHIPPING AND DURING THE INSTALLATION. THIS IS NOT WARRANTY.
We reserve the right to change specifications and/or design without notice or
obligation.
Please state model number of dock board when ordering parts.
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Perma Tech Inc.

SHIMMING DETAILS
-4-
18”
NOTE: Painted yellow guide line recommended
Dwg. #1 FRONT VIEW Dwg. #2
SIDE ELEVATION
PIT DEPTH
20”
Recommended
Dock Height
48”
1/4”
RUN OFF
SLOPE
1/2” Min.
Slope
6.21
Dwg. #3
LS LS LS LS
Leveling & Shims for Base
A
B
CAUTION:
Block securely
while working
under the Dock
DETAIL: SHIMMING, WELDING AND BLOCKING Dwg. #4
Approximately
3” weld at 4 places
19 1/2”
Weld Shims
to Base Frame
Weld Shims
to Center Beam Support
Shim & Weld
at Lip Support
MODEL
MD-66 74”
63”
MD-68 74”
87”
MD-610 74”
111”
MD-612 74”
135”
MD-76 85”
63”
MD-78 85”
87”
MD-710 85”
111”
MD-712 85”
135”
“B” DIM “A” DIM MODEL “B” DIM “A” DIM
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PRELIMINARY OPERATIONS
CAUTION
Never operate the dock leveler when someone is in front of the lip.
STEPS FOR FIRST TIME USAGE:
1. Pull and hold the release chain until the dock strops in its top position. Do not step
on the deck. When the deck lifts to its highest position the lip will extend and lock
into position automatically.
2. Walk to the top of the deck. The ramp will lower to its lowest position (below dock
level) and hold its position.
3. Manually lift the lip 2”. The lip locking mechanism will disengage. Carefully lower the
lip to its vertical position.
4. Pull the release chain until the dock raises 6” above dock level. Stop the ramp by
letting go of the release chain. Walk the ramp down to its stored position with lip
behind the night lock.
5. Continue to raise and lower the dock leveler 10-12 times. This operation will
disperse the lubricants to the bearing surfaces and reduce friction. This procedure
should be performed when the dock is not used for an extended period of time.
NOTE: DAMAGE TO THE DOCK LEVELER AND LIP WILL OCCUR IF THE LIP IS LEFT IN THE EXTENDED
POSITION WHEN A TRUCK BACKS INTO THE DOCK.
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OPERATING INSTRUCTIONS
CAUTION
Never operate the dock leveler when someone is in front of the lip.
Always restrain the truck/trailer being loaded/unloaded, i.e. by use of wheel chocks or
a truck restraint device.
1. Raise the dock leveler by gently pulling the release chain at rear of the deck. (Hold
the chain up until the dock rises to its highest position.) The lip will extend and lock
automatically. (FIGURE #1)
2. To lower the dock into its work position, walk to lip end of the dock. The weight of
the operator will lower the dock onto the truck or trailer. (FIGURE #2)
3. As soon as the lip is on the truck the dock is ready to be used to load or unload truck
or trailer.
4. While in use the dock will raise and lower with the movement of the vehicle and the
trailer.
5. When the truck/trailer departs the lip will fall to vertical and the dock may be walked
down to the cross traffic stored position with lip behind the night lock.
6. If necessary, raise the dock 6” above dock using the release chain, to allow the lip to
fall behind the night lock, and then walk the dock down to the cross traffic stored
position with lip behind the night lock.
WARNING: DAMAGE TO THE DOCK LEVELER AND LIP WILL OCCUR IF THE LIP IS LEFT IN THE
EXTENDED POSITION WHEN A TRUCK BACKS INTO THE DOCK.
LIP SHOULD BE A
MINIMUM OF
4" TO 6" INSIDE THE
TRUCK/TRAILER
FIGURE #1 FIGURE #2
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PARTS LIST FOR
MECHANICAL DOCK LEVELERS
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3
10
15
13
12
11
20
21
9
14
8
7
1
2
16
5
17
19
18
4
6
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PARTS LIST FOR
MECHANICAL DOCK LEVELERS
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Item # Part # Descripti n
15P-MD 001-6, 001-7 Hinge Lip Pin
25P-MD 002-6, 002-7 Lip
35P-MD 003-6, 003-7 Top Deck Assembly
45P-MD 4Lip Latch
55P-MD 5Lip Assist Assembly
65P-MD 006-6,006-8,006-10 Telescopic Toe Guard
75P-MD 7Lifting Arm Assembly
85P-MD 8Hold Down Assembly
95P-MD 009-6, 009-810 Main Spring (Quantity Varies)
10 5P-MD 010-6,010-8,010-10 Base Frame Assembly
11 5P-MD 011-6, 011-7 Rear Hinge Pin
12 5P-MD 012 Cotter Pin
13 5P-MD 013 Back Hold Down
14 5P-MD 014 Hold Down Bracket
15 5P-MD 015 Front Hold Down Pin
16 5P-MD 016 Cotter Pin
17 5P-MD 017 Release Ring
18 5P-MD 018 Cam
19 5P-MD 019 Lip Hinge
20 5P-MD 020 Lifting Arm Pin
21 5P-MD 021-6,021-8,021-10 Spring Adjustment Bar Assembly
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10
12
11
9
87
1
2
5
46
9A
3
* Dual hole configuration
standard for 8’ & 10’ Dock levelers
PARTS LIST FOR LIFTING ARM
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Item # Part # Descripti n
15P-MD 022 Flat Washer
25P-MD 023 Washer Seal
35P-MD 024 Spacer Bushing
45P-MD 025 Roller Bearing
55P-MD 026 Roller
65P-MD 027 Nut
75P-MD 028 Lifting Arm
85P-MD 029 Bolt
95P-MD 030 Pull Pin (6’ DOCK LEVELER)
9A 5P-MD 031 Pull Pin (8’ & 10’ DOCK LEVELER)
10 5P-MD 032 Cotter Pin 1/8” x 1 ½
11 5P-MD 033 Cotter Pin 1/8” x 1”
12 5P-MD 034 Lifting Arm Axle
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1
2
3
4
5
6
7
8
9
10
11
PARTS LIST FOR
RATCHET HOLD DOWN
Item # Part # Descripti n
15P-MD 037 Float Spring Housing
25P-MD 038 Ratchet Bar
35P-MD 039 Release Arm
45P-MD 040 Return Spring
55P-MD 041 Locking Bar
65P-MD 042 Ratchet Housing
75P-MD 043 Top Mounting Bracket
85P-MD 044 Bottom Mounting Bracket
95P-MD 045 Chain Guide Bracket
10 5P-MD 046 Release Chain c/w Pull Ring
11 5P-MD 047 Release Chain Holder
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1
2
3
4
5
6
PARTS LIST FOR
LIP ASSIST ASSEMBLY
Item # Part # Descripti n
15P-MD 048 Pin
25P-MD 049 Push Rod
35P-MD 050 Lock Ring
45P-MD 051 Support, Lip Extend
55P-MD 052 Spring
65P-MD 053 Support, Deck End
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10 9
8
7
1
2
5
4
6
3
PARTS LIST FOR
LIP LATCH ASSEMBLY
Item # Part # Description
15P-MD 054 Lip Latch
25P-MD 055 Roll Pin
35P-MD 056 Chai n
45P-MD 057 S-Hook
55P-MD 058 Lip Stop Spring
65P-MD 059 Quick Link
75P-MD 060 Base Spring
85P-MD 061 Spring Bracket
95P-MD 062 Lock Nut
10 5P-MD 063 HHC Bolt
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TROUBLE SHOOTING
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PROBLEM CORRECTIVE ACTION
1. Ramp fails to come up - Check for proper lubrication of lifting and hold
when release chain is down assemblies.
- Check for dirt and debris in the pit which may be
hindering proper mechanical action.
- Check for proper positioning of the board in the pit.
- Check to make sure the hold down is not bent.
- Check to be sure lifting arm is on the lifting cam
and not binding on the side.
2. Lip fails to extend. - Check to see that operator is holding the release
chain ring until ramp reaches its highest position.
- Check for broken chain or chain joiner.
- Check for lubrication of the lip hinge tubes.
- Check for any binding of the board in the pit which
may impede upward movement of the ramp.
- Check the lip assist spring adjustment.
- Check for proper lifting spring adjustments.
3. Lip extends but fails to lock. - Check the lip latch adjustment.
a) Spring may be disengaged.
b) Spring may have no preload.
c) Wire rope clip may be loose.
- Check to see if the lip extends far enough to
engage latch. See item “b” above.
- Check for violence in the board caused by
excessive lifting spring tension.
- Check to make sure the lip latch is not broken off.
- Check for excessive dirt in the lip hinge tubes.
4. If the lip fails to drop to it’s - Check the lip latch assembly.
vertical (pendant) position Lubricate the latch and hinge tubes so that it
when the truck pulls away. moves freely.
- Check lip hinge tube lubrication.
NOTE
Prior to servicing the dock, always block up and barricade the ramp securely, and then
enter the pit to clean or adjust.
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MAINTENANCE
NOTE: WITH PROPER CARE AND MAINTENANCE, YOUR MECHANICAL DOCK LEVELER WILL GIVE MANY
YEARS OF TROUBLE FREE SERVICE.
LUBRICATION
Lubricate the following dock leveler parts every three months.
Use only the grease or oil specified for each part.
LIGHT OIL: a) Lip hinge tubes
b) Lifting arm roller
c) Lifting arm pivot
d) Lip lifter & latch assembly
e) Cylinder pivot points
GREASE: a) Main spring ends
b) Rear hinge pins
MAIN COUNTER BALANCE SPRING ADJUSTMENT:
Adjust the counter balance spring.
To increase the upward ramp force, turn adjusting nuts clockwise.
To decrease the walk down force, turn adjusting nuts counter clockwise.
NOTE: AD UST MAIN COUNTER BALANCE SPRINGS ONLY AFTER ALL OTHER FUNCTIONS ARE IN
PROPER AD USTMENT.
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Perma Tech Inc.

WARRANTY
IMPORTANT
PLEASE READ CAFEFULLY TO INSURE THAT YOU DO NOT VOID YOUR WARRANTY.
PERMA TECH DOCK LEVELERS – STANDARD WARRANTY
This warranty provides the owner with coverage for a one (1) year period based
on normal eight (8) hour working day consisting of the following conditions:
A) One year structural steel warranty for the base frame, main steel deck and
steel hinged lip
B) One year hydraulic warranty for power pack pump, main cylinder (ram &
casing).
C) One year (365 days) warranty for electrical components, electric motor and
controls by respective manufactures, also complete lip-lifting mechanics, lip
assist assembly, hinged lip tubing, main hinged lip bar, lip crown, main deck
rear hinge lugs and pins, toe guards, hydraulic hose with fittings, hydraulic
cylinder seals.
Perma Tech Dock Levelers has manufactured their equipment with the best
of material and workmanship and should any defect develop or become evident
during the guaranteed periods stated above, we shall repair or replace same upon
notice and inspection by our authorized dealer.
WARRANTY CLAIRIFICATION:
1) Lip crown that has been decreased below the standard to meet the customer’s
requirement due to material handling equipment under clearance, which can
effect the main hinged lip tubing, main hinged lip bar, front plate and capacity.
The hinged lip crown established to satisfy the customer’s requirements must be
maintained but never exceed 80 degrees when open from the pendant position.
2) Weatherseals mounted on sides of unit or on curb, angles are susceptible to
damage by various means which is not part of this warranty.
3) This warranty does not apply in respect to damage to any product or accessory
or attachment thereof, caused by overloading or other misuse, neglect or
accident, nor does this warranty apply to any product, or accessory or
attachment thereof, which have been repaired or altered by other than the
seller or it’s authorized representative in any way, which in transit is not
applicable to warranty as stated above.
4) This warranty will only be valid if the original supplier has received full payment for
the equipment and services rendered and a preventive maintenance program
established within ninety (90) days from date of installation.
WARRANTY RE: Longer operating hours
Customer’s operating with a double shift up to sixteen (16) hours per day will reduce
the complete warranty by half.
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DISTRIBUTED BY:
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Perma Tech Inc.
363 Hamburg Street | Buffalo, NY 14204
TF: 800.362.7325 | TEL: [phone]
FAX: [phone]
Email: [email protected]
www.PermaTechInc.com