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User`s Manual - Curlin, Inc.

1. Fig 62 EE A DANGER Suus AA 2225555552 m HYDRAULIC DOCK LEVEL Ee r a Raise aa lt S 10 4 5 l 2 4 3 11 12 11 12 8 62 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011323 120V 1PH 60 HZ 5011016 6071019 6000549 e TERWNA 2cONDUCTOR O O o 0000538 6008836 6000469 6000477 6000506 632217 632228 8000515 8011374 50173235 February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 63 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011324 208 240V 1PH 60 HZ Fig 63 7 HYDRAULIC DOCK LE USER INSTRUCTIONS On On 4 DANGER to HFPA TOE for PPE Irise and lip will lower vehicle bed Before reaching Je supported by amp Ramp wt n 64 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONA
2. Ramp and lip grades Fig 1 Ramp grade I Ramp and lip grades Vehicle bed for each dock leveler length position from dock 6 Leveler 8 Leveler 10 Leveler in Ramp Lip Lip Ramp Lip 18 0 167 8 8 16 0 A 150 74 x 140 13 2 5 4 kel 12 0 19 4 11 6 14 5 6 6 11 5 3 7 10 0 16 5 8 7 12 3 4 5 9 8 2 0 8 0 13 7 5 8 10 2 2 4 8 2 0 3 a lt 6 0 10 8 3 0 8 1 0 2 6 5 1 4 4 0 8 0 0 2 6 0 1 8 4 8 3 1 2 0 5 2 2 6 3 9 3 9 3 1 4 7 0 0 2 4 5 4 1 8 6 0 1 5 6 4 x 2 0 0 3 8 2 0 3 8 1 0 2 8 1 o 4 0 3 1 11 0 2 3 10 2 1 9 9 7 6 0 5 9 13 8 4 4 12 3 3 5 11 4 z 8 0 8 7 16 6 16 5 144 5 2 13 1 10 0 11 5 19 4 8 6 16 5 69 14 7 m 12 0 14 4 22 2 10 7 18 6 7 5 l5 3 Vehicle bed for each dock leveler length position from dock 6 Leveler 8 Leveler 10 Leveler in Ramp Lip Ramp Lip Ramp Lip 18 0 Ze 173 48 16 0 sss 156 3 0 x 140 Sep 139 13 S 12 0 20 5 8 0 15 3 2 7 12 2 0 4 10 0 17 6 5 0 13 1 0 6 10 5 2 1 8 0 14 7 2 2 11 0 1 6 8 8 3 8 2 lt 6 0 11 9 0 7 8 9 3 7 7 1 5 5 4 0 9 1 3 5 6 8 5 8 5 4 7 1 2 0 6 3 6 3 4 7 7 9 3 8 8 8 0 0 3 5 9 1 2 6 10 0 2 1 10 5 x 2 0 0 7 11 9 0 5 12 0 0 4 12 1 4 0 2 1 14 6 1 6 14 1 1 2 13 8 S 6 0 4 9 17 4 3 6 16
3. Dock level 5 2 Release the RAISE button before the ramp support leg reaches its highest position The ramp will lower to its stored position 5 3 Visually check that the lip is not extended and the m IN ramp is supported by both dock level supports A A support before driving or walking on the ramp Ramp d Za a Aa 9 A should be level with dock floor See Fig 28 up AA 6 Unchock or release vehicle S A 7 Tell vehicle driver Your vehicle may now leave the dock February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 27 2012 4Front Engineered Solutions Inc OPERATION DOCK LEVELERS WITH AUTO RETURN TO DOCK OPTION Before operating the dock leveler read and follow Safety Practices on page 3 Use of dock leveler restricted to trained operators Follow procedures on placard posted near leveler DO NOT USE THE DOCK LEVELER IF IT LOOKS BROKEN OR DOES NOT SEEM TO WORK RIGHT Tell your supervisor it needs repair right away Before pressing button ensure lip avoids contact with vehicle sides and cargo If lip does not lower to vehicle bed reposition vehicle Stay clear of leveler unless lip is supported by vehicle bed or the leveler is stored at dock level Visually check that the lip is supported by the vehicle bed or the ramp is supported by both dock level supports before driving or walking on the ramp Unsupported dock levelers can lower unexp
4. supports 1 Do not operate the dock leveler until a vehicle is in position against the dock bumpers 2 Tell vehicle driver Your vehicle must stay at the dock 3 Chock or hitch vehicle 4 If necessary remove end loads with the ramp in the dock level stored position See Fig 24 Fig 25 NOTE C If the vehicle to be serviced is below dock level see operating instructions for Below Dock Control BDC on page 27 5 To extend the dock leveler lip into the vehicle 5 1 Push and hold the RAISE button The ramp will rise and the lip will extend once the ramp reaches the highest position See Fig 25 5 2 Release the RAISE button once the lip is fully extended 5 3 Ramp and lip will lower until the lip rests on the vehicle bed See Fig 26 6 Proceed with loading or unloading Fig 26 26 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc 7 To return the dock leveler to the stored position when loading or unloading is complete or to load end loads 7 1 Push and hold the RAISE button The ramp will rise and the lip will lower 7 2 Release the RAISE button when the lip clears the vehicle bed The ramp will lower to the dock level stored position 7 3 Check that the li
5. 2012 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE continued DOCK LEVEL SUPPORTS WILL NOT RETRACT FOR Fig 44 BDC t BELOW DOCK OPERATION chain 1 Check for broken chain to dock level support legs See Fig 44 2 Check connection of dock level control chain to the dock e Lc level support legs See Fig 44 3 Check for binding of dock level control chain See Fig Dock level 44 support leg 4 Check for binding in dock level support legs 5 Check length of below dock control chain Adjust chain so dock level support legs are retracted as shown in Fig 44 DOCK LEVEL SUPPORT LEGS WILL NOT SWING FULLY FORWARD NOTE Lip must be pendant 1 Check for binding or debris which may be restricting leg 2 Check below dock control chains to ensure chain has enough slack to allow leg to swing forward Adjust as required See Fig 44 February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 37 2012 4Front Engineered Solutions Inc HYDRAULIC DIAGRAM Fig 45 RAMP CYLINDER LIP CYLINDER PORT C3 GAUGE PORT PORT C2 PORT C1 CV2 SEQUENCE VALVE CS NEEDLE A VALVE Qv Qr cvs PC1 PC2 S 56 nd Q dL PRIMARY RELIEF S lt 2000 PSI Lil Lil LL J 38 6004753M Hydraulic Dock Levele
6. 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011651 575V 3PH 60 HZ Fig 61 A DANGER 1 br AB MTS DOCK LEVELER Ras 2 1 12 7 2 4 3 10 6 60 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011651 575V 3PH 60 HZ Free 2 o RESCH 3 2 TERMNALENDSTORSCREWESS 605 74 2 TERWNA 2CONDUCTOR 800542 5 GONPCTORTATNO 60 6 OVEROAD15 25AMPS STV 608 XFMR 550 600 24 50VA 6011649 8 1 PUSH BUTTON 6000506 9 1 CONTACT BLOCK CONTACT 632228 BODY MOUNTING COLLAR 6000515 DECAL KELLEY HP HK 6011373 FUSE ATQR 1 4 600V CC FERRAZ SHAWMUT 6011974 PRINT WIRING SCHEMATIC 575V 60116515 February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 61 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011323 120V 1PH 60 HZ
7. Disconnect the power and properly tag or lock off before doing any electrical work If it is necessary to make troubleshooting checks inside the control box with the power on USE EXTREME CAUTION Do not place fingers or un insulated tools inside the control box Touching wires or other parts inside the control box could result in electrical shock death or serious injury If you have any problems or questions using or operating the dock leveler contact your local Kelley distributor for assistance February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 3 2012 4Front Engineered Solutions Inc OWNER S RESPONSIBILITIES The owner s responsibilities include the following The owner should recognize the inherent danger of the interface between dock and transport vehicle The owner should therefore train and instruct operators in the safe use of dock leveling devices When a transport vehicle is positioned as closely as practicable to a dock leveling device there shall be at least 4 of overlap between the front edge of the lip and the edge of the floor or sill of the transport vehicle Nameplates cautions instructions and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended Manufacturer s recommended periodic maintenance and inspection procedures in effect at date of shipment shall be followed and written re
8. 1 2 1101 1102 24VAC REMOVE JUMPER DOCKLEVELER HEN INTERLOCK USED RAISE 2 EUR M114 OL101 1141 1142 C NE 3 07 ATA 96195 101 l OPTIONAL DOOR INTERLOCK l 1 Leben 20 2012 4Front Engineered Solutions Inc 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 WIRING DIAGRAMS WITH INTERLOCK AND 6011323 120V 1PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS AUTO RETURN TO DOCK SUPPLY BCPD CB FU 20AMP MAX LEVELER PANEL FLA 11 3A NUM SCCR 5 14 BLK 14 BIK MOT102 GEES EE EE EE Ro oe d 1021 E it 2 a ERA UA aca Di olas co E a booed TY a l dea M SE DAT y q LN Mor 1031 DN S eam 14 BLK zi 11 2 G BP PHASE HERTZ VOLTAGE MOTOR F LA PANEL F L A O L SETTING 1 60 120 11 2A 11 3A 11 2 AMPS TERMINAL STRIP FU109 REMOVE JUMPER RAGE WHEN INTERLOCK USED DOCKLEVELER LEGEND N i 2 OFF y ON BLK MHO 0L102 PANEL WIRING 1 1101 1102 1103 m 1104 CU NL MEE FIELD WIRING BY OTHERS 3 3 pg AINSA2 96 595 TE 1 Ssw1 102 TERMINAL WILL ACCEPT STRANDED DOOR H 3 WIRES ONLY 2 1111 112 4 WIRE COLOR GAUGE 3 H unless otherwise specified IOPTIONAL
9. 14 BLK uds 7 or 120VAC 16 RED mp STRAIGHT BLADE EE 24VAC 16 RED RECEPTACLE a NEUTRAL 4167 WHT ALL RECEPTACLES D GRI PRO SUUM BY OTHERS CAUTION 24VAC ONLY Sine 6011762 240V 3PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS LEVELER SUPPLY BCPD CB FU 6AMP MAX MOTOR PANEL FLA 3 7A CONTACTOR SCCR 5KA 1011 M114 OL101 as EE ee e EE CEU ECCE RT MCA RUP OE Cf IN COL a RECORD CR CC ees 1 21 OE 1021 1 ee eRe MEE DUE 3127 7 2 S MOTOR ft aaa a a ae sat HO EE 3 6FLA G 29106___ Spa cl uror IA ECC DEDE DERE i E E Es BP T 1061 3 4082 JABLE H1 H2 H3 H4 PHASE HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING 3 60 240 3 6A 3 7 3 6AMPS xe 50VA TABLE B 2 xi TRANSFORMER WIRING o T PRIMARY VOLTAGE PRIMARY CONN 1101 24VAC 220 240 H4 H2 REMOVE JUMPER RASE WHEN INTERLOCK USED DOCKLEVELER 1 2 GE ius MIO 0101 LEGEND TERMINAL STRIP P F 96195 PANEL WIRING SSW1 101 eet FIELD WIRING BY OTHERS 1 3 4 NOTE DOOR I L 1151 1152 TERMINALS WILL ACCEPT STRANDED 2 f WIRES ONLY i 1 3 DOOR I WIRE COLOR GAUGE NFPA 4 INTERLOCK i unless otherwise specified eg Sige est a 208 600VAC 14 BLK Nyda 7 NEMA S 15R DECK Pos 120VAC 16 RED D 7 STRAIGHT BLADE SWITCH 24VAC 16 RED New RECEPTACLE D se NEUTRAL El ALL RECEPTACLES BY OTHERS I CAU
10. I IOPTIONAL DOOR INTERLOCK I Leben LEVELER MOTOR doti CONTACTOR M114 OL101 MOT102 LEVELER MOTOR 4 0 1061 XF109 50VA X2 x1 1101 1102 24VAC REMOVE JUMPER DOCKLEVELER WHEN INTERLOCK USED RADE BLK M114 1 2 m 1142 js 05101 5 C 3 1 2 96 95 101 OPTIONAL DOOR INTERLOCK k Tomasa ul LEVELER MOTOR ion CONTACTOR M114 OL101 MOT102 DEED sss LEVELER MOTOR PURIS RPM 3 6FLA 1061 XF109 50VA X3 2 x1 o 1101 1102 24VAC REMOVE JUMPER Ure WHEN INTERLOCK Um Ea M114 iei 1 1141 LL 1142 C 1143 NE 3 S NS February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc 19 WIRING DIAGRAMS WITH INTERLOCK continued 6011326 460 480V 3PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU 3AMP MAX PANEL FLA 1 9AMPS SCCR 5KA G BP TABLE A PHASE HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING 3 60 460 1 8A 1 9A 1 8 AMPS TABLE B TRANSFORMER WIRING PRIMARY VOLTAGE PRIMARY CONN 480 460 H4 H1 TERMINAL STRIP LEGEND PANEL WIRING 1 DOOR EIS FIELD WIRING BY OTHERS 2 NOTE TERMINALS WILL ACCEPT STRANDED WIRES ONLY WIRE COLOR GAUGE NFPA unless otherwise specified 208 600VAC
11. S Hydraulic Dock Leveler KELLEY Model HK and HK S with One Button Control SAFE FRAME 00 This manual applies to dock levelers manufactured beginning October 2012 with the serial numbers 61059443 and higher User s Do notinstall operate service this product unless s e r s a n u a have read and understand the Safety Practices Warnings i i and Installation and Operating Instructions contained in n sta atio n O pe ratio ns this User s Manual Failure to do so could result in death M al nten ance an d P a rts or serious injury Part No 6004753M TABLE OF CONTENTS InfroduGtI f a u u wasy 2 Safety Signal Words 2 Safety RA M sata 3 Owner s Responsibilities 4 Ramp And Lip Grades 5 Installation 6 Wiring DiagramS sie 15 Operation S Hee 25 Planned 31 Maintenance And Lubrication 32 Troubleshooting Guide 34 Hydraulic Diagram
12. 60 HZ 6006452 PLASTIC CONTROL PANEL ENCLOSURE 6006437 CONTROL PANEL LABEL 6006453 3 1 PUSHBUTTON GREEN WITH LINE 6006439 ee CONTACT ASSEMBLY PLASTIC PANEL 6006438 1 CONTACTOR 208 230V 6006428 CONTACTOR 480V 6006430 CONTACTOR 600V 6006431 1 OVERLOAD RELAY 2 5 4A 208 230V 6006433 OVERLOAD RELAY 1 6 2 5A 460 480V 575V 6006432 7 1 PRINT WIRING SCHEMATIC 208 230V 6006450S PRINT WIRING SCHEMATIC 460 480V 6006451S PRINT WIRING SCHEMATIC 575V 6006452S February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 53 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011372 120V 1PH 60 HZ Fig 57 A DANGER ERC gu DOCK LEVELER 54 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011372 120V 1PH 60 HZ 2 3 3 TERMNALENDSTORSCREWESS 60050 4 4 TERMNAL 2conpucToR 605 5 FUSED DISCONNECT TERMINAL BLOCK amer 76 FUSE 05ATIME DELAY BUSSMAN MDL 12A eos CONTACTOR 18A
13. GRN I OPTIONAL DOOR INTERLOCK Ec e February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc 17 WIRING DIAGRAMS WITH INTERLOCK continued 6011524 208 230V 1PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU 10AMP MAX LEVELER MOTOR PANEL FLA SEE TABLE SCCR 5KA 14 BLK CONTACTOR M110 0102 MOT102 APR p PP EN TEA sed 1021 t ixl LEVELER 7 MOTOR PET 1 1 FLA SEE TABLE 3121259 x org i I 14 BLK BLS bo Co erz FE ec ea SEE TABLE G BP 1031 PHASE HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING 1021 1 60 208 7A TIA 7 AMPS 1 60 240 6 6A 6 9A 6 6 AMPS FU109 FU109 LEGEND ERMINAL STRIP REMOVE JUMPER DOCKLEVELER PANEL WIRING A WHEN INTERLOCK USED RASE Wiio SE FIELD WIRING BY OTHERS 1101 1 2 T I 00102 NOTE L2 02 NE 1105 TERMINAL WILL ACCEPT STRANDED AIN A2 96 S95 WIRES ONLY 1 102 DOOR I L WIRE COLOR GAUGE 2 unless otherwise specified 208 600VAC 14 BLK 120VAC 16 RED 24VAC 16 RED NEUTRAL 16 WHT GROUND GRN OPTIONAL DOOR INTERLOCK I l I I I l Lab 18 2012 4Front Engineered Solutions Inc 6004753M Hydraulic Dock Level
14. shims of the proper thickness are to be placed 10 under the ramp cylinder mounting pad and welded out as shown in Fig 13 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc Fig 11 Door jamb d Flush with floor at this point 1 2 sq drive adjustment bolt CCW rotation 3 16 weld both sides 3 long min both sides Fig 12 to raise 3 16 weld 3 16 weld 3 long min both sides 3 16 weld 3 long min Curb steel Fig 13 3l anchor bolt supplied by others Cylinder mounting pad Stagger and weld 6 x 12 shims February 2013 ADANGER Manual support of the lip must be maintained until the lip lock is in place The lip is free to move downward when it is released unless the lip lock is pinned in place DO NOT WORK UNDER THE DOCK LEVELER RAMP OR LIP UNLESS THE MAINTENANCE STRUT AND LIP LOCK ARE IN PLACE AND PINNED Welding with the dock levelers power connected can damage electrical components If the dock leveler has been previously connected turn off power to control box and disconnect all electrical wires from junction box in rear pit wall before welding Failure to do so can result in product damage 14 Finish welding both of the adjusted dock levele
15. 1 2 600V CC FERRAZ SHAWMUT 6011358 14 1 SCHEMATIC HP HK 2PB 3PH 208V 60113275 SCHEMATIC 2PB 240 60117625 SCHEMATIC 2PB 480 60113285 February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 67 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011652 575V 3PH 60 HZ Fig 65 EE 4 DANGER Ian aY fM lt 7 en pedes arri es HYDRAULIC DOCK LEVELER ELLL Z USERINSTRUCTIONS E EC ory 2011 4Front Engineered Solutions Inc 3 9 6660 10 68 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011652 575V 3PH 60 HZ 5011016 6071019 6000549 6000542 6000467 6000473 5011645 6000506 532228 8000515 632217 8011374 5011974 60116525 24 incoming power consult factory February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 69 2012 4Front Engineered Solutions Inc LIMITED WARRANTY MODEL HK THIS LIMITED WARRANTY IS KELLEY S SOLE
16. 14 BLK 120VAC 16 RED 24VAC 16 RED NEUTRAL 16 WHT GROUND GRN 6011651 575V 3PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU MAX PANEL FLA 1 7A SCCR 5KA G BP TABLE A PHASE 2 F L A PANEL F L A O L SETTING 3 60 575 1 6A 1 7 1 6 TRANSFORMER WIRING PRIMARY VOLTAGE PRIMARY CONN 575 H1 H2 LEGEND 7 PANEL WIRING ERMINAL STRIP FIELD WIRING BY OTHERS DOOR I L NOTE TERMINALS WILL ACCEPT STRANDED WIRES ONLY WIRE COLOR GAUGE unless otherwise specified 208 600VAC 14 BLK 120VAC 16 RED 24VAC 16 RED NEUTRAL 16 WHT GROUND GRN LEVELER MOTOR m CONTACTOR M114 OL101 RING p ese Ou REEL LEE LE E 1021 ce ENEE EE 312 MOTOR 5131 Gig eee L ABLA 1 8 T FU106 __ 1061 4062 U xmo 50VA X3 2 x1 o 1101 1102 24VAC REMOVE JUMPER DOCKLEVELER HEN INTERLOCK USED RAISE R e 2 a M114 OL101 1141 sis 1142 1143 N y p 3 7 ANA 9695 OPTIONAL DOOR INTERLOCK geb LEVELER NOTOR m CONTACTOR M114 OL101 saa ae ae Tee pU Roe tU 1021 L Mor 102 SE Bip ed eg LEVELER MOTOR cp DLE EDEN saus Big esses ea ss rs s E EI 15 uL FU106 B 1061 4062 EE XF109 50VA
17. 883 20 x 6 1 2 w 4 Degree BEND 711 886 711 886 20 x 6 1 2 w 7 Degree BEND 711 885 711 885 LIP 7FT WIDE 40K 45K AND 50K CAPACITY 16 x 7 w 4 Degree BEND 711 900 711 900 16 x 7 w 7 Degree BEND 711 899 711 899 18 x 7 w 4 Degree BEND 711 902 711 902 18 x 7 w 7 Degree BEND 711 901 711 901 20 x 7 w 4 Degree BEND 711 904 711 904 20 x 7 w 7 Degree BEND 711 903 711 903 LIP SHAFT 6 w Dock Leveler 712 957 713 786 6 1 2 w Dock Leveler 712 958 713 787 7 w Dock Leveler 712 959 713 788 Retainer Shaft Hinge Pin 035 451 Collar Shaft Hinge Pin 131 5 542 February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc PARTS LIST continued RAMP LIP AND TOE GUARD ASSEMBLIES 4 2 TOE GUARD MIDDLE SLIDING 19 PIT 6 Ig Dock Leveler 155 554 8 Ig Dock Leveler 155 555 TOE GUARD MIDDLE SLIDING 23 PIT 10 Ig Dock Leveler 155 557 5 2 TOE GUARD BOTTOM SLIDING 19 PIT 6 Ig Dock Leveler 155 554 8 Ig Dock Leveler 155 556 TOE GUARD BOTTOM SLIDING 23 PIT 10 Ig Dock Leveler 155 557 6 AR NUT Lock BIC 152878 9 2 SsewShude RES 000 056 3 2 138 837 36 73 327 140 NM uU NN NNI Below Dock Control All 6 and 8 Ig Dock Leveler 6003453 CHAIN Below Dock Control All 10 Ig Dock Levelers 6003452 SUPPORT Dock Level 708 780 SPRING Torsion 030 195 PIN Grooved 5 8 dia x 3 1
18. PANEL WIRING SC er 3 1 ATNZ A2 96 95 Aois FIELD WIRING BY OTHERS SSW1 102 NOTE 1 l TERMINALS WILL ACCEPT STRANDED 3 1151 1152 4 WIRES ONLY I 1 WIRE COLOR GAUGE IOPTIONAL 0008 A i unless otherwise specified INTERLOCK Neate 208 600 14 BLK V d A 120VAC 16 RED a 5 15 n RED ip STRAIGHT BLADE Wi es GROUND x RECEPTACLE ALL RECEPTACLES BY OTHERS s CAUTION 24VAC ONLY For 24V incoming power consult factory 24 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc DOCK LEVELERS WITH STANDARD ONE BUTTON CONTROL BOX Before operating the dock leveler read and follow Safety Practices on page 3 Use of dock leveler restricted to trained operators Follow procedures on placard posted near leveler DO NOT USE THE DOCK LEVELER IF IT LOOKS BROKEN OR DOES NOT SEEM TO WORK RIGHT Tell your supervisor it needs repair right away Before pressing button ensure lip avoids contact with vehicle sides and cargo If lip does not lower to vehicle bed reposition vehicle Stay clear of leveler unless lip is supported by vehicle bed or the leveler is stored at dock level Visually check that the lip is supported by the vehicle bed or the ramp is supported by both dock level supports before driving or walking on the ramp Unsupported dock levelers can lower unexp
19. done by a qualified technician and meet all applicable codes If it is necessary to make troubleshooting checks inside the control box with the power on USE EXTREME CAUTION Do not place your fingers or uninsulated tools inside the control box Touching wires or other parts inside the control box could result in electrical shock death or serious injury 6006461 120V 1 PH 50 60 HZ PRIMARY FUSING AND DISCONNECT DEVICE BY OTHERS L1 N G SUPPLY BCPD CB FU 17AMP MAX xi NCOMING POWER AND THE EE 1 79 EL LEVELER MOTOR CONNECT DIRECTLY TO THE CONTACTOR AND OVERLOADS l l L2 4 DOCK L3 13 LEVELER Rr QE M MOTOR o 7 1HP FLA 11 2A 1 t l 6006462 208 240V 1 PH 60 HZ PRIMARY FUSING AND DISCONNECT DEVICE BY OTHERS SUPPLY BCPD CB FU 10AMP MAX LEGEND M DOCK LEVELER CONTACTOR PB1 LEVELER O DIRECT LEGEND EXTERNA INTERNAL WIRING L CON RAISE DEVICE CONNECTION ECTIONS L1 L2 G j O L NOTE INCOMING POWER AND THE poo 0 LEVELER MOTOR CONNECT DIRECTLY TO THE CONTACTOR AND OVERLOADS cem A l L2 T2 X o x G DOCK bo 3 JN RR X o LEVELER MOTOR 1 FLA 7 0 6 6A J 1 sie circ ES LEGEND M DO
20. leveler reaches its highest position and hold dock leveler in its highest position 12 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc Molded L bumpers J bolts 3 per bumper furnished by Kelley Company Inc Locate and weld to curb angle at time of bumper installation Fig 18 3 8 side of pit to side of bumper mounting plate Full length of bumper mounting plate downhill welds are unacceptable Laminated bumpers Vertical bumper mounting angle seanchor bolt A field installed Laminations must be Supplied by installed vertically others February 2013 b The second person unpins the maintenance strut from the bracket on the ramp and stores it on the subframe See Fig 15 and the instruction label on maintenance strut c The RAISE button may now be released The ramp will lower when the button is released 24 Place the dock leveler in both dock leveler storage position and full below dock end load position If lip is being supported by the curb steel in either position a deflector plate must be created to allow leveler to store and reach its full below dock position without getting hung up on the pit floor Improperinstallation that allows the pendant dock leveler lip to support the weight of the dock leveler could result in death or serious injury It is so
21. manual for wiring information Follow the wiring instructions to set control for proper voltage Wires show in dashed lines are field connections 3 conduit must be installed replacing an existing mechanical dock leveler do so at this time Refer to the conduit requirements on the pit detail publication 5567 and powered dock leveler wiring diagrams and typical installation drawings and powered dock leveler wiring diagram on page 15 24 for electrical requirements Follow all applicable electrical codes and standards Fig 2 V ORI wo Push button control station Za fj Pit center line 12 6 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc February 2013 Before installing the dock leveler read and follow the Safety Practices on page 3 Failure to follow the Safety Practices could result in death or serious injury INSTALLATION OF DOCK LEVELER 6 and 8 long levelers using a standard 19 subframe can be field converted to allow installation in a 24 pit by adding a 4 riser kit Kelley Part No 6004654 Install the new riser leveling feet The riser blocks should be welded to the front frame supports prior to placing in the pit See publication 6003728 and page 46 in this manual 1 Prior to lifting leveler make sure the shipping tie down bolts seen in Fig 14 are in place Install two 3 4 10UNC load centering eye bolt
22. to Dock Option has an ON OFF switch to control the ramp during below dock end loading Pushing and holding the RAISE push button operates a hydraulic cylinder to raise the ramp Releasing the RAISE push button allows the ramp to lower When the dock leveler reaches its full raised position a second hydraulic cylinder extends the dock leveler lip The dock leveler with its lip extended settles onto the vehicle bed forming a bridge After loading pushing and holding the push button raises the ramp and the extended lip lowers to its stored position Releasing the push button allows the dock leveler to lower to its level stored position With the dock leveler in its stored position dock level support legs support the dock leveler ramp at a position level with the dock floor The dock level support legs will retract when the dock leveler lip is extended allowing the ramp and lip to lower onto and follow the vehicle bed up and down as loads are moved across the dock leveler and vehicle 28 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc February 2013 OPERATION continued DOCK LEVELERS WITH AUTO RETURN TO DOCK OPTION Do not operate the dock leveler when anyone is on or in front of it Stay clear of the dock leveler when it is moving Do not walk on dock leveler or lip until the
23. too deep Fig 21 Fig 22 Fig 23 Shim and weld flush Lj NP m n 1 8 MAX I er allowable step alh er 1 2 no greater than Equal alg 5 1 3 size 7 gap e j E agli contact zone at B agit ye et E 14 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc SOLUTION Align the sides parallel and equally spaced with the rear frame angle touching the rear curb angle in one place Fill the gap between the rear curb angle and rear frame angle using shims in weld pattern noted in Fig 10 See Fig 21 Align the leveler with the two square edges The gap on the sides should be even in the most narrow section 1 2 Max per side See Fig 22 If large deformations exist in the concrete work attempt to flatten out the rough surface using a chisel or grinder to take out the large obstructions The rear leveling legs can be installed on out of plane surfaces up to 1 8 at each leg See Fig 23 Weld 4 x 4 shims to the bottom of the adjustable legs WIRING DIAGRAMS CONTROL BOX STANDARD ADANGER NOTE Before doing any electrical work make certain the power For 24V incoming power consult factory is disconnected and properly tagged or locked off All electrical work must be
24. 008169 10 upper seal 6008171 4 Aluminum strip 53 1 2 6008175 Aluminum strip 77 1 2 6008177 Aluminum strip 101 1 2 6008179 5 6 Lower seal 6008168 8 Lower seal 6008170 10 Lower seal 6008172 Aluminum strip 6 upper 6008174 Aluminum strip 8 upper 6008176 Aluminum strip 10 upper 6008178 6 Kelley rear seal 6007671 6 5 Kelley rear seal 6007672 7 Kelley rear seal 6007673 8 TEK screws not shown 215702 9 Chain cup seal 0392 3 4 10 Set screw 6008249 11 W seal 600 W brush 328907 W seal 800 W brush 328908 W seal 600 W brush cut 328910 Corner bulb seal 6009507 13 Transition angle seal optional 6008247 50 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY STANDARD 6006461 120V 1 PH 50 60 HZ 6006462 208 240V 1 PH 60 HZ Fig 55 es O un AAAA QOTO 2 5 SY O OQ O Gs i Q fo O 59 1 k G Ezra 1 CONTROL BOX ASSEMBLY INCLUDES ITEMS 1 6 120V 1 PH 50 60 HZ 6006461 208 230V 1 PH 60 HZ 6006462 PLASTIC CONTROL PANEL ENCLOSURE 6006437 CONTROL PA
25. 00VAC 14 BLK 120VAC 16 a 5 1151 1152 4 24 16 RED H NEUTRAL 16 WHT GROUND GRN IOPTIONAL DOOR 1 INTERLOCK eet SE ws S 4 el Md 5 158 STRAIGHT BLADE DEGH ee Ne RECEPTACLE ALL RECEPTACLES BY OTHERS CAUTION aqvac ONLY s February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 23 2012 4Front Engineered Solutions Inc WIRING DIAGRAMS WITH INTERLOCK AND AUTO RETURN TO DOCK continued 6011652 575V 3PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS LEVELER SUPPLY BCPD CB FU 3AMP MAX MOTOR PANEL FLA 1 7A doli CONTACTOR SCCR 5KA M114 OL101 DERAOHU A A E A A TNN A E La N Day E EE 1021 l MOT102 J aie cid K K S SSS S E S S SI D S I S S ele Oar D LEVELER 3 TARIE Fa BER pL LC CLE DEDE LE ML DC AEE A AE E PLAQUE Se ee ICE ACRI ee Se eee 53 SE 1 7FLA 1 6 At G RUN o BP 1061 4062 TABLE A PHASE HERTZ VOLTAGE MOTOR F LA PANEL O L SETTING 3 60 575 1 6 17A 1 6AMPS H2 109 50VA TERMINAL STRIP 1 2 1 SSES 1102 24VAC 3 4 REMOVE JUMPER RAISE WHEN INTERLOCK USED DOCKLEVELER Rp viio LEGEND 1 2 OPEN at us 1144 05102 C N
26. 1NO NC 120V 6000469 8 1 OVERLOAD 9 13 AMPS 6000477 9 1 PUSHBUTTON 6000506 CONTACT BLOCK N O CONTACT 632228 BODY MOUNTING COLLAR 6000515 DECAL KELLEY HP HK 6011373 SCHEMATIC HP HK 1PB 1PH 120V 60113728 February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 55 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011524 208 240V 1PH 60 HZ Fig 58 Ves a A DAN ER BUUS E DOCK LEVELER I Ras 7 2 5 1 2 4 3 10 11 8 56 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011524 208 240V 1PH 60 HZ 2 PRK MOUNTINGPLATE 3 3 TERMNALENDSTORSCREWESS 600059 4 4 TERWNA 2cONDUCTOR 605 5 2 FUSED DISCONNECT TERMINAL BLOCK UFX 11 600538 76 2 FUSE 05ATIME DELAY BUSSMAN MDL 12A eos CONTACTOR 9A 1NO 1NC 240V 6006834 8 1 OVERLOAD 5 5 8 AMPS 6000476 9 1 PUSHBUTTON 6000506 CONTACT BLOCK N O CONTACT 632228 BODY MOUNTING COLLAR 6000515 DECAL KELLEY HP HK 6011373 SCHEMATIC HP HK 1PB 1PH 208 240V 60115245
27. 2 2 9 15 5 8 0 7 7 20 2 5 7 18 3 4 6 17 1 10 0 10 5 23 0 7 8 20 4 6 3 18 8 m 12 0 13 3 25 9 9 9 22 5 7 9 20 5 4 lip bend 16 lip February 2013 7 lip bend 16 lip optional special order 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc INSTALLATION PIT CHECK 1 Check entire dock leveler pit for proper construction according to certified pit drawings publication 5567 Check to be sure that the pit walls are square and plumb Prep the pit floor for rear leveler legs The pit should be clean and free of any excess debris Chip excess concrete or large residual concrete flash left over from pouring the pit Area surrounding the leveling feet should be smooth and free of excessive lumps Check electrical service running to the pit to assure it agrees with the correct location and voltage for the junction box Inspect the pit and remove all loose trash and construction debris Verify the pit matches pit details for your leveler See the installation troubleshooting on page 14 if the pit varies from the specification LEVELER CHECK PRIOR TO INSTALLATION 1 Visually check that the 4 rear hinge pins and retaining clips are in place 2 Visually check that the lip shaft collars or shaft retainers are in place on both lip rods 3 Verify that both the lip lock and the maintenance strut are und
28. 2 035 338 23 4 KLIPRING Ext 5 8 049 060 LEVER Lip Lock 155 150 SPRING Extension 700 135 1 PIN Roll 3 16 dia x 2 035 149 6 Lg Sash Chain 6001950 PIN Cotter Hair 035 200 29 SCREW Drive 6 x 1 4 Ig 000 518 LABEL SAFETY STRIPE Model HK S Only 6008554 1 Guard Safety Lip Model HK S Only 6 w Dock Leveler 714 220 6 1 2 w Dock Leveler 714 219 7 w Dock Leveler 714 218 2 2 44 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PARTS LIST continued SUBFRAME AND MAINTENANCE STRUT ASSEMBLIES Quantity Description Part Number MAINTENANCE POST 6 LG DECK WITH 20 BACKFRAME 713 308 MAINTENANCE POST 6 LG DECK WITH 24 BACKFRAME 6013622 MAINTENANCE POST 8 LG DECK WITH 20 BACKFRAME 708 882 MAINTENANCE POST 8 LG DECK WITH 24 BACKFRAME 6013623 MAINTENANCE POST 10 LG DECK WITH 24 BACKFRAME 713 345 PIN HINGE 6 8 AND 10 LG MODELS 6004128 4 A RETAINER SHAFT HINGE PIN 236 110 we 9 SCREW DRIVE 000 518 PIN COTTER HAIR 035 200 CHAIN SASH 032 195 1 R 1 1 1 1 1 1 1 1 PIN CLEVIS 035 051 DOCUMENTATION KIT HK1B STANDARD 184 472 MANUAL 6004753 PLACARD 6004007 DOCUMENTATION KIT HK1B ARTD OPTION 184 473 MANUAL 6004753 PLACARD 6004008 DANGER LABEL ENTERING PIT 921 070 13 1 SERIAL TAG 6009761 Included in item 1 February 2013 6004753M
29. 3 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 71 2012 4Front Engineered Solutions Inc Please direct questions about your dock leveler to your local distributor or to 4Front Engineered Solutions Inc Corporate Head Office Your local Kelley distributor is 1612 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 m KELLEY 2012 4Front Engineered Solutions Inc Part No 6004753M
30. 38 Parts 39 Br s 40 Warranty Information 70 Distributor Information 72 INTRODUCTION Welcome and thank you for choosing this dock leveler from KELLEY This dock leveler may be equipped with the optional ENERGY GUARD dock leveler sealing system This User s Manual contains information that you need to safely install operate and maintain the dock leveler It also contains a complete parts list and information about ordering replacement parts Please keep and read this User s Manual before using your new dock leveler SAFETY SIGNAL WORDS You may find safety signal words such as DANGER WARNING or CAUTION throughout this Owner s Manual Their use is explained below This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible death or injury DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury 2 6004753M Hydraulic Dock Leveler 2012 4Front Engineered Solutions Inc Indicates a potentially hazardous situation which if not avoid
31. AND EXCLUSIVE WARRANTY WITH RESPECT TO THE DOCK LEVELER AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES EXPRESS OR IMPLIED KELLEY warrants that this DOCK LEVELER will be free from flaws in material and workmanship under normal use for a period of one 1 year from the earlier of 1 60 days after the date of initial shipment by KELLEY or 2 the date of installation of the DOCK LEVELER by the original purchaser provided that the owner maintains and operates the DOCK LEVELER in accordance with this Owner s Manual KELLEY expressly warrants that the BAG MOTOR GASKETS FITTINGS and SEALS will be free from flaws in material and workmanship under normal use for a period of five 5 years from the earlier of 1 60 days after date of shipment or 2 the date of installation of the DOCK LEVELER by the original purchaser provided the purchaser maintains and operates the DOCK LEVELER in accordance with the Owner s Manual The LIP HINGE for this DOCK LEVELER is warranted for the rated lifetime of the DOCK LEVELER provided that the LIP HINGE is maintained per this Owner s Manual The rated lifetime of the DOCK LEVELER shall be determined by the KELLEY DOCK LEVELER LIFE RATING SYSTEM publication number 10 768 available from KELLEY upon request In the event that this DOCK LEVELER proves deficient in material or workmanship within the applicable Limited Warranty period owner shall so notify KELLEY and 4 Front will at its option 1 Replace the DOCK LE
32. CK LEVELER CONTACTOR PB1 LEVELER RAISE O DIRECT DEVICE CONNECTION PRI LEGEND EXTERNAL CONNECTIONS 95 96 1 2 Op M INTERNAL WIRING February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 15 2012 4Front Engineered Solutions Inc WIRING DIAGRAMS STANDARD 6006450 208 240V 3PH 60 HZ O L PB1 5 96 6006451 460 480V 3PH 60 HZ S PB1 s yee PRIMARY FUSING AND DISCONNECT DEVICE BY OTHERS DOCK SUPPLY BCPD CB FU 6AMP MAX LEVELER MOTOR 1HP FLA 4 3 6A NOTE INCOMING POWER AND THE LEVELER MOTOR CONNECT DIRECTLY TO THE CONTACTOR AND OVERLOADS DOCK LEVELER MOTOR 1HP FLA 1 8A PRIMARY FUSING AND DISCONNECT DEVICE BY OTHERS SUPPLY BCPD CB FU 3AMP MAX NOTE INCOMING POWER AND THE LEVELER MOTOR CONNECT DIRECTLY TO THE CONTACTOR AND OVERLOADS LEGEND M DOCK LEVELER CONTACTOR D I LEVELER RAISE DIRECT DEVICE CONNECTION LEGEND EXTERNAL CONNECTIONS INTERNAL WIRING LEGEND M DOCK LEVELER CONTACTOR PBI LEVELER RAISE O DIRECT DEVICE CONNECTION LEGEND EXTERNAL CONNECTIONS INTERNAL WIRING 16 2012 4Front Engineered Solutions Inc 6004753M Hydraulic Dock Leveler One Button Control
33. DOOR X d 208 600VAC 14 BLK I 120VAC 16 RS INTERLOCK X d 24VAC 16 RED Ss 5 15R NEUTRAL 16 WHT W d STRAIGHT BLADE DECK Pos GROUND GRN SWITCH NS RECEPTACLE ALL RECEPTACLES BY OTHERS z CAUTION LIP Pos 120VAC ONLY switch 6011324 208 240V 1PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU 10AMP MAX PANEL FLA SEE GEN LEER SCCR 5KA 14 CONTACTOR 110 0102 S 1021 LEVELER EE EE E TET X MOTOR SEE TABLE See a es RE pacti e meii ee Raten 1031 E alba Coz EE E E N 14 BLK Bp3 Fe X ege SEE TABLE Came yc u EE G 1041 BP PHASE HERTZ VOLTAGE MOTOR F LA PANEL F L A O L SETTING 1 60 208 7A 71A 7 AMPS 1 60 240 6 6A 6 7A 6 6 AMPS FU109 REMOVE JUMPER RAISE TERMINAL STRIP WHEN INTERLOCK USED DOCKLEVELER Beil 1 2 OFF ON i Mto 01102 1101 1102 5 110 1104 e LEGEND u r 3 W AOA 96395 PANEL WIRING L2 SSw1 102 zea FIELD WIRING BY OTHERS 7 3 4 NOTE N 1111 1112 TERMINALS WILL ACCEPT STRANDED DOOR I L 7 WIRES ONLY 1 2 JOPTIONAL DOOR WIRE COLOR GAUGE INTERLOCK j unless otherwise specified Die et T lt HEN 5 158 208 600VAC 14 BLK 4 DECK Pos yn STRAIGHT BLADE RI fe RED N RECEPTACLE m NEUTRAL WHT ALL RECEPTACLES BY OTHERS I CAUTION LIP Pos I2OVAC ONLY SWITCH February 2013 6004753M Hydraulic Dock Leveler One Button Control Sa
34. FETY INSTRUCTIONS 6008485 x2 138 837 x2 LIP UP LOCK m 700 136 HAZARD 2 Do not work under dock leveler unless this maintenance strut has been secured the upright position See user s manual for proper procedures CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is to user s manual for proper maintenance procedures DANGER 6004007 STANDARD 6004008 WITH ARTD WARNING AND OPERATION PLACARD MOUNTED ON WALL NEAR LEVELER February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 31 2012 4Front Engineered Solutions Inc MAINTENANCE AND LUBRICATION 5 5 Lip hinge Be certain before climbing into the dock leveler pit or assembly Dock level support leg doing any maintenance or repair under the dock leveler cam and hinge that 1 THE MAINTENANCE STRUT AND LIP LOCK ARE SECURELY IN PLACE see Fig 36 on page 33 and 2 the power is disconnected and properly tagged or locked off Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operation section of this manual Place barricades on the dock floor around the dock leveler pit and in the driveway in front of the pit while installing maintaining or repairing the dock leveler NOTICE Use only lubri
35. February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 57 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011325 208V 3PH 60 HZ 6011761 240V 3PH 60 HZ 6011326 460 480V 3PH 60 HZ Fig 60 emmer A DANGER s Z 5 2 1 12 7 2 4 3 10 6 58 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011325 208V 3PH 60 HZ 6011761 240V 3PH 60 HZ 6011326 460 480V 3PH 60 HZ 6011018 6071019 6000549 74 2 TERWNA 2CONDUCTOR 80542 5 GONACTORTATNO INGzAV 60 1 OVERLOAD 2 5 4 AMPS 208 240 6000474 OVERLOAD 1 6 2 5 AMPS 460 480 6000473 XFMR 200 480 23 110 50VA 6011359 8 1 PUSHBUTTON 6000506 9 1 CONTACT BLOCK CONTACT 632228 BODY MOUNTING COLLAR 6000515 DECAL KELLEY HP HK 6011373 FUSE ATQR 1 2A 600V CC FERRAZ SHAWMUT 6011358 13 1 SCHEMATIC HP HK 1PB 1PH 208V 6011325S SCHEMATIC HP HK 1PB 1PH 240V 6011761S SCHEMATIC HP HK 1PB 1PH 480V 6011326 February 2013 6004753 Hydraulic Dock Leveler One Button Control SafeTFrame 59
36. GRIP 1 2 HUB 5 8 GRIP 533424 RESERVOIR KIT 6012632 FILLER CAP BREATHER 6013207 8 1 90 SWIVEL NUT ELBOW 8 6011446 9 1 HOSE HYD RAMP CYL 708 939 HOSE HYD LIP CYL 708 940 11 1 CYLINDER RAMP 6 LONG 713 250 8 LONG 713 296 10 LONG 713 373 PIN CYLINDER 709 409 PIN ROLL 035 096 CLEVIS CYLINDER 712 376 PIN CLEVIS 035 039 PIN COTTER 035 036 48 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PARTS LIST continued HYDRAULIC COMPONENTS AND RETURN TO DOCK LEVEL SWITCH 625 040 5008285 527 110 131 475 6008982 6008987 215 702 131 476 6008286 6008288 6000721 712 027 WIRE NUT SHOWN 161 011 234 281 416 115 ARTD PROXIMITY SWITCH ASSEMBLY INCLUDES ITEMS 22 37 6009078 6011698 6011699 VALVE CHECK PILOT CAR SHOWN 6011700 VALVE CHECK PILOT OP CAR NOT SHOWN 6011701 February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 49 2012 4Front Engineered Solutions Inc PARTS LIST continued OPTIONAL ENERGY GUARD DOCK LEVELLER SEALING SYSTEM Fig 54 Description Quantity Part 6x6 6 5x6 6 7 6 8 6 5 8 7x8 6x10 6 5x10 7x10 Number 6008228 6008229 6008230 6008231 6008232 6008233 6008234 6008235 16008236 1 5 1 2 front seal 6008166 Vertical seal 6008173 3 6 upper seal 6008167 8 upper seal 6
37. Hydraulic Dock Leveler One Button Control SafeTFrame 45 2012 4Front Engineered Solutions Inc ES SES AR E SES WASHER Een m PARTS LIST continued OPTIONAL SUBFRAME RISER KIT Fig 52 2 Rear Angle Cap Plug 1 Field Installed Riser Kit 5 5 gt c 2 B o o o o a 2 o c S 5 H 6004654 6004487 RISER KIT FIELD INSTALLED REAR ANGLE CAP PLUGS KELLEY OPTIONAL February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc 46 PARTS LIST y continued 47 Inc red Solutions 2012 4Front Enginee HYDRAULIC COMPONENTS AND RETURN TO DOCK LEVEL SWITCH Fig 53 AY S Wu 6004753 Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 PARTS LIST continued HYDRAULIC COMPONENTS AND RETURN TO DOCK LEVEL SWITCH MOTOR PUMP UNIT INCLS ITEMS 2 THRU 8 100 120V 1 PH Caen HZ 6011436 200 240V 1 PH 50 60 HZ 6011437 190 240V 3 PH 50 60 HZ 6011438 380 480V 3 PH 50 60 HZ 6011439 575V 3 PH 60 HZ 6011440 o Sp T Fr O RING ELBOW 3 8 HOSE 313214 FTG JIC 8 MALE TO MALE 6 O RING 6006640 LABEL CAUTION 100 120V 1 PH 50 60 HZ 155 988 200 240V 1 PH 50 60 HZ 155 989 190 240V 3 PH 50 60 HZ 156 059 380 480V 3 PH 50 60 HZ 156 060 575V 3 PH 60 HZ 156 192 CABLE
38. L INTERLOCK AND AUTO RETURN TO DOCK 6011324 208 240V 1PH 60 HZ 5011016 6071019 6000549 6000542 0000538 5008836 6000469 6000476 6000506 632217 632228 8000515 6011374 50113245 February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 65 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011327 208V 3PH 60 HZ 6011762 240V 3PH 60 HZ 6011328 460 480V 3PH 60 HZ Fig 64 lt A DANGER T EMNE DRAULIC ELER 66 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011327 208V 3PH 60 HZ 6011762 240V 3PH 60 HZ 6011328 460 480V 3PH 60 HZ 5011018 5017019 5000549 4 rmwwa 2cocpucroR oo 5 coNmcrORiAiNO iNG2V owr p OVERLOAD 2 5 4 AMPS 208 240V OVERLOAD 1 6 2 5 AMPS 460 480V 6000473 XFMR 200 480 23 110 50VA 6011359 8 1 PUSH BUTTON 6000506 9 2 CONTACT BLOCK CONTACT 632228 BODY MOUNTING COLLAR 6000515 SELECTOR SW MAINTAINED 2 POS NEMA 4 4X 13 632217 DECAL KELLEY HP HK 6011374 FUSE ATQR
39. NEL LABEL 6006453 PUSHBUTTON GREEN WITH LINE 6006439 CONTACT ASSEMBLY PLASTIC PANEL 6006438 CONTACTOR 120V 6006427 CONTACTOR 208 230V 6006428 OVERLOAD RELAY 12 18A 120V 6006435 OVERLOAD RELAY 5 5 8A 208 230V 6006434 PRINT WIRING SCHEMATIC 120V 6006461S PRINT WIRING SCHEMATIC 208 230V 6006462S February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 51 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY STANDARD 6006450 208 240V 3PH 60 HZ 6006451 460 480V 3PH 60 HZ 6006452 575V 3PH 60 HZ Fig 56 e S OJ S LN OTN qo x AN QUO OW qOl 1 gO 2 ee amp P S REN d q O ag O fo Ho 52 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc February 2013 PARTS LIST continued CONTROL BOX ASSEMBLY STANDARD 6006450 208 240V 3PH 60 HZ 6006451 460 480V 3PH 60 HZ 6006452 575V 3PH 60 HZ CONTROL BOX ASSEMBLY INCLUDES ITEMS 1 6 208 230V 3 PH 50 60 HZ 6006450 460 480V 3 PH 50 60 HZ 6006451 Hs 3 PH
40. S FULL ABOVE DOCK POSITION 1 Check lip sequence valve pressure setting See Fig 41 LIP FAILS TO DROP TO THE PENDANT POSITION WHEN RAMP IS RAISED FROM VEHICLE 1 Check for damage to lip cylinder and or pivot pins 2 Check for binding in lip hinge 3 Checklip sequence valve pressure setting See Fig 41 Use type 5606 low temp hydraulic oil Check oil level with ramp raised and lip extended Fig 40 Set bypass pressure at 2000 PSIG with ramp raised and lip extended RV1 bypass pressure adjusting screw Turn screw clockwise to increase pressure Detail A Bypass pressure locking nut Fig 41 Set lip sequence pressure at 1500 PSIG Pressure gauge should read 1500 PSI before lip begins to extend Lip sequence valve pressure adjusting screw Turn screw clockwise to increase pressure J Sequence valve locking nut cM d Detail A February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 35 2012 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE continued RAMP WILL NOT RETURN TO STORED POSITION FROM FULL BELOW DOCK POSITION Applies to ARTD option only NOTE Ramp will not raise if a lift vehicle or other heavy material is left on top of the ramp 1 Check to be sure the control box switch is in the ON position 2 Check for electrical power to control box 3 Check to assure that the dock leveler lip is falling to the full pe
41. SafeTFrame February 2013 6006452 575V 3PH 60 HZ WIRING DIAGRAMS STANDARD continued FLA 1 6A RIMARY FUSING AND DISCONNECT DEVICE BY OTHERS SUPPLY BCPD CB FU OTE COMING POWER AND THE LEVELER MOTOR CONNECT LEG END M DOCK LEVELER CONTACTOR D I LEVELER o DIRECT LEGEND EXTERNAL CON RAISE DEVICE CONNECTION PBI DIRECTLY TO THE CONTACTOR AND EDTONS ss pron MT OVERLOADS INTERNAL WIRING o M N 6011372 120V 1PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU 20AMP MAX TEER PANEL FLA 11 34 CONTACTOR SCCR 5KA 14 BLK 14 BLK E a M110 OL102 MOT102 ae 1021 ucc a ae ap eee ee ee K Gallet Casma de MOTOR ath ss i j s 11 11 2FLA E rez l 14 BLK I o X ears INE E EE EE z 11 2A G r 1031 PHASE HERTZ VOLTAGE MOTOR PANEL F LA O L SETTING 1 60 120 11 2 11 3A 11 2 AMPS TERMINAL STRIP ie REMOVE JUMPER DOCKLEVELER N TEGEND WHEN INTERLOCK USED Bi ia PANEL WIRING EE FELD WRNG BY OTHERS 1 1101 1 2 1102 515 1103 1104 d 3 TERMINAL ACCEPT STRANDED 2 DOOR IL Al 2 ES 0595 WIRE COLOR GAUGE NFPA unless otherwise specified 208 600VAC 14 BLK 120VAC 16 RED 24VAC 16 RED NEUTRAL 416 WHT GROUND
42. TION 24VAC ONLY Sinon 22 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc WIRING DIAGRAMS WITH INTERLOCK AND AUTO RETURN TO DOCK continued 6011328 460 480V 3PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS LEVELER SUPPLY BCPD CB FU MOTOR PANEL FLA 1 9AMPS CONTACTOR SCCR 1011 M114 OL101 E S D c lc Mad MN in Foi X9 1021 MOT102 K LEVELER 312 DS MOTOR rosas spa panapas c I A 0 M ma ES SB aslbFe Leger 1 BFA SH 3 BP fU106 X TABLE A S PHASE HERTZ VOLTAGE MOTOR CAT PANEL F L A O L SETTING 1961 4062 3 60 460 1 8A 1 9A 1 8 AMPS H1 H2 H3 H4 a EE TRANSFORMER WIRING XF109 50vA 480 460 H4 H1 2 1 1101 1102 TERMINAL STRIP E 1 boor VL 2 3 LEGEND 7 PANEL WIRING re aa FIELD WIRING BY OTHERS REMOVE JUMPER RAISE E PB1 TERMINALS WILL ACCEPT STRANDED WHEN INTERLOCK USED RT BLK M110 WIRES ONLY 1101 1 2 1141 w 1 mw 1144 OL102 e 95 WIRE COLOR GAUGE EM 35r 9607 unless otherwise specified SSW1 208 6
43. ULAR PURPOSE ALL OF WHICH KELLEY HEREBY DISCLAIMS 70 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc LIMITED WARRANTY MODEL HK S THIS LIMITED WARRANTY IS KELLEY S SOLEAND EXCLUSIVE WARRANTY WITH RESPECT TO THE DOCK LEVELER AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES EXPRESS OR IMPLIED KELLEY warrants that this DOCK LEVELER will be free from flaws in material and workmanship under normal use for a period of one 1 year from the earlier of 1 60 days after the date of initial shipment by KELLEY or 2 the date of installation of the DOCK LEVELER by the original purchaser provided that the owner maintains and operates the DOCK LEVELER in accordance with this Owner s Manual KELLEY expressly warrants that the BAG MOTOR GASKETS FITTINGS and SEALS will be free from flaws in material and workmanship under normal use for a period of five 5 years from the earlier of 1 60 days after date of shipment or 2 the date of installation of the DOCK LEVELER by the original purchaser provided the purchaser maintains and operates the DOCK LEVELER in accordance with the Owner s Manual In the event that this DOCK LEVELER proves deficient in material or workmanship within the applicable Limited Warranty period owner shall so notify KELLEY and 4 Front will at its option 1 Replace the DOCK LEVELER or the deficient portion s thereof without charge to the o
44. VELER or the deficient portion s thereof without charge to the owner or 2 Alter or repair the DOCK LEVELER on site or elsewhere without charge to the owner This Limited Warranty does not cover any failure caused by improper installation abuse improper operation negligence or failure to maintain and adjust the DOCK LEVELER properly Parts requiring replacement due to damage resulting from vehicle impact abuse or improper operation are not covered by this warranty KELLEY DISCLAIMS ANY RESPONSIBILITY OR LIABILITY FOR ANY LOSS OR DAMAGE OF ANY KIND INCLUDING WITHOUT LIMITATION DIRECT INDIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OR LOST PROFITS OR LOST PRODUCTION arising out of or related to the use installation or maintenance of the DOCK LEVELER including premature product wear product failure property damage or bodily injury resulting from use of unauthorized replacement parts or modification of the DOCK LEVELER KELLEY s sole obligation with regard to a DOCK LEVELER that is claimed to be deficient in material or workmanship shall be as set forth in this Limited Warranty This Limited Warranty will be null and void if the original purchaser does not notify KELLEY s warranty department within ninety 90 days after the product deficiency is discovered THERE ARE NO WARRANTIES EXPRESS OR IMPLIED WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF INCLUDING BUT NOT LIMITED TO A WARRANTY OF MERCHANTABILITY OR OF FITNESS FORA PARTIC
45. amaged and have safety hitch pins on chains 4 Visually check that the foot assemblies at the rear of the leveler are in place and undamaged PREPARE SITE Place barricades around pit on dock floor and drive while installing maintaining or repairing dock leveler Power to control box must be from fused disconnect supplied by others For correct fuse size refer to wiring diagrams on pages 15 24 of this manual Fuses to be class CC time delay Before doing any electrical work make certain the power is disconnected and properly tagged or locked off All electrical work must be done by a qualified technician and must meet all applicable codes If it is necessary to make troubleshooting checks inside the control box with the power on USE EXTREME CAUTION Do not place fingers or uninsulated tools inside the control box Touching wires or other parts inside the control box could cause electrical shock resulting in death or serious injury 1 The control station user s manual and dock bumpers are attached to the sub frame of the dock leveler The maintenance strut has a plastic tie wrap holding it to the subframe remove it before placing the leveler into the pit Make sure the customer gets the user s manual and is properly trained 2 Mount and wire push button control station See Fig 2 and pit mounted receptacle See Fig 3 See wiring diagram located on the inside cover of the control box or wiring diagrams on pages 15 24 of this
46. cants shown Improper lubrication or adjustments may cause operational problems Cylinder pivot pins Hydraulic Ramp oil reservoir hinge pins Check all labels every 90 days See page 31 for location and part numbers Replace if required Every 90 days inspect dock bumpers Four inches 4 of bumper protection is required Worn torn loose or missing bumpers must be replaced HYDRAULIC FLUID LEVEL Check the hydraulic fluid level using the dipstick attached to the cap by inserting the cap until it stops Do not screw the cap on to check the fluid level MAINTENANCE AND LUBRICATION CHART Dock level Rear supportieg evinde Deckleveler support cam amp pivot pins legs Every 90 days Lubrication Sc d Eae Not required Not required grease cam i Every 90 days i Cleaning As required to As required to As required to or as required to As required to remove debris remove debris remove debris remove debris remove debris Acceptable Hydraulic Oils Mobil Aero HFA 49011 Exxon Univis Grade JI3 Texaco Aircraft Oil 1554 U S Oil Co Inc ZFI 5606 Low Temp 32 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc MAINTENANCE AND LUBRICATION continued Fig 37 Legend Symbol Lubricate oil Light oil SAE 30 Lubricate grease Molybdenum disulfide NLGI 2 D L
47. cords of the performance of these procedures should be kept Dock leveling devices that are structurally damaged or have experienced a sudden loss of support while under load such as might occur when a transport vehicle is pulled out from under the dock leveling device shall be removed from service inspected by the manufacturer s authorized representative and repaired as needed before being placed back in service The owner shall see that all nameplates caution and instruction markings or labels are in place and legible and that the appropriate operating and maintenance manuals are provided to users Modifications or alterations of dock leveling devices shall be made only with written permission of the original manufacturer When industrial vehicles are driven on and off transport vehicles during the loading and unloading operation the brakes on the transport vehicle shall be applied and wheel chocks or positive restraints that provide the equivalent protection of wheel chocks engaged The dock leveler should never be used outside its vertical working range or vertical lifting range or outside the manufacturer s labeled rated capacity It must also be compatible with the loading equipment and other conditions relating to the dock 4 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc February 2013 RAMP AND LIP GRADES Lip grade
48. ectedly Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brakes Always be certain that the vehicle wheels are chocked or that the vehicle is locked in place by a vehicle restraining device and the brakes are set before loading or unloading Vehicles pulling away from the dock unexpectedly can cause uncontrolled drop of the dock leveler which can result in death or serious injury The maximum uncontrolled drop of a Kelley HK dock leveler from any position is 3 inches Always return the dock leveler to its dock level stored position before allowing vehicle to leave dock If vehicle pulls away from dock before dock leveler is stored the lip will fall to its pendant position and the ramp will drop In addition failure to properly store the dock leveler may leave the leveler in a position below the level of the floor This condition may result in unexpected drop of personnel or material handling equipment and result in death or serious injury Failure to follow these instructions could result in death or serious injury to operators and or bystanders INTRODUCTION The KELLEY HK dock leveler is designed to span and compensate for space and height differences between a loading dock and freight carrier to allow safe efficient freight transfers The KELLEY HK dock leveler with Auto Return to Dock Option uses a push button control to position the dock leveler The Auto Return
49. ectedly Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brakes Always be certain that the vehicle wheels are chocked or that the vehicle is locked in place by a vehicle restraining device and the brakes are set before loading or unloading Vehicles pulling away from the dock unexpectedly can cause uncontrolled drop of the dock leveler which can result in death or serious injury The maximum uncontrolled drop of a Kelley HK dock leveler from any position is 3 inches Always return the dock leveler to its dock level stored position before allowing vehicle to leave dock If vehicle pulls away from dock before dock leveler is stored the lip will fall to its pendant position and the ramp will drop In addition failure to properly store the dock leveler may leave the leveler in a position below the level of the floor This condition may result in unexpected drop of personnel or material handling equipment and result in death or serious injury Failure to follow these instructions could result in death or serious injury to operators and or bystanders OPERATION INTRODUCTION The KELLEY HK dock leveler is designed to span and compensate for space and height differences between a loading dock and freight carrier to allow safe efficient freight transfers The KELLEY HK dock leveler uses a push button control to position the dock leveler Pushing and holding the push butto
50. ed may result in minor or moderate injury NOTICE Notice is used to address practices not related to personal injury One Button Control SafeTFrame February 2013 Read these safety practices before installing operating or servicing the Dock Leveler Failure to follow the safety practices could result in death or serious injury Ifyou do not understand the instructions ask your supervisor to explain them to you or call your local Kelley distributor OPERATION Use restricted to trained operators Follow procedures on placard posted near dock leveler Do not use this unit to service trailers outside its intended working range which is 12 inches above and 12 inches below dock 18 above and 12 below dock on 10 models Do not operate the dock leveler with equipment material or people on the ramp or lip Do not operate the dock leveler when anyone is in front of it unless they are securing the maintenance strut Stay clear of the dock leveler when it is moving KEEP HANDS CLEAR OF HINGES AT ALL TIMES Do not use hands to position dock leveler ramp or lip in vehicle or to store dock leveler Do not use the dock leveler if it looks broken or does not seem to work right Tell your supervisor it needs repair right away Do not stand in the driveway between the dock leveler and a backing vehicle Chock vehicle wheels or lock vehicle in place with a vehicle restraining device and set brakes before loading or u
51. er One Button Control SafeTFrame February 2013 WIRING DIAGRAMS WITH INTERLOCK continued 6011325 208V 3PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU 6AMP MAX PANEL FLA 4 1 SCCR 5 G lii TABLE A El PHASE HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING 3 60 208 4 0A 4 1 4 0 AMPS TRANSFORMER WIRING PRIMARY VOLTAGE PRIMARY CONN LEGEND 208 H4 H3 PANEL WIRING eS FIELD WIRING BY OTHERS NOTE TERMINALS WILL ACCEPT STRANDED WIRES ONLY WIRE COLOR GAUGE NFPA unless otherwise specified 208 600VAC 14 BLK ERMINAL STRIP 120VAC 16 RED 7 2avac 16 RED NEUTRAL 16 WHT 2 DOOR I L GROUND GRN 6011761 240V 3PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU 6AMP MAX PANEL FLA 3 7A SCCR 5KA G T TABLE A PHASE HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING A 60 240 3 6 3 7 3 6AMPS TABLE B TRANSFORMER WIRING PRIMARY VOLTAGE PRIMARY CONN 220 240 H4 H2 LEGEND PANEL WIRING Uri FIELD WIRING BY OTHERS NOTE TERMINALS WILL ACCEPT STRANDED WIRES ONLY l ERMINAL STRIP WIRE COLOR GAUGE unless otherwise specified 208 600VAC 14 BLK 2 120VAC 16 RED 24VAC 16 RED NEUTRAL 16 WHT GROUND GRN DOOR
52. ete could result in death or serious injury NOTICE The dock face must be flush with curb angle to assure proper bumper mounting 20 Mount dock bumpers to face of dock Downhill welds are unacceptable See Fig 17 or 18 21 Wire in electrical cords and connect power to dock leveler ADANGER Manually support the lip when storing the lip lock Stand clear of the lip when removing support The lip is free to move downward when support is removed Anyone in the path of the lip when it moves downward can be struck Keep your hands fingers and head away from the lip when it is released They could be struck by the lip or caught between the lip and other parts of the dock leveler resulting in death or serious injury DO NOT REMOVE MAINTENANCE STRUT WITHOUT HYDRAULIC PRESSURE OR A MECHANICAL LIFTING DEVICE SUPPORTING RAMP Raise ramp with hydraulic pressure or mechanical device before storing maintenance strut Stand clear of ramp and lip when hydraulic pressure or mechanical lift is applied or removed Ramp and lip are free to move downward when support is removed Removing support without hydraulic pressure could allow ramp to drop RAPIDLY If the dock leveler was raised using a mechanical device it should be lowered using the same device 22 Lift up on the hinged lip and store the lip lock under the ramp 23 Two people are needed to store the maintenance strut a One person must push and hold the RAISE button until dock
53. feTFrame 21 2012 4Front Engineered Solutions Inc WIRING DIAGRAMS WITH INTERLOCK AND AUTO RETURN TO DOCK continued 6011327 208V 3PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS LEVELER SUPPLY BCPD CB FU 6AMP MAX MOTOR PANEL FLA 4 1 CONTACTOR SCCR 5 M114 OL101 c ULM RI LEE C CL CDD dy VEM VIC i MK CIE quM I EET M E eege 3127 7 472 x MOTOR EE num icri D AAT WAS EE E 531 Loi es 4 0FLA G 4 0 L BP 1062 TABLE A PHASE HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING 3 60 208 4 0A 4 1A 4 0 AMPS XF109 50VA TABLE B 2 1 TRANSFORMER WIRING PRIMARY VOLTAGE PRIMARY CONN 1101 ane 10 208 H4 H REMOVE JUMPER RAISE WHEN INTERLOCK USED DOCKLEVELER Gei i 1 2 SEO EIS E MED ua 04101 LEGEND ERMINAL STRIP Tou 2 961195 PANEL WIRING SSW1 101 TOES FIELD WIRING BY OTHERS 1 i 3 4 NOTE fr DOOR LL 1151 1152 TERMINALS WILL ACCEPT STRANDED 2 1 l WIRES ONLY d DOOR I WIRE COLOR GAUGE INTERLOCK EE unless otherwise specified Lech M ou 5 15R 208 600VAC
54. heck the pit floor for uneven or excess concrete in the area around the leveling feet 1 6 from the rear wall Use chisel to level out area if necessary 3 Move the dock leveler back to the rear pit curb angle See Fig 6 With the rear leveler angle touching the rear pit angle square up the sides of the pit to the sides of the leveler The gap should be even on both sides The rear frame angle should be within 1 4 on either sides of the pit curb angle NOTE The rear frame angle should be about 1 2 lower than the pit curb angle before leveling This is normal See Fig 7 LEVELING THE REAR FRAME 4 Using a 1 2 square drive 1 2 ratchet or impact tool work from one side to the other turn each of the leveling Screws on the rear angle counter clockwise until the top surface of the rear angle is level with the rear pit curb angle Repeat on each leg until all are legs in contact with the pit floor and the top frame angle is flush with the rear curb angle See Fig 8 NOTICE The rear edge of the dock leveler should be level or slightly 1 16 maximum below dock level The top surface of the dock leveler should be level and a smooth transition with the dock floor curb steel The front end should be level and parallel with the rear frame angle for proper operation Unequal Shimming of the front supports may be required to obtain a level front edge NOTICE Turn off all electrical power to the leveler if it has been previous
55. k RAMP FAILS TO RAISE strut bracket 1 If motor fails to run 1 1 Check that all cords are wired into the junction box D Fi 1 2 Check for electrical power to the control box 1 3 Check ON OFF switch on control box ll ADANGER Before doing any electrical work make certain the power is disconnected and properly tagged or locked off 1 4 Check for loose wires in control box 1 5 Check fuses Replace if required 1 6 If problem can not be found contact a qualified electrician 34 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE continued 2 f motor runs 2 1 Check hydraulic oil level in reservoir Add if required See Fig 39 for proper levels and types of oil to be used 2 2 Check for loose hydraulic hose fittings or broken hoses Repair or replace as required 2 3 Check for binding in ramp cylinder pivots 2 4 Check hydraulic bypass pressure and adjust as required See Fig 40 LIP FAILS TO EXTEND 1 Check for damage to lip cylinder and or pivot pins 2 Check for leakage in lip cylinder or hydraulic hose feeding cylinder Check for binding in lip hinge 4 Check hydraulic oil level in reservoir Add if required See Fig 39 5 Checkhydraulic bypass pressure and adjust as required See Fig 40 6 Checklip sequence valve pressure setting See Fig 41 LIP EXTENDS BEFORE RAMP REACHE
56. lip is fully extended and supported by the vehicle bed Never use a fork truck or other material handling equipment to lower the ramp and lip sections supports 1 Do not operate the dock leveler until a vehicle is in position against the dock bumpers 2 Tell vehicle driver Your vehicle must stay at the dock Fig 30 3 Chock or hitch vehicle B n 4 f necessary remove end loads with the ramp in the dock level stored position See Fig 29 NOTE Lip extend Ramp If the vehicle to be serviced is below dock level see operating yee x instructions for Below Dock Control BDC on page 30 5 To extend the dock leveler lip into the vehicle 5 1 Turn the ON OFF switch to the ON position See Fig 30 5 2 Push and hold the RAISE button The ramp will rise and the lip will extend once the ramp reaches the highest position See Fig 30 5 3 Release the RAISE button once the lip is fully extended 5 4 Ramp and lip will lower until the lip rests on the vehicle bed See Fig 31 Fig 31 6 Proceed with loading or unloading _ C d February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 29 2012 4Front Engineered Solutions Inc OPERATION a continued 7 To return the dock leveler to the stored posi
57. ll increase time OUT counterclockwise will decrease time Tighten needle valve locking nut 1 3 Raise ramp and lip 1 4 Time ramp float down time Ramp should lower to below dock stop per chart at right 1 5 Repeat 1 1 through 1 4 until correct Adjust valve OUT in 1 4 turn increments only to achieve proper lowering time February 2013 PARTS REPLACEMENT Fig 46 Needle valve locking nut Needle vavle adjusting screw Turn screw clockwise to increase time seconds 1 second fully raised to full below dock LENGTH OF DOCK LEVELER PIT SIZE 19 12 23 18 6 amp 8 10 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 39 2012 4Front Engineered Solutions Inc PARTS LIST 1 To determine the correct replacement parts to order for your adjustable dock leveler you will need to know its model number pit size and capacity 2 The model number and capacity can be found on the dock leveler product label located on the fixed toe guard The meaning of each digit in the model number is shown in Fig 47 Example HK6x8 6 wide 8 long 3 To determine the nominal size of your dock leveler see Fig 48 4 You will also need to measure the pit depth to determine pit size for correct replacement parts See Fig 48 To ensure proper function durability and safety of the product only replacement parts that do not interfere with the
58. ly connected Welding with dock levelers power connected can damage the electrical components A ground must be attached to the leveler frame Failure to do so can result in product damage 5 Check and adjust the leveler for square and in firm contact with the rear angle The sides of the leveler should have a 1 2 gap and parallel with the sides of the pit Tack weld the rear angle to rear curb angle in 4 places min 3 8 at or near each leveling screw See Fig 9 and 10 NOTE Do not weld out the rear angle until after setting the front supports 8 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc February 2013 LEVELING THE FRONT FRAME 6 Remove and discard the shipping tie down bolts located at the lower end of the hinged lip assembly See Fig 14 Before welding the dock leveler supports to the front curb angle make sure that the dock leveler support legs line up with the V pocket in the dock leveler support angle Move dock levelers support right or left for the necessary alignment 7 Tack weld the front dock leveler supports to the front curb angle with 3 16 welds as shown in Fig 12 With the lip pendant insert 24 long 1 2 extensions between lip and lip rod onto dock levele
59. metimes necessary to install lip deflector plates to avoid any chance of the pendant lip supporting the weight of the dock leveler either near dock level or during a below dock end load 25 Permanently mount the laminated dock leveler WARNING and OPERATING instruction placard on the wall near the dock leveler control See Fig 19 Make sure the customer gets the user s manual and is properly trained 26 Operate the dock leveler four times through the complete cycle to check operation See Operation section page 25 NOTE If you have any problems or questions using or operating the dock leveler contact your supervisor or local Kelley distributor for assistance 27 Optional where applicable install rear angle cap plugs part number 6004488 into adjustment socket holes Press cap flush with top surface to rear angle See Fig 20 INSTALLATION continued Fig 19 Warning and operating instruction placard s us Ce WN Wf Fig 20 February 2013 6004753 Hydraulic Dock Leveler One Button Control SafeTFrame 13 2012 4Front Engineered Solutions Inc IN STALLATION continued INSTALLATION TROUBLESHOOTING The following procedures apply after the leveler is level in the pit PROBLEM POSSIBLE CAUSE 1 Leveler will not fit properly in pit a Pit is out of square with the sides b One side and rear angle is out of square c Pit floor irregular in rear d Pit is
60. n operates a hydraulic cylinder to raise the ramp Releasing the push button allows the ramp to lower When the dock leveler reaches its full raised position a second hydraulic cylinder extends the dock leveler lip The dock leveler with its lip extended settles onto the vehicle bed forming a bridge After loading pushing and holding the push button raises the ramp and the extended lip lowers to its stored position Releasing the push button allows the dock leveler to lower to its level stored position With the dock leveler in its stored position dock level support legs support the dock leveler ramp at a position level with the dock floor The dock level support legs will retract when the dock leveler lip is extended allowing the ramp and lip to lower onto and follow the vehicle bed up and down as loads are moved across the dock leveler and vehicle February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 25 2012 4Front Engineered Solutions Inc STANDARD OPERATION AWARNING Fig 24 Do not operate the dock leveler when anyone is on or in front of it Stay clear of the dock leveler when it is moving Do not walk on dock leveler or lip until the lip is fully extended and supported by the vehicle bed Never use a fork truck or other material handling equipment to lower the ramp and lip sections
61. n the cylinder support bracket If electrical power is available reconnect power and use the electrical controls to raise the ramp and lip to their full above dock position See operating instructions on front cover of control box If electrical power in not available raise ramp using a chain or other suitable lifting device A DANGER Hydraulic pressure or mechanical support must be maintained on the ramp to hold it in the raised position until the maintenance strut is in place DO NOT WORK UNDER THE DOCK LEVELER RAMP OR LIP UNLESS THE MAINTENANCE STRUT AND LIP LOCK ARE IN PLACE AND PINNED 12 Return power to the leveler control Using the push button control station or a suitable lifting device raise the deck and secure with maintenance strut a Push and hold the RAISE button to extend cylinder until the dock leveler reaches its highest position and hold dock leveler in its highest position b The second person positions the maintenance strut into the bracket located on the underside of the ramp assembly and pins it in place with hairpin clip See Fig 15 and the instruction label on maintenance strut c The second person then locks the lip in extended position with the lip lock provided on the deck ramp Pin the lip lock in place with hairpin clip See Fig 15 and instruction label located on the under side of the dock leveler ramp d Release button control and allow leveler to lock in maintenance position 13 6x16
62. ndant position Lip should be 1 2 to 1 1 2 from the face of the dock when the ramp is in the full below dock position The return to dock switch is connected to the lip and will not operate if the lip remains in the full or partially extended position 4 Check return to dock switch and mounting bracket If hardware is loose or missing the switches can move on the brackets Switch contacts should be closed when dock leveler is full below dock and lip is pendant See wiring diagrams on pages 21 through 24 See Fig 42 NOTE Return to dock level switch should turn off pump motor when ramp reaches approximately 4 to 6 above dock level RAMP LOCK DURING DOWNWARD TRAVEL 1 Check for debris in pit which may be restricting downward travel 2 Downward speed of the ramp is controlled by a needle valve located in the pump motor Turn valve in to eliminate locking See Fig 43 See chart on page 39 for amount of time dock leveler should move from its fully raised position to full below dock position NOTE Do not adjust needle valve more than 1 4 turn Test operation Readjust turning valve a maximum of 1 4 turn between testing During TESTING DO NOT TURN MORE THAN FOUR 4 1 4 TURNS Fig 42 Auto Return to Dock switch assembly Needle valve Nd locking nut Needle valve adjusting screw Turn screw clockwise to increase time 36 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013
63. nloading Stay clear of leveler unless lip supported by the vehicle bed or the ramp is supported by both front dock level supports unsupported leveler can lower unexpectedly Store dock leveler at dock level after below dock end loading Move all equipment material or people off dock leveler and store dock leveler at dock level before allowing the vehicle to pull out SAFETY PRACTICES OPERATION continued Do not use a fork truck or other material handling equipment to lower the ramp Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brakes Ensure lip avoids contact with vehicle sides and cargo If lip does not lower to vehicle bed reposition vehicle INSTALLATION MAINTENANCE AND SERVICE Place barricades on the dock floor around the dock leveler pit and in the driveway in front of the pit while installing maintaining or repairing the dock leveler Do not operate the dock leveler when anyone is in front of it unless they are securing the maintenance strut PUT AND PIN MAINTENANCE STRUT AND LIP LOCK IN PLACE before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler Disconnect the power and properly tag or lock off before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler All electrical troubleshooting or repair must be done by a qualified technician and must meet applicable codes
64. ontrol SafeTFrame 2012 4Front Engineered Solutions Inc February 2013 PARTS LIST continued RAMP LIP AND TOE GUARD ASSEMBLIES Item oe Description Model HK Model HK S LIP 6FT WIDE 30K AND 35K CAPACITY 16 x 6 w 4 Degree BEND 711 858 w 7 Degree BEND 711 857 18 x 6 w 4 Degree BEND 711 860 w 7 Degree BEND 711 859 ae x 6 w 4 Degree BEND 711 862 w 7 Degree BEND 711 861 LIP 7FT WIDE 30K AND 35K CAPACITY 16 x 7 w 4 Degree BEND 16 x 7 w 7 Degree BEND 18 x 7 w 4 Degree BEND 18 x 7 w 7 Degree BEND 20 x 7 w 4 Degree BEND 711 894 711 893 711 896 711 895 711 898 s 6 1 2FT WIDE 30K AND 35K CAPACITY 16 x 6 1 2 w 4 Degree BEND 711 876 16 x 6 1 2 w 7 Degree BEND 711 875 18 x 6 1 2 w 4 Degree BEND 711 878 18 x 6 1 2 w 7 Degree BEND 711 877 20 x 6 1 2 w 4 Degree BEND 711 880 20 x 6 1 2 w 7 Degree BEND 711 879 20 x 7 w 7 Degree BEND 711 897 LIP 6FT WIDE 40K 45K AND 50K CAPACITY 16 x 6 w 4 Degree BEND 711 864 711 864 16 x 6 w 7 Degree BEND 711 863 711 863 18 x 6 w 4 Degree BEND 711 866 711 866 18 x 6 w 7 Degree BEND 711 865 711 865 20 x 6 w 4 Degree BEND 711 868 711 868 20 x 6 w 7 Degree BEND 711 867 711 867 LIP 6 1 2FT WIDE 40K 45K AND 50K CAPACITY 16 x 6 1 2 w 4 Degree BEND 711 882 711 882 16 x 6 1 2 w 7 Degree BEND 711 881 711 881 18 x 6 1 2 w 4 Degree BEND 711 884 711 884 18 x 6 1 2 w 7 Degree BEND 711 883 711
65. p is not extended and the ramp is supported by both dock level supports before driving or walking on the ramp Ramp should be level with dock floor 8 Unchock or release vehicle 9 Tell vehicle driver Your vehicle may now leave the dock BELOW DOCK CONTROL BDC To lower the ramp without extending the lip for end loading below dock level 1 Press the RAISE button and hold it until the ramp is 6 to 12 above dock level Release the RAISE button before the ramp reaches its highest position 2 As ramp is lowering walk onto the ramp and pull the BDC chain located in the middle of the ramp until it is fully extended Hold the chain until the ramp passes below dock level See Fig 27 Release the BDC chain Load or unload end loads When loading or unloading is complete return the dock leveler to the stored position 5 1 Push and hold the RAISE button until the ramp is at least 4 above dock level STAN DARD OPERATION continued A WARNING Before allowing vehicle to leave always return the dock leveler to its dock level stored position with the dock level support legs supported by the front dock level supports Failure to do so may leave the dock leveler in a position below the level of the dock floor This condition may result in unexpected drop of personnel or material handling equipment and result in death or serious injury Fig 27 BDC chain Fig 28
66. ports Failure to do so may leave the dock leveler in a position below the level of the dock floor This condition may result in unexpected drop of personnel or material handling equipment and result in death or serious injury Fig 32 BDC chain Dock level support leg 6 Load or unload end loads a m J Front angle 7 When loading or unloading is complete return the dock dock level leveler to the stored position Turn the ON OFF switch a x a support to the ON position The dock leveler will automatically BT ar Aa T A on A A return to the stored position lt 3i AA 8 Visually check that the lip is not extended the S 4 is supported by both dock level supports before driving or walking on the ramp Ramp should be level with dock floor See Fig 33 9 Turn the ON OFF switch to the OFF position 10 Unchock or release vehicle 11 Tell vehicle driver Your vehicle may now leave the dock 30 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame February 2013 2012 4Front Engineered Solutions Inc PLANNED MAINTENANCE Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or require replacement please call your local Kelley distributor Fig 34 6008554 x2 HK S Model Only SA
67. r One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc February 2013 CONTROL BOX TRANSFORMER 3 PHASE ONLY 1 When replacing the transformer make sure jumper wires are installed per wiring diagrams for appropriate phase and voltage HYDRAULIC OIL HOSES 1 When removing hydraulic oil hose s remove from motor pump assembly first then from cylinder assembly 2 When installing hydraulic oil hose s attach to cylinder first making sure O ring is in place then attach to pump motor assembly A DANGER Be certain before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler that 1 THE MAINTENANCE STRUT AND LIP LOCK ARE SECURELY IN PLACE see Fig 38 and 2 the power is disconnected and properly tagged or locked off After replacing hose and or motor pump assembly run pump motor at least four 4 times with the maintenance strut and lip lock in place This is required to remove air from the system Check oil level and add oil if required Use extreme care when removing maintenance strut and lip lock Ramp and lip could move down rapidly if air remains in the system Run dock leveler four 4 times through the complete operating cycle before placing dock leveler into service MOTOR PUMP ASSEMBLY 1 Tosetthe downward speed of the ramp 1 1 Loosen needle valve locking nut See Fig 46 1 2 Turn valve in 1 4 turn increments only IN clockwise wi
68. r support leveling screw See Fig 12 Using a 1 2 drive 1 2 ratchet or impacttool turn each leveling screw counter clockwise until the top of the levelers is flush with the finished floor pit curb steel where the overhead door meets the floor See Fig 11 Weld the rear frame angle to the rear curb angle using 1 4 bevel joints in the transition plate as your guide See Fig 10 10 After the rear hinge is welded check that all rear leveling February 2013 legs are in contact with the floor of the pit Once all legs are in contact with floor tighten each leg leveling screw counter clockwise to 25 40 ft Ibs Fig 8 Fig 9 IN STALLATION continued A q Leg adjustment A q Rear pit curb angle L o o o o H j Rear n frame angle P d T 1 2 aa Ramp Pit sid curb angle L Frame Rear hinge uprights assembly 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 9 2012 4Front Engineered Solutions Inc IN STALLATION s continued 11 If a field installed riser kit is being used do not use hydraulics to position leveler on maintenance strut before cylinder support riser is in place Use a suitable lifting device to place leveler on maintenance strut per step 12 below then position and weld i
69. r supports in all locations shown in Fig 12 15 Check shims under ramp cylinder pad Adjust thickness if necessary Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury 16 Drill and install 3 4 diameter anchor bolts min 3 deep in ramp cylinder mounting pad Weld shims to pad as noted in Fig 13 17 Remove and discard shipping cotter pins from toe guards on both sides of dock leveler See Fig 16 18 Remove lifting chain or other lifting devices Remove lifting hooks from the sides of the ramp 19 Read the Safety Practices on page 3 and the Operation Instructions on pages 25 through 30 before operating the dock leveler February 2013 IN STALLATION a continued Fig 14 Oy Shipping tie down bolt Fig 15 Insert hairpin clip through maintenance strut pin Maintenance strut pin Maintenance hairpin clip strut Maintenance into lip lock strut bracket I J li LI Fig 16 shipping 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 11 2012 4Front Engineered Solutions Inc IN STALLATION continued A WARNING Improper installation of anchoring devices or installation into aged or unsound concr
70. s into the front and rear of the top plate and hoist leveler into pit The dock leveler should not be lifted in any other manner when place into the pit See Fig 4 Inadequate lifting equipment or practices can cause a load to fall unexpectedly Make sure the lifting chain or other lifting devices are in good condition and have a rated capacity of at least 3500 Ibs for the lifting angle used Never allow anyone to stand on or near the dock leveler when it is lifted or placed into the pit Stand clear of the dock leveler when it is placed into the pit Failure to follow this warning can allow the dock leveler to fall tip or swing into people resulting in death or serious injury NOTICE Route power cord clear of edges and resting surfaces so that itis not damaged during lifting and placement Wires may be routed up through the rear hinge until needed INSERTING THE LEVELER INTO THE PIT 2 Position dock leveler in pit about 7 away from the rear pit wall Connect wires to junction box on the rear pit wall Place the free length of cord inside of frame area free of interference as the leveler is moved into the final position See Fig 5 and wiring diagrams on page 15 24 IN STALLATION continued Fig 4 3 4 10 UNC load centering eyebolt February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 7 2012 4Front Engineered Solutions Inc IN STALLATION a continued NOTE C
71. safe normal operation of the product must be used Incorporation of replacement parts or modifications that weaken the structural integrity of the product or in any way alter the product from its normal working condition at the time of purchase from Kelley could result in product malfunction breakdown premature wear death or serious injury NOTE Kelley DISCLAIMS all liability for failure to comply with this warning WARRANTIES relating to MERCHANTABILITY and or FITNESS FOR INTENDED USE are specifically DISCLAIMED in the event the purchaser fails to comply with this warning Fig 47 LENGTH 6 6 long 8 8 long 10 10 long 12 12 long S Safety Lip Option WIDTH 6 6 wide 6 5 6 1 2 wide 7 T wide Lip Length 16 18 Or 20 Pit Depth 20 Or 24 NOMINAL SIZE WxL FT 6x6 6x8 6x10 6 5x6 6 5x8 6 5x10 7x6 7 8 7 10 40 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 2012 4Front Engineered Solutions Inc February 2013 PARTS LIST continued MODEL HK RAMP LIP AND TOE GUARD ASSEMBLIES Fig 49 February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 41 2012 4Front Engineered Solutions Inc PARTS LIST continued MODEL HK S RAMP LIP AND TOE GUARD ASSEMBLIES Fig 50 42 6004753M Hydraulic Dock Leveler One Button C
72. tion when loading or unloading is complete or to load end loads 7 1 Turn the ON OFF switch to the ON position 7 2 Push and hold the RAISE button The ramp will rise and the lip will lower 7 3 Release the RAISE button when the lip clears the vehicle bed The ramp will lower to the dock level stored position 7 4 Check that the lip is not extended and the ramp is supported by both dock level supports before driving or walking on the ramp Ramp should be level with dock floor 7 5 Turn the ON OFF switch to the OFF position 8 Unchock or release vehicle 9 Tell vehicle driver Your vehicle may now leave the dock BELOW DOCK CONTROL BDC To lower the ramp without extending the lip for end loading below dock level 1 the ON OFF switch to the ON position 2 Press the RAISE button and hold it until the ramp is 6 to 12 above dock level Release the button before the ramp reaches its highest position 3 Turn the ON OFF switch to the OFF position as the ramp begins to lower 4 As the ramp is lowering walk onto the ramp and pull the BDC chain located in the middle of the ramp until it is fully extended Hold the chain until the ramp passes below dock level See Fig 32 5 Release the BDC chain Before allowing vehicle to leave always return the dock leveler to its dock level stored position with the dock level support legs supported by the front dock level sup
73. ubricate pin S H Cleaning n botkends Location frequency of cylinder I i3 Visually inspect J Replace damaged or worn e OT EE NET EE L lem N A ASS ASS AN o UU Hydraulic reservoir See Note 1 Pit 3 mo February 2013 6004753M Hydraulic Dock Leveler One Button Control SafeTFrame 33 2012 4Front Engineered Solutions Inc Rear hinge pin TROUBLESHOOTING GUIDE Be certain before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler that 1 THE MAINTENANCE STRUT AND LIP LOCK ARE SECURELY IN PLACE see Fig 38 and 2 the power is disconnected and properly tagged or locked off Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operation section of Fig 38 Insert hairpin clip through maintenance strut pin Maintenance strut pin Insert this manual Maintenance hairpin clip strut Maintenance into lip loc
74. wner or 2 Alter or repair the DOCK LEVELER on site or elsewhere without charge to the owner This Limited Warranty does not cover any failure caused by improper installation abuse improper operation negligence or failure to maintain and adjust the DOCK LEVELER properly Parts requiring replacement due to damage resulting from vehicle impact abuse or improper operation are not covered by this warranty KELLEY DISCLAIMS ANY RESPONSIBILITY OR LIABILITY FOR ANY LOSS OR DAMAGE OF ANY KIND INCLUDING WITHOUT LIMITATION DIRECT INDIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OR LOST PROFITS OR LOST PRODUCTION arising out of or related to the use installation or maintenance of the DOCK LEVELER including premature product wear product failure property damage or bodily injury resulting from use of unauthorized replacement parts or modification of the DOCK LEVELER KELLEY s sole obligation with regard to a DOCK LEVELER that is claimed to be deficient in material or workmanship shall be as set forth in this Limited Warranty This Limited Warranty will be null and void if the original purchaser does not notify KELLEY s warranty department within ninety 90 days after the product deficiency is discovered THERE ARE NO WARRANTIES EXPRESS OR IMPLIED WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF INCLUDING BUT NOT LIMITED TO A WARRANTY OF MERCHANTABILITY OR OF FITNESS FORA PARTICULAR PURPOSE ALL OF WHICH KELLEY HEREBY DISCLAIMS February 201

User`s Manual - Curlin, Inc.

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