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User`s Manual - Curlin, Inc.

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1. SUPPLY BCPD CB FU 20AMP MAX LEVELER PANEL FLA 11 3A NUM SCCR 5KA 14 BLK 14 BIK MOT102 woe ne ees xs eee DUYN ee ee MAR ee we oe d 1021 E BE E EE WC NN yy GE FAES yty 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 96 595 1 sswi 102 TERMINAL WILL ACCEPT STRANDED DOOR H 3 WIRES ONLY 2 1111 112 4 WIRE COLOR GAUGE 3 H unless otherwise specified OPTIONAL DOOR X d 208 600VAC 14 I 120VAC 16 RS INTERLOCK X d 24VAC 16 RED Cr 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 PANEL FLA SEE GEN LEER SCCR 5KA 14 CONTACTOR M110 0L102 os 1021 LEVELER a EE re eee SI TET X MOTOR FLA SEE TABLE 1031 E alba Coz EE E E N 14 BLK 5131
2. Fig 58 EE DANGER Us DOCK LEVELER I Rss w 2011 4Front Engineered Solutions Ino onn 7 2 5 1 2 4 3 10 11 8 56 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011524 208 240V 1PH 60 HZ Free 2 HPHKMOUNTNGPLATIE 6 3 3 TERMINAL END STOP 605 4 690542 5 2 FUSED DISCONNECT TERMINAL BLOCK UFX 11 600538 2 FUSE 05ATIME DELAY BUSSMAN MDL 12A 608 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 October 2012 6004750K HydraulicPlus Dock Leveler 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 4 DA
3. Fig 65 Na ey 4 DANGER NZ Fe ee HYDRAULIC DOCK LEVEL abe Batre reaching B is 8 to 12 a eck Raise _ e a me mi aes 2011 4Front Engineered Solutions Inc vitaem 1 7 2 4 oo 3 9 10 9 10 68 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011652 575V 3PH 60 HZ 6071019 6000549 6000542 6000467 6000473 0071649 6000506 532228 6000515 632217 8011374 5011974 60116525 For 24V incoming power consult factory October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 69 2012 4Front Engineered Solutions Inc NOTES 70 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc October 2012 LIMITED WARRANTY 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 ow
4. and supported by the vehicle bed Fig 32 Never use a fork truck or other material handling eguipment to lower the ramp and lip sections 5 4 Proceed with loading or unloading IH O October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 29 2012 4Front Engineered Solutions Inc OPERATION y continued DOCK LEVELERS WITH AUTO RETURN TO DOCK A WARNING OPTION 6 T 8 To return the dock leveler to the stored position when loading or unloading is complete or to load end loads 6 1 Turn the ON OFF switch to the ON position 6 2 Push and hold the RAISE button The ramp will rise and the lip will lower 6 3 Release the RAISE button when the lip clears the vehicle bed before reaching its highest position The ramp will lower to the dock level stored position 6 4 Visually 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 6 5 Turn the ON OFF switch to the OFF position Unchock or release vehicle Tell vehicle driver Your vehicle may now leave the dock BELOW DOCK CONTROL BDC WITH ARTD To lower the ramp without extending the lip for end loading below dock level 1 2 30 Turn the ON OFF switch to the ON position Press the RAISE button until the ramp is 6 to 12 above dock level Release the
5. October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 15 2012 4Front Engineered Solutions Inc WIRING DIAGRAMS STANDARD 6006450 208 230V 3PH 50 60 HZ O L PB1 5 96 6006451 460 480V 3PH 60 HZ S PB1 yee PRIMARY FUSING AND DISCONNECT DEVICE BY OTHERS DOCK SUPPLY BCPD CB FU 6AMP 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 O 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 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc October 2012 6006452 575V 3PH 60 HZ WIRING DIAGRAMS STANDARD continued FLA 1 6A RIMARY FUSING AND DISCONNE
6. E E Le s E HEH 4T2 She MIO ADI EE EE KEE EE EE 5131 Loi 4 0 40A d BP 1062 TABLE A PHASE HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING 3 60 208 4 0A 4 1 4 0 AMPS XF109 50VA TABLE B 2 1 TRANSFORMER WIRING us 1 PRIMARY VOLTAGE PRIMARY CONN 1101 24VAC 208 H4 H5 REMOVE JUMPER RAISE WHEN INTERLOCK USED SR Gei 18 d 2 s 1143 cy ua 00101 LEGEND ERMINAL STRIP I 3 3 Al la 9595 PANEL WIRING SSW1 101 TOES FIELD WIRING BY OTHERS 1 1 3 4 NOTE fr DOOR I L 1151 1152 TERMINALS WILL ACCEPT STRANDED 2 1 l WIRES ONLY d 3 DOOR I WIRE COLOR GAUGE INTERLOCK EE unless otherwise specified Lech M 5 15R 208 600VAC 14 BLK or 120VAC 16 RED mp STRAIGHT BLADE EE 24VAC 16 RED RECEPTACLE a NEUTRAL 167 WHT ALL RECEPTACLES D GR 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 DYA DN EE I WA SA E 1021 MOT102 SE EE ET EE RENE WC EE EE FD b LEVELER IU I sat Fe DO wn 3 6FLA G 9106 A Ll uror IA ECC DEDE DERE i E E Es BP T 1061 E 1062 H
7. lc Mad MN MEME CES C Sasia Foi 1021 MOT102 UD UD AN X reso D LEVELER 312 412 MOTOR 1 EE 5131 Fo Xre9wa 1 BFA L i BP fU106 X TABLE A PHASE 2 VOLTAGE MOTOR F L A PANEL F L A O L SETTING 1061 4062 5 60 460 1 8A 1 9A 1 8 AMPS H1 H2 H3 H4 a Ee TRANSFORMER WIRING _ XF109 50VA 480 460 H4 H1 X3 2 X1 1101 1102 TERMINAL STRIP ZENAR 1 DOOR 2 3 LEGEND 7 PANEL WIRING FIELD WIRING BY OTHERS REMOVE JUMPER RASE A VI PB TERMINALS WILL ACCEPT STRANDED WHEN INTERLOCK USED RT BLK M110 WIRES ONLY 1 2 3 I OL102 1101 1141 1142 1143 C 1144 WIRE COLOR GAUGE NFPA i 4 5 AT A2 EE unless otherwise specified SSW1 208 600VAC 14 BLK 120VAC 16 AR 5 1151 1152 4 24VAC 16 RED d 7 NEUTRAL 16 WHT 1 1 i GROUND GRN IOPTIONAL DOOR 1 INTERLOCK EM am S 4 Md un 5 158 mp STRAIGHT BLADE DEGH ee Ne RECEPTACLE ALL RECEPTACLES BY OTHERS CAUTION a vac on s TM October 2012 6004750K HydraulicPlus Dock Leveler 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
8. SafeTFrame October 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011651 575V 3PH 60 HZ Free 2 WHPHKMOUNTNGPLAIE omw 3 2 TERMNALENDSTORSCREWESS ooe 2 TERWNA 2CONDUCTOR 800542 GONPCTORTATNO 6000 OVEROAD15 25AMPS STV 608 XFMR 550 600 24 50VA 6011649 8 1 PUSH BUTTON 6000506 1 CONTACT BLOCK N O 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 October 2012 6004750K HydraulicPlus Dock Leveler 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 Fig 62 EE 4 DANGER SUSY EE Lee HYDRAULIC DOCK LEVEL nis epo ETT 2011 Front Enginsered Solutions Inc snaran SS 10 7 2 5 1 2 A 3 11 12 11 12 8 62 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO R
9. October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 53 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011372 120V 1PH 60 HZ Fig 57 DANGER ERC gu DOCK LEVELER 54 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011372 120V 1PH 60 HZ 2 HPHKMOUNTNGPLATIE 6 3 3 TERMNALENDSTORSCREWESS 60050 4 890542 FUSED DISCONNECT TERMINAL BLOCK UFX 11H 0538 FUSE 05ATIME DELAY BUSSMAN eos CONTACTOR 18A 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 October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 55 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011524 208 240V 1PH 60 HZ
10. 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 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 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 DN AAAA QOTO 2 5 KE ENYA CO Gs i O lol O 59 1 k G Ezra KL 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 PANEL 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 60064615 PRINT WIRING SCHEMATIC 208 230V 60064625 October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 51 2012 4Front Engineered Solutions Inc PARTS LIST
11. DOCKLEVELER REMOVE JUMPER RAISE WHEN INTERLOCK USED BU 1 2 MIIS OL101 52 1141 1142 C 114 M 96 95 IOPTIONAL DOOR INTERLOCK le inol October 2012 6004750K HydraulicPlus Dock Leveler 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 MAX PANEL FLA 1 9AMPS SCCR 5KA TABLE A PHASE HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING 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 I L ce FIELD WIRING BY OTHERS 2 NOTE TERMINALS WILL ACCEPT STRANDED WIRES ONLY WIRE COLOR GAU unless otherwise specified 208 600VAC 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 HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING 5 60 575 1 6A 1 7A 1 6AMPS ERMINAL STRIP 1 DOOR I L 2 LEGEND PANEL WIRING NOTE TERMINALS WILL ACCEPT STRANDED WIRES ONLY WIRE COLOR GAUGE NFPA unless otherwise spe
12. Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury 17 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 18 Remove and discard shipping cotter pins from toe guards on both sides of dock leveler See Fig 16 19 Remove lifting chain or other lifting devices Remove lifting hooks from the sides of the ramp 20 Read the Safety Practices on page 3 and the Operation Instructions on pages 25 through 30 before operating the dock leveler October 2012 6004750K HydraulicPlus IN STALLATION y continued Fig 14 O Shipping tie down b lt E Fig 15 Lip Lip Insert hairpin lock clip through maintenance strut pin Maintenance strut pin hairpin clip into lip lock Maintenance strut bracket r Fig 16 Remove shipping cotter pins Dock Leveler SafeTFrame 11 2012 4Front Engineered Solutions Inc IN STALLATION continued A WARNING Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury NOTICE The dock face must be flush with curb angle to assure proper bumper mounting 21 Mount dock bumpers to face of dock Downhill welds are unacceptable See Fig 17 or 18
13. 7 DEGREE BEND 4 DEGREE BEND 7 DEGREE BEND LIP 6 1 2FT WIDE 40K 45K AND 50K CAPACITY 16 X 6 1 2 16 X 6 1 2 18 X 6 1 2 18 X 6 1 2 20 X 6 1 2 20 X 6 1 2 LIP 7FT WIDE 40K 45K AND 50K CAPACITY 16 X 7 W W 4 DEGREE BEND W 7 DEGREE BEND W 4 DEGREE BEND W 7 DEGREE BEND W 4 DEGREE BEND W 7 DEGREE BEND 4 DEGREE BEND 7 DEGREE BEND 18 X 7 W 18 X 7 W 4 DEGREE BEND 7 DEGREE BEND 4 DEGREE BEND 7 DEGREE BEND LIP SHAFT 711 858 711 857 711 860 711 859 711 862 711 861 711 876 711 875 711 878 711 877 711 880 711 879 711 894 711 893 711 896 711 895 711 898 711 897 711 864 711 863 711 866 711 865 711 868 711 867 711 882 711 881 711 884 711 883 711 886 711 885 711 900 711 899 711 902 711 901 711 904 711 903 DW DOCK LEVELER 712 957 6 1 2 W DOCK LEVELER 712 958 7 W DOCK LEVELER 712 959 RETAINER SHAFT HINGE PIN 035 451 42 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued MODEL HP RAMP LIP AND TOE GUARD ASSEMBLIES TOE GUARD MIDDLE SLIDING 19 PIT 6 LG DOCK LEVELER 155 554 8 LG DOCK LEVELER 155 555 TOE GUARD MIDDLE SLIDING 23 PIT 10 LG DOCK LEVELER 155 557 TOE GUARD BOTTOM SLIDING 19 PIT 6 LG DOCK LEVELER 155 554 8 LG DOCK LEVELER 155 556 TOE GUARD BOTTOM SLIDING 23 PIT 10 LG DOCK LEVELER 155 557 s
14. H3 LEGEND PANEL WIRING FIELD WIRING BY OTHERS NOTE TERMINALS WILL ACCEPT STRANDED WIRES ONLY WIRE COLOR GAUGE NFPA unless otherwise specified 208 600VAC 14 120VAC 16 RED 24VAC 16 RED NEUTRAL f16 WHT GROUND GRN TERMINAL STRIP DOOR I L 6011761 240V 3PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU 6AMP PANEL FLA 3 7A SCCR 5KA TABLE A PHASE HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING 5 60 240 3 6A 3 7A 3 6AMPS TABLE B TRANSFORMER WIRING PRIMARY VOLTAGE PRIMARY CONN LEGEND 220 240 H4 H2 PANEL WIRING peress FIELD WIRING BY OTHERS NOTE TERMINALS WILL ACCEPT STRANDED WIRES ONLY TERMINAL STRIP WIRE COLOR GAUGE unless otherwise specified 208 600VAC 14 BLK 120VAC 16 RED DOOR L 24VAC 16 RED NEUTRAL 16 WHT GROUND GRN 1061 Ge LEVELER MOTOR CONTACTOR M114 OL101 MOT102 LEVELER MOTOR 40 XF109 SOVA X3 2 1 lr 1101 1102 24VAC DOCKLEVELER REMOVE JUMPER RAISE WHEN INTERLOCK USED BLK S M114 01101 1141 1142 N 5 9 2 96 95 101 OPTIONAL DOOR INTERLOCK Le eee cd LEVELER MOTOR n CONTACTOR M114 OL101 MOT102 LEVELER MOTOR 3 6FLA 1061 XF109 50VA x3 2 1 fli 1101 1102 24VAC
15. Leveler 8 Leveler 10 Leveler Raeren 6 Leveler 8 Leveler 10 Leveler in in x x o o o o gt gt o o a a lt lt Below dock Below dock 4 lip bend 16 lip 7 lip bend 16 lip Optional special order October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 5 2012 4Front Engineered Solutions Inc INSTALLATION PIT CHECK 1 Check entire dock leveler pit for proper construction according to certified pit drawings publication 5568 Check to be sure that the pit walls are square and plumb Check electrical service running to the pit to assure it agrees with the correct location and voltage for the junction box Area surrounding the leveling feet should be smooth and free of excessive lumps 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 Visually check that cotter pins are in place on pins on the connecting rod push bar and the lip lifter assembly 4 Verify that gas spring retaining pins have cotter pins installed 5 Verify that both the lip lock and the maintena
16. 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 HydraulicPlus 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 HydraulicPlus dock leveler uses a push button control to position the dock leveler Pushing and holding the push button operates a hydraulic cylinder to raise the ramp Releasing the push button allows the ramp to lower Amechanical linkage extends the dock leveler lip as the ramp lowers from its full raised position and the 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 before the dock leveler reaches its highest position 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
17. 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 FOR A PARTICULAR PURPOSE ALL OF WHICH KELLEY HEREBY DISCLAIMS October 2012 6004750K HydraulicPlus Dock Leveler 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 2012 4Front Engineered Solutions Inc Part No 6004750K
18. 138 604 DANGER LABEL ENTERING PIT 921 070 13 1 DOCUMENTATION KIT HYDRAULIC STANDARD 184 354 DOCUMENTATION KIT HYDRAULIC W OPTIONAL ARTD 184 355 MANUAL HYDRAULICPLUS 6004750 PLACARD INSTRUCTIONS W STANDARD CONTROL BOX 6004006 PLACARD INSTRUCTIONS WITH OPTIONAL ARTD 6004011 SERIAL TAG 6009761 Included in item 1 44 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued OPTIONAL SUBFRAME RISER KIT Fig 51 i 2 c 2 5 o a Optional Features o 5 5 c 2 2 KH o o o o a 2 L c S gt H 6004654 6004487 RISER KIT FIELD INSTALLED REAR ANGLE CAP PLUGS KELLEY OPTIONAL 45 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued HYDRAULIC COMPONENTS AND RETURN TO DOCK LEVEL SWITCH Fig 52 46 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc October 2012 PARTS LIST continued HYDRAULIC COMPONENTS AND RETURN TO DOCK LEVEL SWITCH Item Quantity Description Part Number MOTOR PUMP UNIT INCLUDES ITEMS 2 6 24V 6010691 100 120V 1 PH 50 60 HZ 6011441 200 240V 1 PH 50 60 HZ 6011442 190 240V 3 PH 50 60 HZ 6011443 380 480V 3 PH 50 60 HZ 6011444 575V 3PH 60 HZ 6011445 LABEL CAUTION 24V
19. AR Wurockasi s AR SPACER TOEGUARD we s 2 SRWSODR i 3 1 2 2 2 4 1 17 18 19 PS CHAIN BELOW DOCK CONTROL ALL 10 LG DOCK LEVELERS 6003452 SC Ee eo O Y 2 F J SE E Ee CHAIN BELOW DOCK CONTROL 6 LG DOCK LEVELERS 6012661 CHAIN BELOW DOCK CONTROL 8 LG DOCK LEVELERS 6003453 2 i S 2 z 2 PW GROVEDSEDAXSAg 658 SPRING EXTENSION 700 135 PIN ROLL 3 16 DIA X 2 035 149 6 0 1 23 1 6 1 7 1 1 1 6 LG SASH CHAIN 6001950 8 1 PIN COTTER HAIR 035 200 October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 43 2012 4Front Engineered Solutions Inc PARTS LIST continued SUBFRAME AND MAINTENANCE STRUT ASSEMBLIES Fig 50 Item Quantity Description Part Number 1 1 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 2 4 PIN HINGE 6 8 AND 10 LG MODELS 035 450 3 4 RETAINER SHAFT HINGE PIN 035 451 SCREW DRIVE 000 518 PIN COTTER HAIR 035 200 CHAIN SASH 032 195 DECAL MAINT STRUT 921 074 850 3 i WASHER FLAT 3 8 000 214 9 1 PIN COTTER 035 036 PIN CLEVIS 035 051 DECAL FORK LOCATION
20. 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 uninsulated tools inside the control box Touching wires or other parts inside the control box could result in electrical shock death or serious injury October 2012 6004750K HydraulicPlus Dock Leveler 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 records of the performance of these procedures should be kept Dock leveling devices that are structurally damaged or have experienced a sudden loss o
21. Fe X SEE TABLE RECLAMA EE G 1041 BP PHASE HERTZ VOLTAGE MOTOR F LA PANEL F L A O L SETTING 1 60 208 7A 7 1A 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 BAR GE MO 01102 1101 1102 5 110 1104 e h LEGEND u r 96 95 PANEL WIRING 12 SSW1 102 mc FIELD WIRING BY OTHERS 3 4 NOTE N 1111 1112 TERMINALS WILL ACCEPT STRANDED DOOR I L 7 WIRES ONLY 1 S JOPTIONAL DOOR WIRE COLOR GAUGE INTERLOCK j unless otherwise specified Die et T ES HEN 5 15R 208 600VAC 14 BLK 4 MS DECK Pos wM STRAIGHT BLADE RI GRAC fe FED N RECEPTACLE m NEUTRAL elt ALL RECEPTACLES BY OTHERS I CAUTION LIP Pos 120VAC ONLY SWITCH October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 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 lt CB FU 6AMP MAX MOTOR PANEL HA 41A CONTACTOR M114 OL101 cc RI LEE CL CUM A PR OG GY EY ET EET
22. button before the ramp reaches its highest position Turn the ON OFF switch to the OFF position as the ramp begins to lower 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 33 Release the BDC chain Load or unload end loads When loading or unloading is complete return the dock leveler to the stored position Turn the ON OFF switch to the ON position The dock leveler will automatically return to the stored position Visually 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 See Fig 34 Turn the ON OFF switch to the OFF position 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 See Fig 34 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 33 chain Fig 34 Dock level support leg Front angle dock level support 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutio
23. control chain See Fig 45 Check for binding in dock level support legs DOCK LEVEL SUPPORT LEGS WILL NOT SWING Fig 44 LI Bs PO aur Sc 0 Adn locking nut Needle vavle adjusting screw Turn screw clockwise to increase time FULLY FORWARD NOTE LIP MUST BE PENDANT Dock level 1 Check for binding or debris which may be restricting support leg leg 2 Check below dock control chains to assure chain has enough slack to allow leg to swing forward Adjust as required See Fig 45 October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 37 2012 4Front Engineered Solutions Inc HYDRAULIC DIAGRAM RAMP CYLINDER duse NOT USED PORT C1 A O S CV2 SVI SEOUENCE VALVE FN A VALVE ll 1 PC2 s P O 9 a M PRIMARY RELIEF 2000 PSI Ll I4 EE E A 38 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc CONTROL BOX TRANSFORMER 1 When replacing the transformer make sure jumper wires are installed per wiring diagrams for appropriate voltage DANGER Be certain before climbing into the dock leveler pit or doing any maintenance or repair under th
24. dock leveler that 1 THE MAINTENANCE STRUT AND LIP LOCK ARE SECURELY IN PLACE see Fig 38 on page 34 and 2 the power is disconnected and properly tagged or locked off NOTICE Use only lubricants shown Improper lubrication or adjustments may cause operational problems Every 90 days inspect dock bumpers Four inches 4 of bumper protection is required Worn torn loose or missing bumpers must be replaced Fig 36 Dock level mE support leg Lip hinge cam and hinge a Hydraulic oil reservoir hinge pins Cylinder pivot pin Lip extension mechanism MAINTENANCE AND LUBRICATION CHART Dock Level Yee Mena Cam amp Pivot Pins Every 90 Days e oni Every 90 Days inati SAE 30 On very ays SAE 30 Lubrication Pivot Pins amp SAE 30 Grease front Grease Cam push bar Cylinder Dock Leveler B ide Pivot Pins Pit Legs Every 90 Days Ge 30 y Not Required Not Required Every 90 Days Remove Debris As Required To As Required To As Required To As Required To As Required To Remove Debris Remove Debris Remove Debris Remove Debris or As Required To Remove Debris Check all labels every 90 days See pages 38 58 for location and part numbers Replace if required Every 90 days visually inspect all welds under the leveler for fatigue or failure particularly the lip plate hinge and ramp beams and fro
25. 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 AADANGER 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 Two people are needed to place the dock leveler on the maintenance strut a One person must hold dock leveler in its highest position with electrical controls or other suitable lifting device b The second person positions the mintenance strut into the bracket located on the underside of the ramp assembly and pins it in place with hairpin clip See Fig 15 and instruction label on maintenance strut c Electrical controls may now be released 13 6x16 shims of the proper thickness are to be placed under the ramp cylinder mounting pad and welded out as shown in Fig 13 Fig 11 Poor jamb Flush with floor at this point _ Z I rmn I Fig 12 1 2 sq drive adjustment bolt CCW rotation to raise 3 16 weld
26. 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 October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 25 2012 4Front Engineered Solutions Inc OPERATION y continued DOCK LEVELERS WITH STANDARD CONTROL BOX 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 Chock or hitch vehicle 4 If necessary remove end loads with the ramp the dock level stored position See Fig 25 NOTE 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 control button The ramp will rise until it stops at its highest position See Fig 26 5 2 Release the control button when the ramp reaches its highest position 5 3 Ramp and lip will lower and lip will extend until the lip rests on the vehicle bed See Fig 27 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 notdrive on dock leveler or lip until it 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 5 4 Proceed with loading or unlo
27. 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 HydraulicPlus 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 HydraulicPlus dock leveler uses a push button control to position the dock leveler Pushing and holding the push button operates a hydraulic cylinder to raise the ramp Releasing the switch allows the ramp to lower Amechanical linkage extends the dock leveler lip as the ramp lowers from its full raised position and the leveler with its lip extended settles onto the vehicle bed forming a bridge After loading moving and holding the push button raises the ramp and the extended lip lowers to its stored position Releasing the switch before the dock leveler reaches its highest position 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 low
28. 1 H2 H3 H4 PHASE HERTZ VOLTAGE MOTOR F LA PANEL F L A O L SETTING 3 60 240 3 6 3 7A 5 6AMPS Sot 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 OFF ON BLK M110 1 2 s uo 1143 eg LEGEND ERMINAL STRIP 9 9595 PANEL WIRING SSW1 101 FIELD WIRING BY OTHERS 1 3 4 NOTE DOOR I L 1151 1152 TERMINALS WILL ACCEPT STRANDED 2 1 1 f WIRES ONLY i 3 DOOR I WIRE COLOR GAUGE NFPA 4 INTERLOCK i unless otherwise specified eg e est a 208 600VAC 14 BLK syl NEMA 5 15R DECK Pos 120VAC 16 RED D 7 STRAIGHT BLADE SWITCH 24VAC 16 RED RECEPTACLE D se ALL RECEPTACLES BY OTHERS CAUTION 24VAC ONLY Bur 22 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 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 MAX MOTOR PANEL FLA 1 9AMPS i CONTACTOR SCCR 5KA 01101 DOD D D c
29. 155 811 PIN CLEVIS 1 2 DIA X 1 3 4 035 010 6 1 PIN CLEVIS 3 8 DIA X 2 035 150 PIN CLEVIS 1 2 DIA X 1 1 4 035 049 8 4 PIN COTTER 1 8 DIA X 1 1 4 035 036 1 GAS SPRING 709 437 CLEVIS GAS SPRING 712 271 LINK RH 712 001 LINK LH 712 002 BOLT SOC HD SHLD 712 061 NUT HEX 3 8 16 000 030 KLIPRING 5 8 049 060 ROLLER 700 045 WASHER 378 000 214 18 1 SPACER LIP 6 1 2 WIDE DOCK LEVELER 287 606 SPACER LIP 7 WIDE DOCK LEVELER 287 607 KIT HANGER BRACKET FOR DECK 184 397 October 2012 6004750K HydraulicPlus Dock Leveler 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 5 10 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 6008169 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 Chain cup seal 0392
30. 22 Plug or wire in electrical cords and connect power to dock leveler A DANGER 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 Molded L bumpers a 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 Zo Laminated bumpers Full length of bumper Bh mounting plate angle downhill welds are yf unacceptable Vertical when support is removed Removing support without PEL M OFO hydraulic pressure could allow ramp to drop RAPIDLY If angle 9 Laminations must be supplied by the dock leveler was raised using a mechanical device installed v
31. 6010601 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 HOSE HYDRAULIC MTR PUMP TO RAMP CYLINDER 42 LG CYLINDER RAMP 6 LG 713 250 8 LG 713 296 10 LG 713 373 ltems 14 through 31 used with optional A R T D only October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 47 2012 4 Engineered Solutions Inc PARTS LIST continued HYDRAULIC COMPONENTS AND RETURN TO DOCK LEVEL SWITCH wem Quantity PatNumbe m 9908987 22 2 2 1 3 4 2 17 18 19 20 1 2 ZIP TIE PANDUIT ANCHORS NOT SHOWN 131 476 ARTD ON DECK BRACKET 6008286 581010 ON LIP BRACKET 6008288 26 CAP LIP SWITCH 6000721 CORD MOLDED PLUG 712 027 ltems 14 through 31 used with optional A R T D only 1 1 2 2 2 2 2 2 3 48 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued CONNECTING ROD PUSH BAR AND LIP ASSIST ASSEMBLIES Item Quantity Description Part Number PUSH BAR 2 1 ROD CONNECTING 6 LG DOCK LEVELER 711 848 ROD CONNECTING 8 LG DOCK LEVELER 711 849 ROD CONNECTING 10 LG DOCK LEVELER 712 462 1 3 LEVER LIP LIFTER 6 LG DOCK LEVELER 711 998 LEVER LIP LIFTER 8 AND 10 LG DOCK LEVELER 711 999 LEVER LIP ASSIST
32. CT EVICE BY OTHERS UPPLY BCPD CB FU MAX OTE COMING POWER AND THE LEVELER MOTOR CONNECT LEG END M DOCK LEVELER CONTACTOR PB1 LEVELER o DIRECT LEGEND RAISE DEVICE CONNECTION ot PBI DIRECTLY TO THE CONTACTOR AND EXTERNAL CONNECTIONS OVERLOADS INTERNAL WIRING SL 96 A1 2 VA 6011372 120V 1PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU 20AMP TEER PANEL FLA 11 3A CONTACTOR SCCR 5KA 14 BLK 14 BLK MOT102 M110 OL 102 LEVELER 1021 SE Ke enr H EE EE 1031 1032 0 11 2FLA ix sil Fea 14 BLK sal Per S 11 2A 1031 PHASE HERTZ VOLTAGE MOTOR F L A PANEL F LA O L SETTING 1 60 120 11 2A 11 3A 11 2 AMPS gs DOCKLEVELER REMOVE JUMPER LEGEND TERMINAL STRIP RAISE WHEN INTERLOCK USED PANEL WIRING BLK 1 2 M110 OL102 FIELD WIRING BY OTHERS N as Me e N NOTE 3 4 AN A2 96 95 TERMINAL WILL ACCEPT STRANDED 102 WIRES ONLY 1 WIRE COLOR GAUGE DOOR I L unless otherwise specified 2 208 600VAC 14 120VAC 16 RED 24VAC 16 RED NEUTRAL 16 WHT GROUND GRN OPTIONAL DOOR INTERLOCK Lech October 2012 6004750K HydraulicPlus Dock Leveler SafeTFr
33. ETURN TO DOCK 6011323 120V 1PH 60 HZ 6071019 0000549 s TERWNA 2cONDUCTOR 6000642 6000538 0008830 6000469 6000477 6000506 632217 632228 8000515 8011374 50173235 October 2012 6004750K HydraulicPlus Dock Leveler 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 S lt ADANGER Suus Ger HYDRAULIC DOCK L Ii rieo and lip will lower vehicle bed Before reaching ik level stored position wt 64 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 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 6071019 0000549 6000542 6000538 0008830 6000469 6000476 6000506 632217 632228 8000515 6011374 50113245 October 2012 6004750K HydraulicPlus Dock Leveler 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 3
34. Fig 22 Kalte 1 2 SOLUTION Align the sides parallel and equally 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc 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 Fig 23 1 8 max m _ allowable step no greater than 1 x 3 in size 6 contact zone October 2012 WIRING DIAGRAMS CONTROL BOX STANDARD A DANGER 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 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 CAUT
35. HydraulicPlus Model HP SAFE FRAME V This User s Manual applies to dock levelers manufactured beginning October 2012 with the serial number 61059674 and higher Dy User s M Do not install operate or service this product unless you S e r S a n u a have read and understand the Safety Practices Warnings i Installation and Operating Instructions contained in this n sta atio n d O pe ratio ns d User s Manual Failure to do so could result in death or M al nten ance a nd P a rts serious injury Part No 6004750K TABLE OF CONTENTS tre ce 2 Safety Signal Words 2 Safety EE 3 Owner s Responsibilities 4 Ramp and Lip Grades 5 Installation WE R 6 Wiring Diagrams Standard Control Box 15 Wiring Diagrams With Optional Interlock 17 Wiring Diagrams With Optional Interlock And Auto Return To 21 Operation With Standard Control Box 25 Operation With Optional Auto Return To Dock Contool BOR EE 28 Planned Maintenance 31 Maintenance An
36. ION 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 SUPPLY BCPD CB FU 17AMP xi NCOMING POWER AND THE EE 1 79 EL LEVELER MOTOR CONNECT DIRECTLY TO THE CONTACTOR AND OVERLOADS l l 12 4 DOCK L3 13 LEVELER 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 C O L NOTE T INCOMING POWER AND THE poo LEVELER MOTOR CONNECT DIRECTLY TO THE CONTACTOR AND OVERLOADS cem A H L 3 3 DOCK pni LC O LEVELER MOTOR FLA 7 0 6 6A J 1 1 sie circ ES LEGEND M DOCK LEVELER CONTACTOR 1 LEVELER RAISE O DIRECT DEVICE CONNECTION PRI LEGEND EXTERNAL CONNECTIONS 95 96 A1 A2 INTERNAL WIRING
37. NGER A ELT Z 5 2 1 12 7 2 4 3 10 6 58 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 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 2 TERWNA 2CONDUCTOR 80542 CONTCTORTBAWNO INGzAV 60 1 OVERLOAD 2 5 4 AMPS 208 240V 6000474 OVERLOAD 1 6 2 5 AMPS 460 480V 6000473 XFMR 200 480 23 110 50VA 6011359 8 1 PUSHBUTTON 6000506 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 60113255 SCHEMATIC 1PB 1PH 240 60117615 SCHEMATIC 1PB 1PH 480 60113265 October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 59 2012 4Front Engineered Solutions Inc PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011651 575V 3PH 60 HZ Fig 61 DANGER 1 Kee EE MTS DOCK LEVELER Rss wa ass Front Engineered ne wm n 2 1 12 7 2 4 3 10 6 60 6004750K HydraulicPlus Dock Leveler
38. OCK LEVELER IS RAISED FROM VEHICLE 1 Check the lip extension mechanism for free movement See Fig 41 2 Inspect the lip extension mechanism for bent parts Be sure all parts are clean lubricated and have free movement See Fig 41 3 Make sure all pins are in correct position and in good condition See Fig 42 RAMP WILL NOT RETURN TO STORED POSITION FROM FULL BELOW DOCK POSITION Applies to dock levelers with optional auto return to dock feature 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 Make sure that the return to dock switch plug is tight in the receptacle in the rear pit wall 4 Check to assure that the dock leveler lip is falling to the full pendant 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 5 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 15 through 24 See Fig 43 NOTE Return to dock level switch should turn off pump motor when
39. OTHERS LEVELER SUPPLY BCPD CB FU MOTOR PANEL FLA 1 7A CONTACTOR SCCR 5KA 191 M114 OL101 DERAOHU A AN NAT NAD AF FFON A ad i SUP EE 1021 MOT102 ele E eee GR Rae ce Fee LEVELER 321 gp D MOTOR BER pL LC CLE DEDE LE ML DC M LE IN Wy Y EQ PLAQUE FIELD ICE ACRI ee Yy Fn 53 gy Tn FUA 1 64 de Ee o BP 1061 1062 TABLE PHASE HERTZ VOLTAGE MOTOR F LA PANEL O L SETTING 3 60 575 1 6 17A 1 6AMPS H2 XF109 50VA TERMINAL STRIP 1 2 SSES 1102 24VAC 3 4 REMOVE JUMPER RAISE WHEN INTERLOCK USED DOCKLEVELER Rp viio LEGEND 1 2 OPEN at EE m 0L102 c l PANEL WIRING Den 3 ATNZ A2 961 95 SE FIELD WIRING BY OTHERS SSW1 102 NOTE 1 l TERMINALS WILL ACCEPT STRANDED d 1151 1152 4 WIRES ONLY I 1 WIRE COLOR GAUGE IOPTIONAL 0008 A i unless otherwise specified INTERLOCK Metric 208 600 14 BLK RESO T DE V d A 120VAC 16 RED Ms a 5 15 ip STRAIGHT BLADE Wi GROUND as RECEPTACLE ALL RECEPTACLES BY OTHERS s CAUTION agvac ONLY s For 24V incoming power consult factory d 24 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc DOCK LEVELERS WITH STANDARD CONTROL BOX Before operating the dock leveler read and follow Safety Practic
40. PH 60 HZ Fig 64 lt A DANGER 7 Suus DRAULIC ELER 66 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 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 6011018 5017019 5000549 4 TERMINAL RE 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 1 2 600V CC FERRAZ SHAWMUT 6011358 14 1 SCHEMATIC HP HK 2PB 3PH 208V 60113275 SCHEMATIC 2PB 240 60117625 SCHEMATIC 2PB 480 60113285 October 2012 6004750K HydraulicPlus Dock Leveler 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
41. ading 26 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc Fig 25 Dock level supports Fig 26 Control box mounted to wall lt P Lip ey Ie Ramp Vehicle bed f __ HU Fig 27 In October 2012 DOCK LEVELERS WITH STANDARD CONTROL BOX 6 To return the dock leveler to the stored position when loading or unloading is complete or to load end loads 6 1 Push and hold the control button The ramp will rise and the lip will lower 6 2 Release the control button when the lip clears the vehicle bed before reaching its highest position The ramp will lower to the dock level stored position 6 3 Visually check that the lip is not extended or hung upon trailer Ramp should be level with dock floor 7T Unchock or release vehicle 8 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 control button and hold it until the ramp is 6 to 12 above dock level Release the 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 OPERATION y continued A WARNING Before allowing v
42. ame 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 PANEL FLA SEE TABLE SCCR LEVELER MOTOR CONTACTOR M110 01102 1L1 Elle req 513 x 615 SEE TABLE 14 BLK MOT102 1031 PHASE HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING 1021 1 60 208 7A 7 7 AMPS 1 60 240 6 6 6 9 6 6 AMPS FU109 FU109 LEGEND TERMINAL STRIP DOCKLEVELER REMOVE JUMPER RAISE Suen T E WHEN INTERLOCK USED Wido itd aer FIELD WIRING BY OTHERS 1101 1102 1 2 1103 0102 1105 L2 TERMINAL WILL ACCEPT STRANDED 3 1 96 595 WIRES ONLY l l DOOR I L WIRE COLOR GAUGE NFPA 2 1 l unless otherwise specified Weg SES IOPTIONAL DOOR 24VAC He RED INTERLOCK GROUND bo 18 6004750K HydraulicPlus Dock Leveler October 2012 2012 4Front Engineered Solutions Inc 6011325 208V 3PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU 6AMP PANEL FLA 4 1A SCCR lt 5KA WIRING DIAGRAMS WITH INTERLOCK continued TABLE A PHASE HERTZ VOLTAGE MOTOR F L A PANEL F L A O L SETTING 3 60 208 4 0 4 1 4 0 AMPS TABLE B 208 H4
43. ass pressure and adjust as required See Fig 40 Turn in to increase turn out to decrease Replace cap and tighten when finished LIP FAILS TO EXTEND 1 Check to make sure that the lip extension mechanism is not bent or binding See Fig 41 Check to make sure that the lip extension mechanism is lubricated properly Lubricate as required Make sure all pins and pin retainers are in place and in good condition LIP EXTENDS BUT FAILS TO STAY IN EXTENDED POSITION 1 Check to see that the lip extension mechanism center bolt is straight and free to rotate See Fig 41 2 Check to see that the lip extends far enough to allow the links and connecting rod to align and then reach an over center position October 2012 Fig 39 Use type 5606 low temp hydraulic oil 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 Hanger bracket Swing link Center bolt Connecting rod Push Bar Pit Floor 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc Dock leveler ramp Roller Lip Check oil level with ramp raised and lip extended 35 TROUBLESHOOTING GUIDE continued LIP FAILS TO LOWER TO THE STORED POSITION WHEN THE D
44. before loading or unloading 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 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
45. both sides 3 16 weld 3 long min both sides 3 16 weld 3 long min both sides 3 16 weld 3 long min Fig 13 3 4 anchor bolt U supplied by others Cylinder mounting pad Stagger and weld 6 x 12 shims 10 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc 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 14 Manually lift the hinged lip into the raised position and lock into place with the lip lock provided on the dock leveler ramp Pin lip lock in place with hairpin clip See Fig 15 and instruction label located on the underside of the dock leveler ramp 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 unplug all electrical cords from receptacles in rear pit wall before welding Failure to do so can result in product damage 15 Finish welding both of the adjusted dock leveler supports in all locations shown in Fig 12 16 Check shims under ramp cylinder pad Adjust thickness if necessary
46. cified 208 600VAC 14 BLK 120VAC 16 RED 24VAC 16 RED NEUTRAL 16 WHT GROUND GRN FIELD WIRING BY OTHERS IT 1061 1062 LEVELER MOTOR ion CONTACTOR M114 OL101 YF ETS na yn cv a e TET QUSS Y Fu EVEN Y UN 1021 MOT102 FU O ee Xr gg Gb LEVELER 3 707479 LEVELE 7 EE EE sial FOI gg 18 EN FUt106 X 1061 4062 XF109 50VA 2 xi 4101 u 1102 24VAC DOCKLEVELER REMOVE JUMPER RAISE HEN INTERLOCK USED BLK W a 2 M114 01101 51 1141 1142 1143 AIC RZ 9695 101 IOPTIONAL DOOR INTERLOCK TAF 041 LEVELER MOTOR E CONTACTOR M114 OL101 UU EEG EDS ae ER Cori P DE EE 1021 MOT102 EE Or sss sassa LEVELER 27 79472 LEVELE REESEN 5131 OE 1 7FLA XF109 50VA 1 2 lr 1101 1102 24VAC DOCKLEVELER REMOVE JUMPER RAISE Bie Mu INTERLOCK bn utt S 1141 1142 M wr n4 AIN A2 96 0195 OPTIONAL DOOR INTERLOCK Lech 20 2012 4Front Engineered Solutions Inc 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 WIRING DIAGRAMS WITH INTERLOCK AND 6011323 120V 1PH 60 HZ CB FU TO BE SUPPLIED BY OTHERS AUTO RETURN TO DOCK
47. 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 2 Wi EE qo x VEN QUO OW qOl 1 O o O ee amp P E 52 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc October 2012 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 s 3 PH 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 60064505 PRINT WIRING SCHEMATIC 460 480V 60064515 PRINT WIRING SCHEMATIC 575V 60064525
48. d Lubrication 32 Troubleshooting Guide esses 34 Hydraulic Diagram EE 38 Parts 39 Ee DEI 40 Warranty NR 71 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 A 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 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc In
49. dicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTICE Notice is used to address practices not related to personal injury October 2012 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 If you do not understand the instructions ask your supervisor to explain them to you or call local Kelley distributor OPERATION Use restricted to trained operators Follow procedures on placard posted near dock leveler Do not use this unit to service vehicles 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
50. e 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 reguired to remove air from the system Check oil level and add oil if reguired 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 PARTS REPLACEMENT Fig 46 Needle valve locking nut Needle vavle adjusting screw Turn screw clockwise to increase time Detail A length of pit seconds 1 second dock leveler into service full d to full dockleveler size beet ee Gd HYDRAULIC OIL HOSES idis a 1 When removing hydraulic oil hose s remove from motor 10 23 18 pump assembly first then from cylinder assembly 2 Wheninstalling hydraulic oil hose s attached to cylinder first making sure O ring is in place then attach to pump motor assembly MOTOR PUMP ASSEMBLY 1 set the 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 will increase time OUT counterclockwise will decrease time Tighten needle valve locking nut 1 3 Raise ra
51. ehicle 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 and the hanging pendant See Fig 29 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 28 chain below dock level See Fig 28 Fig 29 Release the BDC chain 9 Dock level 4 Load or unload end loads support leg When loading or unloading is complete return the dock leveler to the stored position Front angle 5 1 Push and hold the control button until the ramp is at dock level least 4 above dock level support 5 2 Release the control button before the ramp reaches its highest position The ramp will lower to its stored position 5 3 Visually 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 See Fig 29 6 Unchock or release vehicle 7 Tell vehicle driver Your vehicle may now leave the dock October 2012 6004750K HydraulicPlus Dock Leveler 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 doc
52. electrical work make certain the power is disconnected and properly tagged or locked off 1 3 Check for loose wires in control box 1 4 If problem can not be found contact a qualified electrician RAMP FAILS TO RAISE Dock levelers with auto return to dock option 1 If motor fails to run 1 1 Checkthat the motor cord and return to dock switch cords are tightly plugged into the pit receptacle 1 2 Check for electrical power to the pit receptacle and control box 1 3 Check ON OFF switch on control box 34 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc Fig 38 Lip Insert hairpin clip through Lip maintenance lock strut pin Maintenance strut pin hairpin clip zi into lip lock Maintenance strut bracket October 2012 TROUBLESHOOTING GUIDE continued Before doing any electrical work make certain the power is disconnected and properly tagged or locked off 1 2 Check for loose wires in control box 1 3 Check fuses Replace if required 1 4 If problem can not be found contact a qualified electrician If motor runs 2 1 Checkhydraulic 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 24 Check for binding in ramp cylinder pivots Check hydraulic byp
53. en in Fig 14 are in place Install two 3 4 10UNC load centering eye bolts 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 dL 3 4 10 UNC bM A WARNING load centering eyebolt Inadequate lifting equipment or practices can cause a load to fall unexpectedly Make sure the lifting chain or other lifting devices in good condition and have Fig 5 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 it is not damaged during lifting and placement Plug end may be routed up through the rear hinge until needed October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 7 2012 4Front Engineered Solutions Inc IN STALLATION y continued INSERTING THE LEVELER INTO THE PIT 2 Position dock leveler in pit about 7 away from the rear pit wall Connect plug to receptacle on the rear pit wall Cut tie wrap on cord to allow bag pan removal for service Place the free length of cord inside of frame area free of interference as the level
54. er is moved into the final position See Fig 5 and wiring diagrams on pages 15 24 NOTE Check 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 legs are 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 adjustment of the front supports may be required to obtain a l
55. er onto and follow the vehicle bed up and down as loads are moved across the dock leveler and vehicle 28 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc October 2012 DOCK LEVELERS WITH AUTO RETURN TO DOCK OPTION 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 30 NOTE If the vehicle to be serviced is below dock level see operating 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 31 Push and hold the RAISE button The ramp will rise until it stops at its highest position See Fig 31 Release the RAISE button Ramp will lower and lip will extend until the lip rests on the vehicle bed See Fig 32 5 2 5 3 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 notdrive on dock leveler or lip until it is fully extended OPERATION y continued Fig 30 n Dock level supports Fig 31 Control box mounted on wall Lip extend Ramp Vehicle bed f
56. ertically others it should be lowered using the same device 23 Lift up on the hinged lip and store the lip lock under the ramp 24 Two people are needed to store the maintenance strut a One person must push and hold the raise button until dock leveler reaches its highest position and hold dock leveler in its highest position 12 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc 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 and the lip will extend when the button is released The hinged lip will extend as the ramp moves down 25 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 Improper installation that allows the pendant dock leveler lip to support the weight of the dock leveler could result in death or serious injury It is sometimes 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 26 Permanently mo
57. es 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 unexpectedly 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 HP 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
58. evel front edge NOTICE Turn off all electrical power to the leveler if it has been previously 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 Fig 7 8 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc October 2012 IN STALLATION y continued 5 Check and adjust the leveler for square and in firm Fig 8 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 the rear curb angle in 4 places min 3 8 at the center and at both ends See Fig 9 and 10 NOTE Do not weld out the rear angle until after setting the front supports 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 See Fig 12 8 With the lip pendant inser
59. f 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 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc October 2012 RAMP AND LIP GRADES Fig 1 Lip grade bed RAMP and LIP grades for each Dock Leveler length Vehicle bed RAMP and LIP grades for each Dock Leveler length position from dock 6
60. k 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 unexpectedly 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 HP 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
61. mp 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 October 2012 6004750K HydraulicPlus Dock Leveler 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 frame leg The meaning of each digit in the model number is shown in Fig 47 Example 6x8 6 wide 8 long 3 To determine the nominal size of your dock leveler see Fig 48 To ensure proper function durability and safety of the product only replacement parts that do not interfere with the 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
62. ms on pages 15 24 of this manual for wiring information Follow the wiring instructions to set control for proper voltage Wires shown 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 publications 5568 and powered dock leveler wiring diagrams and typical installation drawings and powered dock leveler wiring diagrams on pages 15 24 for electrical requirements Follow all applicable electrical codes and standards Fig 2 SC AN M Push button control station 48 Ges Fig 3 Pit center line 10 1 2 1 3 6 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc October 2012 IN STALLATION y continued A WARNING Fig 4 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 45 in this manual 1 Prior to lifting leveler make sure the shipping tie down bolts se
63. nce strut are undamaged and have safety hitch pins on chains 6 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 them to the subframe Remove these items 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 diagra
64. ner 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 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
65. ns 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 LIP UP LOCK 700 136 ADANGER SAFETY INSTRUCTIONS 6008485 x2 138 837 x2 ADANGER CRUSH HAZARD RI Do not work under dock leveler unless this maintenance strut has been secured in the upright position See user s manual for proper procedures 921 074 921 074 DANGER CRUSH HAZARD 92 1 0 7 0 DO NOT ENTER PIT unless dock leveler is to user s manual for proper maintenance procedures DANGER OPERATIONS 6004006 STANDARD 6004011 WITH ARTD WARNING AND OPERATION PLACARD MOUNTED ON WALL NEAR LEVELER October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 31 2012 4Front Engineered Solutions Inc MAINTENANCE AND LUBRICATION 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 ADANGER Be certain before climbing into the dock leveler pit or doing any maintenance or repair under the
66. nt hinge lugs Acceptable Hydraulic Oils Mobil Aero HFA 49011 Exxon Univis Grade JI3 Texaco Aircraft Oil 1554 U S Oil Co Inc 7 1 5606 Low Temp 32 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 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 Cleaning Location Frequency Visually Inspect Replace Damaged Or Worn Hydraulic reservoir see note 1 aln Pit 3 mo Rear hinge pin 4 October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 33 2012 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE A WARNING Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operation section of this manual ADANGER 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 RAMP FAILS TO RAISE 1 If motor fails to run 1 1 Check that the motor cord is tightly plugged into the pit receptacle 1 2 Check for electrical power to the pit receptacle and control box Before doing any
67. purchaser fails to comply with this warning Fig 47 HP X LENGTH 6 6 long 8 8 long 10 10 long 12 12 long WIDTH 6 6 wide 6 5 6 1 2 wide 7 T wide NOMINAL SIZE WxL 6x6 6x8 6x10 6 5x6 6 5 8 6 5 10 7x6 7 8 7 10 40 6004750K HydraulicPlus Dock Leveler SafeTFrame October 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued MODEL HP RAMP LIP AND TOE GUARD ASSEMBLIES Fig 49 October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 41 2012 4Front Engineered Solutions Inc PARTS LIST continued MODEL HP RAMP LIP AND TOE GUARD ASSEMBLIES Item my Description Part Number LIP GET WIDE 30K AND 35K CAPACITY 16 X 6 W 16 X 6 18 X 6 18 X 6 St X e 4 DEGREE BEND W 7 DEGREE BEND W 4 DEGREE BEND W 7 DEGREE BEND W 4 DEGREE BEND W 7 DEGREE BEND T 6 1 2FT WIDE 30K AND 35K CAPACITY 16 X 6 1 2 16 X 6 1 2 18 X 6 1 2 18 X 6 1 2 20 X 6 1 2 20 X 6 1 2 LIP 7FT WIDE 30K AND 35K CAPACITY W 4 DEGREE BEND W 7 DEGREE BEND W 4 DEGREE BEND W 7 DEGREE BEND W 4 DEGREE BEND W 7 DEGREE BEND 4 DEGREE BEND 16 X 7 W 18 X 7 W 7 DEGREE BEND 4 DEGREE BEND 7 DEGREE BEND 2 X T W 4 DEGREE BEND 7 DEGREE BEND Ce 6FT WIDE 40K 45K AND 50K CAPACITY W 4 DEGREE BEND 16 X 7 DEGREE BEND 4 DEGREE BEND
68. ramp reaches approximately 4 to 6 above dock level 36 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc LIP CAPACITY LIP SIZE 25K 30K amp 35K 40K 45K amp 50K 6 FT 16 HOLE 3 HOLE 2 HOLE 1 6 FT 18 HOLE 2 HOLE 1 HOLE 1 6 FT 20 HOLE 1 HOLE 1 HOLE 1 6 1 2 FT 16 HOLE 2 HOLE 1 HOLE 1 6 1 2 FT 18 HOLE 1 HOLE 1 HOLE 1 6 1 2 FT 20 HOLE 1 HOLE 1 HOLE 1 7 FT 16 HOLE 2 HOLE 1 HOLE 1 7 FT 18 HOLE 1 HOLE 1 HOLE 1 7 FT 20 HOLE 1 HOLE 1 HOLE 1 Return to dock switch assembly October 2012 TROUBLESHOOTING GUIDE continued RAMP LOCK DURING DOWNWARD TRAVEL 1 Check for debris in pit which may be restricting downward travel Downward speed of the ramp is controlled by a needle valve located in the pump motor Loosen locking nut and turn valve in clockwise to eliminate locking reduce descent speed Tighten locking nut See Fig 44 See chart on page 29 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 DOCK LEVEL SUPPORTS WILL NOT RETRACT FOR BELOW DOCK OPERATION 1 Check for broken chain to dock level support legs See Fig 45 Check for binding of dock level
69. t 24 long 1 2 extensions La e inem between lip and lip rod onto dock leveler 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 9 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 Pit sid curb angle 10 After the rear hinge is welded check that all rear leveling Fig 10 Bevel groove weld locations legs are in contact with the floor of the pit Once all legs 5 are in contact with floor tighten each leg leveling screw 2 4 2 4 counter clockwise to 25 40 ft Ibs 5 gt lg 5 ENEP a 242 5 5 a gt e gt 5 I J J M Pit rear E curb angle Frame Rear hinge uprights assembly October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 9 2012 4Front Engineered Solutions Inc IN STALLATION y 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 in the cylinder support bracket If electrical power is available reconnect power and use the
70. unt the laminated dock 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 Make sure customer gets user s manual and is properly trained 27 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 local Kelley distributor for assistance 28 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 GC Warning and operating X instruction placard lt Fig 20 Cap plug SR k s RN EUM SS Rear angle October 2012 6004750K HydraulicPlus Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc 13 IN STALLATION continued INSTALLATION TROUBLESHOOTING The following procedures apply after the leveler is level in the pit Fig 21 Shim and weld flush PROBLEM 1 Leveler will not fit properly in pit Lesen 14 POSSIBLE CAUSE Pit is out of square with the sides b One side and rear angle is out of square Pit floor irregular in rear d Pit is too deep

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