User`s Manual - Curlin, Inc.
Contents
1. PARTS LIST Subframe and Maintenance Strut Assemblies QTY PART DESCRIPTION Part Number DOCUMENTATION KIT NOT SHOWN 184 353 MANUAL 6004752 PLACARD WARNING AND INSTRUCTIONS 6001952 MAINTENANCE STRUT ASSEMBLY 6 LG DECK IN 20 PIT 710 042 6 LG DECK IN 24 PIT 6013620 8 LG DECK IN 20 PIT 708 883 8 LG DECK IN 24 PIT 6013621 10 LG DECK IN 24 PIT 712 537 3 PIN HINGE 6004128 4 CLIP RING 3 4 236 110 5 SCREW DRIVE 000 518 1 PIN COTTER HAIR 035 200 DECAL MAINT STRUT 921 074 1 WASHER FLAT 3 8 000 214 DECAL FORK LOCATION 138 604 FOOT ASSEMBLY 6002915 DANGER LABEL ENTERING PIT 921 070 SERIAL TAG 6009761 Note Items 5 8 included in item 2 September 2012 6004752J aFX C Dock Leveler SafeTFrame 33 2012 4Front Engineered Solutions Inc PARTS LIST Optional Subframe Riser Kit and Cap Plug Fig 47 2 RISER KIT FIELD INSTALLED 6004653 2 REAR ANGLE CAP PLUG ne 34 6004752J aFX C Dock Leveler SafeTFrame September 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued Connecting Rod Push Bar and Lip Assist Assemblies Qty Part Description Part Number PUSH BAR 6011490 ROD CONNECTING 6 LG DOCK LEVELER 711 848 8 LG DOCK LEVELER 711 849 10 LG DOCK LEVELER 712 462 LEVER LIP LIFTER 6 LG DOCK LEVELER 711 998 8 AND 10 LG DOCK LEVELER 711 999 LEVER L2. 6008234 6008235 6008236 1 5 1 2 front seal 6008166 Vertical seal 6008173 3 6 upper seal 6008167 8 upper seal 6008169 10 upper seal 2 6008171 4 Aluminum strip 53 1 2 6008175 Aluminum strip 77 1 2 6008177 Aluminum strip 101 1 2 2 6008179 5 6 Lower seal 6008168 8 Lower seal 6008170 10 Lower seal 2 6008172 Aluminum strip 6 upper 2 6008174 Aluminum strip 8 upper 6008176 Aluminum strip 10 upper 2 6008178 7 6 Kelley rear seal 1 6007671 6 5 Kelley rear seal 6007672 7 Kelley rear seal 6007673 8 TEK screws not shown Chain cup seal E 3 4 10 Set screw 11 W seal 600 W brush 328907 W seal 800 W brush 328908 W seal 600 W brush cut 328910 Corner bulb seal Transition angle seal optional September 2012 6004752 aFX C Dock Leveler Safe TFrame 39 2012 4Front Engineered Solutions Inc NOTES 40 2012 4Front Engineered Solutions Inc 6004752J aFX C Dock Leveler SafeTFrame September 2012 NOTES September 2012 6004752 aFX C Dock Leveler Safe TFrame 41 2012 4Front Engineered Solutions Inc NOTES 42 2012 4Front Engineered Solutions Inc 6004752J aFX C Dock Leveler SafeTFrame September 2012 LIMITED WARRANTY THIS LIMITED WARRANTY IS 4FRONTS SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE DOCK LEVELER AND IS IN LIEU OF ANY OTHER GUARANTEES WARRANTIES EXPRESS OR IMPLIED 4FRONT warrants that this DOCK LEVEL
3. KELLEY aFX C Dock Leveler This User s Manual applies to aFX C dock levelers manufactured beginning September 2012 with the serial numbers 61056056 and higher Do not install operate or service this product unless you have read and understand the Safety Practices Warnings Installation and Operating Instructions contained in this User s Manual Failure to do so could result in death or serious injury AIR SUPERIORITY ONLY FROM EELLEY User s Manual Installation Operations Maintenance and Parts Part No 6004752J TABLE OF CONTENTS Tal cele ee ennenen etene 2 Safety Signal V R Ski S 2 SV OS 3 Owner s Responsibilities 4 Ramp And Lip 5 Installation s eee 6 DA a na 15 16 Planned 20 Service Tools 23 gei m 26 Parts ASE m 29 Warranty Information 43 Distributor Information 44 INTRODUCTION Welcome and thank you for choosing this dock leveler from 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 in
4. aFX C leveler if above dock level would be to dock level and if below dock level would be to the full below dock position Always return the dock leveler to its dock level stored position before allowing the vehicle to leave the dock If the vehicle pulls away from the dock before the dock leveler is stored the lip will fall to its pendant position and the ramp will drop In addition failure to properly store the leveler may leave the 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 Failure to follow these instructions could result in death or serious injury to operators and or bystanders INTRODUCTION The KELLEY aFX C 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 aFX C dock leveler uses a push button control to position the dock leveler Pushing and holding the push button operates a fan which inflates an air bag 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 floor forming a bridge After loading pushing and holding the push button raises the ramp and the extended lip lowers
5. maintaining or repairing the dock leveler MAINTENANCE AND LUBRICATION CHART Lip Lip Dock Level Extension Extension Support Leg Mechanism Spring Assist Cam and Hinges Lip Hinge Assembly Hinges Ramp Dock Leveler Hinge Pins Pit Not Not Required Required SAE 30 Lubricate Gas Every 90 Days Every 90 Days Every 90 Days Grease Front Spring amp Clevis Push Bar Pins SAE 30 Lubrication As Required As Required As Required As Required As Required ed Rn Days As Required or as Required to Remove to Remove to Remove to Remove to Remove to Remove to Remove Debris Debris Debris Debris Debris Debris Debris Cleaning BAG CLAMP BAR BOLTS Whenever bag or clamp bar attaching hardware is replaced or reassembled perform the following torque procedure 1 Starting in the center of clamp bar and working outwards torque all 9 nuts to within 29 31 Ft Lbs 2 Visually check that each of the 9 torqued nuts has the same amount of bolt protruding through it and that the round bar inside the bag is not physically underneath the clamp bar See Service Tool Section beginning on page 23 Check all labels every 90 days Replace if required See page 20 for location and part numbers Every 90 days visually inspect all welds under the leveler for fatigue or failure Particularly the lip plate hinge and top plate beams and front hinge lugs Every 90 days visually inspect dock bumper
6. Ensure lip avoids contact with vehicle sides and cargo If lip does not lower to vehicle bed reposition vehicle Do not use a fork truck or other material handling equipment to lower the ramp Move all equipment material or people off dock leveler and store dock leveler at dock level before allowing the vehicle to leave 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 Prior to placing in the pit 8 and longer levelers require 6 long forks if handled with a fork lift 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 Disconnect the power and properly tag or lock off before doing any electrical work If itis 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 i
7. receptacle e Repair or replace wires f Replace fan assembly a If an obstruction is found turn off power before attempting to clear the obstruction b Order the patch kit from your dealer or Kelley to repair holes If holes are too large replace bag assembly c Repair or replace as required See parts list on page 36 37 d Verify motor voltage is between 110 129 volts AC while motor is running at full load September 2012 TROUBLESHOOTING continued POSSIBLE CAUSE a Lip extension mechanism is bent or binding PROBLEM 3 Lip fails to lower to the stored position when the dock leveler is raised from vehicle b Lip assist gas spring pin is in incorrect position 4 Dock level support legs will not retract a Chain not connected for below dock operation b Chain binding c Legs binding d Chain pulling one leg SOLUTION a Check to make sure that the lip extension mechanism is not bent or binding Be sure all parts are lubricated properly Lubricate as required See Fig 40 b Make sure pin is in correct position See Fig 41 and both pins are in good condition a Check connection of dock level control chain to the dock level support legs See Fig 42 b Check for binding of dock level control chain Check for binding in dock level support legs d Check length of below dock control chain Adjust chain so dock level support legs are retracted the same dist
8. 883 20 X 6 5 W 4 BEND 711 886 20 X 6 5 W 7 BEND 711 885 LIP 7 WIDE 40K 45K AND 50K CAPACITY 16 X 7 W 4 BEND 711 900 16 X 7 W 7 BEND 711 899 18 X 7 W 4 BEND 711 902 18 X 7 W 7 BEND 711 901 20 X 7 W 4 BEND 711 904 20 X 7 W 7 BEND 711 903 LIP SHAFT 6 W DOCK LEVELER 712 957 6 5 W DOCK LEVELER 712 958 7 W DOCK LEVELER 712 959 RETAINER SHAFT HINGE PIN 035 451 5 2 TOE GUARD MIDDLE SLIDING 6 LG DOCK LEVELER 155 554 8 LG DOCK LEVELER 155 555 10 LG DOCK LEVELER 23 PIT 155 557 10 LG DOCK LEVELER 19 PIT 155 564 September 2012 6004752J aFX C Dock Leveler SafeTFrame 31 2012 4Front Engineered Solutions Inc PARTS LIST DOCK LEVELER continued Ramp Lip Toe Guards and Lip Lock Assemblies ITEM PART DESCRIPTION Part Number 2 TOE GUARD BOTTOM SLIDING 6 LG DOCK LEVELER 155 554 8 LG DOCK LEVELER 155 556 10 LG DOCK LEVELER 23 PIT 155 557 10 LG DOCK LEVELER 19 PIT 155 565 s o Revma WASHER 6 16 FLAT 30 1 CHAIN BDC 6 6012661 CHAIN BDC 8 6003453 CHAIN BDC 10 6003452 35 1 BAG SHIELD 6 LG DOCK LEVELER ALL CAPACITY 155 295 8 LG DOCK LEVELER 30K 45K CAPACITY 155 295 8 LG DOCK LEVELER 50K CAPACITY 155 400 10 LG DOCK LEVELER ALL CAPACITY 155 400 32 6004752J aFX C Dock Leveler SafeTFrame September 2012 2012 4Front Engineered Solutions Inc
9. Kelley distributor DANGER 700 136 ADANGER CRUSH HAZARD 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 A DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is securely supported by the maintenance strut Place barriers on driveway and dock floor to x2 indicate service work being performed Failure to comply will result in death or serious injury Refer to user s manual for proper maintenance procedures 4 DANGER OPERATIONS 6001952 Danger and operation placard mounted on wall near leveler 20 6004752J aFX C Dock Leveler SafeTFrame September 2012 2012 4Front Engineered Solutions Inc PLANNED MAINTENANCE continued A WARNING Before servicing the dock leveler read and follow the Safety Be certain before climbing into the dock leveler pit or Practices on page 3 and the Operations Instruction section doing any maintenance or repair under the dock leveler on pages 16 through 19 of this User s Manual that 1 THE MAINTENANCE STRUT AND LIP LOCK ARE SECURELY PINNED IN PLACE see page 23 and 2 The Place barricades on the dock floor around the dock leveler power is disconnected and properly tagged or locked off pit and in the driveway in front of the pit while installing
10. NEMA 5 15R By Others September 2012 6004752J aFX C Dock Leveler SafeTFrame 15 2012 4Front Engineered Solutions Inc OPERATION A WARNING Before operating the dock leveler read and follow the Safety Practices on page 3 Use of dock leveler restricted to trained operators Follow procedures on placard posted near 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 or contact your local Kelley distributor Before pressing button ensure lip avoids contact with vehicle sides and cargo If lip does not lower to vehicle floor reposition vehicle Stay clear of leveler unless lip is supported by vehicle floor or the leveler is stored at dock level Visually check that the lip is supported by the vehicle floor or the ramp is supported by both front 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
11. See Fig 28 3 Release the BDC chain 4 Load or unload end loads 5 When loading or unloading is complete return the dock leveler to the stored position 5 1 Push and hold the control button until the ramp raises above dock level 5 2 Release the control button before the ramp reaches its highest position The ramp will lower to its stored position 5 3 Be certain that the lip is not extended and that dock level support legs are in position on their supports before releasing vehicle Ramp should be level with dock floor 6 Remove wheel chocks or release vehicle 7T Tell vehicle driver Your vehicle may now leave the dock 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 27 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 OPERATION continued Below Dock Control BDC Chain September 2012 6004752J aFX C Dock Leveler SafeTFrame 19 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
12. a 120V grounded 5 15R receptacle on the pit wall as shown in Fig 3 Wire receptacle per diagram on page 15 4 f 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 5563 and 5566 and powered dock leveler wiring diagrams and typical installation drawings Fig 3 and powered dock leveler wiring diagram on page 15 for electrical requirements Follow all applicable electrical codes and 2 Visually check that the 4 rear hinge pins and retaining standards clips are in place A WARNING 3 Visually check that the lip shaft collars or shaft retainers Before installing the dock leveler read and follow the are in place on both lip rods Safety Practices on page 3 Failure to follow the Safety Practices could result in death or serious injury 4 Visually check that cotter pins are in place on pins on the connecting rod push bar and the lip lifter assembly 5 Verify that gas spring retaining pins have cotter pins Fig 2 installed 1 6 Verify that both the lip lock and the maintenance strut undamaged and have safety hitch pins on chains E 9 Push Button 7 Visually check that the foot assemblies at the rear of the 48 Control Station leveler are in place and undamaged PREPARE SITE ES A WARNING 3e Place barricades around pit on dock floor and drive while installing maintaining or r
13. 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 PINNED IN PLACE MAINTENANCE STRUT 1 Two people are needed to place the dock leveler on 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 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 31 and the instruction label on maintenance strut c The raise button may now be released LIP LOCK ADANGER Manual support of lip must be maintained until the lip lock is in place The lip is free to move downward when it is released unless lip lock is pinned in place DO NOT WORK UNDER THE DOCK LEVELER RAMP OR LIP UNLESS THE MAINTENANCE STRUT AND LIPLOCK ARE PINNED IN PLACE September 2012 SERVICE TOOLS 2 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 31 and instruction label located on the underside of the dock leveler ramp NOTE To store the maintenance strut follow all instructions on page 12 Fig 31 Lip Insert Hairpin Lip Lock Clip Thro
14. 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 Fig 10 INSTALLATION continued 5 gt 5 gt 2 1 2 Leg OF ania K Rear Pit Curb Angle Pit Side Curb Angle 5 2 1 2 gt amp 5 2 1 2 2 Pit 7 Uprights urb Assembly Angle 6004752J aFX C Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc IN STALLATION Continued 11 Lower the air bag lifting support frame by removing the retainer bolts on top of deck area See Fig 14 Bolts should be discarded The lifting support frame will drop rapidly to the pit floor when the retainer bolts are removed Keep your hands and feet out from under the dock leveler when releasing the frame Failure to do so could result in death or serious injury ADANGER Air pressure or mechanical support must be maintained under 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 NOTE The following procedure requires two persons to lockout and secure the leveler for maintenance 12 Return pow
15. to its stored position Releasing the push button before the dock leveler reaches the 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 For below dock loads the dock level support legs can be retracted by pulling the below dock chain located in the middle of the deck before the deck lowers past dock level 16 6004752J aFX C Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc September 2012 OPERATION continued 1 Wait until a vehicle is in position against the dock Fig 24 n 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 Dock Level NOTE TE a a Supports If the vehicle is to be serviced for a below dock end load see operation instructions for Below Dock Control on page 19 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 25 5 2 Release the control button when the ramp reaches its highest position Fig 25 5 3 Ramp will lower a
16. 712 745 712 812 035 200 000 357 131 434 000 214 131 432 131 457 6008662 000 315 131 485 131 483 155 578 8 LG DOCK LEVELERS 50K CAPACITY 10 LG DOCK LEVELERS ALL CAPACITY PART DESCRIPTION Part Number BAG PAN FAN ASSEMBLY INCLUDES ITEMS 1 20 712 807 LIFTING BAG ASSEMBLY INCLUDES ITEMS 2 3 6 11 AND 16 184 441 000 051 6010111 157 747 155 649 155 650 000 253 711 846 711 845 712 812 035 200 000 357 131 434 000 214 131 432 131 457 6008662 000 315 131 485 131 483 155 578 184 379 September 2012 6004752J aFX C Dock Leveler SafeTFrame 37 2012 4Front Engineered Solutions Inc PARTS LIST continued Fan Piping Assembly Fig 50 SN WR SSH US SA SS NN NN NN W N mm Quanity Description Pate 2 han LS LU FERE C Ee 7 1 115V CONTROL STATION 908 753 CONTROL STATION OPTIONAL DUAL CONTACT 909 052 For use with interlock applications on STAR 4 and AUTO CHOCKS vehicle restraints NIPPLE 155 578 CORD W PLUG 712 027 HOUSING FAN 712 813 38 6004752J aFX C Dock Leveler SafeTFrame September 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued OPTIONAL ENERGY GUARD DOCK LEVELLER SEALING SYSTEM Fig 51 Description Quantity Part 6x6 6 5x6 6x7 6x8 6 5 8 7x8 6x10 6 5x10 7x10 Number 6008228 6008229 6008230 6008231 6008232 6008233
17. 752J
18. D D 137 58 o 8 0 c K 60 108 30 6 0 4 0 8 0 0 2 4 0 2 0 5 2 2 6 2 0 0 0 24 5 4 0 0 E 2 0 0 3 8 2 0 3 8 1 0 2 8 1 E 2 0 L 4 0 3 1 11 0 2 3 10 2 1 9 9 7 L 4 0 6 0 5 9 13 8 4 4 12 3 3 5 11 4 6 0 w D 8 0 8 7 16 6 6 5 14 4 5 2 13 1 D 8 0 e 10 0 11 5 19 4 8 6 16 5 6 9 14 7 10 0 K 12 0 14 4 22 2 10 7 18 6 K 12 0 4 lip bend 16 lip Optional 7 lip bend 16 lip September 2012 6004752J aFX C 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 5563 or 5566 Check to be sure that the pit walls are square and plumb Check electrical service running to the pit to assure it conforms with the correct location and voltage for the junction box Inspect the pit and remove all loose trash and construction debris See the installation troubleshooting on page 14 if the pit varies from the specification LEVELER CHECK PRIOR TO INSTALLATION 1 Visually check that the length of exposed thread on all clamp bar bolts on the airbag are equal to ensure they are properly tightened 2 Mount and wire push button control station See Fig 2 See wiring diagram on page 15 of this User s Manual for wiring information Wires shown in dashed lines are field connections 3 Mount and wire a conduit box with
19. ER 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 4FRONT 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 User s Manual 4FRONT 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 User 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 4FRONT and 4 Front will at its option 1 Replace the DOCK LEVELER or the defective portion of either 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 4AFRONT DISCLAIMS A
20. IP ASSIST 155 811 PIN CLEVIS 1 2 DIA X 1 3 4 035 010 PIN CLEVIS 3 8 DIA X 2 035 150 PIN COTTER 1 8 DIA X 1 1 4 035 036 709 437 71227 712 001 712 002 712 061 000 030 049 060 700 045 WASHER 3 8 000 214 SPACER LIP 6 1 2 WIDE DOCK LEVELER 287 606 7 WIDE DOCK LEVELER 287 607 A NEC 9 September 2012 6004752J aFX C Dock Leveler SafeTFrame 35 2012 4Front Engineered Solutions Inc PARTS LIST continued Air Bag Pan Assembly Fig 49 FOR SHIPPING 6 LG DOCK LEVELERS ALL CAPACITY ITEM QTY PART DESCRIPTION Part Number BAG PAN FAN ASSEMBLY INCLUDES ITEMS 1 20 WASHER 3 8 FLAT LIFTING BAG CLAMP BAR PAN OUTER PAN INNER NUT NYLOK 3 8 16 WHEEL AXLE FRONT AXLE REAR IN COTTER HAIR OLT HEX HD 3 8 16 X 1 1 4 OLT 3 8 16 X 7 ASHER FLAT 3 8 UT RETAINER ING RETAINING FAN MOTOR ASSY 115V UT HEX LOCK 1 4 20 WASHER FLAT 1 4 CREW BUTTON FLG HD 1 4 20 X 3 4 IPPLE 155 578 PATCH KIT BAG NOT SHOWN 184 379 36 6004752J aFX C Dock Leveler SafeTFrame September 2012 2012 4Front Engineered Solutions Inc Az 2 20 y oo PARTS LIST continued Air Bag Pan Assembly 8 LG DOCK LEVELERS 30K 35K 40K and 45K CAPACITY Part Number LIFTING BAG ASSEMBLY INCLUDES ITEMS 2 3 6 11 AND 16 184 442 000 051 713 149 157 747 155 579 155 580 000 253 711 846
21. NY 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 4FRONT 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 4FRONT 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 4FRONT HEREBY DISCLAIMS September 2012 6004752J aFX C Dock Leveler SafeTFrame 43 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 6004
22. OCK LEVELER Ramp Lip Toe Guards and Lip Lock Assemblies Fig 45 30 2012 4Front Engineered Solutions Inc 6004752 aFX C Dock Leveler SafeTFrame Note Rivets Item 40 Bottom Of Ramp Attach Bag Shield Item 39 To Brackets Welded On September 2012 PARTS LIST DOCK LEVELER continued Ramp Lip Toe Guards and Lip Lock Assemblies PART DESCRIPTION Part Number LIP 6FT WIDE 30K AND 35K CAPACITY 16 X 6 W 4 BEND 711 858 16 X 6 W 7 BEND 711 857 18 X 6 W 4 BEND 711 860 18 X 6 W 7 BEND 711 859 20 X 6 W 4 BEND 711 862 20 X 6 W 7 BEND 711 861 LIP 6 1 2 WIDE 30K AND 35K CAPACITY 16 X 6 5 W 4 BEND 711 876 16 X 6 5 W 7 BEND 711 875 18 X 6 5 W 4 BEND 711 878 18 X 6 5 W 7 BEND 711 877 20 X 6 5 W 4 BEND 711 880 20 X 6 5 W 7 BEND 711 879 LIP 7 WIDE 30K AND 35K CAPACITY 16 X 7 W 4 BEND 711 894 16 X 7 W 7 BEND 711 893 18 X 7 W 4 BEND 711 896 18 X 7 W 7 BEND 711 895 20 X 7 W 4 BEND 711 898 20 X 7 W 7 BEND 711 897 LIP 6FT WIDE 40K 45K AND 50K CAPACITY 16 X 6 W 4 BEND 711 864 16 X 6 W 7 BEND 711 863 18 X 6 W 4 BEND 711 866 18 X 6 W 7 BEND 711 865 20 X 6 W 4 BEND 711 868 20 X 6 W 7 BEND 711 867 LIP 6 1 2 WIDE 40K 45K AND 50K CAPACITY 16 X 6 5 W 4 BEND 711 882 16 X 6 5 W 7 BEND 711 881 18 X 6 5 W 4 BEND 711 884 18 X 6 5 W 7 BEND 711
23. ance Fig 41 Lip Capacity Lip Size 30K amp 35K 40K 45K amp 50K 6 18 Hole 1 Hole 1 6 20 Hole 1 Hole 1 6 1 2 16 Hole 1 Hole 1 6 1 2 18 Hole 1 Hole 1 6 1 2 20 Hole 1 Hole 1 7 46 Hole 1 Hole 1 7 48 Hole 1 Hole 1 September 2012 6004752 aFX C Dock Leveler Safe TFrame 27 2012 4Front Engineered Solutions Inc TROUBLESHOOTING continued Fig 42 Dock Level Support Leg PROBLEM POSSIBLE CAUSE SOLUTION 5 Dock level support legs will not swing a Leg is binding a Check for binding or debris which may fully forward be restricting leg b Chain does not allow enough slack b Check below dock control chains to assure chain has enough slack to allow leg to swing forward Adjust as required See Fig 42 6 Lip fails to extend a Lip extension mechanism is bent or a Check to make sure that the lip binding extension mechanism is not bent or binding Be sure all parts are lubricated properly Lubricate as required See Fig 40 b Pins are in incorrect position b Make sure all pins and pin retrainers are in place and in good condition 7 Lip extends but fails to stay in extended a Lip extension mechanism center bolt is a Check to see that the lip extension position bent or binding mechanism center bolt is straight and free to rotate See Fig 40 b Links and connecting rod are not b Check to see that the lip extends aligned far enough to allow the link
24. anging pendant See Fig 27 Failure to do so may leave the 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 6 To return the dock leveler to the stored position when Fig 27 loading or unloading is complete or to load end loads E Dock Level Support Leg 6 1 Push and hold the control button The ramp will rise and the lip will lower o Front Angle Dock Level 6 2 Release the control button when the lip clears the Support vehicle platform before reaching its highest position The ramp will lower to the dock level stored position 6 3 Visually check that lip is not extended or hung up on vehicle Ramp should be level with dock floor 7 Remove wheel chocks or release vehicle 8 Tell vehicle driver Your vehicle may now leave the dock 18 6004752 aFX C Dock Leveler Safe TFrame September 2012 2012 4Front Engineered Solutions Inc BELOW DOCK CONTROL BDC 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 below dock level
25. ar 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 The working range of 10 dock levelers is 18 inches above dock and 12 inches below dock 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 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 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 Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brakes Chock vehicle wheels or lock vehicle in place with a vehicle restraining device and set brakes before loading or unloading SAFETY PRACTICES Visually check that lip is supported by the vehicle platform or the ramp is supported by both dock level supports before driving on the ramp Store dock leveler at dock level after below dock end loading
26. ck Leveler SafeTFrame 11 2012 4Front Engineered Solutions Inc IN STALLATION Continued L 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 19 Mount dock bumpers to face of dock Downhill welds are unacceptable See Fig 17 or 18 20 Reconnect power Store maintenance strut and lip lock Store dock leveler at dock level 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 MOVE THE MAINTENANCE STRUT WITHOUT AIR PRESSURE IN THE BAG ORA MECHANICAL LIFTING DEVICE SUPPORTING RAMP Raise the ramp using air pressure or a mechanical device before storing the maintenance strut Stand clear of the ramp and lip when air pressure or the mechanical lift is applied or removed The ramp and lip are free to move downward when the support is removed Removing the support without air pressure will allow the ramp and lip to drop RAPIDLY If 22 Two people ar
27. d 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 24 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 25 Operate the dock leveler four times through the complete cycle to check operation See Operation section page 16 NOTE If you have any problems or questions using or operating the dock leveler contact your supervisor or local Kelley distributor for assistance 26 Optional where applicable install rear angle cap plugs part number 6004488 into adjustment socket holes Press cap flush with top surface of rear curb angle September 2012 6004752J aFX C Dock Leveler SafeTFrame 13 2012 4Front Engineered Solutions Inc IN STALLATION continued INSTALLATION TROUBLESHOOTING The following
28. e 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 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 Rc fae 4 Bolts 3 Per Bumper Furnished by Kelley Company inc Locate and Weld to Curb i Angle at Time of Bumper insta amp ation ud Fig 18 LAMINATED BUMPERS e dock leveler was raised using a mechanical device 3 8 Side of Pit juif oo ower it using the same device to Side of Bumper Bolt Mounting Plate Field 21 Lift up on the hinged lip and store the lip lock under the Installed ramp 1 4 Supplied Weld Full Length of by Others Bumper Mounting To Plate Downhill Welds amp A Curb are Unacceptable Angle T Se Vertical Bumper mE Laminations Must Installed Vertically 12 6004752 Dock Leveler Safe TFrame September 2012 2012 4Front Engineered Solutions Inc INSTALLATION continued ACAUTION Fia 19 Warning and Operating The hinged lip will extend as the ramp moves down Instruction Placard 23 Place the dock leveler in both dock leveler storage AL position an
29. epairing dock leveler Fig 3 p 1 The control station User s Manual and dock bumpers Pit are attached to the sub frame of the dock leveler The Center en Line 10 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 12 1 user s manual and is properly trained Box Located as Shown 6 6004752J aFX C Dock Leveler SafeTFrame September 2012 2012 4Front Engineered Solutions Inc INSTALLATION 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 6004653 Install the new riser leveling feet The riser blocks should be welded to the front subframe supports and secondary stops prior to placing in the pit See publication 6003727 and page 34 in this manual 1 Prior to lifting leveler make sure the shipping tie down bolts seen in Fig 13 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 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 3 500 Ibs for the lifting angle used Never all
30. eplates 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 6004752J aFX C Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc September 2012 RAMP AND LIP GRADES Fig 1 Ramp Grades UN Ne td Lip Grade IN VEHICLE RAMP and LIP grades for each dock leveler length VEHICLE RAMP and LIP grades for each dock leveler length PLATFORM PLATFORM POSITION from 6 Leveler POSITION from 6 Leveler 8 Leveler 10 Leveler DOCK in RAMP DOCK in 18 0 m 18 0 A 160 A 160 B 140 3 B 14 0 12 0 19 4 11 6 12 0 10 0 16 5 8 7 10 0
31. er to the leveler control Using the aFX push button control or mechanical support raise the deck and secure a One person pushes and holds the RAISE button to inflate the air bag until the dock leveler reaches its highest position 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 Fig 11 j yDoorjemb Flush with floor at this point _ rn ha 21 m mI I Fig 12 1 2 sq drive adjustment bolt CCW to raise 3 16 weld both s 3 16 3 long both rotation ides weld min sides Curb steel 3 16 weld both sides 3 16 weld 3 long min both sides 3 16 weld 3 long min strut Fig 13 Air pressure or mechanical support may now be removed Shipping tie down bolt z O 10 6004752J aFX C Dock Leveler SafeTFrame September 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 15 released unles
32. ing the front supports Fig 6 Fig 7 8 6004752J aFX C Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc September 2012 LEVELING THE FRONT 6 Remove and discard the shipping tie down bolts located at the lower end of the hinged lip assembly See Fig 13 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 and that the leg roller is centered over the its roller track Move dock levelers support right or left for the necessary alignment T Tack weld the front dock leveler supports to the front curb angle See Fig 12 With the lip pendant insert 24 long 1 2 extensions 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 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 September 2012 legs are in contact with the floor
33. n on front of pan assembly to unhook the back of the pan assembly See Fig 38 1 5 Balancing the pan assembly on the rollers roll the assembly to the front of the pit Rollers will roll on frame side angles See Fig 39 2 Toinstall the bag pan assembly 2 1 Rollthe pan assembly back in the pit and align with hooks on the back of the ramp 2 2 Press the front of the bag down and hook the rear axle into the hooks on the back of the ramp 2 3 Position lifting tool in pit and hook tool on pan axle in the center of the pit See Fig 37 2 4 Using both hands pull down on handle Move the handle down to the pit floor See Fig 36 The lifting tool will snap into position supporting the pan in a raised position Remove the pan rollers 2 5 Lower bag pan assembly following instructions on page 23 September 2012 S E RVIC E TOO LS continued FUMER mA o REDE i Pan Rollers NOTE For 8 long 50K capacity and 10 long dock levelers attach pan rollers 19 from front edge Fig 37 6004752J aFX C Dock Leveler SafeTFrame 25 2012 4Front Engineered Solutions Inc TROUBLESHOOTING A WARNING Before troubleshooting the dock leveler read and follow the Safety Practices on page 3 and the Operations Instruction section on pages 16 through 19 of thi
34. nd lip will extend until the lip rests Lip Extend Ramp on the vehicle platform See Fig 26 Push to Raise Vehicle Bed I Fig 26 NO September 2012 6004752 aFX C Dock Leveler Safe TFrame 17 2012 4Front Engineered Solutions Inc OPERATION continued L WARNING Do not drive on dock leveler or lip until it is fully extended and supported by the vehicle platform Never use a fork truck or other material handling equipment to lower the ramp and lip sections NOTICE Never drive on the dock leveler with the lip resting on the trailer and the dock level support legs engaging their lower supports at the same time If a trailer rises during loading or unloading enough to cause the dock level support legs to engage their lower supports with the lip of the leveler in the trailer the operator must get off the leveler and re deploy the leveler into the trailer This will allow the legs to get out of the way and will allow float of the leveler again If this is not done damage to the legs and leveler may occur The likelihood of this event occurring can be greatly reduced by the practice of exhausting the air from the trailer s air ride suspension before deploying the dock leveler 5 4 Proceed with loading or unloading 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 and the lip h
35. ng 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 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 non insulated tools inside the control box Touching wires or other parts inside the control box could result in electrical shock death or serious injury Never allow more than 130 volts to be connected to the 120 volt motor circuit Damage to motor push button air bag and serious personal injury or death may result Fig 23 120V Single Phase 50 60 Hz Single Contact T Circuit Breaker By Others E 20 AMP MAX mom BLK 120V Line 1 RM t 1 Phase e 50 60 Hz Ta Neutral 1 Phase 120V Pit Wall 50 60 Hz Receptacle NEMA 5 15R By Others 120V Single Phase 50 60 Hz Optional Dual Contact Optional Blue Contact Block SS Normally Closed Control Optional Connection to Restraint Field Installed Low Voltage Only Station Star 4 Module Limit Switch See Supplied Mfg Instructions MB Terminals No 21 and No 22 les T0 2 le Auto Chock Terminal Block Circuit Breaker Terminals No 5 and No 24 By Others 20 AMP MAX 1 120V Line 1 Phase 50 60 Hz Neutral Pit Wall 1 Phase 120V Receptacle 50 60 Hz
36. ng both hands carefully raise the handle of the lifting tool As the pan begins to lower you will need to hold the handle to support the pan assembly and prevent the handle from raising rapidly See Fig 35 Lower the pan assembly to the pit floor Remove lifting tool from pit Tool 6004752J aFX C Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc September 2012 REMOVAL ROLLERS The pan removal rollers are used to remove the bag support pan assembly This allows for easy access to service the lifting fan and bag assembly 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 PINNED IN PLACE see page 23 and 2 the power is disconnected and properly tagged or locked off 1 To remove bag support pan assembly 1 1 Raise bag pan assembly See instructions on page 24 1 2 Attach pan rollers kit part 184376 for 19 subframes and 6013799 for 23 subframes to both sides of pan assembly either 16 or 19 back from front edge as shown in Fig 36 NOTE For 8 long 50K capacity and 10 long dock levelers attach pan rollers 19 from front edge as shown in Fig 36 1 3 Lower front of bag pan assembly by raising pan lifting tool as shown in Fig 37 Pan rollers will be supported on frame side angles 1 4 Push dow
37. nside the control box could result in electrical shock death or serious injury September 2012 6004752J aFX C 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 practical 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 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 nam
38. ow 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 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 leveler is moved into the final position See Fig 5 and wiring diagram on page 15 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 Fig 4 3 4 10 UNC load centering eyebolt INSTALLATION continued September 2012 6004752J aFX C Dock Leveler SafeTFrame 7 2012 4Front Engineered Solutions Inc IN STALLATION Continued 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 side
39. procedures apply after the leveler is level in the pit PROBLEM 1 Leveler will not fit properly in pit Fig 20 Shim and weld flush 14 2012 4Front Engineered Solutions Inc POSSIBLE CAUSE 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 too deep Fig 21 1 2 max SOLUTION a1 Align the sides parallel and equally 6004752J aFX C Dock Leveler SafeTFrame 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 noted in Fig 10 See Fig 20 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 21 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 22 Weld 4 x 4 shims to the bottom of the adjustable legs as shown in Fig 4 Fig 22 1 8 MAX Allowable Step Greater than 1 1 x93 in size 6 Contact Zone September 2012 ADANGER WIRING DIAGRAM Before doi
40. s 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 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 adjustment 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 previously connected Welding with dock levelers power connected can damage the electrical components A ground must be attached to the leveler frame 5 Check and adjust the leveler for square shim the rear as required see Fig 20 The sides of the leveler deck should be centered in the pit opening Tack weld the rear angle to rear curb angle in 4 places min 3 8 one at or near each leveling screw NOTE Do not weld out the rear angle until after sett
41. s Four inches 4 of bumper protection is required Worn torn loose or missing bumpers must be replaced September 2012 6004752J aFX C Dock Leveler SafeTFrame 21 2012 4Front Engineered Solutions Inc PLANNED MAINTENANCE continued NOTE Legend Use only lubricants shown Improper lubrication or adjustments Svmbol may cause operational problems Lubricate Oil Light Oil SAE 30 NOTE Ramp hinge pins may be oiled from top of dock by placing Lubricate Grease dock leveler full below dock Molybdenum Disulfide NLGI 2 Check Fasteners or Adjust Torque Torque Noted Fig 30 Cleaning Location Frequency d Lip Rods d Gas Spring Pins d Swing Link Pins Connecting Rod Pins Rear Hinge Pins Bag Bolts Pit 29 31 Ft Lbs 90 Days 22 6004752J aFX C Dock Leveler SafeTFrame September 2012 2012 4Front Engineered Solutions Inc Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operations Instruction section on pages 16 through 19 of this User s 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 PINNED IN PLACE see Fig 31 and text below and 2 The power is disconnected and properly tagged or locked off Air pressure or
42. s User s Manual 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 PINNED IN PLACE see page 23 and 2 The power is disconnected and properly tagged or locked off Before doing any electrical work make certain the power is disconnected and properly tagged or locked off PROBLEM 1 Leveler does not raise Motor fails to run b No electrical power to push button POSSIBLE CAUSE a Fuse blown or breaker tripped NOTE Follow Service Tools use instructions on pages 23 through 25 Fig 40 Hanger Bracket Swing Link Notch p o Ai Center Bolt N Push Bar D M eti Paor SOLUTION a Replace fuse or reset breaker b Check all power supplies to control panel and make sure connections are tight 2 Leveler does not raise or does not raise completely Motor runs 26 6004752J aFX C Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc c Push button is broken d Fan plug loose or unplugged in receptacle e Loose wires in control panel or junction box f Fan assembly damaged broken a Obstruction s preventing the leveler from raising b Holes or leaks in the lifting bag c Loose or misaligned bag fittings or loose bag clamps d Motor voltage too low c Replace push button d Check and tighten connection to
43. s and connecting rod to align and then reach an over center position 28 6004752J aFX C Dock Leveler SafeTFrame September 2012 2012 4Front Engineered Solutions Inc PARTS LIST 1 To determine the correct replacement parts to order for Fig 43 your adjustable dock leveler you will need to know its model number serial number and capacity X 2 The model number and capacity can be found on the dock leveler product label located on the frame leg See Length Fig 47 The meaning of each digit in the model number 6 6 long is shown in Fig 43 8 8 long 10 10 long Example 6 x 8 Frida E en 6 5 6 1 2 wide 7 7 wide 3 To determine the nominal size of your dock leveler see Fig 44 To ensure proper function durability and safety of the product only replacement parts that do not interfere with Fig 44 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 Lip Length 16 18 Or 20 Nominal Size W xL ft September 2012 6004752J aFX C Dock Leveler SafeTFrame 29 2012 4Front Engineered Solutions Inc PARTS LIST D
44. s 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 13 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 14 Disconnect power 15 Finish welding both of the adjusted dock leveler supports in all locations shown in Fig 12 16 Remove and discard shipping cotter pins from toe guards on both sides of dock leveler See Fig 16 NOTE 6 and 8 long levelers in a 24 pit require the installation of a pan riser kit part 184389 Install the pan risers See publication 6013529 or 6003727 17 Remove lifting chain or other lifting devices Remove lifting hooks from the sides of the ramp 18 Read the Safety Practices on page 3 and the Operation Instructions on pages 16 through 18 before operating the dock leveler Fig 16 INSTALLATION continued Fig 14 Retaining Bolts Fig 15 Insert Hairpin Clip Through Maintenance Strut Pin Maintenance Strut Pin Maintenance Strut Maintenance Strut Bracket Hairpin Clip Into Lip Lock Remove Shipping Cotter Pins September 2012 6004752J aFX C Do
45. stall 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 ADANGER 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 may result in minor or moderate injury NOTICE Indicates a potentially hazardous situation which if Notice is used to address practices not related to not avoided could result in death or serious injury 2 6004752J aFX C Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc personal injury September 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 your local Kelley distributor OPERATION Use restricted to trained operators Follow procedures on placard posted ne
46. ugh Maintenance Strut Pin Maintenance Strut Pin Maintenance Strut Hairpin Clip Into Lip Lock Maintenance Strut Bracket 6004752J aFX C Dock Leveler SafeTFrame 23 2012 4Front Engineered Solutions Inc SERVICE TOO LS continued PAN LIFTING TOOL The pan lifting tool is used to raise the front end of the bag support pan assembly This allows for easy access to the pit for cleaning of the pit area 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 PINNED IN PLACE see page 23 and 2 The power is disconnected and properly tagged or locked off 1 2 24 1 1 1 2 1 3 1 4 2 1 2 2 2 3 To raise the bag pan assembly Position dock leveler on maintenance strut See page 23 for instructions Position pan lifting tool part number 908 773 in pit and hook tool on pan axle in the center of the pit See Fig 32 Using both hands pull down on handle This will rotate the pan lifting tool on its wheels pushing the pan assembly upwards See Fig 33 Move the handle down to the pit floor See Fig 34 The lifting tool will snap into position supporting the pan in a raised position Access to pit floor is clear To lower the bag pan assembly Usi
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