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User`s Manual - Curlin, Inc.

1. NTTTTTTTTTTTTTTTTTTT August 2012 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc 30 PARTS L
2. Raises 1 rear Pi Leg OF capu K Rear pit curb angle t side curb angle 5 2 1 2 gt 5 2 1 2 2 August 2012 6004751K aFX and aFX S Dock Leveler SafeTFrame Frame uprights rear Rear hinge 6 urb assembly angle 2012 4Front Engineered Solutions Inc IN STALLATION continued 11 Lower the air bag lifting support frame by removing the Fig 11 retainer bolts on top of deck area See Fig 14 Bolts should be discarded Door jamb s Flush with floor at this point A WARNING BENE 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 3 16 welds 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 3 16 weld NOTE The following procedure requires two p
3. 8 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc August 2012 LEVELING THE FRONT FRAME Fig 8 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 INSTALLATION continued 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 7 Tack weld the front dock leveler supports to the front curb angle See Fig 12 8 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 impact tool turn each leveling screw counter clockwise until the top of the leveler 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 9 Fig 10 10 After the rear hinge is welded check that all rear leveling legs are in contact with the floor of the pit Once all legs are in contact with floor tighten each leg leveling screw counter clockwise to 25 40 ft Ibs Fig 10 5 242 5
4. 16 or 19 Pan Rollers i NOTE For 8 long 50K capacity and 10 long dock levelers attach pan rollers 19 from front edge August 2012 Before troubleshooting the dock leveler read and follow the Safety Practices on page 3 and the Operations Instruction section on pages 16 through 18 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 page 22 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 TROUBLESHOOTING NOTE Follow Service Tools use instructions on pages 22 through 24 Fig 35 Hanger bracket Swing link Dock leveler ramp Roller Lip Center bolt Connecting rod Push Bar Pit Floor 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 August 2012 c Push button is broken d Fan plug loose or unplugged in rec
5. Excess chain can hang ifs or be cut off Ly NOTE The position of the shackle may vary depending on spring tension and chain link size Positions are for reference and can be adjusted as necessary Proper installation will lift the bag rollers approximately 8 off the pit floor when the deck is stored Mtem Quantity ER Description CHAIN SHACKLE 1 4 LIP ASSIST SPRING 3 16 LINK CHAIN CABLE CLAMP AIR BAG LIFTING KIT ANGLE FLAT WASHER UPSET THREAD NUT Re RENE 8 1 TRUSS HD MACH SCR 3 8 16 X 1 000357 August 2012 The mounting angle is connected to the center air bag support pan Ais Link location see chart 8 50k levelers do not use the same location as lower capacity units Incorrect positioning will result in damage to the spring e E of links Leveler Size from E to shackle rask e s m T RH 10 allcapacities _15 15 18 3 6004751K aFX and aFX S Dock Leveler SafeTFrame 33 2012 4Front Engineered Solutions Inc PARTS LIST continued Subframe and Maintenance Strut Assemblies Fig 43 QTY PART DESCRIPTION DOCUMENTATION KIT NOT SHOWN 6001953 6001953 MANUAL 6004751 6004751 PLACARD WARNING AND INSTRUCTIONS 6001952 6001952 MAINTENANCE STRUT ASSEMBLY 6 LG DECK IN 20 PIT 710 042
6. Came 6 LG DOCK LEVELERS ALL CAPACITY ITEM QTY PART DESCRIPTION BAG PAN FAN ASSEMBLY INCLUDES ITEMS 1 20 WASHER SIE FLAT LIFTING BAG CLAMP BAR PAN OUTER PAN INNER NUT NYLOK 38 16 WHEEL R August 2012 6004751K aFX and aFX S Dock Leveler Safe TFrame 37 2012 4Front Engineered Solutions Inc A 20 ITEM 6 9 BEE NE 2 PARTS LIST continued Air Bag Pan Assembly 8 LG DOCK LEVELERS 30K 35K 40K and 45K CAPACITY aFX MODEL only 8 LG DOCK LEVELERS 40K and 45K CAPACITY aFX S MODEL only a _ _BAGIPANIFAN ASSEMBLY INGLUDES TEMS 120 11285 mzer UFTNGBAGASSEMBLY NOLUDES ITEMS 23 8 AND Tj mem WASHER 3 8 FLAT i 6 4 PANOUTER 55 6 o NUT NOK STE 900255 00258 Ce 3 AME FRONT 728 5 eft AXE REAR 72 1252 2 1 BOUL HEXHD 00957 NIPPLE 155 578 155 578 AR BAG NOT SHOWN 184 379 184 379 8 LG DOCK LEVELERS 50K CAPACITY 10 LG DOCK LEVELERS ALL CAPACITY a _ _BAGIPANIFAN ASSEMBLY NOLUDES ITEMS 120 mzer UFTNGBAGASSEMBLY NOLUDES ITEMS 23 8 AND Tjj 5 00 2 urmweBg GAMPBAR a ECCT 156 6
7. 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 0 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 9 147 e 10 0 K 12 0 14 4 22 2 10 7 18 6 7 5 153 K 12 0 4 lip bend 16 lip Optional 7 lip bend 16 lip August 2012 6004751K aFX and aFX S 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 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 mus
8. 710 042 6 LG DECK IN 24 PIT 6013620 6013620 8 LG DECK IN 20 PIT 708 883 708 883 8 LG DECK IN 24 PIT 6013621 6013621 10 LG DECK IN 24 PIT 712 537 712 537 Note Items 5 8 included in item 2 34 6004751K aFX and aFX S Dock Leveler SafeTFrame August 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued Optional Subframe Riser Kit and Cap Plug Fig 44 2 ITEM QTY PART DESCRIPTION aFX August 2012 6004751K aFX and aFX S Dock Leveler SafeTFrame 35 2012 4Front Engineered Solutions Inc PARTS LIST continued Connecting Rod Push Bar and Lip Assist Assemblies Fig 45 ITEM PART DESCRIPTION PUSH BAR 6011490 6011490 ROD CONNECTING 6 LG DOCK LEVELER 711 848 711 848 8 LG DOCK LEVELER 711 849 711 849 10 LG DOCK LEVELER 712 462 712 462 LEVER LIP LIFTER 6 LG DOCK LEVELER 711 998 711 998 8 AND 10 LG DOCK LEVELER 711 999 711 999 LEVER LIP ASSIST PIN CLEVIS 1 2 DIA X 1 3 4 GAS SPRING 25K LEVELERS 1 GAS SPRING 30 45K LEVELERS 709 437 709 437 WASHER 3 8 000 214 000 214 SPACER LIP 6 1 2 WIDE DOCK LEVELER 287 606 287 606 7 WIDE DOCK LEVELER 287 607 287 607 36 6004751K aFX and aFX S Dock Leveler SafeTFrame August 2012 2012 4Front Engineered Solutions Inc 1 2 3 4 5 10 11 12 13 14 15 16 7 PARTS LIST continued Air Bag Pan Assembly Fig 46 FOR SHIPPING
9. 8 NUT NOK STE 900255 00258 7 6 WHEEL 716 eft vern OoOO ii 75 Co AXERER 72 1252 1 oo BOUL HEXHD 90 85 035r wR 1439 38 6004751K aFX and aFX S Dock Leveler SafeTFrame August 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued Fan Piping Assembly Fig 47 ANS N NNNM NN WS N AA N Y NW 2 ian Guamiy Poner RKC Ls cons wes 7 1 115V CONTROL STATION 908 753 CONTROL STATION OPTIONAL DUAL CONTACT 909 052 For use with interlock applications on STAR 4 and AUTO CHOCK vehicle restraints August 2012 6004751K aFX and aFX S Dock Leveler SafeTFrame 39 2012 4Front Engineered Solutions Inc PARTS LIST continued OPTIONAL ENERGY GUARD DOCK LEVELLER SEALING SYSTEM Fig 48 Description Quantity Part 6x6 6 5 6 6 7 6x8 6 5 8 7x8 6x10 6 5x10 7x10 Number 6008228 6008229 6008230 6008234 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 Al
10. 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 42 6004751K aFX and aFX S Dock Leveler SafeTFrame August 2012 2012 4Front Engineered Solutions Inc aFX S LIMITED WARRANTY THIS LIMITED WARRANTY IS 4FRONT S SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE DOCK LEVELER AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES EXPRESS OR IMPLIED 4FRONT 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 da
11. 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 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 Fig 19 INSTALLATION continued Warning and operating instruction placard August 2012 6004751K aFX and aFX S Dock Leveler Safe TFrame 2012 4Front Engineered Solutions Inc 13 IN STALLATION continued INSTALLATION TROUBLESHOOTING The following 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 mcm ae 14 POSSIBLE CAUSE a
12. pan rollers kit part 184376 for 19 subframes and 6013799 for 23 subframes to both sides of the pan assembly either 16 or 19 back from the front edge as shown in Fig 34 NOTE For 8 long 50K capacity and 10 long dock levelers attach pan rollers 19 from front edge as shown in Fig 34 2 24 1 3 After installing the rollers press down on the front of the bag assembly extending the spring to unhook the rear axle from the back of the leveler and pull forward 1 4 Disconnect the bolt from the center pan and remove the lifting kit from the bag support pan assembly 1 5 Balancing the bag support pan assembly on the rollers roll it to the front of the pit The rollers will roll on the frame rails To install the bag pan assembly 2 1 Roll the bag support pan assembly to the back of the pit and align it with the hooks on the back of the ramp 2 2 Tilt the front of the assembly up and attach the support angle that is connected to the bottom of the lifting kit to the hole in the center pan 2 3 Press the front of the bag down and hook the rear axle into the hooks on the back of the ramp 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc Fig 34 2 4 Allow the spring to raise the bag then remove the pan rollers 2 5 Re connect the bolt from the lifting kit to the center pan NOTE See page 34 for clean pit kit parts list and installation instructions
13. 1 864 711 864 711 863 711 863 711 866 711 866 711 865 711 865 711 868 711 868 711 867 711 867 711 882 711 882 711 881 711 881 711 884 711 884 711 883 711 883 711 886 711 886 711 885 711 885 711 900 711 900 711 899 711 899 711 902 711 902 711 901 711 901 711 904 711 904 711 903 711 903 712 957 713 786 712 958 713 787 712 959 713 788 4 2 RETAINER SHAFT HINGE PIN 035 451 2 COLLAR SHAFT HINGE PIN 131 542 5 2 TOE GUARD MIDDLE SLIDING 6 LG DOCK LEVELER 8 LG DOCK LEVELER 10 LG DOCK LEVELER 155 554 155 554 155 555 155 555 155 557 155 557 August 2012 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc 31 PARTS LIST continued Ramp Lip Toe Guards and Lip Lock Assemblies PART DESCRIPTION 2 TOE GUARD BOTTOM SLIDING 6 LG DOCK LEVELER 155 554 155 554 8 LG DOCK LEVELER 155 556 155 556 10 LG DOCK LEVELER 155 557 155 557 NUT LOCK 3 8 16 000 253 000 253 8 4 SCREW TRUSS HEAD 3 8 16 X 1 131 477 131 477 2 ROLLERLIFTER WIRE FORM 101 100 101 100 SPACER TOE GUARD 152 878 152 878 SCREW SHOULDER 131 455 131 455 WASHER 3 8 FLAT 000 214 000 214 WASHER 5 16 FLAT 000 055 000 055 NUT 5 16 18 NYLOC 131 456 131 456 LABEL HAZARD 138 837 138 837 LABEL WARNING 6008485 6008485 LABEL LIP LOCK 700 136 700 136 SPACER PLASTIC PIPE 6001402 6001402 20 SUPPORT DOCK LEVEL 1 LEFT SIDE SHOWN 714 126 714 126 1 RIGHT S
14. Frame 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 nameplates caution and instruction markings or labels are in place and legible and that the appropriate operating and maintenance manuals
15. IDE NOT SHOWN 714 125 714 125 SPRING TORSION 030 195 030 195 PIN GROOVED 035 338 035 338 KLIPRING 049 060 049 060 S HOOK 000 181 000 181 NUT LOCK 3 8 16 000 030 000 030 PIN CLEVIS 5 8 X 3 1 2 LG 6001348 6001348 SPRING TORSION 101 091 101 091 WELDMENT ROLLER ARM 714 070 714 070 PIN COTTER 1 8 X 1 1 4 035 036 035 036 SHOULDER SCREW 1 2 X 4 6001340 6001340 ROLLER CAM FOLLOWER 6001341 6001341 LEVER LIP LOCK 155 150 155 150 SPRING EXTENSION 700 135 700 135 PIN ROLL 3 16 DIA X 2 035 149 035 149 6 LG SASH CHAIN 6001950 6001950 PIN COTTER HAIR 035 200 035 200 SCREW DRIVE 6 X 1 4 LG 000 518 000 518 DECAL AFX 138 871 138 871 39 1 BAG SHIELD 6 LG DOCK LEVELER ALL CAPACITY 155 295 155 295 8 LG DOCK LEVELER 30K 45K CAPACITY 155 295 155 400 8 LG DOCK LEVELER 50K CAPACITY 155 400 155 400 10 LG DOCK LEVELER ALL CAPACITY 155 400 155 400 RIVET 3 16 DIA 131 271 131 271 LIFTER ROLLER ARM LEFT HAND 714 084 714 084 RIGHT HAND 714 083 714 083 BELOW DOCK CONTROL CHAIN ASSEMBLY 6 6012661 6012661 BELOW DOCK CONTROL CHAIN ASSEMBLY 8 6003453 6003453 BELOW DOCK CONTROL CHAIN ASSEMBLY 10 6003452 6003452 6003452 32 6004751K aFX and aFX S Dock Leveler SafeTFrame August 2012 2012 4Front Engineered Solutions Inc PARTS LIST Clean pit kit Fig 42 The upper shackle is connected to Fa gt the ring next to the chain cup ES
16. IST continued Ramp Lip Toe Guards and Lip Lock Assemblies PART DESCRIPTION 1 1 GUARD SAFETY LIP 6 W DOCK LEVELER 6 1 2 W DOCK LEVELER 7 W DOCK LEVELER 2 1 LIP 6FT WIDE 30K AND 35K CAPACITY 16 X 6 W 4 BEND 16 X 6 W 7 BEND 18 X 6 W 4 BEND 18 X 6 W 7 BEND 20 X 6 W 4 BEND 20 X 6 W 7 BEND LIP 6 1 2 WIDE 30K AND 35K CAPACITY 16 X 6 5 W 4 BEND 16 X 6 5 W 7 BEND 18 X 6 5 W 4 BEND 18 X 6 5 W 7 BEND 20 X 6 5 W 4 BEND 20 X 6 5 W 7 BEND LIP 7 WIDE 30K AND 35K CAPACITY 16 X 7 W 4 BEND 16 X 7 W 7 BEND 18 X 7 W 4 BEND 18 X 7 W 7 BEND 20 X 7 W 4 BEND 20 X 7 W 7 BEND LIP 6FT WIDE 40K 45K AND 50K CAPACITY 16 X 6 W 4 BEND 16 X 6 W 7 BEND 18 X 6 W 4 BEND 18 X 6 W 7 BEND 20 X 6 W 4 BEND 20 X 6 W 7 BEND LIP 6 1 2 WIDE 40K 45K AND 50K CAPACITY 16 X 6 5 W 4 BEND 16 X 6 5 W 7 BEND 18 X 6 5 W 4 BEND 18 X 6 5 W 7 BEND 20 X 6 5 W 4 BEND 20 X 6 5 W 7 BEND LIP 7 WIDE 40K 45K AND 50K CAPACITY 16 X 7 W 4 BEND 16 X 7 W 7 BEND 18 X 7 W 4 BEND 18 X 7 W 7 BEND 20 X 7 W 4 BEND 20 X 7 W 7 BEND 3 2 LIP SHAFT 6 W DOCK LEVELER 6 5 W DOCK LEVELER 7 W DOCK LEVELER 714 220 714 219 714 218 711 858 711 857 711 860 711 859 711 862 711 861 711 876 711 875 711 878 711 877 711 880 711 879 711 894 711 893 711 896 711 895 711 898 711 897 71
17. NE aFX aFX S Dock Leveler KELLEY This User s Manual applies to aFX dock levelers manufactured beginning September 2012 with the serial numbers 61056056 AIR SUPERIORITY ONLY FROM KELLEY and higher WARNING 7 M Do not install operate or service this product unless you U S e r S a n u a have read and understand the Safety Practices Warnings n sta atio n O p e ratio ns Installation and Operating Instructions contained in this User s Manual Failure to do so could result death or Maintenance and Parts serious injury Part No 6004751K CONTENTS Introduction 4 16 Safety Signal 2 Planned Maintenance eese 19 Safety isi a TN Wo E 22 Owner s Responsibilities sees 4 sn 25 Ramp and Lip Grade 5 Parts annas 28 51 10 a a qM UN Warranty 2 42 Wining Diagram t 15 Distributor Information canoe ond indo ert eco 44 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
18. Pit 90 days August 2012 6004751K aFX and aFX S Dock Leveler SafeTFrame 21 2012 4Front Engineered Solutions Inc SERVICE TOOLS LA WARNING Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operations Instruction section on pages 16 through 18 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 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
19. 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 Fig 21 IE 1 2 max 6 1S ST re re SOLUTION a1 Align the sides parallel and equally 6004751K aFX and aFX S 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 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 Fig 22 1 8 MAX allowable step no greater than 1 x 3 in size 6 contact zone August 2012 ADANGER 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 meet all applicable codes If it is necessary to make troubleshooting checks inside
20. TIAL 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 August 2012 6004751K aFX and aFX S 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 KELLEY aFX and FX are registered trademarks of 4Front Engineered Solutions Inc 2012 4Front Engineered Solutions Inc Part No 6004751K
21. 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 User 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 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc Indicates 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 August 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 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 The w
22. a 1 2 square drive 1 2 ratchet or impact tool work from one side to the other turn each of the leveling screws on the rear angle counter clockwise until the top surface of the rear angle is level with the rear pit curb angle Repeat on each leg until all are legs in contact with the pit floor and the top frame angle is flush with the rear curb angle See Fig 8 NOTICE The rear edge of the dock leveler should be level or slightly 1 16 maximum below dock level The top surface of the dock leveler should be level and a smooth transition with the dock floor curb steel The front end should be level and parallel with the rear frame angle for proper operation Unequal 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 setting the front supports Fig 6 Fig 7
23. aise the bag support pan assembly when the dock leveler it rested on the maintenance post Reference the chart on page 34 for the upper shackle location on the chain to determine the proper link for connecting the kit to the ring on the deck During normal operation the spring extends as the bag inflates See Fig 32 When pinned on the maintenance strut the spring will raise the bag support pan assembly as the bag deflates Once the bag pan support assembly stops moving there is then easy access for cleaning the pit or installing the bag removal tools for removing the bag See Fig 33 August 2012 S E RVI C E TOO LS continued Fig 32 Fig 33 6004751K aFX and aFX S Dock Leveler SafeTFrame 23 2012 4Front Engineered Solutions Inc S E RVI C E TOO LS continued PAN 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 22 and 2 The power is disconnected and properly tagged or locked off 1 To remove bag support pan assembly 1 1 Allow the lifting spring to deflate the air bag and raise the bag support pan assembly 1 2 Attach
24. 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 labelled rated capacity It must also be compatible with the loading equipment and other conditions relating to the dock 4 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc August 2012 RAMP AND LIP GRADES Fig 1 Ramp grade sp l 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 LIP DOCK in 18 0 18 0 16 0 4 A 16 0 B 14 0 2 2 8 14 0 0 0 V E 12 0 19 4 11 6 E 12 0 10 0 8 7 16 5 10 0 D D 8 80 137 58 8 8 0 0 6 60 108 30 2 6 0 4 0 8 0 0 2 4 0 2 0 5 2 2 6 2 0 0 0 2 4 5 4 0 0 E 2 0 0 3 8 2 0 3 8 1 0
25. aterial 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 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 August 2012 6004751K aFX and aFX S Dock Leveler SafeT
26. ced 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 INSTALLATION continued Fig 4 August 2012 6004751K aFX and aFX S 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 sides 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
27. e event of premature vehicle platform separation 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 16 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc August 2012 1 Wait 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 f necessary remove end loads with the ramp in the dock level stored position See Fig 24 NOTE If the vehicle is to be serviced for a below dock end load see operation instructions for Below Dock Control on page 18 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 5 3 Ramp will lower and lip will extend until the lip rests on the vehicle platform See Fig 26 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 mater
28. eptacle 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 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 38 and 39 d Verify motor voltage is between 110 129 volts AC while motor is running at full load 6004751K aFX and aFX S Dock Leveler SafeTFrame 25 2012 4Front Engineered Solutions Inc TROUBLESHOOTING continued PROBLEM 3 Lip fails to lower to the stored position when the dock leveler is raised from vehicle POSSIBLE CAUSE a Lip extension mechanism is bent or binding 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 30 b Make sure pin is in correct position and both pins are in good condition See Fig 36 a Check connection of dock level control chain to the dock level support legs b Lip assis
29. ersonnel or material handling equipment and result in death or serious injury Below dock control BDC chain dock floor 6 Remove wheel chocks or release vehicle 7T Tell vehicle driver Your vehicle may now leave the dock 18 6004751K aFX and aFX S Dock Leveler SafeTFrame August 2012 2012 4Front Engineered Solutions Inc Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or require replacement please call your local Kelley distributor Fig 29 PLANNED MAINTENANCE ADANGER 24 c A DANGER 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 074E aFX S only 4 Places DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 921 070 comply will result in death or serious injury Refer to user s manual for proper maintenance procedures DANGER OPERATIONS 6001952 Danger and operation placard mounted on wall near leveler August 2012 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc 19 PLANNED MAINTENANCE continued LA WARNING Before servicing the dock leveler read and follow the Safety certai
30. ersons to lockout and secure the leveler for maintenance 12 Return power to the leveler control Using the aFX push button control or mechanical support raise the screw deck and secure 10 a Fig 12 3 long min 1 2 square drive dock leveler support leveling 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 3 16 weld position both sides The second person positions the maintenance strut 3 16 weld into the bracket located on the underside of the ramp 3 UT assembly and pins it in place with hairpin clip See Fig 15 and the instruction label on maintenance strut Air pressure or mechanical support may now be both sides 3 16 weld both sides stop lt 3 16 weld 3 long min 3 16 weld curb steel removed Fig 13 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc August 2012 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 AND THE POWER IS DISCONNECTED AND PROPERLY TAGGED OR LOCKED OFF 13 Manually lift the hinged lip into the raised po
31. g 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 platform sides and cargo If lip does not lower to vehicle platform reposition vehicle platform Stay clear of leveler unless lip is supported by vehicle platform or the leveler is stored at dock level Visually check that the lip is supported by the vehicle platform 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 dock leveler if 3 1 2 or more above dock level is to dock level If leveler is 3 1 2 above dock level to 1 below dock level it will drop to 4 below dock
32. he dock leveler The maintenance strut has a plastic tie wrap holding them 12 13 to the subframe Remove these items before placing 1 the leveler into the pit Make sure the customer gets the user s manual and is properly trained Box located as shown 6 6004751K aFX and aFX S Dock Leveler SafeTFrame August 2012 2012 4Front Engineered Solutions Inc 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 6004652 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 35 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 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 pla
33. ial handling equipment to lower the ramp and lip sections 5 4 Proceed with loading or unloading 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 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 OPERATION continued Fig 24 P Dock level supports Fig 25 Lip S Ramp Push to raise Vehicle floor Fig 26 Om Fig 27 O Dock level support leg ise Front angle Ad dock level support l 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 hanging 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 seri
34. isually 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 22 Check all labels every 90 days Replace if required See page 19 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 bumpers Four inches 4 of bumper protection is required Worn torn loose or missing bumpers must be replaced 20 6004751K aFX and aFX S Dock Leveler SafeTFrame August 2012 2012 4Front Engineered Solutions Inc PLANNED MAINTENANCE continued NOTE Legend Use only lubricants shown Improper lubrication or adjustments 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 Cleaning Fig 30 Location Frequency Lip rods d Gas spring pins Swing link pins d Connecting rod pins d Leg pivot pins d Roller arm pivot pin Air bag bolts 0 4 29 31 ft lbs Rear hinge pins
35. level If lower than 1 below dock level it will drop to full below dock or 8 below dock level 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 This 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 This 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 A mechanical 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 platform forming a bridge Patented airDefense sensors glide along reinforced cams purging stump out and providing fluid free float motion along with free fall protection in th
36. 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 22 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc 1 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 through maintenance strut pin Maintenance strut pin Maintenance strut hairpin clip into lip lock Maintenance strut bracket August 2012 CLEAN PIT KIT The clean pit kit 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 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 22 and 2 The power is disconnected and properly tagged or locked off The clean pit kit as shown will automatically r
37. n 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 18 of this User s Manual that 1 THE MAINTENANCE STRUT AND LIP LOCK ARE SECURELY PINNED IN PLACE see page 22 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 maintaining or repairing the dock leveler MAINTENANCE AND LUBRICATION CHART Lip Lip Dock Level Extension Extension Support Leg Mechanism Spring Assist and Roller Arm Pivot Pins Lip Hinge Assembly Hinges Ramp Dock Leveler Hinge Pins Pit Every 90 Days Every 90 Days SAE 30 Lubricate Gas Every 90 Days Every 90 Days Every 90 Days Grease Front Spring amp Clevis Push Bar Pins SAE 30 Not Not Required Required Lubrication As Required As Required As Required As Required As Required Every 00 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 oe 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 V
38. nd 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 Fig 17 MOLDED L BUMPERS J bolts 3 per bumper furnished by Kelley Company Inc Locate and weld to curb angle at time of bumper installation Fig 18 LAMINATED BUMPERS 3 4 dia 3 8 side of pit anchor to side of bumper bolt 21 Lift up on the hinged lip and store the lip lock under the mounting plate field ramp installed 1 4 supplied Weld full length of by others bumper mounting To plate Downhill welds 4 a curb are unacceptable angle T Vertical pcs SON mere Laminations must be angie installed vertically 12 6004751K aFX and aFX S Dock Leveler SafeTFrame August 2012 2012 4Front Engineered Solutions Inc The hinged lip will extend as the ramp moves down 23 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
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40. of your dock leveler see Fig 39 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 28 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc Fig 38 x _ EE Length 6 6 long 8 8 long 10 10 long Width 6 6 wide 6 5 6 1 2 wide 7 7 wide S Optional Safety Lip Fig 39 Lip length 16 18 Or 20 Pit depth 20 or 24 Nominal Size Wx L ft 6x6 6x8 August 2012 PARTS LIST aFX DOCK LEVELER Ramp Lip Toe Guards and Lip Lock Assemblies Note Rivets Item 40 Attach Bag Shield Item 39 To Brackets Welded On Bottom Of Ramp August 2012 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc 29 PARTS LIST aFX S DOCK LEVELER Ramp Lip Toe Guards and Lip Lock Assemblies Fig 41 o Ec 290 too ese 6 5 gt 2 5 8 on 0 OL gt 6 5 cy 5 5 aj
41. orking 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 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 m
42. ous injury August 2012 6004751K aFX and aFX S Dock Leveler SafeTFrame 17 2012 4Front Engineered Solutions Inc OPERATION continued 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 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 28 Release the BDC chain Load or unload end loads When loading or unloading is complete return the dock leveler to the stored position 5 1 Push and hold the 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 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 p
43. sition 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 August 2012 INSTALLATION continued Fig 14 Retaining bolts Fig 15 Lip Insert hairpin Lip lock clip through maintenance strut pin Maintenance strut pin hairpin strut Maintenance clip into strut bracket lip lock Fig 16 Remove shipping cotter pins 6004751K aFX and aFX S Dock Leveler SafeTFrame 11 2012 4Front Engineered Solutions Inc IN STALLATION continued LA WARNING Improper installation of anchoring devices or installation into aged or unsound concrete could res
44. t 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 Fig 2 5 Verify that gas spring retaining pins have cotter pins installed 1 m 6 Verify that both the lip lock and the maintenance strut Push button are undamaged and have safety hitch pins on chains e control station 48 7 Visually check that the foot assemblies at the rear of the leveler are in place and undamaged SS PREPARE SITE A WARNING EE Place barricades around pit on dock floor and drive while EC installing maintaining or repairing dock leveler i 10 1 The control station User s Manual and dock bumpers line are attached to the sub frame of t
45. t gas spring pin is in incorrect position 4 Dock level support legs will not retract for below dock operation a Chain not connected See Fig 37 b Chain binding b Check for binding of dock level control chain c Legs binding c 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 distance d Chain pulling one leg a The link selected for attachment to the deck is incorrect a Connect the lifting kit chain using a link closer to the spring See chart on page 34 5 Air bag is not lifting when the ramp is on the maintenance post Fig 36 aFX Model aFX S Model Lip Capacity m Hole Lip Size E 30K amp 35K 40K 45K amp 50K ALL CAPACITY 6 16 Hole 2 Hole 1 6 16 Hole 3 6 18 6 18 6 20 6 20 6 1 2 16 6 1 2 16 6 1 2 18 6 1 2 18 6 1 2 20 6 1 2 20 7 16 7 16 7 18 7 18 7 20 August 2012 Lip Size 26 6004751K aFX and aFX S Dock Leveler SafeTFrame 2012 4Front Engineered Solutions Inc TROUBLESHOOTING continued D NN Sa Dock Level Support Leg PROBLEM POSSIBLE CAUSE SOLUTION 6 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
46. 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 WIRING DIAGRAM Fig 23 120V Single Phase 50 60 Hz Con Station Single Contact Circuit Breaker By Others 20 AMP MAX En LE BLK 2 120 d ya 1 Phase e TNT 50 60 Hz T Neural 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 Optional connection to restraint Normally Closed Control Star4 LA terminals C and 17 Field Installed Low Voltage Only Station For Star4 module with 403 controller See Supplied Mfg Instructions MB use 21 and 2 0 0 le 222222 Auto chock terminal block Circuit Breaker JL terminals no 5 and no 24 By Others 20 AMP MAX TT ES un 120V a Line 1 Phase 1 Grn 50 60 Hz Neutral Pit Wall 1 Phase 120V Receptacle 50 60 Hz NEMA 5 15R By Others August 2012 6004751K aFX and aFX S Dock Leveler SafeTFrame 15 2012 4Front Engineered Solutions Inc OPERATION LA WARNING Before operatin
47. to assure chain has enough slack to allow leg to swing forward Adjust as required See Fig 37 7 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 30 b Pins are in incorrect position b Make sure all pins and pin retrainers are in place and in good condition 8 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 35 b Links and connecting rod are not b Check to see that the lip extends aligned far enough to allow the links and connecting rod to align and then reach an over center position August 2012 6004751K aFX and aFX S Dock Leveler Safe TFrame 27 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 serial number and capacity 2 The model number and capacity can be found on the dock leveler product label located on the frame leg See Fig 40 and 41 The meaning of each digit in the model number is shown in Fig 38 Example aFX 6 x 8 aFX S 6 x 8 6 wide Safety Lip 8 long 6 wide 8 long 3 To determine the nominal size
48. ult 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 the dock leveler was raised using a mechanical device lower it using the same device 22 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 a
49. uminum 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 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 40 6004751K aFX and aFX S Dock Leveler SafeTFrame August 2012 2012 4Front Engineered Solutions Inc NOTES August 2012 6004751K aFX and aFX S Dock Leveler SafeTFrame 41 2012 4Front Engineered Solutions Inc aFX LIMITED WARRANTY THIS LIMITED WARRANTY IS 4FRONT S SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE DOCK LEVELER AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES EXPRESS OR IMPLIED 4FRONT 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 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 expressl
50. y 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 The LIP HINGE for this DOCK LEVELER is warranted for the rated lifetime of the DOCK LEVELER provided that the LIP HINGE is maintained per this User s Manual The rated lifetime of the DOCK LEVELER shall be determined by the KELLEY DOCK LEVELER LIFE RATING SYSTEM publication number 10 768 available from KELLEY upon request In the event that this DOCK LEVELER or LIP HINGE prove defective in material or workmanship within the applicable limited warranty period KELLEY will at its option 1 Replace the DOCK LEVELER or LIP HINGE or the defective portion of either without charge to the owner or 2 Alter or repair the DOCK LEVELER or LIP HINGE 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 ANY RESPONSIBILITY OR LIABILITY FOR ANY
51. ys 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 ANY RESPONSIBILITY OR LIABILITY FOR ANY LOSS OR DAMAGE OF ANY KIND INCLUDING WITHOUT LIMITATION DIRECT INDIRECT CONSEQUEN

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