Download aFX™DOCKLEVELER

1612 Hutton Dr. Suite 140 • Carrollton, TX. 75006
Phone: (972) 466-0707 • Fax: (972) 323-2661
aFX DOCKLEVELER
™
Installation and Owner’s Manual
This manual applies to aFX Docklevelers manufactured beginning
January 2005 with serial numbers 10207700 and higher.
5601 R4 01/05
Do not install, operate or service this
product unless you have read and understand the Safety Practices, Warnings, and
Installation and Operating Instructions
contained in this manual. Failure to do so
could result in death or serious injury.
13
5601 R4 01/05
LIMITED WARRANTY
KELLEY warrants that this DOCKLEVELER will be free from defects in material and workmanship under normal use for a period of one (1)
year from the earlier of 1) 60 days after the date of initial shipment by KELLEY, or 2) the date of installation of the DOCKLEVELER by the
original purchaser, provided that the owner maintains and operates the DOCKLEVELER in accordance with this Owner's Manual.
KELLEY expressly warrants that the BAG, MOTOR, GASKETS, FITTINGS and SEALS will be free from defects 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
DOCKLEVELER by the original purchaser, provided the purchaser maintains and operates the DOCKLEVELER in accordance with the
Owner's Manual.
The LIP HINGE for this DOCKLEVELER is warranted for the rated lifetime of the DOCKLEVELER provided that the LIP HINGE is maintained per this Owner’s Manual. The rated lifetime of the DOCKLEVELER shall be determined by the KELLEY DOCKLEVELER LIFE
RATING SYSTEM, publication number 10-768, available from KELLEY upon request.
In the event that this DOCKLEVELER or LIP HINGE prove defective in material or workmanship within the applicable limited warranty
period, KELLEY will, at its option:
1.
Replace the DOCKLEVELER or LIP HINGE, or the defective portion of either, without charge to the owner; or
2.
Alter or repair the DOCKLEVELER or LIP HINGE, on site or elsewhere, without charge to the owner.
The limited warranty stated in the preceding paragraph IS EXCLUSIVE AND IT IS IN LIEU OF ANY OTHER GUARANTEES AND WARRANTIES, EXPRESS OR IMPLIED. The limited warranty does not cover any failure caused by improper installation, abuse, negligence, or failure
to maintain and adjust the DOCKLEVELER properly. Parts requiring replacement due to damage resulting from vehicle impact, abuse, or
improper operation are not covered by this warranty. Kelley disclaims any responsibility or liability for any loss or damage (including,
without limitation, direct, indirect or consequential damages, or lost profits or production time) that results from the use of unauthorized
replacement parts or modification of the DOCKLEVELER. KELLEY sole obligation with regard to a DOCKLEVELER that proves to be
defective in material or workmanship shall be as set forth in its standard warranty above (i.e., KELLEY will, at its option, repair or
replace the DOCKLEVELER or portion thereof, without charge to the purchaser.).
This limited warranty does not cover any failure caused by improper installation, abuse, negligence, or failure to properly maintain and
adjust the DOCKLEVELER. This limited warranty will be void or of no effect if the original purchaser does not notify Kelley's warranty
department within ninety (90) daysafter the product defect is discovered. Parts requiring replacement due to damage resulting from
vehicle impact, abuse, or improper operation are not covered by this warranty. KELLEYdisclaims any responsibility or liability for any loss
or damage that results from the use of unauthorized replacement parts or modification of the DOCKLEVELER.
THERE ARE NO WARRANTIES, EXPRESS OR IMPLIED, WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF,
AND THERE IS NO WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.
KELLEY warranties extend only to the DOCKLEVELER itself.
KELLEY DISCLAIMS all warranties, express or implied, responsibility or liability for loss or damage of any kind
associated with the installation or maintenance of the dockleveler, including any liability for premature product wear,
product failure, property damage or bodily injury arising from improper installation or maintenance of the
DOCKLEVELER.
i
15
5601 R4 01/05
TRUCK BED
POSITION
from DOCK,
(in.)
A
B
O
V
E
D
O
C
K
TRUCK BED
POSITION
from DOCK,
(in.)
RAMP and LIP grades, % for each Dockleveler length
6’ Leveler
8’ Leveler
10’ Leveler
RAMP
LIP
RAMP
LIP
RAMP
LIP
18.0
16.0
14.0
----
----
----
----
17.3
15.6
13.9
4.8
3.0
1.3
12.0
10.0
8.0
20.5
17.6
14.7
8.0
5.0
2.2
15.3
13.1
11.0
2.7
0.6
-1.6
12.2
10.5
8.8
-0.4
-2.1
-3.8
6.0
4.0
2.0
11.9
9.1
6.3
-0.7
-3.5
-6.3
8.9
6.8
4.7
-3.7
-5.8
-7.9
7.1
5.4
3.8
-5.5
-7.1
-8.8
A
B
O
V
E
D
O
C
K
RAMP and LIP grades, % for each Dockleveler length
6’ Leveler
8’ Leveler
10’ Leveler
RAMP
LIP
RAMP
LIP
RAMP
LIP
18.0
16.0
14.0
----
----
----
----
16.7
15.0
13.2
8.8
7.1
5.4
12.0
10.0
8.0
19.4
16.5
13.7
11.6
8.7
5.8
14.5
12.3
10.2
6.6
4.5
2.4
11.5
9.8
8.2
3.7
2.0
0.3
6.0
4.0
2.0
10.8
8.0
5.2
3.0
0.2
-2.6
8.1
6.0
3.9
0.2
-1.8
-3.9
6.5
4.8
3.1
-1.4
-3.1
-4.7
0.0
3.5
-9.1
2.6
-10.0
2.1
-10.5
0.0
2.4
-5.4
1.8
-6.0
1.5
-6.4
B
E
L
O
W
-2.0
-4.0
-6.0
0.7
-2.1
-4.9
-11.9
-14.6
-17.4
0.5
-1.6
-3.6
-12.0
-14.1
-16.2
0.4
-1.2
-2.9
-12.1
-13.8
-15.5
B
E
L
O
W
-2.0
-4.0
-6.0
-0.3
-3.1
-5.9
-8.2
-11.0
-13.8
-0.3
-2.3
-4.4
-8.1
-10.2
-12.3
-0.2
-1.9
-3.5
-8.1
-9.7
-11.4
D
O
C
K
-8.0
-10.0
-12.0
-7.7
-10.5
-13.3
-20.2
-23.0
-25.9
-5.7
-7.8
-9.9
-18.3
-20.4
-22.5
-4.6
-6.3
-7.9
-17.1
-18.8
-20.5
D
O
C
K
-8.0
-10.0
-12.0
-8.7
-11.5
-14.4
-16.6
-19.4
-22.2
-6.5
-8.6
-10.7
-14.4
-16.5
-18.6
-5.2
-6.9
--
-13.1
-14.7
--
Ramp and lip grade, low lip bend, 16” lip.
Ramp and lip grade, standard lip bend, 16” lip.
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 dockleveling devices.
The owner shall see that all nameplates, caution and
instruction markings or labels are in place and legible
and that the appropriate operating and maintenance
manuals are provided to users.
When a transport vehicle is positioned as closely as
practicable to a dockleveling 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.
Modifications or alterations of dockleveling devices
shall be made only with written permission of the
original manufacturer.
When industrial trucks 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.
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.
The dockleveler 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.
Dockleveling 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 dockleveling
device, shall be removed from service, inspected by
the manufacturer’s authorized representative, and
repaired as needed before being placed back in
service.
5601 R4 01/05
16
iiii
CONTENTS
WARRANTY ...........................................................................................................
i
RAMP & LIP GRADES & OWNER’S RESPONSIBILITIES ......................................
ii
CONTENTS & SAFETY SIGNAL WORDS ..............................................................
iii
SAFETY PRACTICES .............................................................................................
iv
INSTALLATION ......................................................................................................
1
WIRING DIAGRAM .................................................................................................
9
OPERATION ...........................................................................................................
10
MAINTENANCE AND LUBRICATION .....................................................................
13
SERVICE TOOLS ...................................................................................................
14
TROUBLESHOOTING ............................................................................................
17
PARTS LIST ...........................................................................................................
20
Safety Signal Words
You may find safety signal words such as DANGER,
WARNING, or CAUTION throughout the owners
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 injury or death.
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.
Indicates a potentially hazardous situation which,
if not avoided, could result in death or serious
injury.
Caution used without the safety alert symbol
Indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
iii
17
5601 R4 01/05
SAFETY PRACTICES
Read these safety practices before installing,
operating or servicing the Dockleveler. 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 Kelley at
1-972-466-0707.
OPERATION:
OPERATION CONTINUED:
Use restricted to trained operators.
Move all equipment, material or people off dockleveler
and store dockleveler at dock level before allowing the
truck to pull out.
Follow procedures on placcard posted near dockleveler.
Do not use this unit to service trailers outside its intended
working range which is 12 inches above and 12 inches
below dock.
Store dockleveler at dock level after below dock end
loading.
Do not operate the dockleveler with equipment, material
or people on the ramp or lip.
INSTALLATION, MAINTENANCE AND
SERVICE:
Do not operate the dockleveler when anyone is in front of
it unless they are securing the maintenance strut.
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 dockleveler.
Stay clear of the dockleveler when it is moving.
Do not operate the dockleveler when anyone is in
front of it unless they are securing the maintenance
strut.
KEEP HANDS CLEAR OF HINGES AT ALL TIMES. Do
not use hands to position dockleveler ramp or lip in truck
or to store dockleveler.
Stay clear of leveler unless lip supported by the truck bed
or the ramp is supported by both front dock level supports; unsupported leveler can lower unexpectedly.
PUT AND PIN MAINTENANCE STRUT AND LIP
LOCK IN PLACE before climbing into the dockleveler
pit or doing any maintenance or repair under the
dockleveler.
Do not use the dockleveler if it looks broken or does not
seem to work right. Tell your supervisor it needs repair
right away.
Disconnect the power and properly tag or lock off
before climbing into the dockleveler pit or doing any
maintenance or repair under the dockleveler.
Do not stand in the driveway between the dockleveler
and a backing truck.
All electrical troubleshooting or repair must be done
by a qualified technician and must meet applicable
codes.
Before chocking wheels or engaging vehicle restraint,
dump air from air ride suspensions and set parking
brakes.
Disconnect the power and properly tag or lock off
before doing any electrical work.
Chock truck wheels or lock truck in place with a truck
restraining device and set brakes before loading or
unloading.
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.
Ensure lip avoids contact with trailer sides and cargo. If
lip does not lower to trailer bed, reposition trailer.
Do not use a fork truck or other material handling equipment to lower the ramp.
5601 R4 01/05
iv
18
INSTALLATION
INSTALLATION
PIT CHECK
1.
Check entire dockleveler 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 agrees with the correct
location and voltage for the junction box.
Before installing the dockleveler, read and follow
the safety practices on page iv. Failure to follow
the safety practices could result in death or
serious injury.
LEVELER CHECK
1.
Visually check that the length of exposed thread
on all clamp bar bolts are equal to ensure they are
properly tightened.
2.
Visually check that the 4 rear hinge pins and
retaining clips are in place.
3.
Visually check that the 2 retaining clips for the
lip rods are in place.
4.
Visually check that all cotter pins are in place on
all pins requiring them on the connecting rod, push
bar, and the lip lifter assembly.
5.
Verify that gas spring retaining pins have cotter
pins installed.
6.
Verify that both the lip support and the maintenance strut have safety hitch pins on chains.
FIGURE 1
PUSHBUTTON
CONTROL BOX
48"
PREPARE SITE
Place barricades around pit on dock floor and drive
while installing, maintaining or repairing dockleveler.
1.
The control station and dock bumpers are
attached to the rear frame of the dockleveler. The
maintenance strut has a plastic tie wrap holding it to
the subframe. Remove these items before placing the
leveler into the pit.
FIGURE 2
PIT
CENTER
LINE 10”
2.
Mount and wire pushbutton control box. See
Figure 1. See Wiring Diagram on page 9 of this
manual for wiring information. Wires shown in orange
dashed lines are field connections.
12”-13”
3.
Mount and wire a box with a 115V grounded
receptacle on the pit wall as shown in Figure 2. Wire
receptacle per diagram on page 9.
4.
If conduit must be installed (replacing an
existing mechanical dockleveler) do so at this time.
Refer to the conduit requirements on the pit detail
publication # 5563 or 5566 and Powered Dockleveler
Wiring Diagrams and Typical Installation Drawings,
publication # 5448, for electrical requirements. Follow
all applicable electrical codes and standards.
BOX LOCATED AS
SHOWN
1
5601 R4 01/05
INSTALLATION
FIGURE 3
INSTALLATION OF DOCKLEVELER
STRING LINE
1.
Shims are to be placed under each of the four
rear upright supports, and the two front dock level
supports including secondary stops. To determine the
proper amount of shims to be placed under each
upright, it is recommended 4” x 4” shims be placed on
the pit floor in the positions shown in Figures 3 and 4.
Stack shims so the dimension from the top of the
shims to the top of the dock floor is 19” (-1/16” +0”) or
23” (-1/16” +0”) for 10 ft. long docklevelers. If 4” riser
kit is to be used on 6 ft. or 8 ft. long docklevelers, use
dimension 23” (-1/16”+0”). A string line may be
stretched across the curb angles over the shims to
measure shim height.
6”
3-3/4”
3-3/4”
29-1/2”
29-1/2”
S
S
PIT FLOOR
FIGURE 4
DOCK FLOOR
REAR PIT
CURB ANGLE
19” OR 23” TO STRING LINE
2.
Remove shims from pit and weld in place on the
bottom of the dockleveler frame under the corresponding upright support.
PIT FLOOR
FIGURE 5
NOTE
On 6’ and 8’ long 23” deep pits, weld shims to the 4”
Riser Kit, Kelley P/N 712-125, and then weld the shim
to the frame as shown in Figure 5.
3.
Place lifting lugs from kit, P/N 184-377, into slots
on side of dockleveler. Place a chain or other suitable
lifting device through lifting lugs. The dockleveler
should not be lifted in any other manner when placed
into the pit. See Figure 6.
TYP WELD
NOTE: WELD TUBES TO
SHIMS AND SHIMS TO
FRAME AS SHOWN
DOCK LEVEL
SUPPORT PADS
Inadequate lifting equipment or practices can cause a
load to fall unexpectedly. Make sure the lifting chain
or other lifting devices are in good condition and have
a rated capacity of at least 3500 lbs for the lifting
angle used. Never allow anyone to stand on or near
the dockleveler when it is lifted or placed into the pit.
Stand clear of the dockleveler when it is placed into
the pit. Failure to follow this warning can allow the
dockleveler to fall, tip, or swing into people, causing
death or serious injury.
TYP WELD
ADDITIONAL 8” LG TUBE AND
SHIMS UNDER SECONDARY
STOPS
FIGURE 6
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.
5601 R4 01/05
2
INSTALLATION
FIGURE 7
REAR HINGE
ASSEMBLY–
FRAME
4.
Position dockleveler in pit about 2 feet away
from rear pit wall. Connect plug to receptacle on the
rear pit wall. See Wiring Diagram on page 9. Cut tie
wrap on cord to allow bag pan removal for service.
1/16"
MAX
5.
Place the dockleveler into the pit. The rear edge
of the dockleveler must be tight against the rear pit
curb angle. See Figure 7.
REAR HINGE
SHOULD BE FLUSH
WITH CURB ANGLE
6.
Use 4” x 12” shims to shim under the dock level
support pads and the maintenance strut bracket. Also
use 4” x 8” shims under secondary stops that are part
of the dock level support pads. Position the dockleveler
level with the dock floor. See Figures 11 & 12.
ASSEMBLIES
NOT FLUSH
REAR HINGE
ASSEMBLY–
FRAME
REAR PIT
CURB ANGLE
REAR UPRIGHT
SUPPORT–
SUBFRAME
NOTE
For tapered pits, use shim kit P/N 712-412 under dock
level support pads. See Figure 5.
7.
Check to confirm that the shimmed height of the
rear support frame is proper for a smooth transition
from the dock to the dockleveler. See Figure 7.
REAR PIT
WALL
SHIM
The rear edge of the dockleveler should be level or
slightly (1/16” maximum) below dock level.
STAGGER SHIMS
FOR BETTER
WELD
FIGURE 8
Shim the front end of the dockleveler LEVEL with the
rear frame of the leveler. See Figure 8. The front and
rear frame must be parallel for proper operation. Add or
remove shims as required. If front and rear pit curb
angles are not parallel do not attempt to shim
dockleveler supports to match pit angles.
IMPROPER INSTALLATION
REAR FRAME & FRONT DOCK LEVEL
SUPPORTS NOT PARALLEL
PROPER INSTALLATION
REAR FRAME & FRONT DOCK LEVEL
SUPPORTS PARALLEL
3
5601 R4 01/05
INSTALLATION
FIGURE 9
8.
Check alignment of the dockleveler with the
sides of the pit. See Figure 9.
REAR PIT
CURB ANGLE
1/2"
1/2"
REAR
HINGE
ASSEMBLY
NOTE
If the pit width conforms to the certified pit drawing,
there will be a 1/2" gap between the ends of the frame
at the rear hinge assembly and the side curb angles. If
this is not the case, the dockleveler will have to be
positioned as required to accommodate dimensional
discrepancies and any additional considerations (e.g.
conduit runs, etc.).
PIT SIDE
CURB
ANGLE
RAMP
FIGURE 10
5"
2-1/2"
3"
3"
1-1/2"
5"
1-1/2"
2-1/2"
3"
Welding with dockleveler’s power connected can
damage electrical components. Ground welder to
dockleveler. If the dockleveler has previously been
electrically connected, turn off power before welding.
Failure to do so can result in product damage.
3"
PIT
REAR
CURB
ANGLE
FRAME
UPRIGHTS
Be certain that the rear hinge assembly is held tightly
against the pit rear curb angle before welding.
FIGURE 11
REAR
HINGE
ASSEMBLY
DOCK LEVEL SUPPORT
SECONDARY STOP
9.
Weld the rear hinge assembly to the rear curb
angle in the pattern for the width of dockleveler being
installed. See Figure 10 for patterns.
WELD
WELD
10. Weld the shims to the dock leveler supports
with three 1/2 inch long welds as shown in Figures 11
& 12.
WELD
WELD
Before welding the shims to the front curb angle
make sure that the dock level support leg lines
up with the “V” pocket in the dock level support
angle and that the leg roller is centered over its
roller track. Move the dock level support right
or left for the necessary alignment. Weld the
shims to the front curb angle with three 1/2 inch
long welds as shown in Figures 11 & 12.
FIGURE 12
DOCK LEVEL SUPPORT
SECONDARY STOP
WELD
WELD
WELD
5601 R4 01/05
4
WELD
INSTALLATION
FIGURE 13
11. After the rear hinge assembly and the dock
level supports have been welded, remove and discard
the shipping tie down bolts located at the lower
corners of the hinged lip assembly. See Figure 13.
12. Lower lifting support frame by removing retainer
bolts on top of deck area. See Figure 14. Bolts should
be discarded.
SHIPPING TIE
DOWN BOLT
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 dockleveler when
releasing the frame. Failure to do so could result in
serious injury.
FIGURE 14
RETAINING BOLTS
5
5601 R4 01/05
INSTALLATION
FIGURE 15
INSERT HAIRPIN
CLIP THROUGH
MAINTENANCE
STRUT PIN
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 DOCKLEVELER RAMP OR LIP
UNLESS THE MAINTENANCE STRUT AND LIP
LOCK ARE IN PLACE AND PINNED.
13. Two people are needed to place the dockleveler
on the maintenance strut. (See page 14)
a) One person must push and hold the raise
button until the dockleveler reaches its highest
position and hold dockleveler in its highest
position with air pressure or mechanical sup
port.
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 Figure 15 and the
instruction label on maintenance strut.
c) Air pressure or mechanical support may now
be removed.
LIP
LOCK
MAINTENANCE
STRUT PIN
RAMP
MAINTENANCE
STRUT
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 DOCKLEVELER
RAMP OR LIP UNLESS THE MAINTENANCE
STRUT AND LIP LOCK ARE IN PLACE AND
PINNED.
FIGURE 16
14. Manually lift the hinged lip into the raised
position and lock into place with the lip lock provided
on the dockleveler ramp. Pin lip lock in place with
hairpin clip. See Figure 15 and instruction label
located on the underside of the dockleveler ramp.
REMOVE
SHIPPING
COTTER PINS
15. Finish welding the shims to dock level supports,
and shims to front curb angle with 3” min. long welds
in the three places shown. See Figures 11 and 12.
16. Weld shims to secondary stops and dock level
supports. See Figures 11 and 12.
17. Install Clean Pit Kit. Refer to installation
instructions supplied with the kit.
18. Remove and discard shipping cotter pins from toe
guards on both sides of dockleveler. See Figure 16.
19. Remove lifting chain or other lifting devices.
Remove lifting hooks from the sides of the ramp.
20. Read the Safety Practices on page iv and the
Operation instructions on page 10 before operating
the dockleveler.
5601 R4 01/05
LIP
6
MAINTENANCE
STRUT BRACKET
INSERT
HAIRPIN
CLIP INTO
LIP LOCK
INSTALLATION
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 dockleveler resulting in death or serious injury.
DO NOT MOVE THE MAINTENANCE STRUT
WITHOUT AIR PRESSURE IN THE BAG OR A
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 dockleveler was raised using a
mechanical device, lower it using the same device.
21. Lift up on the hinged lip and store the lip lock
under the ramp.
22. Two people are needed to store the maintenance strut.
a) One person must push and hold the raise
button until dockleveler reaches its highest
position and hold dockleveler in its highest
position.
b) The second person un-pins the maintenance
strut from the bracket on the ramp and stores it
on the subframe. See Figure 15 and the instruction label on maintenance strut
c) The raise button may now be released. The
ramp will lower and the lip will extend when the
button is released.
The hinged lip will extend as the ramp moves down.
7
5601 R4 01/05
INSTALLATION
FIGURE 17
1" DIA.
Improper installation of anchoring devices or installation into aged or unsound concrete could result in
death or serious injury.
4"
3"
23. Mount dock bumpers to face of dock. See
Figure 17 or 18.
J BOLTS (3) PER BUMPER
FURNISHED BY KELLEY
COMPANY, INC. LOCATE
AND WELD TO CURB
ANGLE AT TIME OF
BUMPER INSTALLATION.
24. Permanently mount the laminated dockleveler
WARNING and OPERATING instruction placards on
the wall near the dockleveler control. See Figure 19.
25. Operate the dockleveler four times through the
complete cycle to check operation. (See Operation
section, page 10.)
CAUTION: THE DOCK FACE MUST BE FLUSH WITH CURB
ANGLE TO ASSURE PROPER BUMPER MOUNTING.
MOLDED "L" BUMPERS
FIGURE 18
NOTE
3/4" DIA.
ANCHOR
BOLT.
FIELD
INSTALLED.
SUPPLIED
BY OTHERS.
3/8" SIDE OF PIT
TO SIDE OF BUMPER
MOUNTING PLATE
If you have any problems or questions using or operating the dockleveler, contact your supervisor or local
Kelley distributor, or KELLEY at 1-972-466-0707 for
assistance.
1/4"
FULL LENGTH
OF BUMPER
MOUNTING
PLATE
VERTICAL
BUMPER
MOUNTING
ANGLE
LAMINATIONS MUST BE
INSTALLED VERTICALLY
LAMINATED BUMPERS
FIGURE 19
WARNING and
OPERATING
INSTRUCTION
PLACARDS
5601 R4 01/05
8
WIRING DIAGRAM
WIRING DIAGRAM
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 the
control box with the power on, USE EXTREME
CAUTION. Do not place your fingers or uninsulated
tools inside the control box. Touching wires or other
parts inside the control box could result in electrical
shock, death or serious injury.
Never allow more than 130 volts to be connected to
the 115 volt motor circuit. Damage to motor,
pushbutton, air bag, and serious personal injury or
death may result.
115V, Single Phase, 50/60 Hz
Single Contact
115V, Single Phase, 50/60 Hz
Optional Dual Contact
OPTIONAL BLUE CONTACT BLOCK
(NORMALLY CLOSED)
FIELD INSTALLED (LOW VOLTAGE ONLY)
SEE SUPPLIED MFG. INSTRUCTIONS
9
5601 R4 01/05
OPERATION
OPERATION
Before operating the dockleveler, read and follow the
Safety Practices on page iv.
Use of dockleveler restricted to trained operators.
Follow procedures on placard posted near dockleveler.
DO NOT USE THE DOCKLEVELER 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 or Kelley at 1-972466-0707.
INTRODUCTION
Before pressing button, ensure lip avoids contact with
trailer sides and cargo. If lip does not lower to trailer
bed, reposition trailer.
The KELLEY aFX dockleveler is designed to span
and compensate for space and height differences
between a loading dock and freight carrier to allow
safe, efficient freight transfers.
Stay clear of leveler unless lip is supported by trailer
bed or the leveler is stored at dock level. Visually
check that the lip is supported by the truck bed or the
ramp is supported by both front dock level supports
before driving or walking on the ramp. Unsupported
docklevelers can lower unexpectedly.
The KELLEY aFX dockleveler uses a pushbutton
control to position the dockleveler. Pushing and
holding the pushbutton operates a fan which inflates
an air bag to raise the ramp. Releasing the
pushbutton allows the ramp to lower.
Before chocking wheels or engaging vehicle restraint,
dump air from air ride suspensions and set parking
brakes.
A mechanical linkage extends the dockleveler lip as
the ramp lowers from its full raised position, and the
leveler with its lip extended settles onto the truck bed
forming a bridge. Patent pending airDefense™ sensors glide along reinforced cams purging stump-out
and providing fluid, free-float motion along with free
fall protection in the event of premature trailer separation.
Always be certain that the truck wheels are chocked,
or that the truck is locked in place by a truck restraining device and the brakes are set before loading or
unloading. Trucks pulling away from the dock unexpectedly can cause uncontrolled drop of the
dockleveler which can result in death or serious injury.
The maximum uncontrolled drop of a Kelley aFX
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 level. If lower
than 1” below dock level, it will drop to full below dock
or 8” below dock level.
After loading, pushing and holding the pushbutton
raises the ramp, and the extended lip lowers to its
stored position. Releasing the pushbutton (before the
dockleveler reaches its highest position) allows the
dockleveler to lower to its level, stored position.
With the dockleveler in its stored position, dock level
support legs support the dockleveler ramp at a
position level with the dock floor.
Always return the dockleveler to its dock level (stored)
position before allowing the truck to leave the dock.
If the truck pulls away from the dock before the
dockleveler 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.
5601 R4 01/05
10
OPERATION
1.
Wait until a truck is in position against the dock
bumpers.
2.
Tell truck driver “Your truck must stay at the
dock.”
3.
Chock or hitch truck.
4.
If necessary, remove end loads with the ramp in
the dock level (stored) position. See Figure 20.
5.
FIGURE 20
DOCKLEVEL SUPPORTS
If the truck is to be serviced for a below dock
end load, see operation instuctions for Below
Dock Level Control on page 12.
To extend the dockleveler lip into the truck:
5.1
FIGURE 21
LIP
Push and hold the control button. The
ramp will rise until it stops at its highest
position. See Figure 21.
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 truck bed. See Figure
22.
RAMP
TRUCK BED
PUSH TO RAISE
FIGURE 22
Do not drive on dockleveler or lip until it is fully
extended and supported by the truck bed.
Never use a fork truck or other material handling
equipment to lower the ramp and lip sections.
5.4
6.
FIGURE 23
Proceed with loading or unloading.
DOCK LEVEL
SUPPORT LEG
To return the dockleveler 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 truck bed (before reaching its
highest position). The ramp will lower to
the dock level (stored) position.
6.3
Visually check that lip is not extended and
dock level support legs are in position on
their supports before releasing truck.
Ramp should be level with dock floor.
7.
Unchock or release truck.
8.
Tell truck driver “Your truck may now leave the
dock.”
FRONT ANGLE
DOCK LEVEL
SUPPORT
Before allowing truck to leave always return the
dockleveler 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
Figure 23. 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.
11
5601 R4 01/05
OPERATION
FIGURE 24
DOCK LEVEL
SUPPORT LEG
BELOW DOCK CONTROL (BDC):
To lower the ramp without extending the lip for end
loading below dock level:
1.
Press the control button and hold it until the
ramp is 6” to 12” above dock level. Release the
button before the ramp reaches its highest
position.
2.
As ramp is lowering, walk onto the ramp and
pull the BDC chain located in the middle of the
ramp until it is fully extended. Hold the chain
until the ramp passes below dock level. See
Figure 25.
3.
Release the BDC chain.
4.
Load or unload end loads.
5.
When loading or unloading is complete, return
the dockleveler 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 truck.
Ramp should be level with dock floor.
6.
Unchock or release truck.
7.
Tell truck driver “Your truck may now leave
the dock.”
FRONT ANGLE
DOCK LEVEL
SUPPORT
Before allowing truck to leave always return the
dockleveler to its dock level (stored) position with the
dock level support legs supported by the front dock
level supports. See Figure 24. Failure to do so may
leave the dockleveler 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.
FIGURE 25
BELOW DOCK
CONTROL
(BDC) CHAIN
5601 R4 01/05
12
MAINTENANCE AND LUBRICATION
FIGURE 26
NOTE
LIP HINGE
ASSEMBLY
Use only lubricants shown. Improper lubrication or
adjustments may cause operational problems.
Before servicing the dockleveler, read and follow the
Safety Practices on page iv and the operation section
of this manual.
DOCK LEVEL
SUPPORT HINGES
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 dockleveler.
RAMP HINGE
PINS (behind
bag assembly)
Be certain, before climbing into the dockleveler pit or
doing any maintenance or repair under the
dockleveler, that: 1) THE MAINTENANCE STRUT
AND LIP LOCK ARE SECURELY PINNED IN PLACE
[see page 14] and 2) the power is disconnected and
properly tagged or locked off.
LIP EXTENSION
MECHANISM
NOTE
Ramp hinge pins may be oiled from top of dock by
placing dockleveler full below dock.
aFX SERIES MAINTENANCE AND LUBRICATION CHART
Bag Clamp
Bar Bolts
Lip
Extension
Mechanism
Lip Extension
Spring Assist
Dock Level
Support Leg
and Roller
Arm
Lip Hinge
Assembly
Ramp
Hinge Pins
Dockleveler
Pit
Lubrication
Not Required
Every 90
Days
(Use Light
Oil)
Every 90 Days
Lubricate Both
Gas Spring
Clevis Pins
w/Grease
Every 90
Days
(Use Light
Oil)
Every 90
Days
(Use Light
Oil)
Every 90
Days
(Use Light
Oil)
Not Required
Adjustment
See Note
Below *
Not Required
Not Required
Not Required
Not Required
Not Required
Not Required
Not Required
As Required
to
Remove
Debris
As Required to
Remove
Debris
As Required
to
Remove
Debris
As Required
to
Remove
Debris
As Required
to
Remove
Debris
Every 90
Days or as
Required
to Remove
Debris **
Cleaning
* Whenever bag or clamp bar attaching hardware is replaced or re-assembled perform the following torque
procedure:
1. Starting in the center of clamp bar and working outwards, torque all 9 nuts to within 29-31 lb.ft.
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 Clean Pit Kit on page 15.
Check all labels every 90 days. Replace if required.
See Parts List page 20 for location and part numbers.
13
5601 R4 01/05
SERVICE TOOLS
SERVICE TOOLS
FIGURE 27
Before servicing the dockleveler, read and follow the
Safety Practices on page iv and the operation section
of this manual.
INSERT HAIRPIN
CLIP THROUGH
MAINTENANCE
STRUT PIN
Be certain, before climbing into the dockleveler pit or
doing any maintenance or repair under the
dockleveler, that: 1) THE MAINTENANCE STRUT
AND LIP LOCK ARE SECURELY PINNED IN PLACE
[see figure 27 and text below] and 2) the power is
disconnected and properly tagged or locked off.
LIP LOCK
MAINTENANCE
STRUT PIN
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 DOCKLEVELER RAMP OR LIP
UNLESS THE MAINTENANCE STRUT AND LIP
LOCK ARE PINNED IN PLACE.
INSERT
HAIRPIN
CLIP INTO
LIP LOCK
MAINTENANCE
STRUT
MAINTENANCE STRUT
1.
Two people are needed to place the dockleveler
on the maintenance strut.
a) One person must push and hold the raise
button until dockleveler reaches its highest
position and hold dockleveler 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 Figure 27 and the
instruction label on maintenance strut.
c) The raise button may now be released.
LIP LOCK
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 DOCKLEVELER
RAMP OR LIP UNLESS THE MAINTENANCE
STRUT AND LIP LOCK ARE PINNED IN PLACE.
2.
Manually lift the hinged lip into the raised
position and lock into place with the lip lock provided
on the dockleveler ramp. Pin lip lock in place with
hairpin clip. See Figure 27 and instruction label
located on the underside of the dockleveler ramp.
To store the maintenance strut follow all instructions
on page 7.
5601 R4 01/05
LIP
14
MAINTENANCE
STRUT BRACKET
RAMP
SERVICE TOOLS
FIGURE 28
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.
Be certain, before climbing into the dockleveler pit or
doing any maintenance or repair under the
dockleveler, that: 1) THE MAINTENANCE STRUT
AND LIP LOCK ARE SECURELY PINNED IN PLACE
[see page 14] and 2) the power is disconnected and
properly tagged or locked off.
1.
FIGURE 29
To raise the bag pan assembly:
1.1
Unhook end of cable from BDC chain.
1.2 Grab handle on cable assembly and pull
towards maintanance strut base. See Figure
28.
1.3 While still pulling on handle, hook end of
cable over maintance strut base. See Figure
29.
2.
CABLE
To lower the bag pan assembly:
2.1
Pull on handle to allow slack in cable.
2.2 Unhook cable from maintance strut base
and allow bag pan to lower. See Figure 30.
2.3
Hook end of cable to BDC chain.
MAINTENANCE STRUT BASE
FIGURE 30
15
5601 R4 01/05
SERVICE TOOLS
FIGURE 31
PAN REMOVAL ROLLERS
The pan removal rollers are used to remove the bag
sup-port pan assembly. This allows for easy access to
service the lifting fan and bag assembly.
16”
or
*19”
PAN ROLLERS
*NOTE: 8’ LONG 50K CAPACITY & 10’ LONG DOCKLEVELERS
ATTACH PAN ROLLERS 19” FROM FRONT EDGE.
Be certain, before climbing into the dockleveler pit or
doing any maintenance or repair under the
dockleveler, that: 1) THE MAINTENANCE STRUT
AND LIP LOCK ARE SECURELY PINNED IN PLACE
[see page 14] 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 15.
FIGURE 32
1.2 Attach pan rollers, Kit P/N 184-376, to
both sides of pan assembly, 16” or 19” back
from front edge as shown in Figure 31.
NOTE
For 8’ long 50K capacity & 10’ long docklevelers attach
pan rollers 19” from front edge as shown in Figure 31.
2.
1.3
Lower front of bag pan assembly by
unhooking cable from maintance strut
base. Pan rollers will be supported on
frame side angles.
1.4
Unhook cable assembly from deck ring.
1.5
Push down on front of pan assembly to
unhook the back of the pan assembly.
See Figure 33.
1.6
Balancing the pan assembly on the
rollers, roll the assembly to the front of the
pit. Rollers will roll on frame side angles.
See Figure 34.
FIGURE 33
FIGURE 34
To install the bag pan assembly:
2.1 Roll the pan assembly back in the pit and
align with hooks on the back of the ramp.
2.2
Hook pan assembly rod on hooks.
2.3
Reattach cable pulley to deck ring.
2.4
Raise bag pan assembly. See
instructions on page 15.
2.5
Remove the pan rollers.
2.6 Lower bag pan assembly following
instructions on page 15.
5601 R4 01/05
16
TROUBLESHOOTING
TROUBLESHOOTING
Before troubleshooting the dockleveler, read and
follow the Safety Practices on page iv and the maintenance and operation sections of this manual.
Be certain, before climbing into the dockleveler pit or
doing any maintenance or repair under the
dockleveler, that: 1) THE MAINTENANCE STRUT
AND LIP LOCK ARE SECURELY PINNED IN PLACE
[see page 14] and 2) the power is disconnected and
properly tagged or locked off.
NOTE
Follow service tool use instructions on pages 15 and
16.
RAMP FAILS TO RAISE WHEN
CONTROL BUTTON IS PUSHED:
Before doing any electrical work, make certain the
power is disconnected and properly tagged or locked
off.
1.
If motor fails to run:
1.1
Check fuse or breaker.
1.2 Check for electrical power to the
pushbutton.
1.3
Check pushbutton on control box.
1.4
Check that fan plug is tight in receptacle.
1.5 Check for loose wires in control box or
junction box.
1.6
Check for power at fan connections.
1.7
Replace fan assembly if required.
17
5601 R4 01/05
TROUBLESHOOTING
2.
FIGURE 35
If motor runs:
HANGER BRACKET
NOTE
LINK
NOTCH
Ramp will not raise if a lift truck or heavy material is
left on top of the ramp.
CENTER BOLT
2.1 Check for any obstructions which may
prevent ramp from raising. If an obstruction is
found, turn off power before attempting to clear
the obstruction.
LIP
ROLLER
CONNECTING ROD
2.2 Check for holes or leaks in the lifting bag.
Use Patch Kit, P/N 184-379 to repair holes. If
holes are too large to repair, replace bag
assembly.
PUSH BAR
PIT FLOOR
2.3 Check for loose or misaligned bag fittings
or a loose bag clamp bar. Repair or replace as
required.
LIP FAILS TO EXTEND:
1.
Check to make sure that the lip extension
mechanism is not bent or binding. See Figure 35.
2.
Check to make sure that the lip extension
mechanism is lubricated properly. Lubricate as
required.
3.
Make sure all pins and pin retainers are in place
and in good condition.
LIP EXTENDS BUT FAILS TO STAY
IN EXTENDED POSITION:
1.
Check to see that the lip extension mechanism
center bolt is straight and free to rotate. See Figure
35.
2.
Check to see that the lip extends far enough to
allow the links and connecting rod to align and then
reach an “over center” position.
5601 R4 01/05
DOCKLEVELER
RAMP
18
TROUBLESHOOTING
FIGURE 36
LIP FAILS TO LOWER TO THE
STORED POSITION WHEN THE
DOCKLEVELER IS RAISED FROM
TRUCK:
1.
Check the lip extension mechanism for free
movement. See Figure 35.
2.
Inspect the lip extension mechanism for bent
parts. Be sure all parts are clean, lubricated andhave
free movement. See Figure 35.
LIP CAPACITY
LIP SIZE
3.
Make sure all pins are in correct position and in
good condition. See Figure 36.
DOCK LEVEL SUPPORT LEGS
WILL NOT RETRACT FOR BELOW
DOCK OPERATION:
25K
30K & 35K
40K, 45K & 50K
6 FT-16"
HOLE 3
HOLE 2
HOLE 1
6 FT-18"
HOLE 2
HOLE 1
HOLE 1
6 FT-20"
HOLE 1
HOLE 1
HOLE 1
6-1/2 FT-16"
HOLE 2
HOLE 1
HOLE 1
6-1/2 FT-18"
HOLE 1
HOLE 1
HOLE 1
6-1/2 FT-20"
HOLE 1
HOLE 1
HOLE 1
7 FT-16"
HOLE 2
HOLE 1
HOLE 1
7 FT-18"
HOLE 1
HOLE 1
HOLE 1
7 FT-20"
HOLE 1
HOLE 1
HOLE 1
1.
Check connection of dock level control chain to
the dock level support legs. See Figure 37.
2.
Check for binding of dock level control chain.
3.
Check for binding in dock level support legs.
FIGURE 37
BDC
CHAIN
4.
Check length of below dock control chain.
Adjust chain so dock level support legs are retracted
the same distance.
DOCK LEVEL SUPPORT LEGS WILL
NOT SWING FULLY FORWARD:
DOCK LEVEL
SUPPORT LEG
1.
Check for binding or debris which may be
restricting leg.
2.
Check below dock control chains to assure
chain has enough slack to allow leg to swing forward.
Adjust as required. See Figure 37.
19
5601 R4 01/05
PARTS LIST
PARTS LIST
FIGURE 38
aFX _ x _
1.
To determine the correct replacement parts to
order for your adjustable dockleveler, you will need to
know its model number, serial number and capacity.
LENGTH
6 = 6' long
8 = 8' long
10 = 10' long
2.
The model number and capacity can be found
on the dockleveler product label located on the fixed
toe guard. The meaning of each digit in the model
number is shown in Figure 38.
Example:
WIDTH
6 = 6' wide
6.5 = 6-1/2' wide
7 = 7' wide
aFX6x8
- 6' wide
- 8' long
FIGURE 39
3.
To determine the nominal size of your
dockleveler, see Figure 39.
4.
To determine the serial number of the unit you
must find the serial tag. The serial tag is located near
the lip on one of the end plates of the ramp beams.
L
LIP LENGTH
16", 18", OR 20"
W
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.
5601 R4 01/05
PIT DEPTH
20
NOMINAL SIZE
W
L
W x L (FT.)
(IN.)
(IN.)
6x6
6x8
6x10
6.5x6
6.5x8
6.5x10
7x6
7x8
7x10
72
72
72
78
78
78
83
83
83
63
87
111
63
87
111
63
87
111
PARTS LIST – RAMP, LIP, TOE GUARDS AND LIP LOCK ASSEMBLIES
16
1
4
39
18
17
3
19
15
20
16
2
34
11
8
38
14
37
13
6
12
35
7
36
33
5
10
7
10
42
8
43
40
44
24
22
29
23
28
32
31
9
46
45
26
25
27
41
30
NOTE: RIVETS (ITEM 41)
ATTACH BAG SHIELD (ITEM 40)
TO BRACKETS WELDED ON
BOTTOM OF RAMP.
21
21
5601 R4 01/05
PARTS LIST – RAMP, LIP, TOE GUARDS AND LIP LOCK ASSEMBLIES
ITEM QTY
1
1
MODEL
DESCRIPTION
ITEM QTY
P/N
RAMP, 25K CAPACITY
aFX6x6
aFX6x8
aFX6x10
aFX6.5x6
aFX6.5x8
aFX6.5x10
aFX7x6
aFX7x8
aFX7x10
2
6' x 6'
6' x 8'
6' x 10'
6-1/2' x 6'
6-1/2' x 8'
6-1/2' x 10'
7' x 6'
7' x 8'
7' x 10'
1
712-657
712-658
712-659
712-667
712-668
712-669
712-677
712-678
712-679
6' x 6'
6' x 8'
6-1/2' x 6'
6-1/2' x 8'
7' x 6'
7' x 8'
6' x 6'
6' x 8'
6-1/2' x 6'
6-1/2' x 8'
7' x 6'
7' x 8'
2
1
6' x 6'
6' x 8'
6' x 10'
6-1/2' x 6'
6-1/2' x 8'
6-1/2' x 10'
7' x 6'
7' x 8'
7' x 10'
712-660
712-661
712-670
712-671
712-680
712-681
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
16" x 7' w.
16" x 7' w.
18" x 7' w.
18" x 7' w.
20" x 7' w.
20" x 7' w.
712-662
712-663
712-672
712-673
712-682
712-683
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
16" x 6' w.
16" x 6' w.
18" x 6' w.
18" x 6' w.
20" x 6' w.
20" x 6' w.
712-664
712-665
712-666
712-674
712-675
712-676
712-684
712-685
712-686
5601 R4 01/05
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
711-876
711-875
711-878
711-877
711-880
711-879
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
711-894
711-893
711-896
711-895
711-898
711-897
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
711-864
711-863
711-866
711-865
711-868
711-867
LIP, 6-1/2FT WIDE, 40K, 45K & 50K CAPACITY
16" x 6-1/2' w.
16" x 6-1/2' w.
18" x 6-1/2' w.
18" x 6-1/2' w.
20" x 6-1/2' w.
20" x 6-1/2' w.
711-852
711-851
711-854
711-853
711-856
711-855
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
711-882
711-881
711-884
711-883
711-886
711-885
LIP, 7FT WIDE, 40K, 45K & 50K CAPACITY
16" x 7' w.
16" x 7' w.
18" x 7' w.
18" x 7' w.
20" x 7' w.
20" x 7' w.
711-870
711-869
711-872
711-871
711-874
711-873
3
4
LIP, 7FT WIDE, 25K CAPACITY
16" x 7' w.
16" x 7' w.
18" x 7' w.
18" x 7' w.
20" x 7' w.
20" x 7' w.
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
LIP, 6FT WIDE, 40K, 45K & 50K CAPACITY
LIP, 6-1/2FT WIDE, 25K CAPACITY
16" x 6-1/2' w.
16" x 6-1/2' w.
18" x 6-1/2' w.
18" x 6-1/2' w.
20" x 6-1/2' w.
20" x 6-1/2' w.
711-858
711-857
711-860
711-859
711-862
711-861
LIP, 7FT WIDE, 30K & 35K CAPACITY
LIP, 6FT WIDE, 25K CAPACITY
16" x 6' w.
16" x 6' w.
18" x 6' w.
18" x 6' w.
20" x 6' w.
20" x 6' w.
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
16" x 6-1/2' w.
16" x 6-1/2' w.
18" x 6-1/2' w.
18" x 6-1/2' w.
20" x 6-1/2' w.
20" x 6-1/2' w.
RAMP, 50K CAPACITY
aFX6x6
aFX6x8
aFX6x10
aFX6.5x6
aFX6.5x8
aFX6.5x10
aFX7x6
aFX7x8
aFX7x10
P/N
LIP, 6-1/2FT WIDE, 30K & 35K CAPACITY
RAMP, 40K & 45K CAPACITY
aFX6x6
aFX6x8
aFX6.5x6
aFX6.5x8
aFX7x6
aFX7x8
DESCRIPTION
LIP, 6FT WIDE, 30K & 35K CAPACITY
16" x 6' w.
16" x 6' w.
18" x 6' w.
18" x 6' w.
20" x 6' w.
20" x 6' w.
RAMP, 30K & 35K CAPACITY
aFX6x6
aFX6x8
aFX6.5x6
aFX6.5x8
aFX7x6
aFX7x8
MODEL
711-888
711-887
711-890
711-889
711-892
711-891
22
2
2
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
LOW BEND
STANDARD BEND
711-900
711-899
711-902
711-901
711-904
711-903
LIP SHAFT
6' w. Dockleveler
6-1/2' w. Dockleveler
7' w. Dockleveler
712-957
712-958
712-959
Retainer, Shaft - Hinge Pin
035-451
PARTS LIST – RAMP, LIP, TOE GUARDS AND LIP LOCK ASSEMBLIES
ITEM QTY
5
2
MODEL
DESCRIPTION
P/N
ITEM QTY
42
TOE GUARD, MIDDLE SLIDING
1
6' lg. Dockleveler
8' lg. Dockleveler
10' lg. Dockleveler
6
2
155-554
155-555
155-557
TOE GUARD, BOTTOM SLIDING
6' lg. Dockleveler
8' lg. Dockleveler
10' lg. Dockleveler
155-554
155-556
155-557
7
8
9
10
11
12
13
14
4
4
1
4
2
2
2
2
NUT, Lock, 3/8-16
SCR., Truss Hd. 3/8-16 x 1
Wshr, Flt 9/16" ID 1-7/8"OD
SPACER, Toe Guard
Screw, Shoulder
Washer, 3/8" Flat
Washer, 5/16" Flat
Nut, 5/16-18 Nyloc
000-253
131-477
000-444
152-878
131-455
000-214
000-055
131-456
15
16
17
18
19
20
2
3
1
1
1
2
DECAL, Lift
LABEL, Warning
DECAL, Lip Lock
LABEL, Dock Product
SERIAL TAG
RIVET, Pop 1/8
138-837
6001044
700-136
712-188
138-822
131-406
21
1
1
22
23
24
25
26
27
28
29
30
31
2
2
4
A/R
2
2
2
2
2
1
32
1
33
34
35
36
37
38
39
1
1
1
1
1
1
2
40
1
41
4
1
SUPPORT, Dock Level
LEFT Side (shown)
RIGHT Side (not shown)
43
44
45
46
2
2
2
2
47
1
MODEL
DESCRIPTION
P/N
LIFTER, ROLLER ARM
Left Hand (25K) shown
Left Hand (35K - 50K)
Right Hand (25K)
Right Hand (35K - 50K)
714-082
714-084
714-081
714-083
Roller Lifter, Wire form
Shoulder Screw 1/2 x 4
Roller, Cam Follower
Spacer, Plastic Pipe
CLEAN PIT KIT (not shown)
6' lg. Dockleveler
8' lg. Dockleveler
10' lg. Dockleveler
101-100
6001340
6001341
6001402
184-491
184-492
184-493
714-126
714-125
SPRING, Torsion
PIN, Grooved
KLIPRING
"S" - Hook
NUT, Lock 3/8-16
Pin, Clevis 5/8" x 3-1/2" lg.
Spring, Torsion
Weldment, Roller Arm
Pin, cotter 1/8" x 1-1/4"
CHAIN, BDC
030-195
035-338
049-060
000-181
000-030
6001348
101-091
714-070
035-036
708-872
CHAIN, Twist Link
6' lg. Dockleveler
8' lg. Dockleveler
10' lg. Dockleveler
218-000
218-041
218-042
LEVER, Lip Lock
SPRING, Extension
PIN, Roll 3/16" dia. x 2"
CHAIN, Sash #35 x 6" lg.
PIN, Cotter - Hair
SCREW, Drive #6 x 1/4" lg.
DECAL, Kelley Logo
155-150
700-135
035-149
032-195
035-200
000-518
138-871
BAG SHIELD
6' lg. Dockleveler - All Capacity
8' lg. Dockleveler - 25K - 45K Capacity
155-295
8' lg. Dockleveler - 50K Capacity
10' lg. Dockleveler - All Capacity
155-400
RIVET, Pop 3/16 dia.
131-271
23
5601 R4 01/05
PARTS LIST – SUBFRAME AND MAINTENANCE STRUT ASSEMBLIES
12
3
4
5
6
2
7
8
9
11
10
1
ITEM QTY
1
1
MODEL
3
4
1
P/N
14
SUBFRAME
aFX6x6
aFX6x8
aFX6x10
aFX6.5x6
aFX6.5x8
aFX6.5x10
aFX7x6
aFX7x8
aFX7x10
2
DESCRIPTION
6' x 6'
6' x 8'
6' x 10'
6-1/2' x 6'
6-1/2' x 8'
6-1/2' x 10'
7' x 6'
7' x 8'
7' x 10'
714-105
714-106
714-107
714-108
714-109
714-110
714-111
714-112
714-113
MAINTENANCE STRUT ASSEMBLY
4
4
6' lg. Dockleveler
8' lg. Dockleveler
10' lg. Dockleveler
710-042
708-883
712-537
PIN, Hinge
Retainer, Shaft - Hinge Pin
035-450
035-451
14
1
MODEL
RISER KIT
DESCRIPTION
000-518
035-200
032-195
708-992
9
10
11
12
1
1
1
2
WASHER, Flat 3/8
PIN, Cotter
PIN, Clevis
DECAL, Fork Location
000-214
035-036
035-051
138-604
13
1
Documentation Kit
Manual
Placard, Dockleveler Warn
Placard, Instructions
184-365
5601
908-715
908-761
24
P/N
OPTIONAL
5 Piece Kit (Deep Pit)
2 Piece Kit (Tapered Pit)
NOTE: ITEMS 5 - 8 INCLUDED IN ITEM 2
5
1
SCREW, Drive
6
1
PIN, Cotter - Hair
7
1
CHAIN, Sash
8
1
DECAL, Maint. Strut
5601 R4 01/05
ITEM QTY
712-125
712-412
PARTS LIST – AIR BAG/PAN ASSEMBLY
3
15
6
FOR
SHIPPING
ONLY
12
13
15
16
11
14
2
4
9
5
10
4
15
8
7
15
8' LG DOCKLEVELERS - 25K,30K,35K,40K, & 45K CAPACITY
6' LG DOCKLEVELERS - ALL CAPACITY
ITEM
QTY
1
1
2
1
3
4
5
6
7
8
9
10
11
12
1
2
1
9
4
1
1
2
9
2
2
2
2
4
9
A/R
13
14
15
16
17
DESCRIPTION
P/N
ITEM
QTY
BAG/PAN/FAN Assembly
(Includes items 2-16 and
items 1-14 on page 27)
714-129
1
1
BAG/PAN/FAN Assembly
(Includes items 2-16 and
items 1-14 on page 27)
712-805
Lifting Bag Assembly
714-128
2
1
184-442
Clamp Bar
Pan, Outer
Pan, Inner
Nut, Nylok, 3/8-16
Wheel
Axle, Front
Axle, Rear
Pin, Cotter, Hair
Bolt, Hex Hd. 3/8-16 x 1-1/4"
Bolt, 3/8-16 x 5-1/2" (25K Capacity)
Bolt, 3/8-16 x 7" (30K - 50K Capacity)
Washer, Flat 3/8
Nut, Retainer
Ring, Retaining
Washer, 3/8" Flat
Patch Kit, Bag (Not Shown)
157-747
156-352
156-350
000-253
711-846
712-745
712-812
035-200
000-357
000-366
131-434
000-214
131-432
131-457
000-051
184-379
3
4
5
6
7
8
9
10
11
12
1
2
1
9
4
1
1
2
9
2
2
2
2
4
9
A/R
Lifting Bag Assembly (Includes items
2,3,6,11, and 16)
Clamp Bar
Pan, Outer
Pan, Inner
Nut, Nylok, 3/8-16
Wheel
Axle, Front
Axle, Rear
Pin, Cotter, Hair
Bolt, Hex Hd. 3/8-16 x 1-1/4"
Bolt, 3/8-16 x 5-1/2" (25K Capacity)
Bolt, 3/8-16 x 7" (30K - 50K Capacity)
Washer, Flat 3/8
Nut, Retainer
Ring, Retaining
Washer, 3/8" Flat
Patch Kit, Bag (Not Shown)
13
14
15
16
17
25
DESCRIPTION
P/N
157-747
155-579
155-580
000-253
711-846
712-745
712-812
035-200
000-357
000-366
131-434
000-214
131-432
131-457
000-051
184-379
5601 R4 01/05
PARTS LIST – AIR BAG/PAN ASSEMBLY
3
15
6
FOR
SHIPPING
ONLY
12
13
15
16
11
14
2
4
9
5
10
4
15
8
7
15
8' LG DOCKLEVELERS - 50K CAPACITY
10' LG DOCKLEVELERS - ALL CAPACITY
ITEM
QTY
1
1
BAG/PAN/FAN Assembly
(Includes items 2-16 and
items 1-14 on page 27)
712-807
2
1
184-441
3
4
5
6
7
8
9
10
11
12
1
2
1
9
6
1
1
4
9
2
2
2
2
4
9
A/R
Lifting Bag Assembly (Includes items
2,3,6,11 and 16)
Clamp Bar
Pan, Outer
Pan, Inner
Nut, Nylok, 3/8-16
Wheel
Axle, Front
Axle, Rear
Pin, Cotter, Hair
Bolt, Hex Hd. 3/8-16 x 1-1/4"
Bolt, 3/8-16 x 5-1/2" (25K Capacity)
Bolt, 3/8-16 x 7" (30K - 50K Capacity)
Washer, Flat 3/8
Nut, Retainer
Ring, Retaining
Washer, 3/8" Flat
Patch Kit, Bag (Not Shown)
13
14
15
16
17
5601 R4 01/05
DESCRIPTION
P/N
157-747
155-649
155-650
000-253
711-846
711-845
712-812
035-200
000-357
000-366
131-434
000-214
131-432
131-457
000-051
184-379
26
PARTS LIST – FAN/PIPING ASSEMBLY
REFERENCE - FAN HOUSING
UNDER CENTER BAG PAN
11
10
5
7
3
6
8
4
8
14
9
ITEM
QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
1
1
5
1
1
1
5
3
1
2
2
1
3
1
2
1
15
4
DESCRIPTION
Fan Motor (115V, 50/60 Hz)
Filter Housing
Filter, Fan
Washer, Flat, 1/4"
Nipple
Cord w/plug
Bushing
Nut, Hex Lock 1/4-20
Screw, Button Hd. 1/4-20 x 1-1/2"
Housing, Fan
Screw, Button Flg. Hd. 1/4-20 x 3/4"
Nut, Wire (Not Pictured)
Screw, Ground (Not Pictured)
Nut, Hex Lock 5/16-18
Control Station, FX
Control Station, Optional Dual Contact
P/N
714-244
712-748
712-196
131-485
155-578
712-027
061-777
000-315
131-484
712-813
131-483
161-011
131-552
131-456
908-753
909-052
27
5601 R4 01/05
PARTS LIST – CONNECTING ROD, PUSH BAR AND LIP ASSIST ASSEMBLIES
12
17
16
13
15
16
19
18
3
2
14
8
8
18
8
1
6
10
9
5
8
5
6
8
10
5
4
ITEM QTY
MODEL
DESCRIPTION
P/N
1
1
PUSH BAR
711-961
2
1
ROD, Connecting
6' lg. Dockleveler
8' lg. Dockleveler
10' lg. Dockleveler
711-848
711-849
712-462
LEVER, LIP Lifter
6' lg. Dockleveler
8' & 10' lg. Dockleveler
711-998
711-999
3
1
4
5
6
1
3
1
LEVER, Lip Assist
PIN, Clevis 1/2" dia. x 1-3/4"
PIN, Clevis 3/8" dia. x 2"
155-811
035-010
035-150
8
9
10
4
1
1
PIN, Cotter 1/8" dia. x 1-1/4"
GAS SPRING
CLEVIS, Gas Spring
035-036
709-437
712-271
12
13
14
15
16
17
18
1
1
2
2
2
1
3
LINK, RH
LINK, LH
BOLT, Soc. Hd. Shld.
NUT, Hex 3/8-16
KLIPRING 5/8"
ROLLER
WASHER, 3/8"
712-001
712-002
712-061
000-030
049-060
700-045
000-214
19
1
SPACER, Lip
6-1/2' wide Dockleveler
7' wide Dockleveler
287-606
287-607
5601 R4 01/05
28