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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