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6004753N — Hydraulic Dock Leveler - One Button Control — Safe

Frame

™

March 2014

Welcome and thank you for choosing this dock leveler from KELLEy

. This dock leveler may be equipped with

the optional ENERGy GUARD

dock leveler sealing system.

This User’s Manual contains information that you need to safely install, operate and maintain the dock leveler. It

also contains a complete parts list and information about ordering replacement parts. Please keep and read this

User’s Manual before using your new dock leveler.

you may find safety signal words such as DANGER, WARNING, or CAUTION throughout this Owner’s Manual.

Their use is explained below:

Indicates an imminently hazardous situation which, if

not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which,

if not avoided, could result in death or serious

injury.

Indicates a potentially hazardous situation which,

if not avoided may result in minor or moderate

injury.

Notice is used to address practices not related to

personal injury.

This is the safety alert symbol. It is used

to alert you to potential personal injury

hazards. Obey all safety messages that

follow this symbol to avoid possible death or injury.

Introduction .................................................................2

Safety Signal Words ...................................................2

Safety Practices..........................................................3

Owner’s Responsibilities ............................................4

Ramp And Lip Grades ................................................5

Installation ..................................................................6

Wiring Diagrams .......................................................15

Operations ................................................................25

Planned Maintenance ...............................................31

Maintenance And Lubrication ...................................32

TabLe of conTenTs

safeTy signaL worDs

Service Tools ............................................................34

Troubleshooting Guide .............................................35

Hydraulic Diagram ....................................................38

Parts Replacement ...................................................39

Parts List...................................................................40

Warranty Information ................................................70

Distributor Information ..............................................72

inTroDUcTion

Содержание HK-S

Страница 1: ...stand the Safety Practices Warnings and Installation and Operating Instructions contained in this User s Manual Failure to do so could result in death or serious injury This User s Manual applies to d...

Страница 2: ...ich if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous sit...

Страница 3: ...er at dock level after below dock end loading Move all equipment material or people off dock leveler and store dock leveler at dock level before allowing the vehicle to pull out OPERATION continued Do...

Страница 4: ...ling devices that are structurally damaged or have experienced a sudden loss of support while under load such as might occur when a transport vehicle is pulled out from under the dock leveling device...

Страница 5: ...9 4 16 5 13 7 10 8 8 0 5 2 2 4 0 3 3 1 5 9 8 7 11 5 14 4 11 6 8 7 5 8 3 0 0 2 2 6 5 4 8 2 11 0 13 8 16 6 19 4 22 2 14 5 12 3 10 2 8 1 6 0 3 9 1 8 0 3 2 3 4 4 16 5 8 6 10 7 6 6 4 5 2 4 0 2 1 8 3 9 6 0...

Страница 6: ...ck leveler Power to control box must be from fused disconnect supplied by others For correct fuse size refer to wiring diagrams on pages 15 24 of this manual Fuses to be class CC time delay Before doi...

Страница 7: ...d in any other manner when place into the pit See Fig 4 Inadequate lifting equipment or practices can cause a load to fall unexpectedly Make sure the lifting chain or other lifting devices are in good...

Страница 8: ...crews are 1 4 from the top transition angle which indicates that legs are in contact with pit floor Repeat on each leg until the transition angle is flush with the rear curb angle See Fig 8 The rear e...

Страница 9: ...Fig 12 8 With the lip pendant insert 24 long 1 2 extensions between lip and lip rod onto dock leveler support leveling screw See Fig 12 Using a 1 2 drive 1 2 ratchet or impact tool turn each leveling...

Страница 10: ...IP 12 Return power to the leveler control Using the push button control station or a suitable lifting device two people are required to perform the following steps to secure the leveler with the maint...

Страница 11: ...p cylinder pad Adjust thickness if necessary Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury 16 Drill and install 3 4 d...

Страница 12: ...PRESSURE OR A MECHANICAL LIFTING DEVICE SUPPORTING RAMP Raise ramp with hydraulic pressure or mechanical device before storing maintenance strut Stand clear of ramp and lip when hydraulic pressure or...

Страница 13: ...eight of the dock leveler could result in death or serious injury It is sometimes necessary to install lip deflector plates to avoid any chance of the pendant lip supporting the weight of the dock lev...

Страница 14: ...noted in Fig 10 See Fig 21 b Align the leveler with the two square edges The gap on the sides should be even in the most narrow section 1 2 Max per side See Fig 22 c If large deformations exist in the...

Страница 15: ...cal 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 plac...

Страница 16: ...2014 4Front Engineered Solutions Inc 16 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 Wiring diagrams standard 6006450 208 240V 3PH 60 Hz 6006451 460 480V 3PH 60 Hz...

Страница 17: ...Engineered Solutions Inc March 2014 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame 17 Wiring diagrams standard continued Wiring diagrams with interlock 6006452 575V 3PH 60 Hz 6011372 12...

Страница 18: ...2014 4Front Engineered Solutions Inc 18 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 Wiring diagrams with interlock continued 6011524 208 230V 1PH 60 Hz...

Страница 19: ...2014 4Front Engineered Solutions Inc March 2014 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame 19 Wiring diagrams with interlock continued 6011325 208V 3PH 60 hz 6011761 240V 3PH 60 HZ...

Страница 20: ...014 4Front Engineered Solutions Inc 20 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 Wiring diagrams with interlock continued 6011326 460 480V 3ph 60 hz 6011651 575V 3PH 60...

Страница 21: ...ont Engineered Solutions Inc March 2014 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame 21 Wiring diagrams with interlock and auto return to dock 6011323 120V 1PH 60 Hz 6011324 208 240V...

Страница 22: ...Engineered Solutions Inc 22 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 Wiring diagrams with interlock and auto return to dock continued 6011327 208V 3PH 60 hz 6011762 24...

Страница 23: ...14 4Front Engineered Solutions Inc March 2014 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame 23 Wiring diagrams with interlock and auto return to dock continued 6011328 460 480V 3ph 60...

Страница 24: ...Solutions Inc 24 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 Wiring diagrams with interlock and auto return to dock continued 6011652 575V 3PH 60 Hz NOTE For 24V incoming...

Страница 25: ...tion before allowing vehicle to leave dock If vehicle pulls away from dock before dock leveler is stored the lip will fall to its pendant position and the ramp will drop In addition failure to properl...

Страница 26: ...leveler until a vehicle is in position against the dock bumpers 2 Tell vehicle driver Your vehicle must stay at the dock 3 Chock or hitch vehicle 4 If necessary remove end loads with the ramp in the d...

Страница 27: ...before driving or walking on the ramp Ramp should be level with dock floor 8 Unchock or release vehicle 9 Tell vehicle driver Your vehicle may now leave the dock BELOW DOCK CONTROL BDC To lower the r...

Страница 28: ...efore dock leveler is stored the lip will fall to its pendant position and the ramp will drop In addition failure to properly store the dock leveler may leave the leveler in a position below the level...

Страница 29: ...til a vehicle is in position against the dock bumpers 2 Tell vehicle driver Your vehicle must stay at the dock 3 Chock or hitch vehicle 4 If necessary remove end loads with the ramp in the dock level...

Страница 30: ...F switch to the OFF position 8 Unchock or release vehicle 9 Tell vehicle driver Your vehicle may now leave the dock BELOW DOCK CONTROL BDC To lower the ramp without extending the lip for end loading b...

Страница 31: ...RNING AND OPERATION PLACARD MOUNTED ON WALL NEAR LEVELER 6008554 x2 HK S Model Only 921 070 921 074 6008485 x2 OPERATIONS 6015283 planned maintenance Fig 34 Every 90 days quarterly inspect all safety...

Страница 32: ...ants shown lmproper lubrication or adjustments may cause operational problems Check all labels every 90 days See page 31 for location and part numbers Replace if required Every 90 days inspect dock bu...

Страница 33: ...3 Legend Symbol Description Lubricate oil Light oil SAE 30 Lubricate grease Molybdenum disulfide NLGI 2 Cleaning Location frequency Visually inspect Replace damaged or worn Rear hinge pin Pit 3 mo Hyd...

Страница 34: ...perform the following steps to secure the leveler with the maintenance strut and lip lock a One person must push and hold the raise button until dock leveler reaches its highest position and hold doc...

Страница 35: ...lace if required 1 6 If problem can not be found contact a qualified electrician 2 If motor runs 2 1 Check hydraulic oil level in reservoir Add if required See Fig 39 for proper levels and types of oi...

Страница 36: ...to the full pendant position Lip should be 1 2 to 1 1 2 from the face of the dock when the ramp is in the full below dock position The return to dock switch is connected to the lip and will not opera...

Страница 37: ...onnection of dock level control chain to the dock level support legs See Fig 44 3 Check for binding of dock level control chain See Fig 44 4 Check for binding in dock level support legs 5 Check length...

Страница 38: ...2014 4Front Engineered Solutions Inc 38 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 Hydraulic diagram Fig 46...

Страница 39: ...POSITION AND PINNED LIP LOCK IS IN PLACE AND SUPPORTING THE LIP see Fig 38 on page 34 and 2 the power is disconnected and properly tagged or locked off After replacing hose and or motor pump assembly...

Страница 40: ...ber is shown in Fig 48 Example HK6x8 6 wide 8 long 3 To determine the nominal size of your dock leveler see Fig 49 4 You will also need to measure the pit depth to determine pit size for correct repla...

Страница 41: ...ns Inc March 2014 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame 41 Parts list continued Model hK ramp lip and toe guard Assemblies 15 3 2 1 14 13 9 4 10 7 11 12 5 6 8 6 8 7 18 19 23 20...

Страница 42: ...Inc 42 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 Parts list continued Model hK S ramp lip and toe guard Assemblies 1 9 26 10 7 11 12 5 6 8 6 8 7 18 19 23 20 21 22 23 4 1...

Страница 43: ...1 898 20 x 7 w 7 Degree BEND 711 897 LIP 6FT WIDE 40K 45K AND 50K CAPACITY 16 x 6 w 4 Degree BEND 711 864 711 864 16 x 6 w 7 Degree BEND 711 863 711 863 18 x 6 w 4 Degree BEND 711 866 711 866 18 x 6 w...

Страница 44: ...ut 5 16 18 Nyloc 131 456 13 2 Hazard label 138 837 14 2 LABEL Warning 6008485 15 1 DECAL Lip Lock 6015283 16 1 Decal Kelley 921 140 17 2 LABEL SAFETY STRIPE Model HK S Only 6008554 18 2 S HOOK 000 181...

Страница 45: ...AINTENANCE POST 8 LG DECK WITH 24 BACKFRAME 6013623 MAINTENANCE POST 10 LG DECK WITH 24 BACKFRAME 713 345 2 4 PIN HINGE 6 8 and 10 lg models 6004128 3 A R Retainer Shaft Hinge Pin 236 110 4 1 SCREW Dr...

Страница 46: ...utton Control SafeTFrame March 2014 PARTS LIST continued OPTIONAL SUBFRAME RISEr kit Item Quantity Description Part Number 1 1 Riser Kit Field Installed 6004654 2 4 Rear Angle Cap Plugs Kelley Optiona...

Страница 47: ...raulic Dock Leveler One Button Control SafeTFrame 47 Parts list continued Hydraulic components and return to Dock level switch 11 12 13 9 9 21 17 20 18 20 20 10 20 19 10 14 16 15 23 26 26 33 24 37 31...

Страница 48: ...RING ELBOW 3 8 HOSE 313214 3 1 FTG JIC 8 MALE TO MALE 6 O RING 6006640 4 1 LABEL Caution 100 120V 1 PH 50 60 Hz 155 988 200 240V 1 PH 50 60 Hz 155 989 190 240V 3 PH 50 60 Hz 156 059 380 480V 3 PH 50 6...

Страница 49: ...Wire Strain Relief 521 110 26 4 Cable Tie Nylon 8 1 4 131 475 27 1 2 X 4 JUNCTION BOX 6008982 28 1 2 X 4 J BOX COVER 6008987 29 2 TEK 12 14 X 3 4 UNC Self Tapping Screw 215 702 30 2 ZIP TIE PANDUIT AN...

Страница 50: ...uminum strip 77 1 2 2 2 2 6008177 Aluminum strip 101 1 2 2 2 2 6008179 5 6 Lower seal 2 2 2 6008168 8 Lower seal 2 2 2 6008170 10 Lower seal 2 2 2 6008172 6 Aluminum strip 6 upper 2 2 2 6008174 Alumin...

Страница 51: ...ssembly Includes items 1 6 120V 1 PH 50 60 Hz 6006461 208 230V 1 PH 60 Hz 6006462 1 1 Plastic control panel enclosure 6006437 2 1 Control panel label 6006453 3 1 Pushbutton green with line 6006439 4 1...

Страница 52: ...ons Inc 52 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 PARTS LIST continued CONTROL BOX ASSEMBLY STANDARD 6006450 208 240V 3PH 60 Hz 6006451 460 480V 3PH 60 Hz 6006452 575...

Страница 53: ...Control panel label 6006453 3 1 Pushbutton green with line 6006439 4 1 Contact assembly plastic panel 6006438 5 1 Contactor 208 230V 6006428 Contactor 480V 6006430 Contactor 600V 6006431 6 1 Overload...

Страница 54: ...red Solutions Inc 54 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011372 120V 1ph 60 hz Fig 58 12 9 7 2 5...

Страница 55: ...000549 4 4 TERMINAL 2 POLE 6000542 5 1 TERMINAL FUSED 6000538 6 1 FUSE 0 5 AMP TIME DELAY FUSE 6008836 7 1 CONTACTOR 18A 120V COIL 50 60 6012549 8 1 OVERLOAD 12 18 AMPS 6013781 9 1 PUSH BUTTON FLUSH B...

Страница 56: ...d Solutions Inc 56 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011524 208 240V 1PH 60 Hz 12 9 7 2 5 1 2...

Страница 57: ...549 4 4 TERMINAL 2 POLE 6000542 5 2 TERMINAL FUSED 6000538 6 2 FUSE 0 5 AMP TIME DELAY FUSE 6008836 7 1 CONTACTOR 9A 240V COIL 50 60 6012551 8 1 OVERLOAD 9 13 AMPS 6012560 9 1 PUSH BUTTON FLUSH BLACK...

Страница 58: ...4753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011325 208V 3PH 60 hz 6011761 240V 3PH 60 HZ 6011326 460 480V 3...

Страница 59: ...HP HK 6011019 3 2 TERMINAL END STOP SCREWLESS 6000549 4 2 TERMINAL 2 POLE 6000542 5 2 CONTACTOR 18A 24V COIL 50 60 6012550 6 1 OVERLOAD 4 6 AMPS 6013883 1 OVERLOAD 1 6 2 5 AMPS 6012557 7 1 MICRON XFM...

Страница 60: ...ed Solutions Inc 60 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK 6011651 575V 3PH 60 Hz 11 8 5 2 1 7 2 4 3...

Страница 61: ...6012916 2 1 BACK PLATE 8X6 FOR HP HK 6011019 3 2 TERMINAL END STOP SCREWLESS 6000549 4 2 TERMINAL 2 POLE 6000542 5 2 CONTACTOR 18A 24V COIL 50 60 6012550 6 1 OVERLOAD 4 6 AMPS 6012557 7 1 MICRON XFMR...

Страница 62: ...62 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011323 120V 1PH 60 Hz Fig 62 13...

Страница 63: ...6 6012916 2 1 BACK PLATE 8X6 FOR HP HK 6011019 3 3 TERMINAL END STOP SCREWLESS 6000549 4 6 TERMINAL 2 POLE 6000542 5 1 TERMINAL FUSED 6000538 6 1 FUSE 0 5 AMP TIME DELAY FUSE 6008836 7 1 CONTACTOR 18...

Страница 64: ...4 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011324 208 240V 1PH 60 hz Fig 63 1...

Страница 65: ...X 6 6012916 2 1 BACK PLATE 8X6 FOR HP HK 6011019 3 3 TERMINAL END STOP SCREWLESS 6000549 4 7 TERMINAL 2 POLE 6000542 5 1 TERMINAL FUSED 6000538 6 1 FUSE 0 5 AMP TIME DELAY FUSE 6008836 7 1 CONTACTOR 1...

Страница 66: ...Dock Leveler One Button Control SafeTFrame March 2014 PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011327 208V 3PH 60 hz 6011762 240V 3PH 60 hz 6011328 46...

Страница 67: ...011019 3 2 TERMINAL END STOP SCREWLESS 6000549 4 4 TERMINAL 2 POLE 6000542 5 2 CONTACTOR 18A 24V COIL 50 60 6012550 6 1 OVERLOAD 4 6 AMPS 6013883 1 OVERLOAD 1 6 2 5 AMPS 6012557 7 1 MICRON XFMR 208 60...

Страница 68: ...nc 68 6004753N Hydraulic Dock Leveler One Button Control SafeTFrame March 2014 PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL INTERLOCK AND AUTO RETURN TO DOCK 6011652 575V 3PH 60 Hz Fig 65 1...

Страница 69: ...R HP HK 6011019 3 2 TERMINAL END STOP SCREWLESS 6000549 4 4 TERMINAL 2 POLE 6000542 5 2 CONTACTOR 18A 24V COIL 50 60 6012550 6 1 OVERLOAD 4 6 AMPS 6012557 7 1 MICRON XFMR 208 600V 120 24V 6012567 8 1...

Страница 70: ...otify Kelley and Kelley will at its option 1 Replace the DOCK LEVELER or LIP HINGE or the deficient portion s thereof without charge to the owner or 2 Alter or repair the DOCK LEVELER or LIP HINGE on...

Страница 71: ...epair the DOCK LEVELER on site or elsewhere without charge to the owner This Limited Warranty does not cover any failure caused by improper installation abuse improper operation negligence or failure...

Страница 72: ...l distributor or to 4Front Engineered Solutions Inc Corporate Head Office 1612 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 Part No 6004753N 2014 4Front Engineered Solutio...

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