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January 2009

6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe

Frame

™

oPeraTion

Dock LeVeLers wiTH sTanDarD

THree bUTTon conTroL box

Before operating the dock leveler, read and follow Safety

Practices on page 3.
Use of dock leveler restricted to trained operators.

Follow procedures on placard posted near leveler
DO NOT USE THE DOCK LEVELER IF IT LOOKS

BROKEN, OR DOES NOT SEEM TO WORK RIGHT. Tell

your supervisor it needs repair right away.
Before pressing button, ensure lip avoids contact with

vehicle sides and cargo. If lip does not lower to vehicle

bed, reposition vehicle.
Stay clear of leveler unless lip is supported by vehicle

bed or the leveler is stored at dock level. Visually check

that the lip is supported by the vehicle bed or the ramp

is supported by both dock level supports before driving

or walking on the ramp. Unsupported dock levelers can

lower unexpectedly.
Before chocking wheels or engaging vehicle restraint,

dump air from air ride suspensions and set parking

brakes.
Always be certain that the vehicle wheels are chocked,

or that the vehicle is locked in place by a vehicle

restraining device and the brakes are set before loading

or unloading. Vehicles pulling away from the dock

unexpectedly can cause uncontrolled drop of the dock

leveler which can result in death or serious injury.
The maximum uncontrolled drop of a Kelley

HK dock

leveler from any position is 3 inches.
Always return the dock leveler to its dock level (stored)

position 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 properly store the dock leveler

may leave the leveler in a position below the level of the

floor. This condition may result in unexpected drop of

personnel or material handling equipment and result in

death or serious injury.
Failure to follow these instructions could result in death

or serious injury to operators and/or bystanders.

inTroDUcTion

The KELLEy

HK Dock Leveler is designed to span and

compensate for space and height differences between a

loading dock and freight carrier to allow safe, efficient freight

transfers.

The KELLEy

HK Dock Leveler with Three Button Control

has a stop button control to stop downward movement of

the ramp and shuts off the raise and extend push-button

controls. A valve will not allow the ramp to lower. The stop

button must be out during normal use.

Pushing and holding the raise push-button operates a

hydraulic cylinder to raise the ramp. Releasing the raise

push-button allows the ramp to lower.

When the dock leveler reaches its full raised position, a

second hydraulic cylinder extends the dock leveler lip. The

dock leveler with its lip extended settles onto the vehicle bed

forming a bridge.

After loading, pushing and holding the push-button raises

the ramp, and the extended lip lowers to its stored position.

Releasing the push-button allows the dock leveler to lower

to its level, stored position.

The Kelley

HK Dock Leveler with Three Button Control

also has a lip extend push-button control to extend the dock

leveler lip before the ramp reaches its full raised position.

Releasing the extend push-button allows the ramp to lower.

With the dock leveler in its stored position, dock level support

legs support the dock leveler ramp at a position level with

the dock floor. The dock level support legs will retract when

the dock leveler lip is extended, allowing the ramp and lip to

lower onto and follow the vehicle bed up and down as loads

are moved across the dock leveler and vehicle.

Содержание HK

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 manual applies to dock lev...

Страница 2: ...s injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Caution used without the safety alert symbol indicates a potentially hazardous situatio...

Страница 3: ...ower unexpectedly Store dock leveler 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...

Страница 4: ...eling 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: ...2 0 14 1 16 2 18 3 20 4 22 5 0 4 1 2 2 9 4 6 6 3 7 9 12 1 13 8 15 5 17 1 18 8 20 5 RAMP and LIP grades for each Dock Leveler length RAMP and LIP grades for each Dock Leveler length 6 Leveler 8 Leveler...

Страница 6: ...rol box must be from fused disconnect supplied by others For correct fuse size refer to wiring diagrams on pages 15 24 of this manual Before doing any electrical work make certain the power is disconn...

Страница 7: ...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 lb...

Страница 8: ...r pit curb angle Repeat on each leg until all are legs in contact with the pit floor and the top frame angle is flush with the rear curb angle See Fig 8 The rear edge of the dock leveler should be lev...

Страница 9: ...eft for the necessary alignment 7 Tack weld the front dock leveler supports to the front curb angle with 3 16 welds as shown in Fig 12 8 With the lip pendant insert 24 long 1 2 extensions between lip...

Страница 10: ...LACE AND PINNED 12 Return power to the leveler control Using the push button control station or a suitable lifting device raise the deck and secure with maintenance strut a Push and hold the RAISE but...

Страница 11: ...4 Finish welding both of the adjusted dock leveler supports in all locations shown in Fig 12 15 Check shims under ramp cylinder pad Adjust thickness if necessary Improper installation of anchoring dev...

Страница 12: ...ury DO NOT REMOVE MAINTENANCE STRUT WITHOUT HYDRAULIC PRESSURE OR A MECHANICAL LIFTING DEVICE SUPPORTING RAMP Raise ramp with hydraulic pressure or mechanical device before storing maintenance strut S...

Страница 13: ...OPERATING instruction placard on the wall near the dock leveler control See Fig 19 Make sure the customer gets the user s manual and is properly trained 25 Operate the dock leveler four times through...

Страница 14: ...g 10 See Fig 20 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 concrete w...

Страница 15: ...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 o...

Страница 16: ...2009 4Front Engineered Solutions Inc 16 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 Wiring diagrams Standard continued 220V 1PH 50 Hz...

Страница 17: ...2009 4Front Engineered Solutions Inc January 2009 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame 17 Wiring diagrams Standard continued 200 480V 3PH 50 60 Hz...

Страница 18: ...2009 4Front Engineered Solutions Inc 18 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 Wiring diagrams Standard continued 380V 3PH 50 Hz...

Страница 19: ...2009 4Front Engineered Solutions Inc January 2009 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame 19 Wiring diagrams Standard continued 575V 3PH 60 Hz...

Страница 20: ...2009 4Front Engineered Solutions Inc 20 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 Wiring diagrams With Optional A R T D 115 208 230V 1PH 50 60 Hz...

Страница 21: ...2009 4Front Engineered Solutions Inc January 2009 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame 21 Wiring diagrams With Optional A R T D continued 220V 1PH 50 Hz...

Страница 22: ...2009 4Front Engineered Solutions Inc 22 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 Wiring diagrams With Optional A R T D continued 200 480V 3ph 50 60 hz...

Страница 23: ...2009 4Front Engineered Solutions Inc January 2009 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame 23 Wiring diagrams With Optional A R T D continued 380V 3PH 50 Hz...

Страница 24: ...2009 4Front Engineered Solutions Inc 24 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 Wiring diagrams With Optional A R T D continued 575V 3PH 60 Hz...

Страница 25: ...the dock leveler may leave the leveler in a position below the level of the floor This condition may result in unexpected drop of personnel or material handling equipment and result in death or seriou...

Страница 26: ...on out Pushing STOP button in at any time stops movement of the ramp If necessary remove end loads with the ramp in the dock level stored position See Fig 24 NOTE If the vehicle to be serviced is belo...

Страница 27: ...p Ramp should be level with dock floor 8 4 Push STOP button in Unchock or release vehicle Tell vehicle driver Your vehicle may now leave the dock Below Dock Control BDC To lower the ramp without exten...

Страница 28: ...el of the 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 deat...

Страница 29: ...or hitch vehicle Pull STOP button out Pushing STOP button in at any time stops movement of the ramp If necessary remove end loads with the ramp in the dock level stored position See Fig 29 NOTE If the...

Страница 30: ...level with dock floor 8 4 Push STOP button in Unchock or release vehicle Tell vehicle driver Your vehicle may now leave the dock Below Dock Control BDC To lower the ramp without extending the lip for...

Страница 31: ...PERATIONS WARNING AND OPERATION PLACARD MOUNTED ON WALL NEAR LEVELER DO NOT LIFT THIS SIDE 700 136 156 241 x2 HK S Model Only 921 070 921 074 Preventive maintenance Fig 34 Every 90 days quarterly insp...

Страница 32: ...d be checked when the leveler is resting on the maintenance post with the lip pendant If the leveler is equipped with A R T D allow the deck to descend to the maintenance post and the lip to fall pend...

Страница 33: ...ve and clean oil pump strainer Legend Symbol Description Lubricate Oil Light Oil SAE 30 Lubricate Grease Molybdenum Disulfide NLGI 2 Cleaning Location Frequency Visually Inspect Replace Damaged Or Wor...

Страница 34: ...CURELY IN PLACE see Fig 38 and 2 the power is disconnected and properly tagged or locked off Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operation section...

Страница 35: ...reservoir Add if required See Fig 39 Check hydraulic bypass pressure and adjust as required See Fig 40 Check lip sequence valve pressure setting See Fig 41 Lip Extends Before Ramp Reaches Full Above D...

Страница 36: ...loose or missing the switches can move on the brackets Switch contacts should be closed when dock leveler is full below dock and lip is pendant See wiring diagrams on pages 15 through 24 See Fig 42 NO...

Страница 37: ...egs See Fig 44 Check for binding of dock level control chain See Fig 44 Check for binding in dock level support legs Check length of below dock control chain Adjust chain so dock level support legs ar...

Страница 38: ...004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 Hydraulic diagram Ramp cylinder 100 mesh Needle valve Fixed shuttle valve 1650 PSIG relief valve Lip cylinder Gage 052 dia 1...

Страница 39: ...LIP LOCK ARE SECURELY IN PLACE see Fig 38 and 2 the power is disconnected and properly tagged or locked off After replacing hose and or motor pump assembly run pump motor at least four 4 times with t...

Страница 40: ...is shown in Fig 47 Example HK6x8P 6 wide 8 long To determine the nominal size of your dock leveler see Fig 48 You will also need to measure the pit depth to determine pit size for correct replacement...

Страница 41: ...ary 2009 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame 41 Parts list continued Model hK ramp lip and toe guard Assemblies 32 15 3 2 16 17 1 14 13 9 4 10 7 11 12 5 6 8 6 8 7 18 19 23...

Страница 42: ...HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 Parts list continued Model hK S ramp lip and toe guard Assemblies 16 17 1 14 13 9 4 10 7 11 12 5 6 8 6 8 7 18 19 23 20 21 22 23 25 1...

Страница 43: ...D 711 898 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...

Страница 44: ...sher 5 16 Flat 000 055 12 2 Nut 5 16 18 Nyloc 131 456 13 2 DECAL Lift 138 578 14 2 LABEL Warning 6001044 15 1 DECAL Lip Lock 700 136 16 1 SERIAL TAG 138 822 17 2 RIVET Pop 1 8 131 406 18 3 S HOOK 000...

Страница 45: ...s 6004128 3 A R Retainer Shaft Hinge Pin 236 110 4 1 SCREW Drive 000 518 5 1 PIN Cotter Hair 035 200 6 1 CHAIN Sash 032 195 7 1 DECAL Maint Strut 921 074 8 1 WASHER Flat 3 8 000 214 9 1 PIN Cotter 035...

Страница 46: ...SafeTFrame January 2009 PARTS LIST continued Optional sUBFRAME RISEr kit Item Quantity Description Part Number 1 1 4 Riser Kit Field Installed 6004523 2 4 Rear Angle Cap Plugs Kelley Optional 6004487...

Страница 47: ...ydraulic Dock Leveler 3 Button SafeTFrame 47 Parts list continued Hydraulic components and return to Dock level switch 1 4 7 5 6 8 9 10 3 12 13 16 14 15 11 19 17 29 26 18 27 30 22 24 23 31 35 31 34 32...

Страница 48: ...Hz 713 368 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 60 Hz 156 060 575V 3 PH 60 Hz 156 192 5 1 DECAL Caution 138...

Страница 49: ...antity Description Part Number 23 1 PIN CYLINDER 709 409 24 2 PIN ROLL 035 096 25 1 CLEVIS CYLINDER 712 376 26 1 PIN CLEVIS 035 039 27 1 PIN COTTER 035 036 28 1 LIP LIFTER 712 377 29 1 CYLINDER LIP 70...

Страница 50: ...utions Inc 50 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 PARTS LIST continued CONTROL BOX ASSEMBLY STANDARD 115 208 230 1PH 50 60 Hz 1 4 7 5 6 8 9 10 3 12 13 16 14 15...

Страница 51: ...4 w holes Nema 4 712 576 2 1 Panel 8 3 4 x 6 7 8 707 975 3 1 Relay Power 700 901 4 3 Contact Block 1 N O 061 732 5 1 Label Wiring Schematic 713 769 6 1 Label Instruction 713 742 7 1 Label Caution 138...

Страница 52: ...Solutions Inc 52 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 PARTS LIST continued CONTROL BOX ASSEMBLY Standard 220V 1PH 50 Hz 1 4 7 5 6 8 9 10 3 12 13 16 14 15 11 19...

Страница 53: ...el 8 3 4 x 6 7 8 707 975 3 1 Relay Power 700 901 4 1 Transformer Control 061 519 5 3 Contact Block 1 N O 061 732 6 1 Label Wiring Schematic 713 771 7 1 Label Instruction 713 742 8 1 Label Caution 138...

Страница 54: ...004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 PARTS LIST continued CONTROL BOX ASSEMBLY Standard 200 480V 3ph 50 60 hz 380V 3PH 50 Hz 575V 3PH 60 Hz 1 4 7 5 6 8 9 10 3 12...

Страница 55: ...Coil 061 876 4 1 Transformer 24V sec 200 480V 3 PH 50 60 Hz 061 906 380V 3 PH 50 Hz 061 901 575V 3 PH 60 Hz 061 905 5 3 Contact Block 1 N O 061 732 6 1 Label Wiring Schematic 200 480V 3 PH 50 60 Hz 71...

Страница 56: ...6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL AUTO RETURN TO DOCK 115 208 230V 1PH 50 60 Hz 1 4 5 6 8 9 10 3 12...

Страница 57: ...w holes Nema 4 712 576 2 1 Panel 8 3 4 x 6 7 8 707 975 3 1 Relay Power 700 901 4 1 Roto Push button 061 727 5 4 Contact Block 1 N O 061 732 6 1 Label Wiring Schematic 713 768 7 1 Label Instruction 708...

Страница 58: ...c 58 6004754F HK and HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 PARTS LIST continued CONTROL BOX ASSEMBLY WITH OPTIONAL AUTO RETURN TO DOCK 220V 1PH 50 Hz 1 4 7 5 6 8 9 10 3 12 13 16...

Страница 59: ...h button 061 727 6 4 Contact Block 1 N O 061 732 7 1 Label Wiring Schematic 713 770 8 1 Label Instruction 708 000 9 1 Label Caution 138 607 10 1 Label U L 11 1 Fuse Holder Single 061 492 12 1 Fuse 250...

Страница 60: ...nd HK S Hydraulic Dock Leveler 3 Button SafeTFrame January 2009 1 4 7 5 6 8 9 10 3 12 13 16 14 15 11 19 20 17 18 2 6 18 PARTS LIST continued CONTROL BOX ASSEMBLY With optional Auto return to dock 200...

Страница 61: ...4V Coil 061 876 4 1 Transformer 24V sec 200 480V 3 PH 50 60 Hz 061 906 380V 3 PH 50 Hz 061 901 575V 3 PH 60 Hz 061 905 5 1 Roto Push button 061 727 6 4 Contact Block 1 N O 061 732 7 1 Label Wiring Sch...

Страница 62: ...EVELER 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 fo...

Страница 63: ...lity 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...

Страница 64: ...stions about your dock leveler to your local 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...

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