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User's Manual aFX®/aFX-S Dock Leveler This User’s Manual applies to aFX dock levelers manufactured beginning September 2012 with the serial numbers 61056056 and higher. Do not install, operate or service this product unless you User’s Manual have read and understand the Safety Practices, Warnings, Installation and Operating Instructions contained in this Installation, Operations, User’s Manual. Failure to do so could result in death or Maintenance and Parts serious injury. Part No. 6004751K conTenTS Introduction .................................................................2 Operation ..................................................................16 Safety Signal Words ...................................................2 Planned Maintenance ...............................................19 Safety Practices..........................................................3 Service Tools ............................................................22 Owner’s Responsibilities ............................................4 Troubleshooting ........................................................25 Ramp and Lip Grade ..................................................5 Parts List...................................................................28 Installation ..................................................................6 Warranty ...................................................................42 Wiring Diagram .........................................................15 Distributor Information ..............................................44 inTroDUcTion Welcome and thank you for choosing this dock leveler from Kelley®. This dock leveler may be equipped with the optional ENERGY GUARD® dock leveler sealing system. This User’s Manual contains information that you need to safely install, operate and maintain the dock leveler. It also contains a complete parts list and information about ordering replacement parts. Please keep and read this User’s Manual before using your new dock leveler. SaFeTy SignaL worDS You may find safety signal words such as DANGER, WARNING, or CAUTION throughout this User’s Manual. Their use is explained below: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Indicates an imminently hazardous situation which, if Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury. not avoided may result in minor or moderate injury. Indicates a potentially hazardous situation which, Notice is used to address practices not related to if not avoided, could result in death or serious personal injury. injury. 2 6004751K — aFX® and aFX-S Dock Leveler — SafeTFrame® August 2012 ©2012 4Front Engineered Solutions, Inc. SaFeTy pracTiceS Visually check that lip is supported by the vehicle platform or the ramp is supported by both dock level supports before Read these Safety Practices before installing, operating driving on the ramp. or servicing the dock leveler. Failure to follow the safety practices could result in death or serious injury. Store dock leveler at dock level after below dock end loading. If you do not understand the instructions, ask your supervisor to explain them to you or call your local Kelley distributor. Ensure lip avoids contact with vehicle sides and cargo. If lip does not lower to vehicle bed, reposition vehicle. operaTion Use restricted to trained operators. Do not use a fork truck or other material handling equipment to lower the ramp. Follow procedures on placard posted near dock leveler. Move all equipment, material or people off dock leveler and Do not use this unit to service vehicles outside its intended store dock leveler at dock level before allowing the vehicle working range which is 12 inches above and 12 inches below to leave. dock. The working range of 10' dock levelers is 18 inches above dock and 12 inches below dock. inSTaLLaTion, MainTenance anD SerVice Place barricades on the dock floor around the dock Do not operate the dock leveler with equipment, material or leveler pit and in the driveway in front of the pit while people on the ramp or lip. installing, maintaining or repairing the dock leveler. Do not operate the dock leveler when anyone is in front of it Do not operate the dock leveler when anyone is in front unless they are securing the maintenance strut. of it unless they are securing the maintenance strut. Stay clear of the dock leveler when it is moving. Prior to placing in the pit, 8' and longer levelers require 6' long forks if handled with a fork lift. KEEP hANDS CLEAR OF hINGES at ALL TIMES. Do not use hands to position dock leveler ramp or lip in vehicle or to PUT AND PIN MAINTENANCE STRUT AND LIP LOCK store dock leveler. IN PLACE before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler. Stay clear of leveler unless lip supported by the vehicle bed or the ramp is supported by both front dock level supports; Disconnect the power and properly tag or lock off unsupported leveler can lower unexpectedly. before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler. Do not use the dock leveler if it looks broken or does not seem to work right. Tell your supervisor it needs repair right All electrical troubleshooting or repair must be done by a away. qualified technician and must meet applicable codes. Do not stand in the driveway between the dock leveler and Disconnect the power and properly tag or lock off before a backing vehicle. doing any electrical work. Before chocking wheels or engaging vehicle restraint, dump If it is necessary to make troubleshooting checks inside air from air ride suspensions and set parking brakes. the control box with the power on, USE EXTREME CAUTION! Do not place fingers or uninsulated tools Chock vehicle wheels or lock vehicle in place with a inside the control box. Touching wires or other parts vehicle restraining device and set brakes before loading or inside the control box could result in electrical shock, unloading. death or serious injury. August 2012 6004751K — aFX® and aFX-S Dock Leveler — SafeTFrame® 3 ©2012 4Front Engineered Solutions, Inc. owner’S reSponSibiLiTieS The owner’s responsibilities include the following: The owner should recognize the inherent danger of the interface between dock and transport vehicle. The owner should, therefore, train and instruct operators in the safe use of dock leveling devices. When a transport vehicle is positioned as closely as practical to a dock leveling device, there shall be at least 4" of overlap between the front edge of the lip and the edge of the floor or sill of the transport vehicle. Nameplates, cautions, instructions and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended. Manufacturer’s recommended periodic maintenance and inspection procedures in effect at date of shipment shall be followed and written records of the performance of these procedures should be kept. Dock leveling devices that are structurally damaged or have experienced a sudden loss of support while under load, such as might occur when a transport vehicle is pulled out from under the dock leveling device, shall be removed from service, inspected by the manufacturer’s authorized representative, and repaired as needed before being placed back in service. The owner shall see that all nameplates, caution and instruction markings or labels are in place and legible and that the appropriate operating and maintenance manuals are provided to users. Modifications or alterations of dock leveling devices shall be made only with written permission of the original manufacturer. When industrial vehicles are driven on and off transport vehicles during the loading and unloading operation, the brakes on the transport vehicle shall be applied and wheel chocks or positive restraints that provide the equivalent protection of wheel chocks engaged. The dock leveler should never be used outside its vertical working range or vertical lifting range or outside the manufacturer’s labelled rated capacity. It must also be compatible with the loading equipment and other conditions relating to the dock. 4 6004751K — aFX® and aFX-S Dock Leveler — SafeTFrame® August 2012 ©2012 4Front Engineered Solutions, Inc. raMp anD Lip graDeS Fig. 1 Ramp grade Lip grade VEHICLE RAMP and LIP grades, % for each dock leveler length VEHICLE RAMP and LIP grades, % for each dock leveler length PLATFORM PLATFORM POSITION from 6' Leveler 8' Leveler 10' Leveler POSITION from 6' Leveler 8' Leveler 10' Leveler DOCK, (in.) RAMP LIPRAMPLIP RAMP LIP DOCK, (in.) RAMP LIPRAMPLIP RAMP LIP 18.0 -- -- -- -- 16.7 8.8 18.0 -- -- -- -- 17.3 4.8 A 16.0 -- -- -- -- 15.0 7.1 A 16.0 -- -- -- -- 15.6 3.0 B 14.0 -- -- -- -- 13.2 5.4 B 14.0 -- -- -- -- 13.9 1.3 O O V V E 12.0 19.4 11.6 14.5 6.6 11.5 3.7 E 12.0 20.5 8.0 15.3 2.7 12.2 -0.4 10.0 16.5 8.7 12.3 4.5 9.8 2.0 10.0 17.6 5.0 13.1 0.6 10.5 -2.1 D D O 8.0 13.7 5.8 10.2 2.4 8.2 0.3 O 8.0 14.7 2.2 11.0 -1.6 8.8 -3.8 C C K 6.0 10.8 3.0 8.1 0.2 6.5 -1.4 K 6.0 11.9 -0.7 8.9 -3.7 7.1 -5.5 4.0 8.0 0.2 6.0 -1.8 4.8 -3.1 4.0 9.1 -3.5 6.8 -5.8 5.4 -7.1 2.0 5.2 -2.6 3.9 -3.9 3.1 -4.7 2.0 6.3 -6.3 4.7 -7.9 3.8 -8.8 0.0 2.4 -5.4 1.8 -6.0 1.5 -6.4 0.0 3.5 -9.1 2.6 -10.0 2.1 -10.5 B -2.0 -0.3 -8.2 -0.3 -8.1 -0.2 -8.1 B -2.0 0.7 -11.9 0.5 -12.0 0.4 -12.1 E E L -4.0 -3.1 -11.0 -2.3 -10.2 -1.9 -9.7 L -4.0 -2.1 -14.6 -1.6 -14.1 -1.2 -13.8 O -6.0 -5.9 -13.8 -4.4 -12.3 -3.5 -11.4 O -6.0 -4.9 -17.4 -3.6 -16.2 -2.9 -15.5 W W D -8.0 -8.7 -16.6 -6.5 -14.4 -5.2 -13.1 D -8.0 -7.7 -20.2 -5.7 -18.3 -4.6 -17.1 O -10.0 -11.5 -19.4 -8.6 -16.5 -6.9 -14.7 O -10.0 -10.5 -23.0 -7.8 -20.4 -6.3 -18.8 C C K -12.0 -14.4 -22.2 -10.7 -18.6 -7.5 -15.3 K -12.0 -13.3 -25.9 -9.9 -22.5 -7.9 -20.5 4° lip bend, 16" lip Optional 7° lip bend, 16" lip August 2012 6004751K — aFX® and aFX-S Dock Leveler — SafeTFrame® 5 ©2012 4Front Engineered Solutions, Inc.
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