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Hydraulic Dock Leveler Model HK and HK-S with One Button Control This User’s Manual applies to dock levelers manufactured beginning March 2014 with the serial number 61106268 and higher. User’s Manual Do not install, operate or service this product unless you...
Distributor Information ..........72 Operations ..............25 Planned Maintenance ..........31 Maintenance And Lubrication ........32 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.
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 ®...
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 practicable to a dock leveling device, there shall be at least 4"...
raMP anD LiP graDes Fig. 1 Ramp grade Lip grade Ramp and lip grades, Ramp and lip grades, Vehicle bed Vehicle bed % for each dock leveler length % for each dock leveler length position position 6' Leveler 8' Leveler 10' Leveler 6' Leveler 8' Leveler...
insTaLLaTion PiT cHeck subframe, remove it before placing the leveler into the 1. Check entire dock leveler pit for proper construction pit. Make sure the customer gets the user’s manual and according to certified pit drawings (publication 5567). Check is properly trained. to be sure that the pit walls are square and plumb.
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6' and 8' long levelers using a standard 19" subframe can be field converted to allow installation in a 24" pit by adding a 4" riser kit, Kelley Part No. 6004654. Install the new riser leveling feet. The riser blocks should be welded to the front frame supports prior to placing in the pit.
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insTaLLaTion, continued noTe: noTe: Do not weld out the rear angle until after setting the front Check the pit floor for uneven or excess concrete in the area supports. around the leveling feet 1"-6" from the rear wall. Use chisel to level out area if necessary.
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insTaLLaTion, continued LeVeLing THe fronT fraMe Fig. 8 6. Remove and discard the shipping tie down bolts located Transition angle at the lower end of the hinged lip assembly. See Fig. 14. Curb angle Before welding the dock leveler supports to the front Raises curb angle make sure that the dock leveler support legs rear...
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insTaLLaTion, continued 11. If a field installed riser kit is being used, do not use Fig. 11 hydraulics to position leveler on maintenance strut before Door jamb cylinder support riser is in place. Use a suitable lifting Flush with floor at this point device to place leveler on maintenance strut per step 12 below, then position and weld in the cylinder support bracket.
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insTaLLaTion, continued Fig. 14 Welding with the dock levelers power connected can damage electrical components. If the dock leveler has been previously connected, turn off power to control box Shipping tie and disconnect all electrical wires from junction box in down bolt rear pit wall before welding.
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20. Mount dock bumpers to face of dock. Downhill welds are J bolts (3) per bumper unacceptable. See Fig. 17 or 18. furnished by Kelley Company, Inc. Locate 21. Wire in electrical cords and connect power to dock leveler. and weld to curb angle at time of bumper installation.
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(See Operation section, page 25.) noTe: If you have any problems or questions using or operating the dock leveler, contact your supervisor or local Kelley ® distributor for assistance. 26. Optional (where applicable), install rear angle cap plugs (part number 6004488) into adjustment socket holes.
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insTaLLaTion, continued insTaLLaTion TroUbLesHooTing The following procedures apply after the leveler is level in the pit. ProbLeM PossibLe caUse soLUTion 1) Leveler will not fit properly in pit. a) Pit is out of square with the sides. a) Align the sides parallel and equally spaced with the rear frame angle touching the rear curb angle in one place.
wiring DiagraMs — conTroL box — sTanDarD noTe: Before doing any electrical work, make certain the power For 24V incoming power consult factory. is disconnected and properly tagged or locked off. All electrical work must be done by a qualified technician and meet all applicable codes.
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.
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sTanDarD oPeraTion Fig. 24 Do not operate the dock leveler when anyone is on or in front of it. Stay clear of the dock leveler when it is moving. Do not walk on dock leveler or lip until the lip is fully extended and supported by the vehicle bed.
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sTanDarD oPeraTion, continued 7. To return the dock leveler to the stored position when loading or unloading is complete, or to load end loads: Before allowing vehicle to leave always return the dock 7.1 Push and hold the raise button. The ramp will leveler to its dock level (stored) position with the dock rise and the lip will lower.
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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.
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oPeraTion, continued Dock LeVeLers wiTH aUTo-reTUrn To Dock Fig. 29 oPTion Do not operate the dock leveler when anyone is on or in front of it. Stay clear of the dock leveler when it is moving. Do not walk on dock leveler or lip until the lip is fully extended and supported by the vehicle bed.
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oPeraTion, continued 7. To return the dock leveler to the stored position when loading or unloading is complete, or to load end loads: Before allowing vehicle to leave always return the dock 7.1 Turn the “ON/OFF” switch to the “ON” position. leveler to its dock level (stored) position with the dock level support legs supported by the front dock level 7.2 Push and hold the “RAISE”...
Every 90 days (quarterly) inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible. If any are missing or require replacement, please call your local Kelley distributor. Fig. 34 6008554 (x2) (HK-S Model Only) 6008485 (x2) 138-837 (x2) 6015283 921-074 921-070...
MainTenance anD LUbricaTion Fig. 35 Lip hinge Dock level support leg Be certain, before climbing into the dock leveler pit or assembly cam and hinge doing any maintenance or repair under the dock leveler, that: 1) THE MAINTENANCE STRUT IS IN POSITION AND PINNED, LIP LOCK IS IN PLACE AND SUPPORTING THE LIP [see Fig.
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MainTenance anD LUbricaTion, continued Fig. 37 Legend Symbol Description Lubricate - oil Light oil - SAE 30 Lubricate - grease Molybdenum disulfide NLGI #2 Cleaning Lubricate pin (Location - frequency) on both ends of cylinder Visually inspect (Replace damaged or worn) Hydraulic reservoir See Note 1 Pit - 3 mo...
serVice TooLs LiP Lock Before servicing the dock leveler, read and follow the Safety Practices on page 3, and the Operations Instruction The lip is free to move downward when it is released section on pages 16 through 18 of this User’s Manual. unless lip lock is in its support position.
TroUbLesHooTing gUiDe, continued Fig. 39 Use type 5606 (low temp.) Be certain, before climbing into the dock leveler pit or hydraulic oil. doing any maintenance or repair under the dock leveler, that: 1) THE MAINTENANCE STRUT AND LIP LOCK ARE SECURELY IN PLACE, [see Fig.
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TroUbLesHooTing gUiDe, continued LiP exTenDs before raMP reacHes fULL aboVe Fig. 41 Dock PosiTion: Set lip sequence 1. Check lip sequence valve pressure setting. See Fig. 41. pressure at 1500 PSIG. Pressure gauge should LiP faiLs To DroP To THe PenDanT PosiTion wHen read 1500 PSI raMP is raiseD froM VeHicLe: before lip begins...
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TroUbLesHooTing gUiDe, continued 2. Downward speed of the ramp is controlled by a needle Fig. 43 valve located in the pump/motor. Turn valve in to eliminate locking. See Fig. 43. See chart on page 39 for amount of time dock leveler should move from its fully raised position to full below dock position.
ParTs rePLaceMenT conTroL box TransforMer — 3 PHase onLy Fig. 47 1. When replacing the transformer make sure jumper wires are installed per wiring diagrams, for appropriate phase and voltage. HyDraULic oiL Hoses 1. When removing hydraulic oil hose(s) remove from motor/pump assembly first then from cylinder assembly.
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 Pit Depth or serious injury.
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ParTs LisT, continued raMP, LiP, anD Toe gUarD asseMbLies item Quantity Description Model Hk Model Hk-s LIP, 6FT WIDE, 30K AND 35K CAPACITy 16" X 6' W. 4 DEGREE BEND 711-858 — 16" X 6' W. 7 DEGREE BEND 711-857 —...
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PIN, GROOVED 5/8" DIA. X 3-1/2 035-338 KLIPRING, EXT. 5/8" 049-060 LEVER, LIP LOCK 6015269 GUARD, SAFETy LIP - MODEL HK-S ONLy 6' W DOCK LEVELER 714-220 6-1/2' W DOCK LEVELER 714-219 7' W DOCK LEVELER 714-218 TOE GUARD, MIDDLE SLIDING - 19" PIT 6' LG.
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ParTs LisT, continued sUbfraMe anD MainTenance sTrUT asseMbLies Fig. 52 item Quantity Description Part number MAINTENANCE POST, 6' LG. DECK WITH 20" BACKFRAME 713-308 MAINTENANCE POST, 6' LG. DECK WITH 24" BACKFRAME 6013622 MAINTENANCE POST, 8' LG. DECK WITH 20" BACKFRAME 708-882 MAINTENANCE POST, 8' LG.
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ParTs LisT, continued HyDraULic coMPonenTs anD reTUrn To Dock LeVeL swiTcH item Quantity Description Part number MOTOR/PUMP UNIT (INCLS. ITEMS 2 THRU 8) 100-120V, 1 PH, 50/60 Hz 6011436 200-240V, 1 PH, 50/60 Hz 6011437 190-240V, 3 PH, 50/60 Hz 6011438 380-480V, 3 PH, 50/60 Hz 6011439...
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ParTs LisT, continued HyDraULic coMPonenTs anD reTUrn To Dock LeVeL swiTcH item Quantity Description Part number LIP LIFTER 712-377 CyLINDER, LIP 708-887 PIN, GROOVED, 3" LG 700-050 KLIPRING, EXT. 5/8" 049-060 PIN, GROOVED, 1-1/8" LG 700-049 HN-ANSI B18.2.2 - 1/4 - 20 214-161 AC INDUCT PROX SWITCH, N/O, 18 MM 625-040...
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10' Lower seal. 6008172 Aluminum strip 6' upper 6008174 Aluminum strip 8' upper 6008176 Aluminum strip 10' upper 6008178 6' Kelley rear seal 6007671 6.5' Kelley rear seal 6007672 7' Kelley rear seal 6007673 TEK screws (not shown) 215702 Chain cup seal...
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ParTs LisT, continued conTroL box asseMbLy — sTanDarD 6006461 — 120V, 1 PH, 50/60 Hz 6006462 — 208-240V, 1 PH, 60 Hz Fig. 56 item Quantity Description Part number — CONTROL BOX ASSEMBLy (INCLUDES ITEMS 1-6) 120V, 1 PH, 50/60 Hz 6006461 208-230V, 1 PH, 60 Hz 6006462...
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ParTs LisT, continued conTroL box asseMbLy — sTanDarD 6006450 — 208-240V, 3PH, 60 Hz 6006451 — 460-480V, 3PH, 60 Hz 6006452 — 575V, 3PH, 60 Hz Fig. 57 6004753N — Hydraulic Dock Leveler - One Button Control — Safe Frame March 2014 ™...
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ParTs LisT, continued conTroL box asseMbLy — sTanDarD 6006450 — 208-240V, 3PH, 60 Hz 6006451 — 460-480V, 3PH, 60 Hz 6006452 — 575V, 3PH, 60 Hz item Quantity Description Part number — CONTROL BOX ASSEMBLy (INCLUDES ITEMS 1-6) 208-230V, 3 PH, 50/60 Hz 6006450 460-480V, 3 PH, 50/60 Hz 6006451...
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PUSH BUTTON, FLUSH, BLACK 6012561 SELECTOR SWITCH, 2 POSITION 6012565 CONTACT BLOCK SWITCH, NO, STD 6012563 BODy, MOUNTIN COLLAR 6012562 DECAL-KELLEy HP/HK-2PB 6014268 SCHEMATIC,HP/HK,2PB,1PH,208-240V 6011324S March 2014 6004753N — Hydraulic Dock Leveler - One Button Control — Safe Frame ™...
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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 — 460-480V, 3PH, 60 Hz Fig. 64 6004753N — Hydraulic Dock Leveler - One Button Control — Safe Frame March 2014 ™...
Kelley warrants that this DOCK LEVELER will be free from flaws 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 DOCK LEVELER by the original purchaser, provided that the owner maintains and operates the DOCK LEVELER in accordance with this User’s Manual.
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Kelley warrants that this DOCK LEVELER will be free from flaws 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 DOCK LEVELER by the original purchaser, provided that the owner maintains and operates the DOCK LEVELER in accordance with this User’s Manual.
Please direct questions about your dock leveler to your local distributor or to 4Front Engineered Solutions, Inc. Corporate Head Office: your local Kelley distributor is: ® 1612 Hutton Dr. Suite 140 Carrollton, TX. 75006 Tel. (972) 466-0707 Fax (972) 323-2661 HyDRAULICPLUS™...
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