Kelley aFX-C User Manual
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Kelley aFX-C User Manual

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aFX-C Dock Leveler
This User's Manual applies
to aFX-C dock levelers
manufactured beginning March
2014 with the serial numbers
61106268 and higher.
User's Manual
Do not install, operate or service this product unless you
Installation, Operations,
have read and understand the Safety Practices, Warnings,
Installation and Operating Instructions contained in this
Maintenance and Parts
User's Manual. Failure to do so could result in death or
serious injury.
Part No. 6004752K

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Summary of Contents for Kelley aFX-C

  • Page 1 Dock Leveler This User’s Manual applies to aFX-C dock levelers manufactured beginning March 2014 with the serial numbers 61106268 and higher. User’s Manual Do not install, operate or service this product unless you Installation, Operations, have read and understand the Safety Practices, Warnings,...
  • Page 2 Installation ..............6 Warranty Information ..........43 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.
  • Page 3 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.
  • Page 4 It must also be compatible with the loading equipment and other conditions relating to the dock. 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ®...
  • Page 5 -18.8 -12.0 -14.4 -22.2 -10.7 -18.6 -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 March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 6 Remove these items before placing the leveler into the pit. Make sure the customer gets the 12"-13" user’s manual and is properly trained. Box Located as Shown 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 7 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. 6004653. Install the new riser leveling feet. The riser blocks should be welded to the front subframe supports and secondary stops prior to placing in the pit.
  • Page 8 4 places min 3/8", one at or near each leveling screw. noTe: Do not weld out the rear angle until after setting the front supports. 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 9 Pit Side Curb Angle Fig. 10 5" 2-1/2" 5" 5" 2-1/2" 5" 2-1/2" 2-1/2" 5" 5" Frame Rear Uprights Rear Hinge Curb Assembly Angle March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 10 Fig. 15 and the instruction label on maintenance strut. Fig. 13 c) Air pressure or mechanical support may now be removed. Shipping tie down bolt 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 11 18. Read the Safety Practices on page 3, and the Operation Instructions on pages 16 through 18 before operating the dock leveler. Fig. 16 Remove Shipping Cotter Pins March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 12 Others. beam near lip lock. Bumper Mounting Plate. Downhill Welds Curb 1/4" are Unacceptable. Angle Vertical Bumper Mounting Laminations Must Be Angle Installed Vertically 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 13 (See Operation section, page 16.) 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.
  • Page 14 Fig. 22 Shim and weld flush 1/8" MAX Allowable Step No Greater than Equal 1" x 3" in size 1/2" max. 6" Contact Zone 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 15 20 AMP MAX 120V Line GRN Motor 1 Phase 50/60 Hz Neutral 1 Phase 120V Pit Wall 50/60 Hz Receptacle NEMA 5-15R (By Others) March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 16 The KELLEy aFX-C dock leveler is designed to span and ® Before operating the dock leveler, read and follow the compensate for space and height differences between a Safety Practices on page 3. loading dock and freight carrier to allow safe, efficient freight Use of dock leveler restricted to trained operators.
  • Page 17 5.3 Ramp will lower and lip will extend until the lip rests on the vehicle platform. See Fig. 26. Push to Raise Vehicle Bed Fig. 26 March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 18 Ramp should be level with dock floor. 7. Remove wheel chocks or release vehicle. 8. Tell vehicle driver “your vehicle may now leave the dock.” 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 19 This condition may result in unexpected drop of personnel or material handling equipment and result in death or serious injury. March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 20 If any are missing or require replacement, please call your local Kelley distributor. Fig. 29 6008485 (x2) 138-837 (x2) 6015283 921-074 921-070 (x2) 6001952 Danger and operation placard (mounted on wall near leveler) 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 21 90 days visually inspect dock bumpers. Four inches (4") of bumper protection is required. worn, torn, loose or missing bumpers must be replaced. March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 22 Lip Rods Gas Spring Pins Swing Link Pins Connecting Rod Pins Leg Pivot Pins Air Bag Bolts Rear Hinge Pins 29-31 Ft-Lbs. 90 Days 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 23 DO NOT WORK UNDER THE DOCK LEVELER RAMP OR LIP UNLESS THE MAINTENANCE STRUT IS IN PLACE AND PINNED, AND LIP LOCK IS IN PLACE AND SUPPORTING THE LIP. March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 24 See Fig. 2.2 Lower the pan assembly to the pit floor. Fig. 35 2.3 Remove lifting tool from pit. 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 25 Remove the pan rollers. 2.5 Lower bag pan assembly following instructions on page 23. March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 26 36-37. d) Motor voltage too low. d) Verify motor voltage is between 110-129 volts AC while motor is running at full load. 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 27 Chain pulling one leg. d) Check length of below dock control chain. Adjust chain so dock level support legs are retracted the same distance. Fig. 41 March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 28 Check to see that the lip extends aligned. far enough to allow the links and connecting rod to align and then reach an “over center” position. 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 29 6 x 8 6 x 10 6.5 x 6 6.5 x 8 6.5 x 10 7 x 6 7 x 8 7 x 10 March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 30 Ramp, Lip, Toe Guards and Lip Lock Assemblies Fig. 45 Note: Rivets (Item 40) Attach Bag Shield (Item 39) To Brackets Welded On Bottom Of Ramp. 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 31 6' LG. DOCK LEVELER 155-554 8' LG. DOCK LEVELER 155-555 10' LG. DOCK LEVELER, 23" PIT 155-557 10' LG. DOCK LEVELER, 19" PIT 155-564 March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 32 PIN, COTTER 1/8" X 1-1/4" 035-036 ChAIN, BDC — 6' 6012661 ChAIN, BDC — 8' 6003453 ChAIN, BDC — 10' 6003452 6" LG. SASh ChAIN 6001950 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 33 DECAL, FORK LOCATION 138-604 FOOT ASSEMBLy 6002915 DANGER LABEL - ENTERING PIT 921-070 SERIAL TAG 6009761 Note: Items 5 - 8 included in item 2. March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 34 Optional Subframe Riser Kit and Cap Plug Fig. 47 item Quantity Description part number RISER KIT (FIELD INSTALLED) 6004653 REAR ANGLE CAP PLUG 6004487 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 35 NUT, hEX 3/8-16 000-030 KLIPRING 5/8" 049-060 ROLLER 700-045 WAShER, 3/8" 000-214 SPACER, LIP 6-1/2' WIDE DOCK LEVELER 287-606 7' WIDE DOCK LEVELER 287-607 March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 36 NUT, hEX LOCK 1/4-20 000-315 WAShER, FLAT, 1/4" 131-485 SCREW, BUTTON FLG. hD 1/4-20 X 3/4" 131-483 NIPPLE 155-578 PATCh KIT, BAG (NOT ShOWN) 184-379 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 37 NUT, hEX LOCK 1/4-20 000-315 WAShER, FLAT, 1/4" 131-485 SCREW, BUTTON FLG. hD 1/4-20 X 3/4" 131-483 NIPPLE 155-578 PATCh KIT, BAG (NOT ShOWN) 184-379 March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 38 115V CONTROL STATION 908-753 CONTROL STATION (OPTIONAL DUAL CONTACT)* 909-052 *For use with interlock applications on STAR 4 and AUTO CHOCK vehicle restraints. ® ® 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 39 W/seal 600 W brush 328907 W/seal 800 W brush 328908 W/seal 600 W brush cut 328910 Corner bulb seal 6009507 Transition angle seal (optional) 6008247 March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 40 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 41 March 2014 6004752K — aFX-C Dock Leveler — Safe Frame ® ©2014 4Front Engineered Solutions, Inc.
  • Page 42 6004752K — aFX-C Dock Leveler — Safe Frame March 2014 ® ©2014 4Front Engineered Solutions, Inc.
  • Page 43 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.
  • Page 44 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 ®...

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