Kelley HK User Manual
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Kelley HK User Manual

Hydraulic dock leveler with three button control
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Hydraulic Dock Leveler
Model HK and HK-S
with Three Button Control
This manual applies to dock
levelers manufactured beginning
October 1, 2008 with the serial
numbers 10251301 and higher.
User's Manual
Do not install, operate or service this product unless you
have read and understand the Safety Practices, Warnings,
Installation, Operations,
and Installation and Operating Instructions contained in
Maintenance and Parts
this User's Manual. Failure to do so could result in death
or serious injury.
Part No. 6004754F

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  • Page 1 Hydraulic Dock Leveler Model HK and HK-S with Three Button Control This manual applies to dock levelers manufactured beginning October 1, 2008 with the serial numbers 10251301 and higher. User’s Manual Do not install, operate or service this product unless you...
  • Page 2 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™...
  • Page 3 Kelley distributor for unsupported leveler can lower unexpectedly. assistance. Store dock leveler at dock level after below dock end loading. January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 4 It must also be compatible with the loading equipment and other conditions relating to the dock. 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™...
  • Page 5 -20.5 -12.0 -14.4 -22.2 -10.7 -18.6 4˚ lip bend, 16" lip. 7˚ lip bend, 16" lip (optional special order) January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 6 Make sure the customer gets the user’s manual and is properly trained. 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™...
  • Page 7 Dock LeVeLer 6' and 8' long levelers using a 19" frame can be converted to a 24" pit by adding a 4" riser conversion 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.
  • Page 8 3/8" at the center and at both ends. See Fig. 9 and 10. noTe: Do not weld out the rear angle until after setting the front supports. 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 9 Bevel groove weld locations 5" 2-1/2" 5" 5" 2-1/2" 5" 2-1/2" 2-1/2" 5" 5" rear curb angle Frame Rear hinge uprights assembly January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 10 Fig. 13. 3/4" anchor bolt (supplied Cylinder by others) Stagger and weld mounting pad 6" x 16" shims 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 11 19. Read the safety Practices on page 3, and the Operation Fig. 16 Instructions on pages 25 through 30 before operating the dock leveler. Remove shipping cotter pins January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 12 The second person unpins the maintenance strut from the bracket on the ramp and stores it on the subframe. See Fig. 15 and the instruction label on maintenance strut. 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™...
  • Page 13 (part number 6004488) into adjustment socket holes. Press cap flush with top surface to rear angle. see fig. Fig. 20 Rear angle Cap plug January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 14 Shim and weld flush 1/8" max allowable step no greater than Equal 1/2" max. 1" x 3" in size 6" contact zone 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 15 Touching wires or other parts inside the control box could result in electrical shock, death or serious injury. 115/208/230, 1PH, 50/60 Hz January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 16 DiagraMs — sTanDarD, continued 220V, 1PH, 50 Hz 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 17 DiagraMs — sTanDarD, continued 200-480V, 3PH, 50/60 Hz January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 18 DiagraMs — sTanDarD, continued 380V, 3PH, 50 Hz 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 19 DiagraMs — sTanDarD, continued 575V, 3PH, 60 Hz January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 20 DiagraMs — wiTH oPTionaL a.r.T.D. 115/208/230V, 1PH, 50/60 Hz 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 21 DiagraMs — wiTH oPTionaL a.r.T.D., continued 220V, 1PH, 50 Hz January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 22 DiagraMs — wiTH oPTionaL a.r.T.D., continued 200-480V, 3PH, 50/60 Hz 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 23 DiagraMs — wiTH oPTionaL a.r.T.D., continued 380V, 3PH, 50 Hz January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 24 DiagraMs — wiTH oPTionaL a.r.T.D., continued 575V, 3PH, 60 Hz 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 25 Failure to follow these instructions could result in death or serious injury to operators and/or bystanders. January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 26 6.4 Ramp and lip will lower until the lip rests on the vehicle bed. See Fig. 26. Proceed with loading or unloading. 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 27 28. Push “STOP” button in. Unchock or release vehicle. Tell vehicle driver “your vehicle may now leave the dock”. January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 28 Failure to follow these instructions could result in death or serious injury to operators and/or bystanders. 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™...
  • Page 29 6.4 Ramp and lip will lower until the lip rests on the vehicle bed. See Fig. 31. Proceed with loading or unloading. January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 30 33. Push “STOP” button in. Unchock or release vehicle. Tell vehicle driver “your vehicle may now leave the dock”. 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 31 138-837 (x2) 700-136 921-074 921-070 OPERATIONS 6004009 (STANDARD) 6004010 (WITH ARTD) WARNING AND OPERATION PLACARD (MOUNTED ON WALL NEAR LEVELER) January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 32 *acceptable Hydraulic oils: Mobil aero Hfa (49011) exxon Univis grade Ji3 Texaco aircraft oil #1554 U.s. oil co.,inc. #Zfi-5606 (Low Temp.) 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 33 Visually Inspect (Replace Damaged Or Worn) Hydraulic Reservoir See Note 1 Pit - 3 Mo Rear Hinge Pin January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 34 1.4 Check for loose wires in control box. 1.5 Check fuses. Replace if required. 1.6 If problem can not be found, contact a qualified electrician. 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™...
  • Page 35 Check for damage to lip cylinder and/or pivot pins. Check for binding in lip hinge. Check lip sequence valve pressure setting. See Fig. 41. January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 36 Do not adjust needle valve more than 1/4 turn. Test operation. Readjust turning valve a maximum of 1/4 turn between testing. During TEsTING DO NOT TURN MORE ThAN fOUR (4) 1/4 TURNs. 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™...
  • Page 37 Check below dock control chains to ensure chain has enough slack to allow leg to swing forward. Adjust as required. See Fig. 44. January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 38 1350 ± 25 PSIG 120 PSIG sequence valve .052 dia. Fixed shuttle valve Needle 1650 PSIG valve relief valve 100 mesh 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 39 1.5 Repeat 1.1 through 1.4 until correct. adjust valve “oUT” in 1/4 turn increments only to achieve proper lowering time. January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 40 INTENDED UsE are specifically DIsCLAIMED in the event the purchaser fails to comply with this warning. 6x10 6.5x6 6.5x8 6.5x10 7x10 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 41 ParTs LisT, continued MoDeL Hk raMP, LiP, anD Toe gUarD asseMbLies Fig. 49 January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 42 ParTs LisT, continued MoDeL Hk-s raMP, LiP, anD Toe gUarD asseMbLies Fig. 50 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 43 7' w. Dock Leveler 712-959 713-788 Retainer. shaft - hinge Pin 035-451 — Collar, Shaft - Hinge Pin — 131-542 January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 44 714-220 6-1/2' w Dock Leveler 714-219 7' w Dock Leveler 714-218 Decal, Kelley 921-140 ® Kelley Product Tag 712-188 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 45 DOCUMENTATION KIT, hydraulic w/Three Button Controls (A.R.T.D Option) 184-475 Manual 6004754 Placard 6004010 Danger Label — Entering Pit 921-070 *Included in item 1. January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 46 2. Rear angle cap plug item Quantity Description Part number 4" Riser Kit field Installed 6004523 Rear Angle Cap Plugs (Kelley) Optional 6004487 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 47 ParTs LisT, continued HyDraULic coMPonenTs anD reTUrn To Dock LeVeL swiTcH Fig. 53 (Optional — with ARTD option only) January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 48 RAMP CYL. 708-939 HOSE, HyD. LIP CyL. 708-940 CYLINDER, RAMP 6' Long 713-250 8' Long 713-296 10' Long 713-373 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 49 049-060 PIN, GROOVED, 1-1/8" Lg 700-049 A.R.T.D. switch assy. 6006573 NUT, Hx Lock, 1/4-20 000-300 Deck position switch 6006572 January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 50 ParTs LisT, continued conTroL box asseMbLy — sTanDarD 115/208/230, 1PH, 50/60 HZ Fig. 54 9 10 4 14 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 51 061-728 Contact Block - 1 N.C. 061-730 Wire, 16 GA x 3" Lg Black 151-042 Connector, Solderless Lug 061-674 January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 52 ParTs LisT, continued conTroL box asseMbLy — sTanDarD 220V, 1PH, 50 HZ Fig. 55 12 13 5 15 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 53 061-728 Contact Block - 1 N.C. 061-730 Wire, 16 GA x 3" Lg Black 151-042 Connector, Solderless Lug 061-674 January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 54 — sTanDarD 200-480V, 3PH, 50/60 HZ 380V, 3PH, 50 HZ 575V, 3PH, 60 HZ Fig. 56 12 13 5 15 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 55 061-728 Contact Block - 1 N.C. 061-730 Wire, 16 GA x 3" Lg Black 151-042 Connector, Solderless Lug 061-674 January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 56 ParTs LisT, continued conTroL box asseMbLy wiTH oPTionaL aUTo-reTUrn To Dock 115/208/230V, 1PH, 50/60 HZ Fig. 57 12 13 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 57 061-728 Contact Block - 1 N.C. 061-730 Wire, 16 GA x 3" Lg Black 151-042 Connector, Solderless Lug 061-674 January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 58 ParTs LisT, continued conTroL box asseMbLy wiTH oPTionaL aUTo-reTUrn To Dock 220V, 1PH, 50 HZ Fig. 58 17 18 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 59 061-728 Contact Block - 1 N.C. 061-730 Wire, 16 GA x 3" Lg Black 151-042 Connector, Solderless Lug 061-674 January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 60 — wiTH oPTionaL aUTo-reTUrn To Dock 200-480V, 3PH, 50/60 HZ 380V, 3PH, 50 HZ 575V, 3PH, 60 HZ Fig. 59 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame January 2009 ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 61 061-728 Contact Block - 1 N.C. 061-730 Wire, 16 GA x 3" Lg Black 151-042 Connector, Solderless Lug 061-674 January 2009 6004754F — HK and HK-S Hydraulic Dock Leveler, 3 Button — Safe Frame ™ ©2009 4Front Engineered Solutions, Inc.
  • Page 62 Base Limited Warranty: KELLEY warrants that this DOCK LEVELER will be free from defects 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 Owner's Manual.
  • Page 63 Base Limited Warranty: KELLEY warrants that this DOCK LEVELER will be free from defects 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 Owner's Manual.
  • Page 64 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 ©2009 4Front Engineered Solutions, Inc.

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