Welcome to the Kelley Dock Leveler Owner’s Manual․ This guide covers the safe installation, operation, and maintenance of your Kelley aFX-C dock leveler, ensuring regulatory compliance․
1․1 Overview of the Kelley Dock Leveler
The Kelley Dock Leveler, part of the aFX-C series, is designed for safe and efficient operation between loading docks and freight carriers․ Manufactured from March 2014 onward, it features a hydraulic system, adjustable ramp, and lip extension for precise alignment․ Built for durability, it ensures smooth transitions and adheres to safety standards, making it a reliable solution for industrial docking needs․
1․2 Importance of the Owner’s Manual
This manual is essential for the safe and efficient use of the Kelley Dock Leveler․ It provides critical information on safety practices, installation, operation, and maintenance․ Reading and understanding this manual ensures compliance with industry standards, prevents accidents, and extends the lifespan of the equipment․ It also includes troubleshooting tips and warranty details for comprehensive support․
1․3 Safety Signal Words and Their Meanings
This manual uses safety signal words to alert users to potential hazards․ DANGER indicates an imminently hazardous situation that could result in death or serious injury․ WARNING signifies a potentially hazardous situation that could lead to death or injury if not avoided․ CAUTION highlights risks of minor injury or equipment damage․ Understanding these signals is crucial for safe operation․
Safety Practices
Always follow safety practices to prevent accidents․ Stay clear of moving parts, avoid overloading, and ensure only trained operators use the dock leveler․ Notify supervisors of any issues immediately․
2․1 General Safety Guidelines
Adhere to all safety practices to ensure safe operation․ Only trained personnel should operate the dock leveler, and always maintain a safe distance from moving parts․ Regularly inspect the equipment, and never exceed the rated capacity․ Immediately report any damage or malfunction to your supervisor; Proper training is essential to prevent accidents and ensure compliance with safety standards․
2․2 Warning Labels and Placards
Warning labels and placards are strategically placed near the dock leveler to alert operators of potential hazards․ These labels include safety signal words like DANGER, WARNING, or CAUTION, indicating risks of injury or death․ Always read and understand these labels before operating the equipment․ If any labels are missing or damaged, contact your local Kelley distributor for replacements immediately․
2․3 Restricted Use of the Dock Leveler
Operation of the Kelley dock leveler is restricted to trained personnel only․ Do not use the leveler with people, equipment, or material on the ramp or lip․ Never operate the leveler if it appears damaged or malfunctions․ Stay clear of hinges during operation and avoid touching the ramp or lip to prevent injury․ Always follow placard instructions and inform your supervisor of any issues immediately․
Installation
Ensure proper installation by following pre-installation requirements and pit preparation guidelines․ Remove all shipping parts and ensure the dock leveler is correctly aligned and leveled․ Always refer to the provided instructions for precise assembly and alignment to guarantee safe and efficient operation․ Do not weld the rear angle until after setting the front supports․
3․1 Pre-Installation Requirements
Before installing the Kelley dock leveler, ensure the pit is prepared with a compatible subframe and curb angles․ Verify that all components are undamaged and compatible with the dock’s structural requirements․ Check that the pit dimensions match the leveler’s specifications, and ensure the area is clear of obstructions․ Consult local building codes for compliance and ensure proper ventilation and electrical connections are available․ Always follow the manufacturer’s guidelines for a safe and successful installation․
3․2 Installation Steps
Place the dock leveler into the prepared pit, ensuring proper alignment with the subframe․ Secure the unit by welding the rear hinges and curb angles․ Tighten all bolts according to torque specifications․ Connect electrical and hydraulic systems as outlined in the manual․ Ensure the pan assembly is level and properly supported․ Check for obstructions and test the leveler’s operation before finalizing the installation․
3․3 Pit and Subframe Considerations
Ensure the pit is level and meets the specified depth for proper installation․ The subframe must be compatible with the dock leveler’s size and weight capacity․ Weld rear hinges and curb angles securely to prevent movement․ For pits deeper than standard, install riser kits to maintain functionality․ Verify all components are properly aligned before finalizing the installation to ensure safe and efficient operation․
Operation
Operate the dock leveler safely by following procedures in this manual․ Ensure trained personnel only use the equipment, adhering to safety practices and proper lip alignment with vehicles;
4․1 Operating Instructions
Operate the dock leveler by following these steps: raise the ramp, extend the lip, and lower it onto the vehicle bed․ Ensure the ramp is level with the dock floor before allowing vehicles to leave․ Always maintain proper lip alignment and use the maintenance strut for safety during adjustments or repairs․ Refer to the manual for detailed cycle procedures and emergency stop protocols․ Ensure all safety practices are followed strictly to prevent accidents and maintain equipment longevity․
4․2 Cycle of Operation (Raise, Extend, Lower)
Begin by raising the ramp until it is level with the dock floor․ Next, extend the lip to rest securely on the vehicle bed․ Finally, lower the ramp and lip together to complete the cycle․ Ensure proper alignment and safety at each stage․ Always consult the manual for detailed procedures to maintain safe and efficient operation․
4․3 Emergency Procedures
In case of malfunction, immediately stop the dock leveler and ensure the area is clear․ Engage the maintenance strut for support if needed․ Contact your supervisor and authorized service representatives for assistance․ Never attempt repairs without proper training or equipment․ Always prioritize safety to prevent accidents and ensure compliance with operational guidelines․
Maintenance
Regular maintenance is crucial for optimal performance․ Inspect and lubricate moving parts, check torque specifications, and ensure all components are secure․ Schedule routine checks every 90 days to prevent issues․ Always use the maintenance strut for safe repairs and follow the recommended maintenance schedule to ensure reliability and longevity of the dock leveler․
5․1 Scheduled Maintenance Tasks
Perform regular inspections every 90 days, including checking lip alignment, chain tension, and hydraulic fluid levels․ Lubricate moving parts and ensure all bolts are torqued to specifications․ Replace worn components promptly and maintain dock bumpers․ Always use the maintenance strut when working under the ramp or lip for safety․ Schedule professional servicing annually to maintain warranty validity and ensure optimal performance․ Follow the maintenance schedule outlined in this manual to prevent unexpected malfunctions and extend the lifespan of your Kelley dock leveler․
5․2 Torque Specifications for Bolts and Nuts
Torque specifications vary by bolt type․ Lip rods, gas spring pins, and leg pivot pins require 29-31 Ft-Lbs․ Rear hinge pins and connecting rod pins need 90 Ft-Lbs․ Use a torque wrench to ensure accuracy․ Under or over-torqueing can lead to structural compromise or malfunction․ Always refer to the specific torque chart in this manual for precise values during maintenance or repairs․
5․3 Maintenance Strut Requirements
Always use a maintenance strut to support the dock leveler ramp and lip during maintenance․ Ensure the strut is securely pinned and the lip lock is engaged before starting work․ This prevents unexpected movement and ensures safety․ Never work under the ramp or lip without proper support․ Regularly inspect and maintain the strut to ensure reliability and optimal performance during servicing․
Troubleshooting
This section identifies common issues with the Kelley dock leveler, such as lip misalignment or low motor voltage, and provides diagnostic steps to resolve them effectively․
6․1 Common Issues and Solutions
Common issues include lip misalignment, low motor voltage, and uneven chain tension․ Solutions involve adjusting alignment, verifying voltage, and equalizing chain length․ Regular maintenance and inspections prevent these issues, ensuring smooth operation and safety․ Always refer to the troubleshooting guide for detailed diagnostic steps and solutions to maintain optimal functionality of your Kelley dock leveler․
6․2 Diagnostic Steps for Malfunction
Diagnose malfunctions by checking power supply, hydraulic systems, and control chains․ Inspect for misalignment, worn parts, or obstructions․ Verify motor voltage and chain tension․ Consult the troubleshooting guide for specific issues․ If problems persist, contact an authorized Kelley service representative for professional assistance to ensure safe and effective resolution․
6․3 Contacting Authorized Service Representatives
Contact authorized Kelley service representatives for parts, repairs, or troubleshooting․ Call 972-466-0707 or 800-525-2010 for assistance․ Visit your local distributor or the Kelley website for support․ Always use authorized services to ensure safety and warranty compliance․
Parts List
The Kelley dock leveler includes key components like the ramp, lip, and support legs․ Optional accessories such as the Energy Guard sealing system are also available․ Refer to the parts list section for detailed descriptions and part numbers․
7․1 Key Components of the Dock Leveler
The Kelley dock leveler features a robust steel frame, ramp, and lip for smooth transition between dock and vehicle․ Key components include support legs, lifting mechanisms, and lip locks․ Additional parts like chains, gas springs, and bolts ensure proper functionality․ These components work together to provide a safe and efficient loading solution, with optional upgrades available for enhanced performance․
7․2 Optional Accessories and Upgrades
Enhance your Kelley dock leveler with optional features like the Energy Guard Sealing System for improved energy efficiency․ Additional upgrades include rear angle cap plugs and subframe riser kits for increased versatility․ These accessories ensure compatibility with various dock configurations and provide long-term durability, optimizing your loading operations while maintaining safety and performance standards․
Warranty Information
KELLEY warrants the dock leveler to be free from material and workmanship defects under normal use for one (1) year from shipment or installation date․
8․1 Warranty Coverage and Duration
KELLEY warrants this dock leveler to be free from defects in material and workmanship under normal use for one year from the earlier of shipment or installation date by the original purchaser․ This warranty covers parts and labor for defects, ensuring your dock leveler operates safely and efficiently․ Proper maintenance is required for warranty validity, and claims must be made through authorized service representatives․
8․2 Conditions for Warranty Validity
Your warranty remains valid if the dock leveler is installed, operated, and maintained according to this manual․ Regular inspections and scheduled maintenance must be performed as specified․ Unauthorized modifications or misuse void the warranty․ All claims must be submitted through authorized Kelley distributors or service representatives within the warranty period for proper evaluation and resolution․
Distributor Information
Contact your local authorized Kelley distributor for genuine parts, service, and support․ Distributors provide assistance with installation, maintenance, and troubleshooting to ensure optimal performance and safety․
9․1 Contact Details for Local Distributors
For assistance, contact your local authorized Kelley distributor at 972-466-0707 or 800-525-2010․ They provide support for replacement parts, placards, and maintenance, ensuring compliance with safety standards and optimal dock leveler performance․
9․2 Replacement Parts and Support
Replacement parts for your Kelley dock leveler are available through authorized distributors․ Ensure all parts are genuine to maintain safety and performance․ Common replacements include rivets, chains, and maintenance struts․ Contact your local distributor for assistance with orders and inquiries, ensuring your dock leveler operates efficiently and safely․
Common Operational Issues
Common issues include lip misalignment, uneven ramp movement, and chain tension problems․ Regular maintenance and proper alignment can prevent these issues, ensuring safe operation․
10․1 Lip Alignment and Adjustment
Proper lip alignment is crucial for safe and efficient operation․ Misalignment can cause damage or safety hazards․ Adjust the lip regularly to ensure it rests correctly on the vehicle bed․ Refer to the manual for specific adjustment procedures․ If issues persist, contact an authorized service representative to avoid operational disruptions and ensure compliance with safety standards․
10․2 Chain Tension and Adjustment
Proper chain tension ensures smooth operation and prevents damage․ Check chain tension monthly and adjust as needed using the provided instructions․ Over-tensioning can cause premature wear, while under-tensioning may lead to misalignment․ Always refer to the manual for specific torque specifications․ If unsure, consult a trained technician to maintain optimal performance and safety standards․
Optional Features
The Kelley dock leveler offers optional features like the Energy Guard sealing system for improved dock sealing and rear angle cap plugs to prevent debris entry․
11․1 Energy Guard Sealing System
The Energy Guard Sealing System enhances dock sealing efficiency by providing a tight barrier between the dock leveler and vehicle․ This optional feature reduces energy loss, prevents debris entry, and ensures a secure connection during loading/unloading operations․ It is designed to improve overall dock performance and safety while minimizing environmental impact and operational costs․
11․2 Rear Angle Cap Plugs
Rear Angle Cap Plugs (Part No․ 6004487) are optional components designed to cover adjustment socket holes on the dock leveler․ They prevent debris and contaminants from entering the sockets, ensuring optimal functionality and safety․ These plugs are installed during assembly or as a retrofit, enhancing the leveler’s durability and meeting specific operational requirements․
Regulatory Compliance
This manual ensures compliance with industry standards and regulations, guaranteeing safe operation and adherence to legal requirements․ Regular inspections maintain reliability and prevent potential legal issues․
12․1 Industry Standards and Regulations
The Kelley dock leveler is designed to meet industry standards and regulations, ensuring safe and reliable operation․ Compliance with these standards is verified through regular inspections and adherence to safety practices․ This ensures the dock leveler operates within legal requirements, preventing potential legal issues and maintaining workplace safety․ Proper maintenance and operation further guarantee ongoing compliance․
Thank you for choosing the Kelley dock leveler․ Always follow safety practices, proper installation, and maintenance procedures for safe and efficient operation․ Refer to this manual for guidance and contact authorized service representatives for any concerns․
13․1 Final Tips for Safe and Efficient Use
Always follow safety practices and maintain regular inspections․ Ensure proper training for operators and use protective equipment․ Keep the dock leveler clean and lubricated․ Never exceed the rated capacity․ Be aware of your surroundings and communicate clearly with nearby personnel․ Regularly review this manual to stay informed on best practices for optimal performance and safety․