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installation, continuedinstallation of dock leveler6' and 8' long levelers using a standard 19" subframe can befield converted to allow installation in a 24" pit by adding a 4"riser kit, Kelley Part No. 6004653. Install the new riser levelingfeet. The riser blocks should be welded to the front subframesupports and secondary stops prior to placing in the pit. Seepublication #6003727 and page 34 in this manual.Fig. 41. Prior to lifting leveler make sure the shipping tie downbolts seen in Fig. 13 are in place. Install two 3/4”-10UNCload centering eye bolts into the front and rear of the topplate and hoist leveler into pit. The dock leveler shouldnot be lifted in any other manner when place into the pit.See Fig. 4.Inadequate lifting equipment or practices can cause aload to fall unexpectedly. Make sure the lifting chain orother lifting devices are in good condition and have arated capacity of at least 3,500 lbs for the lifting angleused. Never allow anyone to stand on or near the dockleveler when it is lifted or placed into the pit. Stand clearof the dock leveler when it is placed into the pit. Failureto follow this warning can allow the dock leveler to fall,tip, or swing into people, resulting in death or seriousinjury.Route power cord clear of edges and resting surfacesso that it is not damaged during lifting and placement.Plug end may be routed up through the rear hinge untilneeded.3/4" - 10 UNCload centeringeyeboltFig. 5inserting the leveler into the pit2. Position dock leveler in pit about 7" away from therear pit wall. Connect plug to receptacle on the rear pitwall. Cut tie wrap on cord to allow bag pan removal forservice. Place the free length of cord inside of framearea, free of interference as the leveler is moved intothe final position. See Fig. 5 and wiring diagram on page15.NOTE:Check the pit floor for uneven or excess concrete in the areaaround the leveling feet 1"-6" from the rear wall. Use chiselto level out area if necessary.March 20146004752K — afx-c Dock Leveler — SafeTFrame 7 2014 4Front Engineered Solutions, Inc.

installation, continued3. Move the dock leveler back to the rear pit curb angle.See Fig. 6. With the rear leveler angle touching the rearpit angle, square up the sides of the pit to the sides ofthe leveler. The gap should be even on both sides.Fig. 6NOTE:The rear frame angle should be about 1/2" lower than the pitcurb angle before leveling. This is normal. See Fig. 7.leveling the rear frame4. Using a 1/2" square drive (1/2" ratchet or impact tool)work from one side to the other, turn each of the levelingscrews on the rear angle, counter-clockwise until thetransition angle of the rear angle is level with the rear pitcurb angle and the leveling screws are 1/4" from the toptransition angle which indicates that legs are in contactwith pit floor. Repeat on each leg until the transitionangle is flush with the rear curb angle. See Fig 8.The rear edge of the dock leveler should be level orslightly (1/16" maximum) below dock level.Fig. 7The top surface of the dock leveler should be level and asmooth transition with the dock floor curb steel. The frontend should be level and parallel with the rear frame anglefor proper operation. Unequal adjustment of the frontsupports may be required to obtain a level front edge.1/2"Turn off all electrical power to the leveler if it has beenpreviously connected. Welding with dock levelers powerconnected can damage the electrical components. Aground must be attached to the leveler frame.5. Check and adjust the leveler for square, shim the rearas required, see Fig. 20. The sides of the leveler deckshould be centered in the pit opening. Tack weld the rearangle to rear curb angle in 4 places min 3/8", one at ornear each leveling screw.NOTE:Do not weld out the rear angle until after setting the frontsupports.8 2014 4Front Engineered Solutions, Inc.6004752K — afx-c Dock Leveler — SafeTFrame March 2014

installation, continuedleveling the FRONT frame6. Remove and discard the shipping tie down bolts locatedat the lower end of the hinged lip assembly. See Fig.13.Before welding the dock leveler supports to the front curbangle make sure that the dock leveler support legs lineup with the "V" pocket in the dock leveler support angleand that the leg roller is centered over the its roller track.Move dock levelers support right or left for the necessaryalignment.Fig. 8Transition angleCurbangleRaisesrearangle1/4"7. Tack weld the front dock leveler supports to the front curbangle. See Fig. 12.8. With the lip pendant insert 24" long 1/2" extensionsbetween lip and lip rod onto dock leveler support levelingscrew. See Fig. 12. Using a 1/2" drive (1/2" ratchet orimpact tool) turn each leveling screw counter-clockwiseuntil the top of the leveler is flush with the finished floor/pit curb steel where the overhead door meets the floor.See Fig. 11.finish welding rear frame9. Weld the rear frame angle to the rear curb angle using1/4" bevel joints in the transition angle as your guide.See Fig. 10.Legs are in contactwith pit floor whenthe leveling screwsare 1/4" from thetop of the transitionangleLegadjustmentFig. 9Rear PitCurb Angle10. After the rear hinge is welded check that all rear levelinglegs are in contact with the floor of the pit by visuallyinspecting that the leveling screws are 1/4" from the topof the transition angle. Once all legs are in contact withfloor, tighten each leg leveling screw counter-clockwiseto 25-40 ft. lbs.RearFrameAngleEqual GapRampPit Side Curb AngleFig. 105"2-1/2"5"2-1/2"5"5"March 20142-1/2"2-1/2"FrameUprights6004752K — afx-c Dock Leveler — SafeTFrame 5"5"PitRearCurbAngleRear HingeAssembly9 2014 4Front Engineered Solutions, Inc.

installation, continued11. Lower the air bag lifting support frame by removing theretainer bolts on top of deck area. See Fig. 14. Boltsshould be discarded.Fig. 11Door jambFlush with floor at this pointThe lifting support frame will drop rapidly to the pit floorwhen the retainer bolts are removed. Keep your handsand feet out from under the dock leveler when releasingthe frame. Failure to do so could result in death or seriousinjury.Air pressure or mechanical support must be maintainedunder the ramp to hold it in the raised position until themaintenance strut is in place. DO NOT WORK UNDERTHE DOCK LEVELER RAMP OR LIP UNLESS THEMAINTENANCE STRUT IS IN PLACE AND PINNED, ANDLIP LOCK IS IN PLACE AND SUPPORTING THE LIP.NOTE:The following procedure requires two persons to lockout andsecure the leveler for maintenance.12. Return power to the leveler control. Using the aFXpush-button control or mechanical support, raise thedeck and secure.Fig. 121/2" sq. driveadjustment boltCCW rotationto raise3/16" weld(both sides)3/16" weld3" long (min.)3/16" weld3" long (min.)(both sides)Curb steel3/16" weld(both sides)a) One person pushes and holds the RAISE buttonto inflate the air bag until the dock leveler reachesits highest position. Hold dock leveler in its highestposition.3/16" weld3" long (min.)(both sides)Curb steelb) The second person positions the maintenance strutinto the bracket located on the underside of the rampassembly and pins it in place with hairpin clip. SeeFig. 15 and the instruction label on maintenancestrut.c) Air pressure or mechanical support may now beremoved.3/16" weld3/16" weld3" long (min.)Fig. 13Shipping tiedown bolt10 2014 4Front Engineered Solutions, Inc.6004752K — afx-c Dock Leveler — SafeTFrame March 2014

installation, continuedFig. 14Retaining BoltsManual support of the lip must be maintained until the liplock is in place. The lip is free to move downward whenit is released unless the lip lock is in position supportingthe lip. DO NOT WORK UNDER THE DOCK LEVELERRAMP OR LIP UNLESS THE MAINTENANCE STRUT IS INPLACE AND PINNED, AND LIP LOCK IS IN PLACE ANDSUPPORTING THE LIP.13. To engage lip lock, manually lift lip to fully raised position.Pull lip lock outward as far as it will go. Release lip lock.Slowly lower lip onto lip lock. See instruction label ondock leveler beam near lip lock.Fig. 1514. Disconnect power.Insert hairpinclip throughmaintenancestrut pin15. Finish welding both of the adjusted front dock levelersupports in all locations shown in Fig. 12.16. Remove and discard shipping cotter pins from toeguards on both sides of dock leveler. See Fig. 16.LipLiplockMaintenancestrut pinNOTE:6' and 8' long levelers in a 24" pit require the installationof a pan riser kit, part #184389. Install the pan risers. Seepublication #6013529 or #6003727.MaintenancestrutMaintenancestrut bracket17. Remove lifting chain or other lifting devices. Removelifting hooks from the sides of the ramp.18. Read the Safety Practices on page 3, and the OperationInstructions on pages 16 through 18 before operatingthe dock leveler.Fig. 16RemoveShipping CotterPinsMarch 20146004752K — afx-c Dock Leveler — SafeTFrame 11 2014 4Front Engineered Solutions, Inc.

installation, continued22. Two people are needed to store the maintenance strut.Improper installation of anchoring devices or installationinto aged or unsound concrete could result in death orserious injury.The dock face must be flush with curb angle to assureproper bumper mounting.19. Mount dock bumpers to face of dock. Downhill welds areunacceptable. See Fig. 17 or 18.20. Reconnect power. Store maintenance strut and lip lock.Store dock leveler at dock level.a) One person must push and hold the raise buttonuntil dock leveler reaches its highest position andhold dock leveler in its highest position.b) The second person unpins the maintenance strutfrom the bracket on the ramp and stores it on thesubframe. See Fig. 15 and the instruction label onmaintenance strutc) The raise button may now be released. The rampwill lower and the lip will extend when the button isreleased.Fig. 17Manually support the lip when storing the lip lock. Standclear of the lip when removing support. The lip is free tomove downward when support is removed. Anyone in thepath of the lip when it moves downward can be struck.Keep your hands, fingers and head away from the lipwhen it is released. They could be struck by the lip orcaught between the lip and other parts of the dock levelerresulting in death or serious injury.DO NOT MOVE THE MAINTENANCE STRUT WITHOUTAIR PRESSURE IN THE BAG OR A MECHANICAL LIFTINGDEVICE SUPPORTING RAMP. Raise the ramp using airpressure or a mechanical device before storing themaintenance strut. Stand clear of the ramp and lip whenair pressure or the mechanical lift is applied or removed.The ramp and lip are free to move downward when thesupport is removed. Removing the support without airpressure will allow the ramp and lip to drop RAPIDLY. Ifthe dock leveler was raised using a mechanical device,lower it using the same device.21. Lift lip completely. Push lip lock inward as far as it willgo. Slowly lower lip. See instruction label on dock levelerbeam near lip lock.Fig. 18LAMINATED BUMPERS3/8" Side of Pitto Side of BumperMounting Plate1/4"Weld Full Length ofBumper MountingPlate. Downhill Weldsare Unacceptable.VerticalBumperMountingAngle12 2014 4Front Engineered Solutions, Inc.6004752K — afx-c Dock Leveler — SafeTFrame 3/4" Dia.AnchorBolt.FieldInstalled.Suppliedby Others.To1/4"CurbAngleLaminations Must BeInstalled VerticallyMarch 2014

installation, continuedFig. 19The hinged lip will extend as the ramp moves down.Warning and OperatingInstruction Placard23. Place the dock leveler in both dock leveler storageposition and full below dock end load position. If lip isbeing supported by the curb steel in either position, adeflector plate must be created to allow leveler to storeand reach its full below dock position without gettinghung up on the pit floor.Improper installation that allows the pendant dock levelerlip to support the weight of the dock leveler could resultin death or serious injury. It is sometimes necessary toinstall lip deflector plates to avoid any chance of thependant lip supporting the weight of the dock levelereither near dock level or during a below dock end load.24. Permanently mount the laminated dock levelerWARNING and OPERATING instruction placard on thewall near the dock leveler control. See Fig. 19. Makesure the customer gets the User’s Manual and is properlytrained.25. Operate the dock leveler four times through the completecycle to check operation. (See Operation section, page16.)NOTE:If you have any problems or questions using or operatingthe 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.Press cap flush with top surface of rear curb angle.March 20146004752K — afx-c Dock Leveler — SafeTFrame 13 2014 4Front Engineered Solutions, Inc.

installation, continuedinstallation troubleshootingThe following procedures apply after the leveler is level inthe pit.PROBLEM1) Leveler will not fit properly in pit.POSSIBLE CAUSESOLUTIONa) Pit is out of square with the sides.a1) Align the sides parallel and equallyspaced with the rear frame angletouching the rear curb angle in oneplace. Fill the gap between the rearcurb angle and rear frame angle usingshims in weld noted in Fig. 10. SeeFig 20.b) One side and rear angle is out ofsquare.b) Align the leveler with the two squareedges. The gap on the sides shouldbe even in the most narrow section(1/2" Max. per side). See Fig. 21.c) Pit floor irregular in rear.c) If large deformations exist in theconcrete work, attempt to flattenout the rough surface using a chiselor grinder to take out the largeobstructions. The rear leveling legscan be installed on out of planesurfaces up to 1/8" at each leg. SeeFig. 22.d) Pit is too deep.d) Weld 4" x 4" shims to the bottom ofthe adjustable legs as shown in Fig 4.Fig. 21Fig. 20Fig. 22Shim and weld flushEqualgap1/2" max.1/8" MAXAllowable StepNo Greater than1" x 3" in size6"ContactZone14 2014 4Front Engineered Solutions, Inc.6004752K — afx-c Dock Leveler — SafeTFrame March 2014

Wiring diagramBefore doing any electrical work, make certain the poweris disconnected and properly tagged or locked off. Allelectrical work must be done by a qualified technicianand meet all applicable codes. If it is necessary to maketroubleshooting checks inside the control box with thepower on, USE EXTREME CAUTION. Do not place yourfingers or non insulated tools inside the control box.Touching wires or other parts inside the control boxcould result in electrical shock, death or serious injury.Never allow more than 130 volts to be connected to the120 volt motor circuit. Damage to motor, push-button, airbag, and serious personal injury or death may result.Fig. 23120V, Single Phase, 50/60 HzSingle ContactControlStationCircuit Breaker(By Others)20 AMP MAX120V1 Phase50/60 HzBLKLineGRNGrnWHTNeutralOptional Blue Contact Block(Normally Closed)Field Installed (Low Voltage Only)See Supplied Mfg. InstructionsControlStationOptional Connection to RestraintStar 4 Module Limit SwitchTerminals No. 21 and No. 22To:Circuit Breaker(By Others)20 AMP MAXAuto Chock Terminal BlockTerminals No. 5 and No. 24BLKLineGRN MotorGrnWHTNeutralMarch 20141 Phase 120V50/60 HzPit WallReceptacleNEMA 5-15R(By Others)120V, Single Phase, 50/60 HzOptional Dual Contact120V1 Phase50/60 HzMotorPit WallReceptacleNEMA 5-15R(By Others)6004752K — afx-c Dock Leveler — SafeTFrame 1 Phase 120V50/60 Hz15 2014 4Front Engineered Solutions, Inc.

OperationINTRODUCTIONBefore operating the dock leveler, read and follow theSafety Practices on page 3.Use of dock leveler restricted to trained operators. Followprocedures on placard posted near dock leveler.DO NOT USE THE DOCK LEVELER IF IT LOOKSBROKEN, OR DOES NOT SEEM TO WORK RIGHT. Tellyour supervisor it needs repair right away, or contactyour local Kelley distributor.Before pressing button, ensure lip avoids contact withvehicle sides and cargo. If lip does not lower to vehiclefloor, reposition vehicle.Stay clear of leveler unless lip is supported by vehiclefloor or the leveler is stored at dock level. Visually checkthat the lip is supported by the vehicle floor or the rampis supported by both front dock level supports beforedriving or walking on the ramp. Unsupported docklevelers can lower unexpectedly.Before chocking wheels or engaging vehicle restraint,dump air from air ride suspensions and set parkingbrakes.Always be certain that the vehicle wheels are chocked,or that the vehicle is locked in place by a vehiclerestraining device and the brakes are set before loadingor unloading. Vehicles pulling away from the dockunexpectedly can cause uncontrolled drop of the dockleveler which can result in death or serious injury.The KELLEY aFX-C dock leveler is designed to span andcompensate for space and height differences between aloading dock and freight carrier to allow safe, efficient freighttransfers.The KELLEY aFX-C dock leveler uses a push-buttoncontrol to position the dock leveler. Pushing and holdingthe push-button operates a fan which inflates an air bag toraise the ramp. Releasing the push-button allows the rampto lower.A mechanical linkage extends the dock leveler lip as the ramplowers from its full raised position, and the leveler with its lipextended settles onto the vehicle floor forming a bridge.After loading, pushing and holding the push-button raisesthe ramp, and the extended lip lowers to its stored position.Releasing the push-button (before the dock leveler reachesthe highest position) allows the dock leveler to lower to itslevel, stored position.With the dock leveler in its stored position, dock level supportlegs support the dock leveler ramp at a position level withthe dock floor.For bel

2 6004752K — aFX-C Dock Leveler — SafeTFrame March 2014 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 .