This manual provides essential guidance for the installation, operation, and maintenance of Kelley AFX and AFX-S dock levelers (serial numbers 61056056 and higher), ensuring safe and efficient loading dock operations.
1.1 Purpose and Scope of the Manual
This manual is designed to provide comprehensive instructions for the safe and effective use of the Kelley AFX dock leveler. It covers essential guidelines for installation, operation, and maintenance to ensure optimal performance and longevity of the equipment. The manual is intended for operators, installers, and maintenance personnel, offering detailed procedures and safety precautions to minimize risks. It applies to Kelley AFX and AFX-S dock levelers with serial numbers 61056056 and higher, manufactured from September 2012 onward. By following this manual, users can ensure compliance with safety standards and achieve efficient loading dock operations with minimal downtime.
1.2 Key Features of the Kelley AFX Dock Leveler
The Kelley AFX dock leveler features a push-button control system for easy operation, allowing precise positioning to bridge space and height differences between docks and freight carriers. It utilizes a simple yet efficient mechanism that relies on deck weight and gravity for automatic lip extension, eliminating the need for manual flip-lip adjustments or hydraulic assistance. Designed for safety and durability, the AFX model ensures smooth transitions and efficient loading operations. Its robust construction and user-friendly controls make it a reliable solution for various industrial applications, providing consistent performance and minimizing downtime in busy loading environments.
Safety Practices and Warnings
Adherence to safety practices is critical to prevent accidents. Always follow installation and operational guidelines to avoid potential hazards. Failure to comply may result in serious injury or death.
2.1 General Safety Guidelines
General safety guidelines are essential to ensure safe operation of the Kelley AFX dock leveler. Always read and understand this manual before installation or operation. Ensure all personnel are properly trained and authorized to operate the equipment. Never overload the dock leveler beyond its rated capacity. Always secure the dock leveler to the dock pit to prevent movement during operation. Regularly inspect the equipment for damage or wear, and address any issues promptly. Never attempt to operate the dock leveler if it is not functioning correctly. Failure to follow these guidelines can result in serious injury or equipment damage.
2.2 Hazardous Situations to Avoid
Several hazardous situations must be avoided when operating the Kelley AFX dock leveler. Never allow the lip to come into contact with the freight carrier before the dock leveler is properly positioned, as this can cause damage or injury. Avoid overloading the dock leveler beyond its rated capacity, as this can lead to structural failure. Do not use the dock leveler as a bridge or platform for personnel to cross between the dock and the vehicle. Never bypass or disable safety features, such as the lip stop or hold-down mechanism, as this can result in catastrophic accidents. Always ensure proper maintenance is performed to prevent mechanical failures during operation.
Installation of the Kelley AFX Dock Leveler
Ensure proper site preparation, including a level and structurally sound dock area. Follow the step-by-step installation guide to align and secure the dock leveler correctly.
3.1 Pre-Installation Checklist
Before installing the Kelley AFX dock leveler, ensure the following steps are completed:
- Verify the serial number matches the manual’s compatibility (e.g., 61056056 and higher for AFX models).
- Inspect the site for a level and structurally sound dock area.
- Gather all necessary tools and hardware provided with the dock leveler.
- Review the installation manual thoroughly with your team.
- Brief all personnel on safety protocols and installation procedures;
- Ensure all safety equipment is available and functional.
Failure to complete these steps may result in improper installation or safety hazards.
3.2 Step-by-Step Installation Process
Follow these steps to install the Kelley AFX dock leveler:
- Uncrate the dock leveler and inspect for damage.
- Position the unit at the dock opening, aligning it with the header plate.
- Secure the dock leveler to the concrete using anchor bolts.
- Connect hydraulic lines and electrical components as specified.
- Test the control panel functions to ensure proper operation.
- Extend the lip to confirm smooth movement and alignment.
- Perform a final safety inspection before operational use.
Refer to the manual for detailed diagrams and torque specifications.
Operating the Kelley AFX Dock Leveler
Operate the Kelley AFX dock leveler using the control panel with push-button functionality for smooth lip extension and retraction, ensuring safe and efficient loading operations.
4.1 Control Panel Functions
The control panel of the Kelley AFX dock leveler features intuitive push-button controls for easy operation; It includes buttons for lip extension, retraction, and leveling, ensuring precise control. The panel is designed to be user-friendly, allowing operators to manage the dock leveler efficiently. Safety features are integrated into the control system to prevent accidental activation. Proper training is essential for understanding the panel’s functions and ensuring safe operation. Always refer to the manual for detailed instructions on using the control panel effectively. Improper use can lead to safety hazards, so adherence to guidelines is critical. Regular checks of the panel are recommended.
4.2 Lip Extension and Retraction Mechanisms
The Kelley AFX dock leveler features an automatic lip extension and retraction mechanism, operated via the control panel. The lip extends to bridge the gap between the dock and the vehicle, ensuring safe and efficient loading. Retraction is equally straightforward, with the lip returning to its stored position. The mechanism relies on deck weight and gravity, eliminating the need for manual adjustments or hydraulic assistance. Proper alignment and maintenance are crucial to ensure smooth operation. Always ensure the lip is clear of obstructions and avoid walking under it during movement. Regular lubrication of moving parts is recommended for optimal performance. Safety is paramount.
Maintenance and Repair
Regular maintenance, including lubrication of moving parts and thorough inspections, ensures optimal performance and longevity of the Kelley AFX dock leveler. Address repairs promptly using genuine parts.
5.1 Regular Maintenance Schedule
To ensure optimal performance, follow this maintenance schedule:
– Weekly: Lubricate all moving parts, including hinges and pivot points, using a high-quality grease.
– Monthly: Inspect the spring tension and adjust if necessary. Check the deck for damage or wear.
– Quarterly: Grease the lip hinge and roller bearings. Inspect the control panel for proper function.
– Every 6 Months: Perform a thorough inspection of the entire unit, including the frame, deck, and lip. Address any issues promptly to prevent downtime. Regular maintenance ensures safety and longevity of the Kelley AFX dock leveler.
5.2 Troubleshooting Common Issues
Addressing common issues ensures smooth operation of the Kelley AFX dock leveler.
– If the lip fails to extend, check for obstructions or damaged rollers.
– For uneven deck alignment, adjust the spring tension according to the manual.
– If the control panel malfunctions, verify connections and reset if necessary.
– Lubricate moving parts if the leveler operates sluggishly.
– For hydraulic issues, inspect fluid levels and check for leaks.
– If problems persist, consult the manual or contact Kelley support. Regular troubleshooting prevents downtime and ensures safety.
Parts and Accessories
Kelley AFX dock leveler manuals include a complete parts list for easy identification and ordering. All parts and information are consolidated for convenience, ensuring quick access.
6.1 Complete Parts List
The manual provides a detailed parts list for the Kelley AFX dock leveler, including components like the deck, frame, lip, control panel, and hydraulic system. It also lists safety accessories and maintenance items. Each part is identified with specific numbers and descriptions, ensuring easy identification and ordering. Users can reference this list to locate exact replacements or upgrades. The parts list is organized by category, making it simple to navigate. Diagrams and charts may be included to visually identify parts. This section is essential for maintenance and repairs, ensuring users can quickly find what they need to keep the dock leveler operational.
6.2 Ordering Replacement Parts
To order replacement parts for the Kelley AFX dock leveler, refer to the complete parts list in this manual. Identify the part number and description, then contact your local Kelley distributor or authorized service provider. Provide the serial number of your dock leveler to ensure compatibility. Orders can also be placed directly through Kelley’s customer service or online portal. Be sure to verify lead times and shipping details. For urgent needs, expedited shipping options may be available. Always use genuine Kelley parts to maintain safety and performance. If unsure about compatibility, consult your distributor or Kelley’s technical support team.
Warranty and Liability Information
Kelley warrants the AFX dock leveler against defects in materials and workmanship for a limited period from the date of delivery. Liability is limited to repair or replacement of defective parts.
7.1 Limited Warranty Details
Kelley’s limited warranty covers the AFX dock leveler for defects in materials and workmanship for a specified period, commencing from the date of delivery. The warranty ensures that any defective parts will be repaired or replaced free of charge during this period. Coverage includes mechanical and electrical components, excluding normal wear and tear or damage caused by improper use or maintenance. Warranty claims must be submitted in writing to Kelley or an authorized distributor, providing proof of purchase and detailed descriptions of the defect. Full warranty terms and conditions are outlined in the official product manual, ensuring clarity and understanding for users.
7.2 Exclusions and Limitations
The warranty does not cover damage resulting from misuse, unauthorized modifications, or failure to follow the manual’s instructions. Normal wear and tear, improper installation, or environmental factors like extreme temperatures or corrosion are also excluded. Additionally, damage caused by improper maintenance or third-party repairs is not covered. The warranty does not extend to accessories or parts not manufactured by Kelley. For a comprehensive understanding of exclusions, refer to the official manual. Any disputes or questions regarding warranty coverage should be directed to Kelley or its authorized distributors for clarification and resolution.