RITE-HITE 13GD480708M Owner'S Manual Download Page 1

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HL-900

Dock Leveler

Owners Manual

This Manual Covers Dock Levelers Built After Serial Numbers:

13GD480708M and up

PRINTED IN U.S.A.

RITE-HITE

PRINT SHOP

PUBLICATION NO. 1213

APRIL 2016

part of the SMOOTH TRANSITION DOK SYSTEM

By Rite-Hite

MADE IN U.S.A.

Summary of Contents for 13GD480708M

Page 1: ...Manual This Manual Covers Dock Levelers Built After Serial Numbers 13GD480708M and up PRINTED IN U S A RITE HITE PRINT SHOP PUBLICATION NO 1213 APRIL 2016 part of the SMOOTH TRANSITION DOK SYSTEMTM B...

Page 2: ...2 Pub No 1213 April 2016 Genisys HL 900 Dock Leveler Owner s Manual NOTES...

Page 3: ...5 2600 The Rite Hite products in this manual are covered by one or more of the following U S patents 5882167 6065172 6070283 6085375 6092970 6106212 6116839 6190109 6276016 6311352 6318947 6322310 636...

Page 4: ...cations will not cause the tag to deteriorate or become unreadable RITE HITE does not recommend any particular lockout device but recommends the utilization of an OSHA approved device refer to OSHA re...

Page 5: ...l or damage to the equipment Before starting installation or maintenance check and follow the safety procedures of the facility where the dock leveler is being installed Never enter a truck trailer un...

Page 6: ...e as shown under Safety Warnings on the inside front cover of this manual Always barricade the leveler at dock level and drive level to prevent any unauthorized use of the leveler Remove the Maintenan...

Page 7: ...e kept 5 As with any piece of machinery dock equipment requires routine maintenance lubrication and adjustments Your local RITE HITE representative offers owners the option of a Planned Maintenance Pr...

Page 8: ...l fall to the pendant position inside the dock bumpers See Storing Leveler b Levelers with Automatic Return to Dock ARTD If the lip is on the truck trailer and the truck departs the leveler will move...

Page 9: ...position on units without a Safe T Lip c If the lip extended too far quickly push and release the RAISE button to slightly retract the lip d If the lip was not extended far enough and hits the lip su...

Page 10: ...and electrical connections for damage Repair or replace if worn or damaged NOTE If control box has evidence of condensation a Inspect conduit Conduit should be routed to enter through the bottom or s...

Page 11: ...Pub No 1213 April 2016 11 Genisys HL 900 Dock Leveler Owner s Manual MAINTENANCE PROCEDURES FIGURE 8 HYDRAULIC POWERED LEVELER LUBRICATION OIL SAE 30 Weight NOTE Check Hydraulic Fluid level...

Page 12: ...t 2 Adjust ARTD Cam a Adjust collars so the front edge of ARTD cam is 1 16 behind the centerline of the ARTD limit switch See figure 10 b Tighten front collar while holding the 1 16 adjustment c Push...

Page 13: ...increase platform speed while lowering velocity fuse may lock up as a result of increased platform speeds while lowering 6 Tighten locknut without turning valve body or adjustment screw 7 Reinstall o...

Page 14: ...ctory set at 0 70 3 Adjustments should be no more than 1 8 turn increments 4 Tighten locknut without turning valve body or adjustment screw 5 Reinstall O ring and protective cap and tighten cap 6 Re t...

Page 15: ...er Turn out counter clockwise in 1 4 turn increments Or set valve at starting point 3 1 2 turns clockwise from fully out 5 Repeat procedure to verify fall time as needed to fall according to step 1 1...

Page 16: ...r power units built after March 2015 5 1 2 turns Tighten adjustment nut once at factory starting point 5 Press RAISE button and run the platform up until the lip extends 6 Verify that the lip extends...

Page 17: ...eck oil level when unit is held open with the maint support See Figure 9 Refill if necessary 4 Platform does not lower a Velocity fuse has locked up a Attempt to raise the unit to unlock the velocity...

Page 18: ...00 PSI Optional 2W N O Valve For IFC 8 1 P T C Check Valve RAMP Port LIP Port TANK Port 2 5 X 13 62 S A 6 2 5 x 16 62 S A 8 2 75 x 20 62 S A 10 12 1 5 x 6 S A Pump 1 1 GPM 750 PSI M P 3 2 PSI 1 047 FI...

Page 19: ...RD LEDs LD1 LD1 LD4 02 01 00 REST STATE F F T F T F T T 02 01 01 RAISE SEQUENCE F F ITL ITL M T T T F T T 02 01 02 AUTOMATIC RETURN TO DOCK T F ITL ITL T T T F T T 02 01 03 COMBINED POWER UNIT SEQ F T...

Page 20: ...ER AUX BOARD LEDs LD10 LD10 LD4 02 01 00 REST STATE F T F T F T T 02 01 01 RAISE SEQUENCE F ITL M T T T F T T 02 01 02 AUTOMATIC RETURN TO DOCK T ITL T T T F T T 02 01 03 COMBINED POWER UNIT SEQ F T T...

Page 21: ...LA 1 PH CONNECTON DETAIL A B C D IF ROTATION IS WRONG REVERSE T5 5 AND T8 8 T1 T2 T1 T2 T1 T2 T1 T2 P1 P2 T3 T5 T2 T4 T8 P1 P2 T3 T5 T2 T4 T8 1 2 3 J 4 1 2 3 4 J 3 PH CONNECTON DETAIL E F G IF ROTATIO...

Page 22: ...NNECT SEE NOTE 4 BY OTHERS A BRANCH CIRCUIT DISCONNECT SHALL BE LOCATED WITHIN A 50 FT RADIUS AND BE VISIBLE FROM THE CONTROL BOX LOCATION REFERENCE LATEST EDITION OF NEC SECTION 430 Thermally Protect...

Page 23: ...R FIELD WIRING TO BE MINIMUM 10 12GA 60 75 C COPPER WIRE INSULATED SUFFICIENTLY FOR INCOMING VOLTAGE 3 ALL CONTROL FIELD WIRING TO BE MINIMUM 14GA 60 75 C COPPER WIRE ONLY INSULATED SUFFICIENTLY FOR I...

Page 24: ...NT SCHEMATIC GEN II CONTROLS J11 1 J11 2 URC CONTROLS CR1 A CR1 B N O CONTACT MUST BE DRY CONTACT CLOSES WHEN THE RESTRAINT IS ENGAGED OR IN HORN OVERRIDE MODE NOTE DIP SWITCH 2 DOWN IF EQUIPPED UP TO...

Page 25: ...1L1 N 1L1 N 10GA MIN 9 DISCONNECT NOTES FUSED DISCONNECT IS NOT PROVIDED BY RITE HITE PRODUCTS CORPORATION DISCONNECT MUST BE PROVIDED BY OTHERS AND INSTALLED PER LATEST EDITION OF UL508A AND NEC REQ...

Page 26: ...NT SCHEMATIC GEN II CONTROLS J11 1 J11 2 URC CONTROLS CR1 A CR1 B N O CONTACT MUST BE DRY CONTACT CLOSES WHEN THE RESTRAINT IS ENGAGED OR IN HORN OVERRIDE MODE NOTE DIP SWITCH 2 DOWN IF EQUIPPED UP TO...

Page 27: ...8 1 J10 4 J10 3 J10 2 J10 1 J9 2 J9 1 J11 3 J11 2 J11 1 J11 5 J11 4 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 108 X2 WH X1 RD 108 K3 K2 K1...

Page 28: ...COM DETAIL C RESTRAINT CONTROLS IF EQUIPPED LEVELER POWER CB CRx SEE NOTE 1 2 3 J103 BL 12V BL 1OL JMPR 1MCR 96 95 A2 A1 12VDC 2W DETAIL D LEVELER MOTOR WIRING BASE 1MCR A2 A1 12VDC 2W J103 BL 12V BL...

Page 29: ...GND GN H1 BN H4 OR 2L1 2L2 2FU1 2FU2 H2 VT H3 BL X2 WH 120v 60VA TRANSFORMER X1 RD BONDING JUMPER SEE NOTE 6 GND GN 480v TRANSFORMER PRIMARY FUSING 0 5 AMP 600v CLASS CC REJ DUAL ELM TD 2FU1 2FU2 X2...

Page 30: ...PARTS LIST Leveler Length and Capacity Item Qty Description 6 Long 8 Long 10 Long 12 Long 1 1 Frame HL9 RHH40 361 ___ 361 ___ 361 ___ 361 ___ 2 1 Platform 401 ___ 401 ___ 401 ___ 401 ___ 3 1 Lip Weldm...

Page 31: ...75 SERR FLG 142701 142701 142701 142701 21 4 Nut 313 18 TRW Palnut ZP 56540 56540 56540 56540 22 3 Pin Cotter 12Dia X 1 5L 51903 51903 51903 51903 23 2 Channel Formed Weatherseal 12GA 489 ___ 489 ___...

Page 32: ...art Number 1 1 Control Box Complete 228 xxx 2 1 Control Box Enclosure 4 x 4 x 2 N4XF 117342 3 1 Push Button N12 N4 57075 1 Push Button N4X 118316 4 1 Control Box Cover Decal Raise 3 x 3 Hole 30 5MM Op...

Page 33: ...Pub No 1213 April 2016 33 Genisys HL 900 Dock Leveler Owner s Manual...

Page 34: ...END BELOW DOCK ENDLOADING TO STORE LEVELER WARNING OPERATIONAL INSTRUCTIONS RITE HITE PRODUCTS CORP MILWAUKEE WI 53223 1 800 456 0600 WARNING 102 103 307 301 310 602 309 311 304 302 303 313 208 707 2x...

Page 35: ...41 210 1 Motor Overload Relay 145118 211 1 Transformer fuse assembly 146341 212 1 Transformer 60VA 230 460V 144800 Transformer 60VA 575V 144801 213 2 Ground lug 55902 214 2 Ground lug decal 105454 215...

Page 36: ...0 PLATFORM RAISE LIP EXTEND BELOW DOCK ENDLOADING TO STORE LEVELER WARNING OPERATIONAL INSTRUCTIONS RITE HITE PRODUCTS CORP MILWAUKEE WI 53223 1 800 456 0600 WARNING 102 103 307 301 310 602 309 311 30...

Page 37: ...133366 703 4 Lock washer 6 51826 704 4 Standoff Male Female 6 32 2 5 length 133365 705 4 Screw round head 6 32 0 25 length 133366 706 4 Lock washer 6 51826 707 2 Screw round head 8 32 0 5 length 5164...

Page 38: ...OWER UNIT Main Cylinder Port Lip Cylinder Port TOP VIEW SIDE VIEW 3 7 6 5 9 4 8 1 10 11 12 16 14 15 13 17 14 18 19 14 20 21 22 24 14 23 23 SIDE VIEW TANK END VIEW Optional IFC ESB Parts Breakdown NOTE...

Page 39: ...ttle Valve 118823 118823 118823 118823 10 1 Ramp Cylinder Hose Fitting Power Unit 55267 55267 55267 55267 11 1 Ramp Cylinder Hose Assembly 108961 119776 119844 117058 12 1 Velocity Fuse 129343 129342...

Page 40: ...13 April 2016 Genisys HL 900 Dock Leveler Owner s Manual HYDRAULIC REPLACEMENT PARTS BASE BUCHER POWER UNIT 6 15 5 14 2 16 3 7 9 8 10 21 13 19 11 20 18 12 17 1 4 32 26 26 27 28 29 25 31 30 33 24 21 27...

Page 41: ...16 1 Plug fitting 137254 137254 137254 137254 17 1 ESB Kit 120v 128904 128904 128904 128904 1 IFC Kit 120v 128903 128903 128903 128903 18 1 ESB valve 128906 128906 128906 128906 1 IFC valve 128907 12...

Page 42: ...552 51552 51552 8 1 Guide Rod 122290 122290 122290 122290 9 1 Shoulder Bolt w PEL 313 x 38 x 25 20 ZP 104394 104394 104394 104394 10 2 Flange Bushing 375 x 50 x 50L 68162 68162 68162 68162 11 2 Retain...

Page 43: ...Pub No 1213 April 2016 43 Genisys HL 900 Dock Leveler Owner s Manual NOTES...

Page 44: ...been installed on Genisys products or the installation has not been carried out in accordance with Genisys installation instructions If a part is replaced during the standard warranty period it will...

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