RITE-HITE Genisys HL-900 Owner'S Manual Download | Manualshive

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Model:

HL‑900

Publication:

AMEN00160 2021‑08‑17

Genisys™ HL‑900 Dock Leveler

Owner's Manual

Language:

English

NOTICE TO USER

Motor FLA/Connection Detail     7
Type 1 Control Box: 120V/208-240V, 50/60HZ
Single Phase   8
Wiring: 115V Single Phase     9
Wiring: 230V Single Phase   11
Wiring: 3 Phase     13

Standard   16
Below Dock Loading   16
Dock Level (Or Lower) End Loading     17
Storing Leveler     17

MAINTENANCE

Planned Maintenance 19
Lubrication     20
Leveler Adjustments     20
Hydraulic Schematic   25

TROUBLESHOOTING

LED Status Chart – Standalone Controls 27
LED Status Chart – Dok-Commander Controls 27

HL-900   28
Type 1 Control Box   31
Control Box 32
Haldex Power Unit     34
Bucher Power Unit   36
Automatic Return to Dock (ARTD) (Optional) 38
Decals 39

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Summary of Contents for Genisys HL-900

Page 1: ...le Phase 11 Wiring 3 Phase 13 OPERATION Standard 16 Below Dock Loading 16 Dock Level Or Lower End Loading 17 Storing Leveler 17 MAINTENANCE 18 Planned Maintenance 19 Lubrication 20 Leveler Adjustments 20 Hydraulic Schematic 25 TROUBLESHOOTING 26 LED Status Chart Standalone Controls 27 LED Status Chart Dok Commander Controls 27 PARTS HL 900 28 Type 1 Control Box 31 Control Box 32 Haldex Power Unit ...

Page 2: ... A 55 21 99616 4421 E U 49 5693 98700 The Rite Hite products in this manual are covered by one or more of the following U S patents 6065172 6070283 6085375 6092970 6106212 6116839 6190109 6311352 6322310 6360394 6368043 6488464 6524053 6726432 6773221 6832403 7032267 7062814 7213285 7216391 7363670 7380305 7503089 7533431 7546655 7584517 7681271 7823239 7841823 7877831 7914042 8006811 8065770 8141...

Page 3: ...ite Hite representative offers owners the option of a Planned Maintenance Program P M P As part of this service your local Rite Hite representative will do all routine maintenance lubrication and adjustments 6 Dock equipment that is structurally damaged shall be removed from service inspected by a manufacturer s authorized representative and repaired as needed before being placed back in service 7...

Page 4: ...se damage to the equipment personal property and or the environment or cause the equipment to operate improperly NOTE A note is used to inform you of important installation operation or maintenance information Lockout Procedure Barricade work area and post safety warnings Power supply and control must Be disconnected or locked in OFF position using a lockout device approved by local codes Have sig...

Page 5: ... page 18 WARNING Cancer and Reproductive Harm www P65Warnings ca gov WARNING Power moving components Serious injury could occur Slip hazard Do not use equipment as a step Pinch hazard Keep all extremities away WARNING 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 until its bra...

Page 6: ...1 08 17 COMPONENTS HL9 COMPONENTS 210706 PDF L B K J C E F G H I A B M D A Lip Weldment B Lip Hinge Pin C Lip Lug D Platform E Full Range Toeguard F Ramp Cylinder G Lip Cylinder H Frame I Power Unit J Maintenance Strut Chain K Maintenance Strut L Velocity Fuse M Lip Keeper Figure 1 ...

Page 7: ...mm2 208 240 1 60 75HP 5 0 B 14 AWG 2 5 mm2 14 AWG 2 5 mm2 14 AWG 2 5 mm2 12 AWG 4 mm2 208 240 1 60 1 0HP 6 6 D 7 1 J 14 AWG 2 5 mm2 12 AWG 4 mm2 12 AWG 4 mm2 10 AWG 6 mm2 208 240 3 60 1 0HP 3 8 E 3 0 E 2 7 E 14 AWG 2 5 mm2 14 AWG 2 5 mm2 12 AWG 4 mm2 12 AWG 4 mm2 380 415 3 50 1 0HP 2 5 F 1 7 F 1 5 F 14 AWG 2 5 mm2 14 AWG 2 5 mm2 14 AWG 2 5 mm2 14 AWG 2 5 mm2 440 480 3 50 1 0HP 1 9 F 1 5 F 1 3 F 14...

Page 8: ...UIREMENTS SEE NOTE 1 FUSED DISCONNECT 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 Protected With Auto Reset J BOX J BOX MOTOR PIT LEGEND SEE PAGE 22 FOR MOTOR CONNECTION DETAIL FLA M NOTE 1 All Incoming Power From Disconnect to Control Box and Leveler Motor...

Page 9: ...Rite Hite Owner s Manual Genisys HL 900 Dock Leveler Publication AMEN00160 2021 08 17 9 ELECTRICAL Wiring 115V Single Phase For field wiring and Motor FLA Connection Detail go to page 7 Figure 4 ...

Page 10: ...Genisys HL 900 Dock Leveler Owner s Manual Rite Hite 10 Publication AMEN00160 2021 08 17 ELECTRICAL Wiring 115V Single Phase Continued HL9 115V SCHEMATIC_UPDATED 2016 6 9 PDF Figure 5 ...

Page 11: ...Rite Hite Owner s Manual Genisys HL 900 Dock Leveler Publication AMEN00160 2021 08 17 11 ELECTRICAL Wiring 230V Single Phase For field wiring and Motor FLA Connection Detail go to page 7 Figure 6 ...

Page 12: ...Genisys HL 900 Dock Leveler Owner s Manual Rite Hite 12 Publication AMEN00160 2021 08 17 ELECTRICAL Wiring 230V Single Phase Continued HL9 230V 1PH SCHEMATIC_UPDATED 2016 6 9 PDF Figure 7 ...

Page 13: ...Genisys HL 900 Dock Leveler Publication AMEN00160 2021 08 17 13 ELECTRICAL Wiring 3 Phase FOR MOTOR CONTACTOR WIRING CONTACT RITE HITE FOR TRANSFORMER WIRING CONTACT RITE HITE FOR LEVELER MOTOR WIRING CONTACT RITE HITE Figure 8 ...

Page 14: ...Genisys HL 900 Dock Leveler Owner s Manual Rite Hite 14 Publication AMEN00160 2021 08 17 ELECTRICAL Wiring 3 Phase Continued For field wiring and Motor FLA Connection Detail go to page 7 Figure 9 ...

Page 15: ...Rite Hite Owner s Manual Genisys HL 900 Dock Leveler Publication AMEN00160 2021 08 17 15 ELECTRICAL Wiring 3 Phase Continued HL9 3PH SCHEMATIC_UPDATED 210706 PDF Figure 10 ...

Page 16: ...s the leveler will move to its lowest position and the lip will fall to the pendant position inside the dock bumpers Levelers with Automatic Return to Dock ARTD If the lip is on the truck trailer and the truck departs the leveler will move to its lowest position and the lip will begin to lower As the lip drops toward the pendant position the ARTD system automatically returns the leveler to the sto...

Page 17: ...ns End load at dock level and above can be handled with the leveler in its stored position If the lip extended too far quickly push and release the RAISE button to slightly retract the lip If the lip was not extended far enough and hits the lip keepers repeat this step allowing the lip to extend farther 3 When loading unloading is complete continue with normal operation or return the leveler to st...

Page 18: ...e strut removal 1 Have an assistant raise leveler to its highest position with lip fully extended 2 Release safety clip and remove retaining pin 3 Lift the maintenance strut off base 4 Return maintenance strut to its storage location DANGER When working with electrical or electronic controls make sure that power source has been locked out according to approved local electrical codes Post safety wa...

Page 19: ...Inspect all conduit boxes control boxes 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 side of the enclosure A drip leg may be needed if the conduit is filling with water b Inspect the seal on the cover of the enclosure The seal should be securely a...

Page 20: ... under the hydraulic leveler platform or lip without installing the maintenance strut Make sure that the power source has been locked out and tagged according to approved local electrical codes WARNING Adjustments must be completed by trained technician only NOTICE Check the oil level before making any adjustments The adjustments shown are factory averages Field adjustment may be necessary None of...

Page 21: ...9 mm behind the center of the roller Front Collar NOTE There should be a small amount of free movement between the ARTD cam and the rear collar when the rear collar is pushed against the ARTD cam The lip stop bolt must be correctly adjusted Figure 12 before the ARTD cam is adjusted 1 Raise leveler and install a maintenance strut securely behind the header or mini header to allow the lip to hang pe...

Page 22: ...ncrease the platform speed when lowering the leveler NOTE Velocity fuse may lock up as a result of increased platform speeds while lowering the leveler 3 Tighten locknut without turning valve body or adjustment screw 4 Reinstall O ring and protective cap and tighten cap 5 Re test the unit several times to verify the setting The sequence valve Figure 14 controls the lip extension 1 Remove protectiv...

Page 23: ... Relief Valve Set at 1250PSI Do NOT adjust without permission from Rite Hite Pilot To Open Lip To Ramp Cylinder Check Valve 3 1 Ramp Pilot To Close Check Valve 3 1 Sequence Valve Sequence Valve To Lip Cylinder To Ramp Cylinder Flow Control Valve System Relief Valve Ramp Pilot to Close Check Valve 3 1 DO NOT adjust the system relief valve set at 1 250 PSI without permission from Rite Hite Lip Pilot...

Page 24: ...t 6 Tighten locknut on flow control valve The sequence valve Figure 15 on page 23 controls the lip extension 1 When the leveler is fully raised and the lip does not extend the sequence valve is set too high 2 Loosen adjustment nut 3 Turn adjustment screw in completely clockwise with an Allen wrench 4 Turn adjustment screw counter clockwise to get to factory starting point For power units built bef...

Page 25: ...ation Check Valve 8 1 P O Check Valve Orifice Plug 047 Adjustable System Relief Valve 1200 PSI Adj Shuttle Valve 100 PSI at 1 4 GPM Backpressure Adjustable Sequence Valve 1000 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 Velocity Fuse 6 GPM 6 2 5 GPM 8 5 GPM 10 12 Buc...

Page 26: ...o an oil level check when unit is held open with the maintenance strut See Figure 11 on page 20 Refill if necessary 4 Platform does not lower Velocity fuse has locked up Attempt to raise the unit to unlock the velocity fuse Debris is lodged on or around the leveler Do an check for and remove any lodged debris on or around the leveler 5 Platform raises very slowly Weight on top of platform Remove w...

Page 27: ... 02 04 00 Emergency Stop State If Equipped F F T F F T 02 05 00 Run Fault State F T T LED Status Chart Dok Commander Controls Varies depending on operation F Off ITL Interlock input on M Lights when button pressed P Pulsing Flashing set to steady using DIP switches T Steady On MICRO CONTROL BOARD POWER BOARD LEVELER AUX BOARD INPUTS OUTPUTS OUTPUTS FIELD PUSH BUTTONS 12VDC 12VDC RELAY 12VDC ARTD I...

Page 28: ...ock Leveler Owner s Manual Rite Hite 28 Publication AMEN00160 2021 08 17 PARTS HL 900 32 30 15 14 31 21 8 37 7 20 18 5 9 19 25 26 27 17 9 16 6 4 10 12 11 13 33 1 2 3 23 24 29 34 28 22 35 10 22 40 HL9 PARTS 05152020 PDF ...

Page 29: ...17 0051517 0051517 0051517 14 1 Maintenance Strut 1inOD 413 100 413 100 413 100 413 100 1 Maintenance Strut 1inOD With ADS 413 102 413 102 413 102 413 102 15 1 Maintenance Strut Chain 0144170 0144170 0144170 0144170 16 2 Pin Clevis 75 X 3 875L 2Hole CRM 0129231 0129231 0129231 0129231 17 2 Pin Clevis HD 75 DIA X 3 5L Hole 125Dia C 1038 0130015 0130015 0130015 0130015 18 1 Pin Clevis 1 X 6 25L 2Hol...

Page 30: ... 101 33 1 Washer 75 Split LK Heavy ZP 0051814 0051814 0051814 0051814 34 4 Washer 1 125 SAE ZP 0139809 0139809 0139809 0139809 35 2 Lip Keepers 0129201 0129201 0129201 0129201 36 1 Decal Sheet Manufacturing Not Shown 0128116 0128116 0128116 0128116 37 4 Ring Rtng Ext E 875OD 0129308 0129308 0129308 0129308 38 1 Operational Sign Not Shown 0128111 0128111 0128111 0128111 39 1 Decal Sheet Field Not S...

Page 31: ...xxx 2 1 Control Box Enclosure 4 x 4 x 2 N4XF 0117342 3 1 Push Button N12 N4 0057075 1 Push Button N4X 0118316 4 1 Control Box Cover Decal Raise 3 x 3 Hole 30 5MM Oprtr 0117414 5 1 Decal V PH FLA 230 xxx 6 1 Decal UL ULC Consult Rite Hite 7 1 Contact Block NO 30 5MM 600V 1 5 HP 0118315 NOTE For ordering purposes the leading 0 or 00 may need to be dropped from Part Number e g 0054321 could be 54321 ...

Page 32: ...x HL9 ENCLOSURE LAYOUT 2021 07 09 PDF EXTERIOR DECAL NOTE 1 Place item 310 in upper portion of enclosure when item 309 is not present INTERIOR DECAL NOTE 1 Item 302 303 and 304 place in available space on rear of enclosure 2 Item 305 and 306 are not shown Apply in available space in enclosure cover or tub ...

Page 33: ...feet Not needed if ordering new enclosure 0147845 303 1 Fuse replacement decal 0144850 307 1 Cover decal stand alone pit leveler 0144361 Cover decal stand alone pit leveler IFC 0144357 308 1 Emergency stop overlay decal English 0144836 309 1 Operation danger warning decal for pit leveler 0144844 Operation danger warning decal for pit leveler IFC 0144846 QTY DESCRIPTION PART 310 1 Lockout tagout mu...

Page 34: ...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 PUPARTS4 EPS IFC ESB Parts Breakdown Optional Side View Tank End View 23 23 PUOPTIFC B 4 EPS NOTE 4 lb ft max torque on solenoid valve steam nut ref item 24 over tightening may cause valve coil failure ...

Page 35: ...8823 0118823 10 1 Ramp Cylinder Hose Fitting Power Unit 0055267 0055267 0055267 0055267 11 1 Ramp Cylinder Hose Assembly 0108961 0119776 0119844 0117058 12 1 Velocity Fuse 0129343 0129342 0129346 0129346 13 1 Pin Clevis 1 x 4 75L ZP 0122972 0122972 0122972 0122972 14 7 Cotter Pin 0051907 0051907 0051907 0051907 15 1 Ramp Cylinder 0129344 0129340 0129341 0129341 16 1 Pin Clevis 1 x 2 555L ZP 013001...

Page 36: ...HL 900 Dock Leveler Owner s Manual Rite Hite 36 Publication AMEN00160 2021 08 17 PARTS Bucher Power Unit 18 19 11 20 12 17 15 27 28 29 32 31 30 33 24 21 27 23 2 16 3 7 9 8 10 21 22 26 33 6 25 26 30 13 14 4 1 5 ...

Page 37: ...0159384 0159384 15 1 Breather cap 0141470 0141470 0141470 0141470 16 1 Plug fitting 0137254 0137254 0137254 0137254 17 1 ESB Kit 120V 0128904 0128904 0128904 0128904 IFC Kit 120V 0128903 0128903 0128903 0128903 18 1 ESB valve 0128906 0128906 0128906 0128906 IFC valve 0128907 0128907 0128907 0128907 19 1 ESB IFC Coil 120V 0017273 0017273 0017273 0017273 20 1 Harness 0019091 0019091 0019091 0019091 ...

Page 38: ...Bolt w PEL 313 x 38 x 25 20 ZP 0104394 0104394 0104394 0104394 10 2 Flange Bushing 375 x 50 x 50L 0068162 0068162 0068162 0068162 11 2 Retainer Clip 50 Dia 0019650 0019650 0019650 0019650 12 2 Collar Shaft 3 8ID x 7 8OD Blk 0068163 0068163 0068163 0068163 13 2 Flat Washer 3 8ID x 7 8OD 18 8 SS 0018261 0018261 0018261 0018261 14 1 Cam Pivot Tube 3 156L 0125410 0125410 0125410 0125410 15 1 Rotory Ca...

Page 39: ...t 0148720 02 3 1 Warning Trained Personnel Decal 0128121 02 4 1 Genisys Logo Decal 0128121 03 5 1 Made in USA Decal 0128121 04 Part of decal sheet 148720 and are purchased together under this part number Part of decal sheet 128121 and are purchased together under this part number NOTE For ordering purposes the leading 0 or 00 may need to be dropped from Part Number e g 0054321 could be 54321 or 01...

Page 40: ...premises for the purpose of repairing or replacing the Product or y return of the Product to the Rite Hite F O B Rite Hite s factory NOT WARRANTED Rite Hite does not warrant against and is not responsible for wear items such as fuses batteries bulbs vision and seals No implied warranty shall be deemed to cover damages that result directly or indirectly from i the unauthorized modification or repai...

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