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RITE-HITE STR-4200 Dok-Lok, Owner'S Manual

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RITE-HITE STR-4200 Dok-Lok Owner'S Manual Download Page 24

STR-4200™ Dok-Lok

®

 

Owner's Manual

 Rite-Hite

®

24 Publication: 

AMEN00102 2017-07-06

MAINTENANCE 
Hydraulic

Hose Routing

NOTICE

DO NOT 

over-tighten hose fittings. 

4 Lb-ft Max torque on valve stem nut, over tightening 

may cause valve/coil failure

Stand Alone hoses are not trimmable
Remote power hoses are trimmable

Stand Alone Power Unit

L

 Port

Hose

P

 Port

Hose

L

 Port

Hose

P

 Port

Hose

L

 Port

Hose

2x 

Bulkhead

Fittings

 L

 P

 2x

 L

 L

 P

Combination Power Unit

L

 Port

Hose

P

 Port

Hose

L

 Port

Hose

P

 Port

Hose

L

 Port

Hose

2x 

Bulkhead

Fittings

P

 Port

Hose

 2x

 L

 P

 P

 L

 L

 P

 2x

 = 2x Bulkhead Fittings 

 P

 = P Port Hose 

 L

 = L Port Hose

Figure 9 

Summary of Contents for STR-4200 Dok-Lok

Page 1: ...intenance 14 Lubrication 15 Troubleshooting 15 Hydraulic 24 ELECTRICAL Power Board Stand Alone 28 Combo Power Unit Power Board 29 Restraint Micro Board 30 Wiring Pedestrian Vu 32 Wiring Approach Vu 34 Wiring Outside Light Box 35 PARTS Carriage and Track 36 Hydraulic 38 Electrical 40 Signs 42 Approach Vu Truck Sensor 43 WARRANTY 44 Language English The English version of this manual shall prevail o...

Page 2: ...7831 7914042 8006811 8065770 8141189 8191194 8286757 8287223 8303235 8307956 8443474 8464384 8464846 8465245 8497761 8499897 8544130 8547234 8590087 8590673 8616826 8657551 8662535 8678736 8690087 8905198 9010501 9096170 9096397 9126775 9139384 9145273 9150367 9174811 9227799 9230419 and may be covered by additional pending U S and foreign patent applications Rite Hite ThinMan Safe T Lip Hydrachek...

Page 3: ...te 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 The m...

Page 4: ...engagement is that the trailer is parked firmly against a 4in 102mm trade standard thick dock bumper The activation deactivation is solely controlled from inside of the building by pressing the Lock raise button or the Unlock lower button The normal mode of the hook is in the lower STORED position with support cylinders retracted showing a flashing red light trailer not secured at the inside of th...

Page 5: ...d E Slope Extension F Hook Support G Base Plate Assembly H Roller Track Assembly I Return Springs and Tubes J Support Cylinders K Power Unit L Carriage Roller Assembly M Carriage Assembly N Hook O Outside Signs P Inside Sign Q Outside Lights R Control Box Approach Vu Optional S Light and Alarm T Truck Sensor U Approach Vu Sign O P Q R K A B C S D E F G H L M N J I T Figure 1 ...

Page 6: ...nt 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 control must Be disconnected or locked in OFF position using a lockout device approved by local codes Have signage that Clearly states repairs are being made Identifies person responsible for lockout co...

Page 7: ... assembly must be free of plates or other obstructions Always operate Dok Lok vehicle restraint from top of dock Dok Lok vehicle restraints should be operated by authorized personnel who have read and understand Owner s Manual Contact your local Rite Hite representative or Rite Hite U S 800 456 0600 with any questions Failure to follow these procedures could allow unexpected trailer loading dock s...

Page 8: ...ING LOCK button pressed Trailer has backed into loading dock and is parked firmly against dock bumpers Hook rotates from STORED position to entrap R I G while support cylinders extend to support carriage If horn sounds go to FAULT State from LOCKING State if not go to Restraint LOCKED CAUTION If trailer can not be restrained due to a lift gate or other obstruction that could become damaged go to H...

Page 9: ...her means prior to entering If horn and red light are on after UNLOCK control is pressed hook may be held by R I G To release hook Back trailer up against dock Repeat UNLOCK operation Red flashing Alerts truck driver not to move Restraint UNLOCKING UNLOCK button pressed Hook travels from LOCKED position to STORED position while support cylinders retract to a STORED position If horn sounds go to FA...

Page 10: ... calling 1 800 456 0600 If red light is on and or horn sounds DOK LOK is not properly engaged Check operation of DOK LOK Vehicle may not be against dock R I G may not be compatible Hook travel may be obstructed Before using HORN OVERRIDE secure vehicle by other means Reset system by engaging HORN OVERRIDE control again Then repeat UNLOCK operation When in HORN OVERRIDE mode Both red and green Ligh...

Page 11: ...OK LOK DO NOT ENTER TRAILER ENTER TRAILER Visually inspect before loading unloading vehicle DOK LOK hook must secure rear impact guard See warnings on side panel Additional warning labels manuals and other information are available by calling 1 800 456 0600 If red light is on and or horn sounds DOK LOK is not properly engaged Check operation of DOK LOK Vehicle may not be against dock R I G may not...

Page 12: ...N LED MANUFACTURING ENGINEER FINISH PRODUCTS CORPORATION THIRD ANGLE PROJECTION 2010 RITE HITE REVISION STATUS DRAWN BY RESPONSIBLE ENGINEER DO NOT SCALE DRAWING MATERIAL CONFIDENTIAL ALL SHEETS ARE THE SAME M SVEUM REFERENCE X THIS DOCUMENT IS THE PROPERTY HEREIN IS CONFIDENTIAL DO NOT PRODUCTS CORPORATION CONSENT OF RITE HITE DISCLOSE EXCEPT WITH WRITTEN USE REPRODUCE COPY OR ANGLE XXX XX TOLERA...

Page 13: ...ion it may be necessary to raise leveler before performing maintenance DANGER B A When working under dock leveler platform or lip 1 Install Safe T Strut with the assistance of another person Raise leveler until platform reaches its highest position and lip extends Maintain this position A Have assistant insert the smaller end of the Safe T Strut through hole in the middle of leveler lip and place ...

Page 14: ...Inspect hydraulic hoses and power unit for signs of leakage Check oil fluid level and fill with appropriate fluid as needed 9 Inspect outside junction and light box They should be securely mounted If loose or damaged inspect all wires and wire connections 10 Inspect switch wires from Dok Lok vehicle restraint to junction box Look for kinks crushed areas etc 11 Inspect all conduit boxes control box...

Page 15: ... and on outside of lower spring tubes as shown Troubleshooting Normal Restraint Function in Fault State If STR faults immediately LOCKED State was never achieved All cylinders retract unit stores and inside RED light and HORN Outside RED light inside RED light and HORN If STR faults after being in LOCKED State All cylinders remain extended hook stays up but support cylinders do not function Outsid...

Page 16: ...r Hook needs to be lubricated Lubricate hook shaft Severed hose Replace damaged hose as required Sensor s out of adjustment Verify appropriate LED is lit when LOCK button or UNLOCK button is pressed Check for defective push button board or ribbon cable Disconnect cylinder and check extension retraction without hook attached Verify wiring per electrical schematic 5 Is operational but hook drops cau...

Page 17: ... Switch Flag Lock Sensor SW1 Unlock Sensor SW2 Support Limit Switch SW3 Limit Switch Flag 34 06 00 Position support limit switch so switch is activated when ylinder rod is extended and resting in support pocket NOTE Adjusting switch too high could result in damage to switch A 3 4 deep well socket or section of 1 OD round works well to simulate engaged cylinder rod Position support limit switch so ...

Page 18: ...limit switch body wire harness mounting bolt holes fixed guide plunger w roller Fixed Guide Plunger with Roller Mounting Bolt Holes Wire Harness Limit Switch Body Green Black White Red not used Green ground wire of limit switch does not have to be tested A continuity test lamp may be used instead of a multimeter Sensor 1 SW1 and Limit Switch 3 SW3 are wired in series into SW1 input on micro contro...

Page 19: ...1 COM G hydraulic power unit multimeter Multimeter COM M1 G 1 Shorted Set multimeter to ohms Take readings between leads M1 to ground motor casing and COM to ground motor casing Reading should be Infinite 0 ohms no needle movement Any reading indicates bad motor windings 2 Mechanical Binding Motor hums Motor leads show continuity between all windings Shaft does not move Figure 8 ...

Page 20: ...K TERMINAL BLOCK NO J13 1 J13 2 J14 3 Membrane J7 16 J7 17 J12 1 J12 2 J12 3 J12 4 J11 2 J11 1 J7 19 J15 1 N A J9 3 J10 3 J10 3 J5 4 J7 3 J7 2 J2 1 6 POWER BOARD LEDS LD2 LD10 LD9 LD7 MICRO CONTROL BOARD LEDS LD20 LD23 LD30 LD52 LD17 LD19 LD11 LD13 LD18 LD12 LD49 LD48 LD15 LD42 LD50 LD9 LD10 LD10 LD1 LD8 LD6 NO 01 01 00 State Sequence No Locked State T F F P F P F P P F F F F T T F F T F T 01 01 0...

Page 21: ... Stop cycling once Dok Lok barrier travels up and down without hesitation 5 To exit FILL MODE Press DIAGNOSTIC button or Press no buttons for 5 minutes or Cycle power Fill Mode Input Outputs Chart C Chirp on State Entry F Off P Pulsing Flashing T Steady On MICRO CONTROL BOARD POWER BOARD INPUTS OUTPUTS PUSH BUTTONS 12VDC 115 230VAC Lock Unlock Horn Silence Inside Red light Inside Green light Corne...

Page 22: ...M1 LOCK Motor ouptut 2 M2 UNLOCK 12VDC power supply ok TERMINAL BLOCK NO J7 16 J7 17 J12 1 J12 2 J12 3 J12 4 J12 6 J12 5 J11 2 J11 1 J7 19 J15 2 J15 3 J15 4 J15 5 J9 3 J10 3 J5 4 J5 3 J2 1 6 POWER BOARD LEDS LD2 LD1 LD7 MICRO CONTROL BOARD LEDS LD17 LD19 LD11 LD13 LD18 LD12 LD16 LD14 LD49 LD48 LD15 LD37 LD40 LD20 LD39 LD9 LD10 LD1 LD3 STEP 1 Diagnostics entered F F F F F F F F P F C F F F F F F F ...

Page 23: ...Rite Hite Owner s Manual STR 4200 Dok Lok Publication AMEN00102 2017 07 06 23 ...

Page 24: ... may cause valve coil failure Stand Alone hoses are not trimmable Remote power hoses are trimmable Stand Alone Power Unit L Port Hose P Port Hose L Port Hose P Port Hose L Port Hose 2x Bulkhead Fittings L P 2x L L P Combination Power Unit L Port Hose P Port Hose L Port Hose P Port Hose L Port Hose 2x Bulkhead Fittings P Port Hose 2x L P P L L P 2x 2x Bulkhead Fittings P P Port Hose L L Port Hose F...

Page 25: ...r Combo Valve Block L Port to Power Unit or Combo Valve Block Combination Power Unit LP Lower Port to STR4 RP Raise Port to STR4 SOL 3 RAMP DIVERT Solenoid SOL 2 LIP BLOCK Solenoid LO Leveler Lip Out Port SOL 1 RAISE Solenoid SOL 2 LIP BLOCK Solenoid SOL 3 RAMP DIVERT Solenoid T Return to Tank Port RO Leveler Ramp Out Port NOTE Located Adjacent To Leveler Power Unit Only On Combination Power Units...

Page 26: ...HOOK CYLINDER 1 25 x 3 x 5 ROD AUXILLARY MANIFOLD MOUNTED ON CARRIAGE 6SAE HOLDING CHECK VALVE 50PSI VMS ORIFICE 020 ADJUSTABLE SYSTEM RELIEF 675 PSI MOTOR 120 1 60 MAIN SUPPORT CYLINDER RH 3 5 x 9 MAIN SUPPORT CYLINDER LH 3 5 x 9 P 6SAE PCC CV PP CV L 6SAE 4SAE HR 4SAE RV HL NOTE THIS HOSE IS A 4SAE HOSE Pilot To Close Check Valve Pilot To Open Check Valve Check Valve Relief Valve 2000 PSI P L MR...

Page 27: ...AE HR 4SAE RV HL 4SAE RI 6SAE RV LI RO 6SAE RAMP DIVERT SOL3 PCC CV RAISE SOL 1 RP 6SAE LIP BLOCK SOL2 LO 4SAE T 6SAE LP 6SAE LIP OUT RAMP OUT COMBINATION POWER UNIT VALVE BLOCK LOCATED ADJACENT TO LEVELER POWER UNIT Check Valve Pilot To Close Check Valve 50 PSI 020 Orifice Relief Valve 675 PSI Check Valve Pilot To Close Check Valve Pilot To Open Check Valve Relief Valve 2000 PSI NOTE THIS HOSE IS...

Page 28: ...105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 FROM CUSTOMER MAIN POWER SAFETY PROTECTION DEVICE 110 120v 1PH 60HZ USE 20 0A DUAL ELEMENT TIME DELAY FUSE 1L1 N 1L1 N DUMMY L1 SEE NOTE 2 FUSED DISCONNECT BY OTHERS N G 1FU1 1L1 N SEE NOTE 8 J7 3 J7 2 J7 1 J2 6 J2 5 J2 4 J2 3 J2 2 J2 1 J3 2 J3 1 J5 4 J5 3 J5 2 J5 1 G 120VAC 0 3 AMPS BK WH RAISE SOL WKX SOL1 RESTRA...

Page 29: ...7 LD2 LD1 LD9 LD8 LD7 LD10 K3 K2 K1 J3 J5 J7 J2 J11 M2 RSOL1 RSOL2 RSOL3 M1 12VDC POWER CIRCUIT BOARD SEE DETAIL A 10FU1 MOTOR 12FU1 SOLENOID 11FU1 PWR SUPPLY J2 12V 12V 12V 12V 12V 12V X1 L1 X2 N M1 M2 MCOM SCOM 12VDC 12VDC 12VDC 12VDC 12VDC 12VDC RSOL1 RSOL2 RSOL3 G 120VAC 0 3 AMPS BK WH RAMP DIVERT SOL WKC SOL3 G 120VAC 0 3 AMPS BK WH G 120VAC 0 3 AMPS BK WH LIP BLOCK SOL WKV SOL2 RAISE SOL WKX...

Page 30: ...STR 4200 Dok Lok Owner s Manual Rite Hite 30 Publication AMEN00102 2017 07 06 ELECTRICAL Restraint Micro Board ...

Page 31: ...Rite Hite Owner s Manual STR 4200 Dok Lok Publication AMEN00102 2017 07 06 31 ELECTRICAL Restraint Micro Board Continued ...

Page 32: ...STR 4200 Dok Lok Owner s Manual Rite Hite 32 Publication AMEN00102 2017 07 06 ELECTRICAL Wiring Pedestrian Vu Leveler Stored to Unlock Restraint Figure 11 ...

Page 33: ...Rite Hite Owner s Manual STR 4200 Dok Lok Publication AMEN00102 2017 07 06 33 ELECTRICAL Wiring Pedestrian Vu Continued Leveler Stored to Close Overhead Door Figure 12 ...

Page 34: ...STR 4200 Dok Lok Owner s Manual Rite Hite 34 Publication AMEN00102 2017 07 06 ELECTRICAL Wiring Approach Vu ...

Page 35: ...Wiring Outside Light Box NOTE Must use LED outside bulbs 40 Wire OSR White Wire Red Wire 42 Wire 12V White Wire Red Wire 41 Wire OSG Red Lamp Green Lamp Light Box Cover Red Lamp Green Lamp Light Box Cover White Wire Red Wire Red Wire White Wire 41 Wire OSG 42 Wire 12V 40 Wire OSR Figure 13 ...

Page 36: ... 16 15 14 30 10 43 25 51 52 13 5 21 23 31 52 51 36 35 60 62 58 62 60 61 62 59 54 59 64 27 40 40 9 21 7 8 26 6 20 45 26 20 22 42 20 45 20 22 42 22 7 8 40 9 40 21 55 19 2 1 34 32 24 20 26 33 3 48 31 29 47 38 37 39 49 12 20 46 17 63 22 65 68 66 67 4 11 22 26 NOTE Deck of carriage weldment removed for clarity ...

Page 37: ...2285 32 2 Bolt Hex 31 18 X 75 51670 33 2 Bolt Hex 50 13 X 2 00 117076 34 2 Nut 50 13 Nylock 51507 35 2 Bolt Hex 10 24 X 50 118149 36 2 Washer 10 Lock 51770 37 1 Mechanical Limit Switch 117531 38 2 Screw 25 20 X 1L Soc Hd 58151 39 2 NUT 25 20 HEX FLG ZP 51552 40 4 Fitting Elbow 90º 6 SAE M 6 JIC M 55267 41 1 Serial Model Decal STR4 117780 42 2 Pin Clevis 75 X 5 75L 119887 43 1 Pin Clevis 50 X 2 125...

Page 38: ...ydrualic Fitting 6 MORB 6 MJ 55386 12 1 Auxillary Manifold 139415 13 2 Hose Assy Aux Manifold To BHD Fitting 142570 14 1 Solenoid Coil 130499 15 1 Solenoid Valve 130498 QTY DESCRIPTION PART 16 1 Hose Assy Right Side Support Cylinder MR Main Raise 142757 17 1 Hose Assy Right Left Side Support Cylinder ML Main Lower 117715 18 2 Hydraulic Plug 6MORB 118308 19 8 Cotter Pin 188 DIA X 1 50L ZP 51907 20 ...

Page 39: ...QTY DESCRIPTION PART 31 1 Hirschmann Plug Rect Harn Assy Stand Alone Power Unit 117888 32 1 Combination Valve Block Assembly Complete 139410 33 3 Solenoid Coil 142975 34 1 Hydraulic Valve WKC SOL3 139355 35 1 Hydraulic Valve WKX SOL1 139406 36 1 Hydraulic Valve WKV SOL2 139356 37 1 Hydraulic Relief Valve 139397 38 1 Hydraulic Check Valve 139405 39 1 Hydraulic Check Valve 139407 40 3 Hirschmann Plu...

Page 40: ... R 6 7 R 6 6 R 6 5 R 6 4 R 6 3 R 6 2 R 6 1 R 6 0 R 5 9 R 5 8 R 5 7 R 5 6 R 5 5 R 5 4 R 5 3 R 5 2 R 5 1 R 5 0 R 4 9 R 4 8 R 4 7 R 4 5 R 4 4 R 4 3 R 4 2 R 4 1 R 4 0 R 3 9 R 3 8 R 3 5 R 3 4 R 3 3 R 3 2 R 3 1 R 3 0 R 2 9 R 2 8 R 2 7 R 2 6 R 2 5 R 2 4 R 2 3 R 2 2 R 2 1 R 2 0 R 1 9 R 1 8 R 1 7 R 1 6 R 1 5 R 1 4 R 1 3 R 1 2 R 1 1 R 1 0 R 9 R 8 R 7 R 6 R 5 R 4 R 3 R 2 R 1 L 2 J 4 J 3 J 2 D 7 7 D 7 6 D 7 5...

Page 41: ...vanced Control Package 141502 309 1 Horn override enable decal If equipped 144831 1 Control power ON OFF decal If equipped 144829 1 Unlock enable decal If equipped 144830 310 1 Danger warning decal 144774 311 1 Lockout tagout multiple disconnect warning decal 114331 313 1 Circuit board UL rating decal 144859 501 1 15A fuse 0 25 x 1 25 Motor Fuse 115V control box 57864 502 1 1A fuse 5mm x 20mm Sole...

Page 42: ...STEMTM STR 4200 Dok Lok 4 2 3 25 25 10 5 MADE IN U S A 10 1 2 5 8 1 2 1 8 1 3 6 25 12 25 4 PRINTED IN U S A RITE HITE PRINT SHOP PUBLICATION NO 1352 Copyright 2012 JUNE 2014 Vehicle Restraint Owners Manual This Manual Covers Restraints Built After Serial Numbers 05GD150001W and up part of the SMOOTH TRANSITION DOK SYSTEMTM STR 4200 Dok Lok 4 2 3 25 25 10 5 MADE IN U S A 10 1 2 2 3 4 QTY DESCRIPTIO...

Page 43: ...ting Weldment Base 150695 2 1 Mounting Weldment Extension 150691 3 2 Bolt 25 20 x 1 136880 4 2 Screw 8 32X1 00 Phillips Head ZP 51689 5 2 Nut 8 32 Nylock ZP 141611 6 4 Anchor Concrete 375 dia X 3 5L Hex Head ZP 105046 7 1 Installation Instructions Truck Sensor 150697 8 1 Truck Sensor 150688 9 1 Extension Weldment for shelters over 36 deep 151306 Not Shown ...

Page 44: ...es 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 repair of t...

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