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DUAL-DOK

®

2200

Combined Lift & Leveler System

Owners Manual

This Manual Covers DUAL-DOKs

®

Built After Serial Numbers:

C78008 and up

PRINTED IN U.S.A.

RITE-HITE

PRINT SHOP

PUBLICATION NO. 1290

PART NUMBER: 134072

JANUARY 2010

MADE IN U.S.A.

• To change unit to Lift Mode, push and release

"DOWN"

button with no

load on platform.

• Do not place load on plaftorm unless unit is in Lift Mode.

• When lift operations are complete, always return platform to dock height.

Push and release leveler

"RAISE"

button to change unit to Leveler Mode.

A pulsing horn indicates that the platform has been below dock for 15

minutes.

MANUAL FUNCTIONS

Leveler Raise: Disengage Pins
Lip Extend: Extend Lip
Auto-Lip: Unlock Velocity Fuse
Lift Up: Raise Lift
Lift Down: Lower Lift

Press "MANUAL/RESET" button to reset
DUAL-DOK after a fault has been cleared at
dock height. If a fault has been cleared below
dock height, press "MANUAL/REST" button and
corresponding manual function button to move
unit to dock height.

ADDITIONAL WARNINGS AND INSTRUCTIONS ON SIDE OF ENCLOSURE

1. Do not operate leveler with anyone standing on or in front of leveler.
2. Do not operate in any mode with anyone standing under or in front of leveler.
3. Never enter a truck/trailer until its brakes are set, air has been dumped from air ride suspension (if applicable), and you have visually inspected to be sure truck/trailer is
securely held in place by a vehicle restraint or wheel chock per OSHA regulations.

•

Outside light is on when LED flashes.

•

Check outside lights is both LEDs are off.

•

The outside light switch must be

turned to RED to operate the system.

Do not turn switch to GREEN unit

loading/unloading is complete.

Verify that the platform is at dock height and that no load is on
platform. Push to Raise platform.

Push and hold

"MOMENTARY PAUSE"

to pause any movement of platform

and lip. Release to continue operation.

•

To position for below dock

endload, Push and release

"RAISE"

button.

•

To store from below dock

endload, Push and
immediately release (pulse)

"RAISE"

button.

Push both to extend lip. Release both to lower leveler onto trailer.

• In Auto-Lip mode, lip
automatically extends
whenever the

"DOWN"

button

is pushed.
• To engage Auto-Lip, push
and release

"AUTO-LIP"

button with platform at dock
height.
• To cancel Auto-Lip, push and
relase

"AUTO-LIP"

button

with platform at dock height.

Push to lower lift.

Push to raise lift.

MANUAL/RESET

PAUSE

MOMENTARY

END LOADING

LIP EXTEND

LEVELER RAISE

LIFT DOWN

LIFT UP

AUTO-LIP

OUTSIDE LIGHT

WARNING

WARNING

Lip

Platform

LEVELER

LIFT

MILWAUKEE, WISCONSIN 1-800-456-0600

COMBINED LIFT & LEVELER SYSYEM

0126280 RE

V

. X

X

R

R

F1

F2

F3

F4

1
2
3
...
»

Содержание DUAL-DOK 2200

Страница 1: ...ruck trailer until its brakes are set air has been dumped from air ride suspension if applicable and you have visually inspected to be sure truck trailer is securely held in place by a vehicle restrai...

Страница 2: ...2 Pub No 1290 January 2010 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual NOTES...

Страница 3: ...557 5 546 623 5 553 987 5 582 498 5 664 930 5 702 223 5 762 459 RE 37 570 5 882 167 5 964 572 6 010 297 6 052 268 6 065 172 6 070 283 6 074 157 6 085 375 6 092 970 6 106 212 6 116 839 6 190 109 6 220...

Страница 4: ...he tag to deteriorate or become unreadable RITE HITE Corporation does not recommend any particular lockout device but recommends the utilization of an OSHA approved device refer to OSHA regulation 191...

Страница 5: ...wn under Safety Warnings on preceding page TO ENGAGE SUPPORT LATCH 1 Bring platform to dock floor height 2 Pull activation chain in an upward motion to lower support latch 3 While holding the activati...

Страница 6: ...nd that one person attempt to lift the lip alone To engage the lip support press the MANUAL RESET button along with the LIP OUT button to extend the lip Pull out the lip support bar as shown below Tur...

Страница 7: ...20 The LED will change from GREEN position to the RED No controls will functions until the outside light has been changed to RED Remove wheel chocks and or restraint only when loading or unloading is...

Страница 8: ...l weight on the platform empty forklift stack of pallets can cause the system to display a fault condition The rear pivot pins will engage automatically if the DUAL DOK system is not operated for 5 mi...

Страница 9: ...es should be 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 Mai...

Страница 10: ...elow dock for 15 minutes MANUAL FUNCTIONS Leveler Raise Disengage Pins Lip Extend Extend Lip Auto Lip Unlock Velocity Fuse Lift Up Raise Lift Lift Down Lower Lift Press MANUAL RESET button to reset DU...

Страница 11: ...ed Lift Leveler System Owner s Manual INSTALLATION INSTRUCTIONS CONTINUED Before starting installation or maintenance check and follow the safety procedures of the facility where the DUAL DOK is being...

Страница 12: ...ING CHAIN ROUTE SUGGESTED LIFTING CHAIN ROUTE HOOK BACK OVER CHAIN LIFTING UNIT 4 PLACES BE SECURE WHEN SHIPPING BANDS MUST INSTALLATION MUST BE BEHIND ROUTING OF WIRE BUNDLES DURING CHAIN WHEN LIFTIN...

Страница 13: ...t Down Lower Lift Press MANUAL RESET button to reset DUAL DOK after a fault has been cleared at dock height If a fault has been cleared below dock height press MANUAL REST button and corresponding man...

Страница 14: ...e with anyone standing under or in front of leveler 3 Never enter a truck trailer until its brakes are set air has been dumped from air ride suspension if applicable and you have visually inspected to...

Страница 15: ...SE FRAME ASSEMBLY FLOOR MOUNTING PLATES FOR CLARITY DIAGRAM ONLY SHOWS BASE FRAME AND PIT FRONT OF PIT BACK OF PIT SIDE OF PIT 4 ROLLER BAR REAR PIN PLATES NOTE IF SHIMMING IS REQUIRED POSITION SHIMS...

Страница 16: ...NSTALLATION INSTRUCTIONS CONTINUED DETAIL REAR SEAL CHANNEL 6 5 7 WIDE UNITS 7 5 WIDE UNITS 53074 53075 56518 56519 BRUSH SEAL CHANNEL SECTION A A A A 25 TYP 53073 2 REF 53074 2 REF NOTE 1 EACH PER SI...

Страница 17: ...the following safety devices a Push in the selector valve b Turn on power c Disengage the support latch by returning the platform to dock height by pressing and holding the Lift UP and MANUAL RESET b...

Страница 18: ...8 With the DUAL DOK system in the Lift Mode lower the unit about 12 and then return to dock height RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual INSTALLATION INSTRUCTIONS CONTINUED Th...

Страница 19: ...TE HITE Dual Dok Combined Lift Leveler System Owner s Manual INSTALLATION INSTRUCTIONS CONTINUED IMPORTANT Position Pivot Block With Chamfer Facing Rear Hinge Pin 6 Ref 1 4 Ref 1 4 1 4 1 4 Tack 2 Side...

Страница 20: ...rresponding manual function button to move unit to dock height ADDITIONAL WARNINGS AND INSTRUCTIONS ON SIDE OF ENCLOSURE 1 Do not operate leveler with anyone standing on or in front of leveler 2 Do no...

Страница 21: ...ut Solenoid Pin Disengage Solenoid Limit Switch Power Pins Disengaged Limit Switch Pins Engaged Limit Switch At Dock Height Limit Switch Below Dock Height Limit Switch Platform Separation Limit Switch...

Страница 22: ...ort latch by pulling the activation chain and pressing and holding the Lift DOWN button until the platform stops decending as shown in Figure 2 Pulling the selector valve activation chain out to preve...

Страница 23: ...IGHT WARNING WARNING Lip Platform LEVELER LIFT MILWAUKEE WISCONSIN 1 800 456 0600 COMBINED LIFT LEVELER SYSYEM 0126280 REV XX R R F1 F2 F3 F4 FIGURE 20 STORED POSITION Control Box Outside Lights Red G...

Страница 24: ...ight ADDITIONAL WARNINGS AND INSTRUCTIONS ON SIDE OF ENCLOSURE 1 Do not operate leveler with anyone standing on or in front of leveler 2 Do not operate in any mode with anyone standing under or in fro...

Страница 25: ...or in front of leveler 3 Never enter a truck trailer until its brakes are set air has been dumped from air ride suspension if applicable and you have visually inspected to be sure truck trailer is se...

Страница 26: ...er 3 Never enter a truck trailer until its brakes are set air has been dumped from air ride suspension if applicable and you have visually inspected to be sure truck trailer is securely held in place...

Страница 27: ...visually inspected to be sure truck trailer is securely held in place by a vehicle restraint or wheel chock per OSHA regulations Outside light is on when LED flashes Check outside lights is both LEDs...

Страница 28: ...e suspension if applicable and you have visually inspected to be sure truck trailer is securely held in place by a vehicle restraint or wheel chock per OSHA regulations Outside light is on when LED fl...

Страница 29: ...draulic velocity fuses These fuses act as check valves to stop fluid flow if the flow exceeds the valve s rating Both lift and ramp cylinders have an in line velocity fuse at the base of the cylinder...

Страница 30: ...ing the Lift DOWN button until the platform stops decending as shown in Figure 2 Pulling the selector valve activation chain out to prevent scissors movement as shown in Figure 4 If lip needs to be ex...

Страница 31: ...ins with anti seize lubricant See Figure 28 5 Spray lubricate on all pins and cylinder rods See Figure 28 6 Check hydraulic reservoir for proper fluid level 7 Check all hydraulic cylinders hoses and f...

Страница 32: ...the safety devices as described in the following Danger 8 Check for fluid leaks and verify that the hydraulic fluid level is correct with the unit resting at dock height in the stored position See Fig...

Страница 33: ...orm is not at dock height Function Key Descriptions Main PLC Inputs Displays the status of control box PLC inputs Main PLC Outputs Displays the status of control box PLC outputs Faults Displays the la...

Страница 34: ...1 COM 2 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 IN 9 IN 10 COM 1 COM 1 COM 1 COM 2 COM 2 NORMALLY CLOSED HELD OPEN NORMALLY OPEN HELD CLOSED NORMALLY CLOSED HELD OPEN NORMALLY OPEN HELD CLOSED NORMAL...

Страница 35: ...202 0208 0209 0200 0201 0202 0203 0204 0205 0206 0207 0205 0204 0203 0202 0201 0200 PLATFORM BELOW DOCK LEVEL PLATFORM BELOW DOCK LEVEL PLC I O INDICATOR LIGHT ON PLC I O INDICATOR LIGHT ON OR OFF L S...

Страница 36: ...RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual FAULT CODES Never be under the DUAL DOK platform or lip without Engaging the support latch by pulling the activation chain and pressing...

Страница 37: ...long too long Oil is low in tank Check the oil level in tank Hydraulic hose is broken or valve Replace any broken or worn is leaking hoses or valves Filter or return line is plugged Replace filter Rem...

Страница 38: ...unning to long or Verify all limit switch wire time out loose connections with 24VDC connections voltages and PLC input terminals continuities Gate limit switches or cables Verify that the gate limit...

Страница 39: ...Replace pin limit switch assembly Power was interrupted when motor Disengage pins by pressing the was running while lifting up unit Leveler RAISE button along with the MANUAL RESET button Then raise u...

Страница 40: ...hat the lip limit switch and or limit switch actuator is assembly is not damaged or improperly set set incorrectly Pressure on lip sequence valve Increase the pressure on lip SV1 is set too low sequen...

Страница 41: ...L OPERATION extended into pivot blocks RESET button along with Lift UP button until platform is at dock height or stops automatically Leveler Mode Platform Locked or not lowering onto 1 Press and hold...

Страница 42: ...isengaged 2 Press and hold MANUAL OPERATION RESET button along with Lift DOWN button until platform is at dock height 3 If platform went below dock height press and hold MANUAL OPERATION RESET button...

Страница 43: ...etc c Check oil filter for excessive contamination d Remove and examine return line for debris e Check collar and key connecting pump to motor f Check hoses valves and fittings for leaks or damage g...

Страница 44: ...ht selector switch is f Verify that outside light selector switch turned to outside GREEN is turned to outside RED Verify that outside light selector switch E6206 is wired and operating properly g No...

Страница 45: ...witch is used verify that limit switch wires are connected to terminals 24VDC and E6500 e No power to PLC e Check 110 VAC secondary fuse 10FU1 on lower terminal block assembly Check power across 24 VD...

Страница 46: ...while the pins are disengaged and the motor is running Motor overload is tripped Reset overload or replace if necessary Measure amp draw on one power lead and compare to Full Load Amp rating FLA on mo...

Страница 47: ...ion keys of the message center Compare limit switch states to State Chart Check or replace A0202 valve coil and wiring terminated at junction box g Hydraulic system g Check and or repalce A0200 3 way...

Страница 48: ...ght May be held closed e Hydraulic system e Check and or repalce A0200 and A0201 3 way 2 position spool valve and or A0202 normally closed pilot operated poppet valve May be stuck Increase the pressur...

Страница 49: ...nd terminals 24 VDC 24 COM of PLC for 24 VDC c Electrical system c Check outside light selector switch E6206 for loose wires or damaged components Check voltage to outside light bulbs for 24 VAC Check...

Страница 50: ...t switch states to State Chart Check push buttons and pendant station for loose wires or damaged components 17 Unit will not complete a Electrical System a Check all limit switch inputs using the weig...

Страница 51: ...Pub No 1290 January 2010 51 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual HYDRAULIC SCHEMATIC FIGURE 32 HYDRAULIC SCHEMATIC FOR STANDARD CAPACITY DUAL DOK SYSTEM...

Страница 52: ...NOTES FUSED DISCONNECT IS OPTIONAL FROM RITE HITE PRODUCTS CORPORATION FUSED DISCONNECT MUST BE INSTALLED PER LATEST EDITION OF UL508A AND NEC REQUIREMENTS A BRANCH CIRCUIT DISCONNECT SHALL BE LOCATED...

Страница 53: ...ELM TD 13FU1 DUAL ELM TD 2 10A 250V 24VDC BL 24 VDC 24 COM 1762 L40BWA PLC DISPLAY GND 24VDC BL 24 BL 24 BL 24 BL COMM PORT COMM PORT COMM CABLE 212 222 219 221 220 218 217 216 215 214 213 211 210 209...

Страница 54: ...GHT SELECTOR SWITCH BUTTON LIFT DOWN BUTTON LIFT UP BUTTON AUTO LIP BUTTON LIP OUT BUTTON BUTTON MANUAL RESET RAISE LEVELER 1762 L40BWA PLC SS1 OX E6204 RD E6205 WH 24VDC BK FACTORY INSTALLED OVERHEAD...

Страница 55: ...IN 11 PIN POSITION LS1 SWITCH FLOAT PLATFORM LEVEL RETRACTED LIP EXTENDED LIP SCISSORS SEPARATED SEPARATION PLATFORM BELOW DOCK AT DOCK HEIGHT ENGAGED PINS DISENGAGED PINS TO LINE 501 FROM LINE 324 4...

Страница 56: ...2 WH X2 WH 1OL 96 24VAC 70VA A2 SURGE SUPPR 1MCR A1 95 JMPR X2 X2 WH X2 WH X2 WH BEACON HORN NOT ALARM OUTSIDE CAUTION RED LIGHT OUTSIDE GREEN LIGHT INTERLOCK OUTPUT LEVELER STORED STARTER MOTOR DRY C...

Страница 57: ...RD A0203 A0203 RD SOLENOID 2 PLATFORM LIP SOLENOID 3 LIFT DOWN A0202 A0202 RD A0201 RD A0201 SOLENOID 1 LIFT UP A0200 X2 WH LIFT UP X2 LIP OUT SOLENOID X2 X2 WH AUTO LIP SOLENOID PLATFORM LIP SOLENOID...

Страница 58: ...5 H P 1725 R P M 380v 3 PH 50 Hz FLA 11 0A LEVELER MOTOR 7 5 H P 1725 R P M 480v 3 PH 60 Hz FLA 10 0A LEVELER MOTOR 7 5 H P 1725 R P M 575v 3 PH 60 Hz FLA 8 0A H1 H4 H3 H2 H1 H4 H3 H2 H1 H3 H2 H4 H1...

Страница 59: ...10 IN 14 IN 13 IN 12 IN 11 PLATFORM LEVEL LS6 LIP RETRACTED LS5 LIP EXTENDED LS5 SCISSORS SEPARATED LS4 PLATFORM SEPARATION LS3 IN 15 IN 19 IN 18 IN 17 IN 16 NOT USED NOT USED NOT USED FLOAT SWITCH LS...

Страница 60: ...Position Desc EO200 201 Pin Limit Switch Desc EO206 207 Lip Limit Switch Desc EO204 Platform Separation Limit Switch Arm Location At Center Of Switch Neutral Position Arm Location At Center Of Switch...

Страница 61: ...Pub No 1290 January 2010 61 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual NOTES...

Страница 62: ...System Owner s Manual REPLACEMENT PARTS PLATFORM 57 58 And 59 8 Foot Only 59 2 1 3 4 7 8 9 14 13 12 11 16 15 18 17 36 33 39 35 38 41 52 56 28 29 30 31 32 28 33 40 43 44 41 42 45 13 12 47 46 56 50 49...

Страница 63: ...074 24 4 Brush Seal 85 1 2 Long 56518 56518 56518 25 2 Flat Washer 3 4 SAE 51715 51715 51715 26 1 Maintenance Latch 05310 05298 05298 27 1 Extension Spring 1 7 8 O D x 10 3 4 Long 52129 52129 28 2 Ret...

Страница 64: ...9 18 17 16 15 13 12 9 10 38 10 39 10 10 40 38 40 41 10 44 43 42 48 49 47 15 45 50 40 40 21 20 24 23 22 8 7 6 5 4 3 Includes Items 4 5 6 And 7 54 59 58 62 56 65 10 14 37 34 33 67 35 36 32 31 29 Include...

Страница 65: ...181 06181 19 2 Bushing 2 O D x 1 3 4 I D 52330 52330 52330 20 4 Hex Hd Screw 1 2 13 UNC x 1 1 2 Long 58061 58061 58061 21 4 Lockwasher 1 2 51831 51831 51831 22 2 Cylinder Pin Retainer Plate 59699 5969...

Страница 66: ...9 18 17 16 15 13 12 9 10 38 10 39 10 10 40 38 40 41 10 44 43 42 48 49 47 15 45 50 40 40 21 20 24 23 22 8 7 6 5 4 3 Includes Items 4 5 6 And 7 54 59 58 62 56 65 10 14 37 34 33 67 35 36 32 31 29 Include...

Страница 67: ...20 UNC 51552 51552 51552 56 1 Guide Rod 59385 59385 59385 57 2 Cotter Pin 1 8 x 1 Long 51901 51901 51901 58 1 Limit Switch Mounting Plate 15763 15763 15763 59 4 Lockwasher 3 8 51833 51833 51833 60 4 N...

Страница 68: ...56549 3 1 Base Frame 05308 05336 05202 4 4 Cotter Pion 1 long 51901 51901 51901 5 4 Washer flat 7 16 I D x 13 16 O D 51700 51700 51700 6 1 RITE HITE Logo Decal 54100 54100 54100 7 1 Bellows Curtain F...

Страница 69: ...ference 06181 3 1 Lip Cylinder Reference 01380 4 1 Rear Pin Cylinder Reference 06182 5 1 Selector Valve Assembly 06283 6 4 90 Male Elbow 3 8 NPT 8 MJ 55153 7 1 Hose Assembly 06291 8 1 90 Male Elbow 3...

Страница 70: ...ence 06181 3 1 Lip Cylinder Reference 06694 4 1 Rear Pin Cylinder Reference 06182 5 1 Selector Valve Assembly 06283 6 4 90 Male Elbow 3 8 NPT 8 MAORB 55153 7 1 Velocity Fuse 7 5 GPM 06195 8 1 90 Male...

Страница 71: ...06181 3 1 Lip Cylinder Reference 01380 4 1 Rear Pin Cylinder Reference 06182 5 1 Selector Valve Assembly 06283 6 4 90 Male Elbow 3 8 NPT 8 MJ 55153 7 1 Velocity Fuse 7 5 GPM 06195 8 1 90 Male Elbow 3...

Страница 72: ...outside light switch must be turned to RED to operate the system Do not turn switch to GREEN unitl loading unloading is complete Verify that the platform is at dock height and that no load is on platf...

Страница 73: ...9 1 Chase Nipple 1 2 55818 20 1 Cord Grip 55714 21 1 Locknut 1 2 55715 22 1 Pendent Station with Cord 16971 23 1 Horn 65750 24 1 Fuse Specification Decal Consult Factory 25 1 Voltage Phase FLA Decal C...

Страница 74: ...outside light switch must be turned to RED to operate the system Do not turn switch to GREEN unitl loading unloading is complete Verify that the platform is at dock height and that no load is on platf...

Страница 75: ...75V 65689 54 2 Terminal Block Covers with Hardware 65650 55 1 Primary Fuse Block 57605 56 1 Primary Fuse Block Cover 65651 57 2 3A Class CC Fuse 240V 65676 2 2A Class CC Fuse 380V 65677 2 1 4A Class C...

Страница 76: ...19 45 44 43 2 5 1 6 7 11 28 Top 15 Bottom 23 Top 22 Bottom 25 Top 24 Bottom 26 Top 27 Bottom 9 10 16 Top 17 Bottom 18 Top 19 Bottom 20 Top 21 Bottom 37 15 GND 24VDC E0200 E0201 E0202 E0203 EO204 EO20...

Страница 77: ...204 16467 21 1 Receptacle Plug and Harness Assembly A0203 16468 22 1 Float Switch and Harness Assembly 16471 23 1 Limit Switch and Harness Assembly Plat Lev 16554 24 1 Limit Switch and Harness Assembl...

Страница 78: ...Part Number 1 1 Fixed P C F C 55192 2 2 Check 100 PSI 55193 3 6 24 VAC H C Coil 55360 4 2 Valve 2 way N O Spool 203 204 55189 5 2 Check 5 PSI 55234 6 1 Valve 2 way N C Poppet 202 55185 7 1 Check 75 PS...

Страница 79: ...51831 51831 51831 6 12 Flat Washer 1 2 STD 51738 51738 51738 7 24 Hex Hd Screw 1 2 13 UNC x 1 1 2 Long 51674 51674 51674 8 4 Guardrite Rail 9600 68 9600 92 9600 116 9 4 Column Newel Cap 55651 55651 5...

Страница 80: ...gnal Light Box Complete 6 2 2 4 5 12 25 6 25 3 4 Item Qty Description Part Number 1 1 Outside Light Box With Lamp Assemblies and Lens 18761 2 2 Round Head Screw 8 32 x 3 8 Long 18364 3 2 Light Bulb GE...

Страница 81: ...Pub No 1290 January 2010 81 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual NOTES...

Страница 82: ...82 Pub No 1290 January 2010 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual NOTES...

Страница 83: ...Pub No 1290 January 2010 83 RITE HITE Dual Dok Combined Lift Leveler System Owner s Manual NOTES...

Страница 84: ...ities and or specified design parameters and not oth erwise abused Periodic lubrication and adjustment is the sole responsibility of the owner This warranty is RITE HITE s exclusive warranty RITE HITE...

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