SPECIFICATION ELIMINATOR TM -GAPMASTER TM II: 610G Series

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5 FROMMELT USE SPECIFICATION ELIMINATOR TM -GAPMASTER TM II: 610G Series SITE INFORMATION: Dock Height: " Door Size: Width ' - " Height ' - " Driveway Approach % of Grade Total Bumper Protection " Dock Shelter(s) to Service Trucks/Trailer Heights from ' 12 - " 6 to ' 13 - " 6 (shortest) (tallest) Yard Jockey Truck Leveler Jumbo TM Leveler Step Back Trailers Lift Gate Trailers Frommelt 2003 Frommelt Products Corporation a RITE-HITE Company 8900 N. Arbon Drive, Milwaukee, WI P.O. Box , Milwaukee, WI or Fax: (414) Intelligent Dock Design sm Date 2/15/13 Qty 10 End User Owens Illinois Sold To H&R Developments City State Montreal Canada Entering Rep. McCormick Equipment Dest. Rep. Canado Narcan Salesperson Joe McCormick Info OPTIONS: 4" Side Frame Width Obstructions/Cutouts (provide sketch to applications) Reefer Hook Profile Info Foam Backer: 18" Foam backer Full Width Foam Backer Curtain Style: Integral Hood Flat Top Over Sides (not gutter) Pull Ropes Curtain Weights Firefighter C4-Curtain Fire Retardant Foam & Fabric Unit Markings: Rep Label Only - No Header Logo Custom Logo & Rep Label Door # & Rep Label CL#: Door #(s): (1) 610 Series Bumper (2) 610 Series Bumpers FABRIC INFORMATION: Curtain Fabric & Color: 40 oz Vinyl Black FR COMMENTS/NOTES: 10 of 34 units MARK FOR LaSALLE #2 DOCK (other 24 units need to be tapered) RHC No. Authorization Signatures/Company Date: FROMMELT USE - FOR FROMMELT USE ONLY - FOR FROMMELT USE ONLY - Work Area Week Day Foam#s Ship VIA Page of - FOR FROMMELT USE ONLY - FOR FROMMELT USE ONLY- F16EG610IIPAF505C

6 FROMMELT USE SPECIFICATION ELIMINATOR TM -GAPMASTER TM II: 610G Series SITE INFORMATION: Dock Height: " Door Size: Width ' - " Height ' - " Driveway Approach % of Grade Total Bumper Protection " Dock Shelter(s) to Service Trucks/Trailer Heights from ' 12 - " 6 to ' 13 - " 6 (shortest) (tallest) Yard Jockey Truck Leveler Jumbo TM Leveler Step Back Trailers Lift Gate Trailers Frommelt 2003 Frommelt Products Corporation a RITE-HITE Company 8900 N. Arbon Drive, Milwaukee, WI P.O. Box , Milwaukee, WI or Fax: (414) Intelligent Dock Design sm Date 2/15/13 Qty 24 End User Owens Illinois Sold To H&R Developments City State Montreal Canada Entering Rep. McCormick Equipment Dest. Rep. Canado Narcan Salesperson Joe McCormick Info OPTIONS: 4" Side Frame Width Obstructions/Cutouts (provide sketch to applications) Reefer Hook Profile Info Foam Backer: 18" Foam backer Full Width Foam Backer Curtain Style: Integral Hood Flat Top Over Sides (not gutter) Pull Ropes Curtain Weights Firefighter C4-Curtain Fire Retardant Foam & Fabric Unit Markings: Rep Label Only - No Header Logo Custom Logo & Rep Label Door # & Rep Label CL#: Door #(s): (1) 610 Series Bumper (2) 610 Series Bumpers FABRIC INFORMATION: Curtain Fabric & Color: 40 oz Vinyl Black FR COMMENTS/NOTES: 24 of 34 units RHC No. Authorization Signatures/Company Date: FROMMELT USE - FOR FROMMELT USE ONLY - FOR FROMMELT USE ONLY - Work Area Week Day Foam#s Ship VIA Page of - FOR FROMMELT USE ONLY - FOR FROMMELT USE ONLY- F16EG610IIPAF505C

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9 DOK-BOX TM PIT FORMING KIT Conventional methods for pouring dock leveler pits can be costly and time-consuming. The revolutionary Dok-Box TM Pit Forming Kit by Rite-Hite minimizes costs associated with pouring a dock leveler pit. The exclusive Dok-Box design slides and hooks together to easily create the pit you need. Reduces pit forming costs u Quickly slides and hooks together on-site without the need for additional hardware. u No cutting of wood forms required. u Each unit ships complete with front and rear squaring support members and center spacer support. u Side and rear curb angles are integral to the panels. u Two basic designs: new construction and retro-fit. Rear Squaring Support Member Quick-Hook TM Fastening System Superior structural design u 9-gauge steel side and rear panels. u 1 1 /2" x 9-gauge steel concrete anchors welded at 16'' O.C. u Tapered design for water run-off. u Paint: one coat gray primer. Options u Dock bumper mounting plates (11" wide by 20" or 24" high). u Dok-Lok mounting plate (29" wide by 20" high). Front Squaring Support Member Optional Dok-Lok Mounting Plate Optional Dock Bumper Mounting Plate Reduce Dock Leveler Pit Forming Costs. The Dok-Box Leveler Pit Forming Kit by Rite-Hite is an efficient system for forming dock leveler pits by doubling as a curb angle and a concrete pit form. The proprietary Dok-Box comes complete with front and rear squaring members for efficient, time saving set-up. The Quick-Hook Fastening System saves you time and money by sliding together to create the leveler pit that you need. Dok-Box Pit Forming Kit is backed with Rite-Hite s exclusive 1-year money back guarantee.

10 DOK-BOX TM SPECIFICATIONS DOK-BOX Comparison Worksheet CONVENTIONAL PIT FORMING DOK-BOX TM PIT FORMING Labor rate/hour: $ Number of laborers: $ Hours to assemble, support and anchor: $ hours to remove and store forms: $ TOTAL LABOR COST: $ ADDITIONAL COSTS: Curb Steel: $ Wood Forms (Take cost of forms divided by number of usages): $ Conventional Pit Forming Kit TOTAL COST: $ Labor rate/hour: $ Number of laborers: $.25 hours to assemble and anchor Dok-Box: $ TOTAL LABOR COST: $ Dok-Box material cost: $ Dok Box Pit Forming Kit TOTAL COST: $ SAVINGS over conventional Pit Forming: $ Simple Installation Pour pit floor. Set Dok-Box in place with squaring members - NO FORMS REQUIRED. Anchor to pit floor - Helps assure squareness. Pour around Dok-Box. Let cure. Remove squaring bars - Ready for leveler installation 8900 North Arbon Drive Milwaukee, WI USA (414) (800) FAX: (414) Mailing Address: Rite-Hite P.O. Box Milwaukee, WI USA A15DBB1108B RITE-HITE, Frommelt, Dok-Box TM, Quick-Hook TM and Dok-Lok are trademarks of the RITE-HITE Holding Corporation. RITE-HITE products may be covered by one or more U.S. Patents with other U.S. and foreign patents pending. RITE-HITE reserves the right to make product improvements without prior notice.

11 DOK-BOX INSTALLATION INSTRUCTIONS Standard Dok-Box Kit Components: 2 Side Panels (left side and right side) 1 Rear Panel 1 Steel Front Squaring Member 1 Steel Rear Squaring Member 1 Wood Center Squaring Member Retrofit Unit - Existing Pit Optional Components: Front Curb Angle Dock Bumper Mounting Brackets Dok-Lok Mounting Bracket Side Panel 1. After reviewing the dock leveler manufacturer's pit details for accurate sizes, be sure that: Front Curb The opening in the floor be cut at least 12" wider than the finished pit width, and 9" longer than the finished pit length. 2. Place the front curb angle on a flat surface. Place the right side panel T-Opening on top of the curb angle. Swivel the right side panel counter clockwise. Swivel it back to its vertical position allowing the panel to snap inplace. Repeat the procedure for the left side panel. (Figure 1). Figure 1 3. Using the Quick-Hook tabs, connect the side panels to the rear panel. (Figure 2). 4. Insert both squaring support members and the center support spacer supplied with Dok-Box. Figure 2 5. Clamp 2" x 4" support boards or steel tubes (by others) to the side and rear panels and hang the Dok-Box from the existing dock floor. (Figure 3). Ensure that the top of the rear and side panels are flush. 6. Align electrical conduit (if required) with the hole in the side panel and slide through hole. 7. Slide optional bumper mounting plates (if supplied) into position. Ensure they are square with side panels and tack weld into position. Figure 3 8. Ensure that the top of the side and rear panels are flush and square. (Figure 4). Verify correct width and length of the Dok-Box opening at top and bottom. Cover openings at the dock face, using plywood forms to assure a matching building wall finish. 9. Pour concrete, first the sides and then the floor, around the Dok-Box Retrofit Unit. Remove clamps and support boards, then clean and finish off all areas where concrete was poured. Let the concrete cure. Remove both squaring support bars and center support spacer. Apply touch up paint as needed. 13 R 13 Figure 4 (Updated July 2003) IMPORTANT - Concrete behind Dok-Box must be well vibrated. Recommended minimum thickness is 8 for pit walls, floor and dock face.

12 DOK-BOX INSTALLATION INSTRUCTIONS Retrofit Unit - New Pit 1. After reviewing the dock leveler manufacturer's pit details for accurate sizes, be sure that: The opening in the foundation wall is at least 12" wider than the finished pit width. If bumper mounting plates are being used, additional space must be allowed. The pit floor slab is at least 6" wider than the finished pit width and 3" longer than the finished pit length (including the foundation wall). The correct pit depth is created. The front pit curb angle and optional Dok-Lok. mounting plate are poured in at front of pit floor slab. The pit floor slab is poured with a 1/2" slope downward from rear to front. Figure 1 2. After clearing the pit floor of any debris, position the side and rear panels. Using the "Quick-Hook " tabs, connect the side panels to the rear panel. (Figure 1) 13 R Shim the Dok-Box as necessary to be flush with the finished floor line. Ensure that the top of the side and rear side panels are flush and square. (Figure 2) Slide optional bumper mounting plates (if used) into position. Ensure they are square with side panels and tack weld into position. Figure 2 4. Insert both squaring support members and the center support spacer (not shown), and verify correct width at top and bottom of pit. (Figure 3) 5. Anchor the Dok-Box to the pit floor slab, using Ram-set nails or tap cons in the pre-drilled side panel flanges. 6. Align electrical conduit (if required) with the hole in the side panel and slide through hole. (Note: be sure to consider and allow for control box location.) Cover front opening at the dock face, using plywood forms to assure a matching building wall finish. Figure 3 7. Prepare for and pour concrete around the Dok-Box. Clean and finish off all areas where concrete was poured. Let the concrete cure. 8. Remove both squaring support members and center spacer. Apply touch up paint as needed. (Updated July 2003) IMPORTANT - Concrete behind Dok-Box must be well vibrated. Recommended minimum thickness is 8 for pit walls, floor and dock face.

13 RHH50 High Capacity Dock Leveler Owners Manual part of the SMOOTH TRANSITION DOK SYSTEM TM MADE IN U.S.A. This Manual Covers Dock Levelers Built After Serial Numbers: 10EH030001M and up PRINTED IN U.S.A. RITE-HITE PRINT SHOP PUBLICATION NO APRIL 2012

14 RITE-HITE RHH50 Dock Leveler Owner s Manual NOTES 2 Pub. No April 2012

15 RITE-HITE RHH50 Dock Leveler Owner s Manual TABLE OF CONTENTS NOTICE TO USER SAFETY WARNINGS OWNER RESPONSIBILITY OPERATION INSTRUCTIONS MAINTENANCE PROCEDURES LUBRICATION CHART LEVELER ADJUSTMENTS TROUBLESHOOTING ELECTRICAL WIRING CHARTS ELECTRICAL SCHEMATICS REPLACEMENT PARTS - CONTROL BOX HYDRAULIC SCHEMATIC REPLACEMENT PARTS - HYDRAULICS REPLACEMENT PARTS - LEVELER ASSEMBLY REPLACEMENT PARTS - AUTOMATIC RETURN TO DOCK (ARTD) REPLACEMENT PARTS - ENDLOAD LEGS STANDARD WARRANTY BACK COVER PRODUCT SPECIFIC WARRANTY RITE-HITE warrants the RHH50 Dock Leveler for five-years parts and one-year labor from date of shipment in accordance with Rite-Hite's Standard Warranty Policy. NOTICE TO USER Your local RITE-HITE representative provides a Planned Maintenance Program (P.M.P.) which can be fitted to your specific operation. Call your local representative or the RITE-HITE Corporation at The RITE-HITE products in this manual are covered by one or more of the following U.S. patents: 5,271,183; 5,323,503; 5,546,623; 5,553,987; 5,582,498; 5,664,930; 5,702,223; 5,762,459 (RE: 37,570); 5,882,167; 6,065,172; 6,070,283; 6,085,375; 6,092,970; 6,106,212; 6,116,839; 6,190,109; 6,220,809; 6,276,016; 6,311,352; 6,318,947; 6,322,310; 6,360,394; 6,368,043; 6,431,819; 6,488,464; 6,499,169; 6,502,268; 6,505,713; 6,524,053; 6,634,049; 6,654,976; 6,726,432; 6,773,221; 6,832,403; 6,880,301; 6,892,411; 7,032,267; 7,062,814; 7,134,159; 7,213,285; 7,216,391; 7,363,670; 7,380,305; 7,503,089; 7,553,431; 7,584,517; 7,681,271; 7,823,239; 7,841,823; 7,877,831 and pending U.S and foreign patent applications. RITE-HITE, LEVEL-RITE, THINMAN TM, SAFE-T-LIP, HYDRACHEK, WHEEL-LOK TM, DOK-LOK, DUAL-DOK, SAFE-T-STRUT TM, DOK-COMMANDER, JUMBO TM, HYDRA-RITE TM, SAFE-T-GATE, and SMOOTH TRANSITION DOK SYSTEM TM, are trademarks of RITE-HITE Corporation. Pub. No April

16 RITE-HITE RHH50 Dock Leveler Owner s Manual SAFETY WARNINGS DO NOT OPERATE When working with electrical or electronic controls, make sure that the power source has been locked out and tagged out according to OSHA regulations and approved local electrical codes. XXXXXXXXXXXX XXXXXXXXXXX FIGURE 1 - LOCKOUT/TAGOUT LOCKOUT/TAGOUT PROCEDURES The Occupational Safety and Health Administration (OSHA) requires, in addition to posting safety warnings and barricading the work area (including, but not limited to, trucking office and loading docks), that the power supply has been locked in the OFF position or disconnected. It is mandatory that an approved lockout device is utilized. An example of a lockout device is illustrated. The proper lockout procedure requires that the person responsible for the repairs is the only person who has the ability to remove the lockout device. In addition to the lockout device, it is also a requirement to tag the power control in a manner that will clearly note that repairs are under way and state who is responsible for the lockout condition. Tagout devices have to be constructed and printed so that exposure to weather conditions, or wet and damp locations, 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 regulation ). RITE-HITE also recommends the review and implementation of an entire safety program for the Control of Hazardous Energy (Lockout/Tagout). These regulations are available through OSHA publication This is the highest level statement. Failure to follow the listed instructions will most likely result in severe injury or death. The statements used with this level of warning deal with a safe operating procedure. If the procedure is ignored the possibility of personal injury may exist. This is a statement of serious hazard. Failure to follow the listed instructions could place the individual at risk of serious injury or death. IMPORTANT is used to draw attention to a procedure that needs to be followed to prevent machine damage. 4 Pub. No April 2012

17 RITE-HITE RHH50 Dock Leveler Owner s Manual OTHER IMPORTANT OPERATIONAL SAFETY WARNINGS Never be under the dock leveler platform or lip without: Installing the Safe-T-Strut TM or other supporting device. If lip needs to be extended, follow procedures shown under Safety Devices on the following page. Turning off power to the control box. Locking out and tagging out the main power source, as shown under Safety Warnings on preceding page. Always barricade the dock leveler at ground level and dock level from any form of traffic when maintenance is required. Inspect the dock leveler monthly to ensure that there are no broken or worn parts which could cause injury to personnel 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 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. Never operate the leveler with you, anyone, or anything on, or in front of the leveler, or without a truck/trailer parked in position, or from on the truck/trailer bed. DO NOT operate with anyone under platform or in front of the lip. When leveler is not in use, always store it so that it is supported by the lip supports and that it is level with the surrounding dock floor. If a malfunction does occur, always call your authorized RITE-HITE service representative immediately. Pub. No April

18 RITE-HITE RHH50 Dock Leveler Owner s Manual SAFETY DEVICES Never be under the dock leveler platform or lip without: Installing the Safe-T-Strut tm. See below right. This can be done with the assistance of another person by: - Raise leveler until platform reaches its highest position and lip extends. Continue to maintain this position. Post warnings and barricades at dock level and at drive level to indicate that work is being done around and under the leveler platform. Lockout/Tagout power to the leveler and post warnings when work is being performed on the leveler. - Then have assistant insert the smaller end of the Safe-T-Strut TM through the hole in the middle of the leveler lip and place the strut s wider open end over the base located on the leveler s front frame. Align the holes on the base and the Safe-T- Strut TM so that the leveler may be secured with the retaining pin and safety clip. - Release the pushbutton on powered levelers allowing the Safe-T-Strut TM to rest on the underside of the lip. Lockout/Tagout power supply. - Turn off the power to the control box. - Lockout/tagout the main power source, 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 Maintenance Support. For Safe-T-Strut TM removal, have an assistant raise the leveler to its highest position with lip fully extended. Release the safety clip and remove retaining pin. Lift strut off base, and remove from lip. Return the Safe-T-Strut TM to the proper storage position. If you are unable to install the Maintenance Support properly, contact your authorized RITE-HITE Service Representative or RITE- HITE Customer Service at FIGURE 2 - INSTALL SAFE-T-STRUT TM SUPPORT 6 Pub. No April 2012

19 RITE-HITE RHH50 Dock Leveler Owner s Manual 1. The owner should recognize the inherent danger of the interface between dock and transport vehicle. The owner should, therefore, train and instruct operators in the safe use of dock equipment in accordance with the information provided below. The manufacturer shall publish, provide to the initial purchaser, and make the following information readily available to owners: Installation instructions Recommended initial and periodic inspections procedures Maintenance procedures Operating instructions Descriptions or specifications for replaceable or repairable parts Tables identifying the grade (slope) for all variations of length or configuration of the dock equipment, and Information identifying the maximum uncontrolled drop encountered upon sudden removal of support while within the working range of the equipment. It shall be the responsibility of the owner to verify that the material listed in this section has been received and that it is made available for the instruction and training of presonnel entrusted with the use or maintenance of the dock equipment. 2. When a transport vehicle is parked at a loading dock, it is important that the vehicle is relatively perpendicular to the dock face and in close contact with at least one of the dock bumpers. 3. Nameplates, cautions, instructions, and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended. 4. Manufacturer s recommended periodic maintenance and inspection procedures in effect at date of shipment shall be followed, and written records of the performance of these procedures should be kept. OWNER RESPONSIBILITY 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 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 manufacturer shall make available replacement nameplates, caution/instruction labels, and operating/maintenance manuals upon request of the owner. The owner shall see that all nameplates, caution/instruction markings or labels are in place and legible, and that the appropriate operating/maintenance manuals are provided to users. 8. Modifications or alterations of dock equipment shall be made only with written permission of the original manufacturer. These changes shall also satisfy all safety recommendations of the original equipment manufacturer for the particular application of the dock equipment. 9. In order to be entitled to the benefits of the standard product warranty, the dock equipment must have been properly installed, maintained and operated within its rated capacities and/or specific design parameters, and not otherwise abused. 10. It is recommended that trailers equipped with air ride suspensions should remove the air from the suspension to minimize trailer bed drop, prior to loading or unloading. 11. When industrial trucks are driven on and off transport vehicles during the loading and unloading operation, the brakes on the transport vehicle shall be applied and wheel chocks or a positive restraining device shall be engaged. 12. In selecting dock equipment, it is important to consider not only present requirements but also future plans or adverse environments. Pub. No April

20 RITE-HITE RHH50 Dock Leveler Owner s Manual OPERATION INSTRUCTIONS NORMAL OPERATION 1. Activate the leveler by pushing and holding the RAISE button to raise the platform. While pressing the RAISE button, if equipped, push the LIP EXTEND button to fully extend the lip when the lip has cleared trailer bed. See figure 3. b. 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 stored position without operator assistance. FIGURE 3 - POWERED DOCK LEVELER 2. When lip is fully extended, release RAISE and if equipped, LIP EXTEND buttons. The leveler will automatically lower onto the truck/trailer bed. See figure 4. NOTES: a. Be sure the lip is in full contact with the truck/trailer bed before loading or unloading truck/trailer. END LOADING OPERATION NOTES: On units without a Safe-T-Lip, end load at dock level and above can be handled with the leveler in its stored position. 1. For units with Safe-T-Lip, or all below dock end loads, activate the leveler by pushing and holding the RAISE button until the lip clears the lip supports. While pressing the RAISE button, if equipped, push the LIP EXTEND button briefly to extend the lip beyond the lip supports. See figure 5. FIGURE 5 - END LOAD OPERATION - LIP POSITION FIGURE 4 - NORMAL OPERATION 2. When lip extends about 2 inches, release RAISE and if equipped, LIP EXTEND buttons. The leveler will lower to the below dock position with the lip positioned between the face of the loading dock and the truck/trailer bed. See figure See Storing Leveler. NOTES: a. Levelers without Automatic Return to Dock (ARTD) If the truck/trailer departs, the leveler will move to its lowest position and the lip will fall to the pendant position inside the dock bumpers. See Storing Leveler. FIGURE 6 - END LOAD OPERATION 8 Pub. No April 2012

21 NOTES: a. If the lip extended too far, quickly push and release the RAISE button to slightly retract the lip. b. If the lip was not extended far enough and hits the lip supports, repeat this step allowing the lip to extend farther. RITE-HITE RHH50 Dock Leveler Owner s Manual OPERATION INSTRUCTIONS (Continued) STORING LEVELER 1. To store the leveler, push and hold the RAISE button until leveler is about 6 inches above dock level and lip is fully pendant. 2. Release RAISE button. Leveler will lower to dock level with lip resting in the lip supports. See figure For units with Safe-T-Lip, if equipped, pull and hold the End Load Leg Chain as the leveler lowers for below dock end loads. See figure 7. DO NOT pull chain for dock level end loads. 4. When loading/unloading is complete, continue with normal operation or return the leveler to stored position. See Storing Leveler. NOTE: On Powered 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 stored position without operator assistance. End Load Leg Chain FIGURE 7 - END LOAD OPERATION (EQUIPPED WITH SAFETY LEGS) FIGURE 8 - LEVELER STORED Pub. No April

22 RITE-HITE RHH50 Dock Leveler Owner s Manual MAINTENANCE PROCEDURES Read and obey these instructions to prevent personal injury. Post safety warnings and barricade work area, at dock level and at ground level, to prevent unauthorized use of the dock position before maintenance has been completed. Make sure to install the maintenance support strut before proceeding with any repair work. Make sure leveler power is disconnected (locked out and tagged out according to OSHA regulations and approved local codes) before performing any welding on the leveler. DO NOT use the MOMENTARY PAUSE button as an Emergency Stop or maintenance tool. SUGGESTED LEVELER MAINTENANCE NOTE: Follow maintenance procedures below as outlined. Include the specific steps for your leveler model. NOTE: Your local RITE-HITE representative provides a Planned Maintenance Program (P.M.P.) which can be fitted to your specific operation. Call your local representative. 5. Inspect all weather seals (if installed) and replace if worn or damaged. 6. Inspect dock bumpers. Four inches (4") of bumper protection is required. Worn, torn, loose or missing bumpers must be replaced. 7. Check conditions of concrete, angles and welds. Repair or replace if necessary. 8. Inspect structure, hinge pins, clevis pins and cotter pins for abnormal wear. 9. 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 adhered to the cover with no signs of peeling or bubbling. Repair or replace if worn or damaged. c. For non-metalic enclosures, breather vent part number may be installed. The vent is NEMA 4X and will not change the enviromental rating of the control box. 10. With the leveler supported by the maintenance strut, check hydraulic fluid level in tank. Add fluid if necessary. Use only Rite-Hite approved hydraulic fluids. Daily 1. Remove debris on and around leveler. Be sure the hinge section of the lip and the platform is clean. 2. Check unit for proper operation. 360 Days 1. Perform Daily and 90-Day Maintenance. 2. Check and tighten control box mounting hardware. 3. Retorque all shoulder bolts on units equipped with Safe-T-Lip. See figure Days 1. Perform all Daily Maintenance. 2. Clean pit. 3. Inspect lip out mechanism (pins, lip lugs, lip cylinder). Replace if worn. 4. Lubricate the leveler with the proper lubricants. See figure Pub. No April 2012

23 RITE-HITE RHH50 Dock Leveler Owner s Manual LUBICATION CHART NOTE: Inside and under slots on Safe-T-Lip. Oil SAE 30 Weight Dry Spray Lubricant Grease NOTE: Apply grease only if zerk fittings are present. NOTE: Check Hydraulic Fluid Level. FIGURE 9 - LEVELER LUBRICATION Safe-T-Lip Shoulder Bolt Torque Specifications Torque Range: Ft-Lbs. FIGURE 10 - SHOULDER BOLT TORQUE Pub. No April

24 RITE-HITE RHH50 Dock Leveler Owner s Manual LEVELER ADJUSTMENTS DO NOT operate leveler with anyone standing on or in front of the lip. NEVER go under the hydraulic leveler platform or lip without installing the Maintenance Support. Make sure that the leveler power is locked out and tagged out according to OSHA regulations and approved local codes. LIPSTOPBOLT The lip stop bolt adjusts the position of the lip when the leveler is stored to allow the lip to be centered on lip supports when stored. NOTE: Lip stop bolt will need to be adjusted on longer lips to allow lip to be centered in the lip keepers. ARTD CAM ADJUSTMENT NOTE: Before continuing be sure the lip stop bolt is properly adjusted. See figure Raise leveler and install a strut securely behind the header or mini-header to allow the lip to hang pendant and rest against the lip stop bolt. 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 12. b. Tighten front collar while holding the 1/16 adjustment. c. Push the rear collar forward as much as possible and tighten. ARTD cam assembly should rotate freely. 3. Run the leveler to test the adjustment. Verify that the lip falls a minimum of 4 before ARTD is initiated. If not, move the cam forward slightly. NOTE: It is not recommended to position the ARTD cam in front of the ARTD limit switch centerline. 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. Lip Stop Bolt Lip In Keepers This Edge Of Cam To Be Positioned 1/16 Behind The Center Of Roller As Shown. Front Washer Front Collar ARTD Cam Rear Collar FIGURE 11 - LIP STOP BOLT 7/8 Ref. C L 1/16 ARTD Cam Adjustment Detail (Shown With Lip Pendant And Lip Stop Bolt Adjusted) ARTD Limit Switch FIGURE 12 - ARTD LIMIT SWITCH 12 Pub. No April 2012

25 RITE-HITE RHH50 Dock Leveler Owner s Manual LEVELER ADJUSTMENTS (Continued) Adjustments to be completed by trained technician only. SHUTTLE VALVE ADJUSTMENT (Controls Leveler Descent) NOTE: Check oil level before making any adjustments. 1. Leveler must be adjusted to lower, from full raised position with lip extended to the header stops in less than 13 to 18 seconds. 2. Remove protective cap and O-ring. Loosen locknut without turning valve body or adjustment screw. Turn adjustment screw to vary platform lowering speed. Adjustments should be no more than 1/8 turn increments. 3. Turn adjustment screw counterclockwise to decrease the lowering speed of platform (excessive loosening can eliminate platform lowering). 4. Turn adjustment screw clockwise to increase the lowering speed of platform (velocity fuse may lock-up as a result of increased platform speeds while lowering). 5. Tighten locknut without turning valve body or adjustment screw. 6. Reinstall o-ring and protective cap and tighten cap. 7. Re-test the unit several times to verify the setting. SEQUENCE VALVE ADJUSTMENT (Controls Lip Extension) NOTE: Check oil level before making any adjustments. 1. Leveler must be adjusted to extend the lip in 3 to 4 seconds. 2. Remove protective cap and O-ring. Loosen locknut without turning valve body or adjustment screw. Turn adjustment screw to vary lip extension speed. Adjustments should be no more than 1/8 turn increments. 3. Turn adjustment screw clockwise to decrease the speed the lip will extend. (If the lip begins to extend at any time before the platform has fully raised, the Sequence Valve setting is too low.) 4. Turn adjustment screw counterclockwise to increase the speed the lip will extend. (When the leveler is fully raised and the lip does not extend, the Sequence Valve is set too high.) 5. Tighten locknut without turning valve body or adjustment screw. 6. Reinstall o-ring and protective cap and tighten cap. 7. Re-test the unit several times to verify the setting. Ramp Cylinder Port 19/32" - Preset Lip Cylinder Port 1/2" - Preset Check Valve (P.T.C.) 6 Threads Infinite Lip Control (IFC) Valve Shuttle Valve Cylinder Return Port (On Tank) Sequence Valve Check Valve (P.O.) Relief Valve 6 Threads FIGURE 13 - POWER UNIT END HEAD Pub. No April

26 RITE-HITE RHH50 Dock Leveler Owner s Manual TROUBLESHOOTING Problem Probable Cause Solution 1. Platform does not raise a. Power has been disconnected. a. Verify that power has not been disconnected. Verify that disconnect circuit breaker or fuses are not tripped. b. The motor has been miswired. b. Verify that the motor has been wired according to the motor wiring diagram. c. Overload tripped. c. Push RESET on overload relay. d. Debris is lodged on or around d. Check for and remove any lodged the leveler. materials on or around the leveler. e. Hydraulic fluid level is low. e. Check oil level when the unit is held open with the maint. support. Refill if necessary. 2. Leveler runs continuously. a. The pushbutton, contact block a. Repair or replace components. or motor contactor damaged. 3. Lip extends slowly and/or does not a. Debris on lip hinge. a. Remove debris from the lip hinge. extend. b. Lip impacted or bent. b. Lubricate per maintenance procedures or replace lip. c. Hydraulic fluid level low. c. Check oil level when unit is held open with the maint. support. Refill if necessary. 4. Platform does not lower. a. Velocity fuse has locked up. a. Attempt to raise the unit to unlock the velocity fuse. b. Debris is lodged on or around b. Check and removed any lodged the leveler. debris on or around leveler. 5. Platform raises very slowly. a. Weight on top of platform. a. Remove weight from platform. b. Hydraulic fluid level is low. b. Check oil level when the unit is held open with the maint. support. Refill if necessary. c. Low voltage c. Verify ± 10% nominal voltage while unit is running. d. Power unit/pump/motor failure. d. Replace power unit assembly. 6. Lip does not store properly. a. The lip stop bolt is not adjusted a. Verify that the lip stop bolt is properly properly. adjusted. b. Debris. b. Remove debris. c. Lip supports. c. Repair or replace the lip supports. 7. Fuse or circuit breaker trips. a. Undersized fuse or circuit a. Verify 25 amp for 120VAC/1PH and breaker. 10 amp for 240VAC/1PH. b. Low voltage. b. Verify ± 10% nominal voltage while unit is running. c. Short circuit in wiring. c. Check wiring connections and verify. d. Wire gage is to small. Distance d. Verify minimum wire gage per is too long. distance is correct. See chart on page Pub. No April 2012

27 RITE-HITE RHH50 Dock Leveler Owner s Manual ELECTRICAL WIRING CHARTS Full Motor Load (Amps) Voltage / Phase / Hertz 1HP Motor / 1 / / 1 /50/ / 3 / / 3 / 50/ / 3 / / 3 / Minimum Wire Size Chart for Various Line Lengths and Line Loads Line Length ( In Feet ) /1 1HP /1 1HP /3 1HP /3 1HP /3 1HP /3 1HP Pub. No April

28 (-) (+) RT RITE-HITE RHH50 Dock Leveler Owner s Manual ELECTRICAL SCHEMATICS FROM CUSTOMER MAIN POWER & SAFETY PROTECTION DEVICE v. 1PH. 60HZ. USE 25.0A DUAL ELEMENT TIME DELAY FUSES SEE NOTE 3 L1 1FU1 1L1 1L1 1L1(BK) 1MCR 1OL T1 LEVELER MOTOR-1 H.P. (SEE MOTOR FLA CHART) 3450 RPM, 115v. 1 PH. 50/60 Hz. (THERMALLY PROTECTED WITH AUTOMATIC RESET) 102 N DUMMY N N N(WH) M BLU ORG BRN RED WHT YEL BLK G FUSED DISCONNECT (BY OTHERS) SEE NOTE 9 #12GA. MIN., 90 C T2 SEE NOTE 3 G T1 T2 105 SEE NOTE FU1 H2(RD) 1L1(BK) N(WH) 0.5A 250V DUAL ELM TD 110 "EMERGENCY STOP" H2(RD) H2A(RD) PB3 "RAISE" H2B(RD) ESB INTERFACE RELAYS CR1-1 (A1) (A2) 120VAC N(WH) E-STOP CIRCUIT 111 H3(RD) CR1-1 H2A(RD) CR1-2 H2B(RD) CR1-2 N(WH) (14) H3(RD) H5(RD) (11) H5(RD) H5 (11) (14) LS2 "DOOR INTERLOCK" (4) TERMINAL BLOCK JUMPER (3) H5A H5A(RD) (A1) (A2) 120VAC (A1) 1MCR 70VA JMPR (95) (A2) 1OL (96) N(WH) LEVELER CONTROLS 115 H5B(RD) G N.O. SHOWN WITH DOOR CLOSED. H5B(RD) H3(RD) H4A(RD) PB1 TO DOK-LOK CONTROL BOX FOR RESTRAINT INTERCONNECT "LIP OUT" H4(RD) H4 LS1 "ARTD LIMIT SWITCH" 4(BLK) G 12(WHT) N.O. H ~ ~ V L S1 6 TMR1: SINGLE SHOT N(WH) ARTD CIRCUIT H3(RD) CONTACT BLOCK IS N.O. WHEN E-STOP IS NOT REQUIRED PB2 H7(RD) H7 7 (BLK) SOLENOID 1 LIP OUT 120 VAC, 0.3 AMPS X2 (WHT) X2/N N(WH) LIP OUT CIRCUIT 122 H3(RD) H3 (MAINTENANCE PENDANT TERMINAL) 1. REFER ALL INSTALLATION AND SERVICE TO QUALIFIED PERSONNEL. 2. INCOMING POWER FIELD WIRING - SEE MINIMUM WIRE SIZE CHART 3. POWER FROM DISCONNECT TO CONTROL BOX AND LEVELER MOTOR FIELD WIRING TO BE MINIMUM #10GA. 60 /75 C COPPER WIRE, INSULATED SUFFICIENTLY FOR INCOMING VOLTAGE. 4. ALL CONTROL FIELD WIRING TO BE MINIMUM #14GA. 60 /75 C COPPER WIRE ONLY, INSULATED SUFFICIENTLY FOR INCOMING VOLTAGE. 5. ALL INTERNAL CONTROL BOX WIRING TO BE #16GA. MINIMUM, 90 C, RED COPPER WIRE UNLESS OTHERWISE NOTED, INSULATED SUFFICEINTLY FOR INCOMING VOLTAGE. 6. TORQUE REQUIREMENTS: CONTACTOR: LB-IN (MIN-MAX) OVERLOAD RELAY: 16 LB-IN GROUND TERMINAL: 35 LB-IN TERMINAL BLOCK: LB-IN (MIN-MAX) 7. LS1 PROVIDED BY RITE-HITE WITH LEVELER FOR ARTD. LS2 PROVIDED BY RITE-HITE OR OTHERS FOR OVERHEAD DOOR. 8. SEE OWNERS MANUAL FOR COMPLETE OPERATING INSTRUCTIONS. 9. FUSED DISCONNECT NOTES: - FUSED DISCONNECT IS NOT PROVIDED BY RITE-HITE PRODUCTS CORPORATION. FUSED DISCONNECT MUST BE PROVIDED BY OTHERS AND INSTALLED PER LATEST EDITION OF UL508A AND NEC REQUIREMENTS. - 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] 10. LEGEND: DENOTES WIRE CONNECTIONS THRU TERMINAL BLOCK. DENOTES FIELD WIRES. DENOTES WIRE NUT CONNECTION DENOTES MALE/FEMALE PLUG CONNECTION FIGURE 14 - ELECTRICAL SCHEMATIC - 120V./60HZ. SINGLE PHASE 16 Pub. No April 2012

29 (-) (+) RT RITE-HITE RHH50 Dock Leveler Owner s Manual ELECTRICAL SCHEMATIC (Continued) FROM CUSTOMER MAIN POWER & SAFETY PROTECTION DEVICE v. 1PH. 50/60HZ. USE 10.0A DUAL ELEMENT TIME DELAY FUSES SEE NOTE 3 L1 1FU1 1L1 1L1 1L1(BK) 1MCR 1OL T1 LEVELER MOTOR-1 H.P. (SEE MOTOR FLA CHART) 3450 RPM, 230v. 1 PH. 50/60 Hz. (THERMALLY PROTECTED WITH AUTOMATIC RESET) 102 L2 1FU2 1L2 1L2 1L2(BK) M BLU ORG RED WH BRN YEL BLK G FUSED DISCONNECT (BY OTHERS) SEE NOTE 9 #12GA. MIN., 90 C T2 SEE NOTE 3 G T1 T2 2FU1 2FU2 TRANSFORMER PRIMARY FUSING 1.0 AMP. 600v. CLASS CC REJ DUAL ELM TD 105 2L1 230v. 2L2 (H1) (H3) (H2) (H4) 106 CAUTION 107 TRANSFORMER FOR HYDRAULIC LEVELER CONTROLS ONLY! DO NOT USE TO POWER AUXILIARY EQUIPMENT. 50VA 0.5 AMP. 250v. DUAL ELM TIME DELAY 108 H2(RD) (X1) 10FU1 (X2) 120v. #12GA. MINIMUM, GREEN X2(WH) "EMERGENCY STOP" H2(RD) H2A(RD) PB3 "RAISE" H2B(RD) ESB INTERFACE RELAYS CR1-1 (A1) (A2) 120VAC X2(WH) E-STOP CIRCUIT 111 H3(RD) CR1-1 CR1-2 CR1-2 H2A(RD) H2B(RD) X2(WH) H3(RD) (14) H5(RD) (11) H5(RD) H5 (11) (14) LS2 "DOOR INTERLOCK" (4) TERMINAL BLOCK JUMPER (3) H5A H5A(RD) (A1) (A2) 120VAC (A1) 1MCR 70VA JMPR (95) (A2) 1OL (96) X2(WH) LEVELER CONTROLS 115 H5B(RD) G N.O. SHOWN WITH DOOR CLOSED. H5B(RD) H3(RD) H4A(RD) PB1 TO DOK-LOK CONTROL BOX FOR RESTRAINT INTERCONNECT "LIP OUT" H4(RD) H4 LS1 "ARTD LIMIT SWITCH" 4(BLK) G 12(WHT) N.O. H ~ ~ V L S1 6 TMR1: SINGLE SHOT X2(WH) ARTD CIRCUIT H3(RD) CONTACT BLOCK IS N.O. WHEN E-STOP IS NOT REQUIRED PB2 H7(RD) H7 7 (BLK) SOLENOID 1 LIP OUT 120 VAC, 0.3 AMPS X2 (WHT) X2/N X2(WH) LIP OUT CIRCUIT 122 H3(RD) H3 (MAINTENANCE PENDANT TERMINAL) 1. REFER ALL INSTALLATION AND SERVICE TO QUALIFIED PERSONNEL. 2. INCOMING POWER FIELD WIRING - SEE MINIMUM WIRE SIZE CHART 3. POWER FROM DISCONNECT TO CONTROL BOX AND LEVELER MOTOR FIELD WIRING TO BE MINIMUM #14GA. 60 /75 C COPPER WIRE, INSULATED SUFFICIENTLY FOR INCOMING VOLTAGE. 4. ALL CONTROL FIELD WIRING TO BE MINIMUM #14GA. 60 /75 C COPPER WIRE ONLY, INSULATED SUFFICIENTLY FOR INCOMING VOLTAGE. 5. ALL INTERNAL CONTROL BOX WIRING TO BE #16GA. MINIMUM, 90 C, RED COPPER WIRE UNLESS OTHERWISE NOTED, INSULATED SUFFICEINTLY FOR INCOMING VOLTAGE. 6. TORQUE REQUIREMENTS: CONTACTOR: LB-IN (MIN-MAX) OVERLOAD RELAY: 16 LB-IN GROUND TERMINAL: 35 LB-IN TERMINAL BLOCK: LB-IN (MIN-MAX) 7. LS1 PROVIDED BY RITE-HITE WITH LEVELER FOR ARTD. LS2 PROVIDED BY RITE-HITE OR OTHERS FOR OVERHEAD DOOR. 8. SEE OWNERS MANUAL FOR COMPLETE OPERATING INSTRUCTIONS. 9. FUSED DISCONNECT NOTES: - FUSED DISCONNECT IS NOT PROVIDED BY RITE-HITE PRODUCTS CORPORATION. FUSED DISCONNECT MUST BE PROVIDED BY OTHERS AND INSTALLED PER LATEST EDITION OF UL508A AND NEC REQUIREMENTS. - 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] 10. LEGEND: DENOTES WIRE CONNECTIONS THRU TERMINAL BLOCK. DENOTES FIELD WIRES. DENOTES WIRE NUT CONNECTION DENOTES MALE/FEMALE PLUG CONNECTION FIGURE 15 - ELECTRICAL SCHEMATIC V. 50/60HZ. SINGLE PHASE Pub. No April

30 (-) (+) RT RITE-HITE RHH50 Dock Leveler Owner s Manual ELECTRICAL SCHEMATIC (Continued) FROM CUSTOMER MAIN POWER & SAFETY PROTECTION DEVICE v. 3PH. 60HZ. USE 6.0A DUAL ELEMENT TIME DELAY FUSES v. 3PH. 50/60HZ. USE 4.0A DUAL ELEMENT TIME DELAY FUSES v. 3PH. 60HZ. USE 4.0A DUAL ELEMENT TIME DELAY FUSES 575v. 3PH. 60HZ. USE 4.0A DUAL ELEMENT TIME DELAY FUSES L1 L2 1FU1 1FU2 1L1 1L2 SEE NOTE 3 1L1 1L2 ONE LEVELER PER OVERLOAD PROTECTION DEVICE. [REFERENCE LATEST EDITION OF NEC, SECTION 430] 1MCR 1OL SEE NOTE 3 T1 T2 M LEVELER MOTOR-1 H.P. (SEE MOTOR FLA R.P.M. 240v. 3 PH. 60 Hz. T1 T2 T CONNECT T1, T2, T3 TO TERMINALS 1, 2, 3. IF ROTATION IS WRONG, REVERSE ANY 2 LINES. LEVELER MOTOR-1 H.P. (SEE MOTOR FLA R.P.M. 380v. 3 PH. 50/60 Hz. T1 T2 T CONNECT T1, T2, T3 TO TERMINALS 1, 2, 3. IF ROTATION IS WRONG, REVERSE ANY 2 LINES L3 1FU3 G FUSED DISCONNECT (BY OTHERS) SEE NOTE 9 1L3 1L3 #16GA. MIN., 90 C, BLACK, COPPER WIRE 2FU1 2L1 2FU2 TRANSFORMER PRIMARY FUSING: CLASS CC REJ DUAL ELM TD v. USE 1.0 AMP. 600v v. USE 0.5 AMP. 600v. 575v. USE 0.4 AMP. 600v. 2L2 T3 G LEVELER MOTOR-1 H.P. (SEE MOTOR FLA R.P.M. 480v. 3 PH. 60 Hz. T1 T2 T LEVELER MOTOR-1 H.P. (SEE MOTOR FLA R.P.M. 575v. 3 PH. 60 Hz. T1 T2 T (H1) CAUTION TRANSFORMER FOR HYDRAULIC LEVELER CONTROLS ONLY! DO NOT USE TO POWER AUXILIARY EQUIPMENT. (H3) (H2) (H4) 50VA 0.5 AMP. 250v. DUAL ELM TIME DELAY CONNECT T1, T2, T3 TO TERMINALS 1, 2, 3. IF ROTATION IS WRONG, REVERSE ANY 2 LINES. CONNECT T1, T2, T3 TO TERMINALS 1, 2, 3. IF ROTATION IS WRONG, REVERSE ANY 2 LINES. 108 H2(RD) (X1) 10FU1 (X2) 120v. #12GA. MINIMUM, GREEN X2(WH) "EMERGENCY STOP" H2(RD) H2A(RD) PB3 "RAISE" H2B(RD) ESB INTERFACE RELAYS CR1-1 (A1) (A2) 120VAC X2(WH) E-STOP CIRCUIT 111 H3(RD) CR1-1 CR1-2 CR1-2 H2A(RD) H2B(RD) X2(WH) H3(RD) (14) H5(RD) (11) H5(RD) H5 (11) (14) LS2 "DOOR INTERLOCK" (4) TERMINAL BLOCK JUMPER (3) H5A H5A(RD) (A1) (A2) 120VAC (A1) 1MCR 70VA JMPR (95) (A2) 1OL (96) X2(WH) LEVELER CONTROLS 115 H5B(RD) G N.O. SHOWN WITH DOOR CLOSED. H5B(RD) H3(RD) H4A(RD) PB1 TO DOK-LOK CONTROL BOX FOR RESTRAINT INTERCONNECT "LIP OUT" H4(RD) H4 LS1 "ARTD LIMIT SWITCH" 4(BLK) G 12(WHT) N.O. H ~ ~ V L S1 6 X2(WH) TMR1: SINGLE SHOT ARTD CIRCUIT H3(RD) CONTACT BLOCK IS N.O. WHEN E-STOP IS NOT REQUIRED PB2 H7(RD) H7 7 (BLK) SOLENOID 1 LIP OUT 120 VAC, 0.3 AMPS X2 (WHT) X2/N X2(WH) LIP OUT CIRCUIT 122 H3(RD) H3 (MAINTENANCE PENDANT TERMINAL) 1. REFER ALL INSTALLATION AND SERVICE TO QUALIFIED PERSONNEL. 2. INCOMING POWER FIELD WIRING - SEE MINIMUM WIRE SIZE CHART 3. POWER FROM DISCONNECT TO CONTROL BOX AND LEVELER MOTOR FIELD WIRING TO BE MINIMUM #14GA. 60 /75 C COPPER WIRE, INSULATED SUFFICIENTLY FOR INCOMING VOLTAGE. 4. ALL CONTROL FIELD WIRING TO BE MINIMUM #14GA. 60 /75 C COPPER WIRE ONLY, INSULATED SUFFICIENTLY FOR INCOMING VOLTAGE. 5. ALL INTERNAL CONTROL BOX WIRING TO BE #16GA. MINIMUM, 90 C, RED COPPER WIRE UNLESS OTHERWISE NOTED, INSULATED SUFFICEINTLY FOR INCOMING VOLTAGE. 6. TORQUE REQUIREMENTS: CONTACTOR: LB-IN (MIN-MAX) OVERLOAD RELAY: 16 LB-IN GROUND TERMINAL: 35 LB-IN TERMINAL BLOCK: LB-IN (MIN-MAX) 7. LS1 PROVIDED BY RITE-HITE WITH LEVELER FOR ARTD. LS2 PROVIDED BY RITE-HITE OR OTHERS FOR OVERHEAD DOOR. 8. SEE OWNERS MANUAL FOR COMPLETE OPERATING INSTRUCTIONS. 9. FUSED DISCONNECT NOTES: - FUSED DISCONNECT IS NOT PROVIDED BY RITE-HITE PRODUCTS CORPORATION. FUSED DISCONNECT MUST BE PROVIDED BY OTHERS AND INSTALLED PER LATEST EDITION OF UL508A AND NEC REQUIREMENTS. - 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] 10. LEGEND: DENOTES WIRE CONNECTIONS THRU TERMINAL BLOCK. DENOTES FIELD WIRES. DENOTES WIRE NUT CONNECTION DENOTES MALE/FEMALE PLUG CONNECTION FIGURE 16 - ELECTRICAL SCHEMATIC - 3 PHASE 18 Pub. No April 2012

31 RITE-HITE RHH50 Dock Leveler Owner s Manual NOTES Pub. No April

32 H5A A H10 N H5A A H10 N RITE-HITE RHH50 Dock Leveler Owner s Manual REPLACEMENT PARTS - CONTROL BOX 2 3 4, 5, , ,15,16,17, 18,19, TOP TOP 23 1 TOP 1 NC 2 1 NC 2 3 NO NC 2 3 NO 4 H3 10FU 1 1L1 H4 H4 H4 H7 H7 H7 H5 H5 H5 H9 H9 X2/N X2/N H3 H3 1L1 1L1 1L2 1L2 L1 A2 95 AMP + T1 L2 96 T2 L3 T OUTSIDE LEFT 29 OUTSIDE RIGHT 40 INSIDE LEFT 30 INSIDE RIGHT FIGURE 17 - CONTROL BOX ASSEMBLY 20 Pub. No April 2012

33 RITE-HITE RHH50 Dock Leveler Owner s Manual CONTROL BOX REPLACEMENT PARTS LIST Item Qty. Description Part Number 1 1 Control Box Complete 178.xxx 2 1 Control Box Enclosure 187.xxx 3 1 Push Button Operator (22.5MM) Red, N12/N Push Button Operator (22.5MM) Red, N4X Contact Block Mounting Latch Contact Block, Black, NO Contact Block, Black, NC Push Button Operator (22.5MM) Black, N12/N Push Button Operator (22.5MM) Black, N4X Emergency Stop Operator (22.5MM), N12/N Emergency Stop Operator (22.5MM), N4X Ground Lug Fuse Holder A Fuse, 250V Slo-Blow (Installed Without Transformer) Terminal Jumper Disconnect Plug Assembly Red Terminal Block - Control Circuit Red Terminal Block With Plug - Control Circuit Black Terminal Block, 600V, 50A (1L1/ 1L2) - Incoming Power Black Terminal Block - Control Circuit White Terminal Block, 600V, 50A (N) - Incoming Power White Terminal Block - Control Circuit End Anchor Terminal Block Mounting Din Rail Back Panel, Drilled, 10 x Leveler Motor Contactor, 3Ph, 9A 120VAC Coil, W/ XFMR Leveler Motor Contactor, 3Ph, 16A 120VAC Coil, 1PH - BASE Leveler Overload Relay, 230/380/460/575/3PH Leveler Overload Relay, 230/1/50/ Leveler Overload Relay, 120/1/ Leveler Control Fuse, 0.5A 250V Dual Element Transformer Primary Fuse, 0.5A CC Rej. Dual Element V Transformer Primary Fuse, 0.5A CC Rej. Dual Element V Transformer Primary Fuse, 0.5A CC Rej. Dual Element 575V Single Shot Time, ARTD E-Stop Relay - HYDRA-RITE TM Decal Lockout/Tagout Corrosion Pad Timer Mounting Bracket Transformer, 50VA 240/480V Transformer, 50VA 380V Transformer, 50VA 575V Ground Harness Decal E-Stop Overlay Decal Control Box - W/IFC Decal Control Box - W/O IFC Decal Fuse Replacement W/O Transformer Decal Fuse Replacement W/ Transformer Decal UL/ULC - Consult Rite-Hite Decal Voltage/Phase/FLA 188.xxx 39 1 Decal Operation W/O IFC Decal Operation W/ IFC Decal Electrical Schematic - Pub. No April

34 RITE-HITE RHH50 Dock Leveler Owner s Manual NOTES 22 Pub. No April 2012

35 RITE-HITE RHH50 Dock Leveler Owner s Manual HYDRAULIC SCHEMATIC RAMP CYLINDER 4" BORE LIP CYLINDER 2.5" BORE X 6" STROKE VELOCITY FUSE 7 GPM LIP RAMP RETURN.063 DIA N.O. VALVE (OPTION) SEQUENCE VALVE 1000 PSI SHUTTLE VALVE P.O. CHECK RELIEF VALVE 1200 PSI.109 DIA M MOTOR / PUMP PSI FIGURE 18 - HYDRAULIC SCHEMATIC Pub. No April

36 RITE-HITE RHH50 Dock Leveler Owner s Manual REPLACEMENT PARTS - HYDRAULICS , , 5, , 28, 26, 29 7, FIGURE 19 - HYDRAULIC ASSEMBLY PARTS AND ROUTING , 26, 29 FIGURE 20 - POWERUNIT AND IFC PARTS 24 Pub. No April 2012

37 RITE-HITE RHH50 Dock Leveler Owner s Manual HYDRAULICS REPLACEMENT PARTS LIST Item Qty. Description Part Number 1 1 Powerunit / V 1PH 50/60HZ 1HP RLF(1200PSI) Powerunit Assy. SPX 110/240V/1PH IFC(110V) Powerunit / V 3PH 50/60HZ 1HP RLF(1200PSI) Powerunit Assy. SPX 240/460V/3PH IFC(110V) Powerunit /575V 3PH 50/60HZ 1HP RLF(1200PSI) Powerunit Assy. SPX 575V/3PH IFC(110V) Cylinder Hydraulic 4 x Length SA 2Port See Below 3 1 Pin Clevis x 4.000L ZP Pin Clevis 1.25 x 4.625L 2Hole Pin Cotter.188 DIA. x 1.50L ZP CYL HYD 2.5 BR x 6 STR 2Port Pin Clevis x ZP Washer Flat 1.00 SAE ZP Lip Cyl.. Hose Assy..25 4FJS (6 Long) Lip Cyl.. Hose Assy..25 4FJS (8, 10 & 12 Long) Ramp Cyl. Hose Assy FJS 6FJS (6 Long) Ramp Cyl. Hose Assy FJS 6FJS (8, 10 & 12 Long) Elbow 90 #8 MAORB Fuse Velocity 7 GPM #8 FORB #8 MJ Elbow 90 #8 MJ #8 FJS Elbow 90 L #4 MAORB #4 MJ Elbow MP.25 HB Elbow 90 L #6 MAORB #6 MJ Decal Oil Hyd. BIO FL(85+%) Hose.25ID (Bulk) Fitting Y.25BARB Fitting STRT.38NPT.25BARB System Relief Valve Shuttle Valve Sequence Valve Check Valve - Pilot To Open Check Valve - Pilot To Close Tank Seal / O-Ring (Not Shown) Oil Tank Cap Oil Tank Oil Tank Screws Valve SPL DACT 2W 2P NO SAE8 (IFC Option Only) Solenoid Coil 115/1(IFC Option Only) Hirschmann Connector Assy. (IFC Option Only) Oil Tank Plug CAP Wall J CAP.188 WALL L/ M CAP.25 WALL RAMP CYLINDER USAGE CHART (Item 2) Frame Depth LEVELER LENGTH 6' Long 80" Long 8' Long 10' Long 12' Long 20" 14" " " " " " 16" " " " " " W/ ADS N/A 23" " " 14" " " " " " 16" " " " " " W/ ADS N/A 23" " Pub. No April

38 RITE-HITE RHH50 Dock Leveler Owner s Manual REPLACEMENT PARTS - LEVELER ASSEMBLY , 43, LH 36 RH LH 40 RH LH 38 RH FIGURE 21 - LEVELER ASSEMBLY 26 Pub. No April 2012

39 RITE-HITE RHH50 Dock Leveler Owner s Manual LEVELER ASSEMBLY REPLACEMENT PARTS LIST Item Qty. Description J Cap. P/N L/M Cap. P/N 1 1 Frame Weldment Consult Factory 2 1 Platform Weldment Consult Factory 3 1 Safe-T-Lip Assembly Consult Factory Safe-T-Lip Assembly W/Slot Cover Consult Factory 4 1 Safe-T-Lip Plate Consult Factory Safe-T-Lip Plate For Slot Cover Consult Factory 5 6 Spool Module OD Spool Module OD Shoulder Bolt 1.25 DIA Grease Fitting (Not Shown) Spool Module OD Lip Lug Mount Spool Module OD Lip Lug Mount Lip Lug (Safe-T-Lip) Bolt x 2L Hex ZP Washer Split LK.75 DIA Heavy ZP Plate Slot Cover Slot Cover Opt. (Not Shown) Screw x 1 SQ NK G5 ZP Slot Cover Opt. (Not Shown) Nut Nylock Mach. ZP Slot Cover Opt. (Not Shown) Lip Weldment 1" Thick Consult Factory 16 2 Pin Clevis.875 x 13L Pin Clevis.875 x 13L Stainless Steel Pin Lip Hinge or 1.42 x 34.88L (6' Wide) 774d d101 Pin Lip Hinge or 1.42 x 34.88L (6' Wide) Stainless Steel 776d d101 Pin Lip Hinge or 1.42 x 38.75L (6.5' & 7' Wide) 774d d102 Pin Lip Hinge or 1.42 x 38.75L (6.5' & 7' Wide) Stainless Steel 776d d Pin Cotter.188 DIA. x 1.50L ZP Busing Machine 1.50 OD x 1.00 ID x.134 THK ZP Washer Flat 1" SAE ZP Pin Tension.25 DIA. ZP Bolt Hex UNC ZP Nut Hex GR5 ZP Washer Split Lock.75 DIA Heavy ZP Power Unit 1HP RLF(1200PSI) See Pages Screw x 1L Hex GR5 ZP Washer.31 Flat ZP Nut NYLK FLG ZP Cylinder Hydraulic 4" Bore SA 2PORT See Pages Pin Clevis 1.25 x 4L 2Hole ZP Pin Clevis 1.25 x 4.625L 2Hole ZP Cylinder Hydraulic 2.5" Bore x 6 Stroke 2Port Pin Clevis 1 x 3.625L ZP Decal Oil Hyd. Bio. FL(85+%) Toeguard Assembly And Parts See Page Bolt x 1L Hex G5 ZP Washer Flat.38 ZP Nut Nylock UNC ZP Safe-T-Strut See Page Chain Assembly - Safe-T-Strut Decal Serial/Model Leveler (Rite-Hite) Decal Patent Oil Hydraulic MIL - Measured By Quarts Oil Hydraulic BIO- Measured By Quarts Decal Sheet Ties Wire Nylock BLK 13.50L Ring Retaining External (E).875OD Pub. No April

40 RITE-HITE RHH50 Dock Leveler Owner s Manual REPLACEMENT PARTS - LEVELER ASSEMBLY (Continued) , 43, LH 36 RH LH 40 RH LH 38 RH FIGURE 21 - LEVELER ASSEMBLY 28 Pub. No April 2012

41 RITE-HITE RHH50 Dock Leveler Owner s Manual LEVELER ASSEMBLY REPLACEMENT PARTS LIST Leveler Length Item Qty. Description 6 Long 80 / 8 Long 10 Long 12 Long 35 1 Toeguard Assy. 2FAN LH 755d d d d102 Toeguard Assy. 3FAN LH 759d d Toeguard Assy. 2FAN RH (Not Shown) 754d d d d102 Toeguard Assy. 3FAN RH (Not Shown) 758d d Toeguard Fan Ext..075 x 12 LH (3 Fan Only) 752d d Toeguard Fan Ext..075 x 12 RH (3 Fan Only) 752d d Toeguard Fan Full.075 x 12 RH 756d d d d Toeguard Fan Full.075 x 12 LH (Not Shown) 756d d d d Toeguard Fan Extd. 14GA x 11 1Slot 416d d d d101 REPLACEMENT PARTS - SAFE-T-STRUT (From Page 27) RHH50 - J Capacity L (52.75 ) (55 ) 80L (55 ) (60.75 ) 8L (57 ) (60.75 ) 10L (55 ) (60.75 ) 12L (57 ) (60.75 ) RHH50 - L or M Capacity L (52.75 ) (55 ) 80L (53.75 ) (60.75 ) 8L (58.5 ) (60.75 ) 10L (55 ) (60.75 ) 12L (57 ) (60.75 ) Pub. No April

42 RITE-HITE RHH50 Dock Leveler Owner s Manual REPLACEMENT PARTS - AUTOMATIC RETURN TO DOCK FIGURE 22 - AUTOMATIC RETURN TO DOCK (ARTD) PARTS Item Qty. Description Part No. 1 1 Lip Cylinder, Single Acting Clevis Pin, 1.00Dia. x 3.625L ZP Hd. Clevis Pin, 1 x 3.531L ZP Mtg. Bracket HD17/HL Starp Loop.05THK.5ID Cotter Pin.12DIA x 1.5L Guide Rod Shoulder Bolt w/pel.313 x.38 x ZP Flange Bushing.375 x.50 x.50l Retainer Clip.50 Dia Collar Shaft 3/8ID x 7/8OD Blk Flat Washer 3/8ID x 7/8OD 18-8 SS Cam Pivot Tube 3.156L Rotory Cam 3.125L Counter Weight Plate 3.125L Sht. Metal Screws #4 x.375l Limit Switch Assembly Bolt Hex UNC x.75 Gr5 ZP Washer.25 LK MED ZP Bolt.25-20UNC.5L HHCS ZP Cotter Pin.19 X 1.5 ZP Pub. No April 2012

43 RITE-HITE RHH50 Dock Leveler Owner s Manual REPLACEMENT PARTS - ENDLOAD LEGS FIGURE 23 - ENDLOAD LEG ASSEMBLY Item Qty. Description Part Number 1 1 Linkage Endload Leg HGT Loop Anchor 3L (Not Shown) Chain Assembly Lanyard Twist #1/0 ZP 510dXXX 4 3 S-Hook.219 Wire Extension Spring.654 OD Wire (.0915Dia.) Chain Assembly ELL To Lip Lug 7.25L Pub. No April

44 RITE-HITE STANDARD WARRANTY RITE-HITE warrants that its products will be free from defects in design, materials, and workmanship for a period of 365 days from the date of shipment. All claims for breach of this warranty must be made within 30 days after the defect is or can, with reasonable care, be detected and in no event no more than 30 days after the warranty has expired. In order to be entitled to the benefits of this warranty, the products must have been properly installed, maintained, and operated within their rated capacities and/or specified design parameters, and not otherwise abused. Periodic lubrication and adjustment is the sole responsibility of the owner. This warranty is RITE- HITE s exclusive warranty. RITE-HITE EXPRESSLY DISCLAIMS ALL IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS. Non-standard warranties, if any, must be specified by RITE-HITE in writing. In the event of any defects covered by this warranty, RITE-HITE will remedy such defects by repairing or replacing any defective equipment or parts, bearing all the costs for parts, labor, and transportation. This shall be the exclusive remedy for all claims whether based on contract, negligence, or strict liability. LIMITATION OF LIABILITY RITE-HITE SHALL NOT IN ANY EVENT BE LIABLE FOR ANY LOSS OF USE OF ANY EQUIPMENT OR INCI- DENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, WHETHER FOR BREACH OF WARRANTY, NEG- LIGENCE, OR STRICT LIABILITY. Global Sales & Service Office: RITE-HITE 8900 N. Arbon Drive P.O. Box Milwaukee, Wisconsin Phone: Representatives in all Major Cities

45 L O A D I N G D O C K B U M P E R S P R O T E C T Y O U R I N V E S T M E N T Rite-Hite offers the most complete line of dock bumpers to help protect your building and loading dock equipment investment. Your local Rite-Hite Representative will survey your loading dock conditions to determine the most effective bumper design and application for your operation. Important considerations include: Dock approach: level, decline or incline Dock height Air-ride trailers Mounting face conditions Use of yard jockeys Types of trailers serviced Quantity and frequency of trailers

46 L O A D I N G D O C K B U M P E R S D O K S A V E R D O C K B U M P E R Application Maximum dock protection Long-term solution for the most harsh loading dock conditions 10-year limited warranty 1 /2" Steel Full Width, Full Height Back Plate Features/Specifications Completely enclosed box construction uses 1 /2" thick high-carbon steel Designed to withstand 75,000 pounds of pressure Unique design allows dock bumper to float upon impact and eliminates steel rods Rubber Slats Full width and height back plate is included with every DokSaver dock bumper Load pressure is absorbed and distributed over entire back plate 1 /2" Steel Most popular model DOKSAVER dock bumpers BUMPER MODEL PROJECTION A SIZE BxC EST.WEIGHT (LBS.) DS " 12" x 13.5" 58 DSV " 20" x 10.5" 85 DSV " 24" x 10.5" 90 DS " 12" x 13.5" 62 DSV " 20" x 10.5" 90 DSV " 24" x 10.5" 100 Many other models available DokSaver Bumper Cut- Away Side View

47 STR 4100 Dok Lok Vehicle Restraint Owner s Manual part of the SMOOTH TRANSITION DOK SYSTEM TM MADE IN U.S.A. This Manual Covers Restraints Built After Serial Numbers: 09GE and up PRINTED IN U.S.A. RITE HITE PRINT SHOP PUBLICATION NO NOVEMBER 2012

48 RITE HITE STR 4100 DOK LOK Owner s Manual TABLE OF CONTENTS INTRODUCTION SAFETYWARNINGS OWNERS RESPONSIBILITY DEFINITION AND FUNCTION FEATURES OPERATING PROCEDURE MAINTENANCE TROUBLESHOOTING COMPONENTTESTING HORN OVERRIDE CODE VALVE BLOCK ASSEMBLIES ELECTRICALSCHEMATIC STAND ALONE POWER UNIT ELECTRICALSCHEMATIC COMBINATION POWER UNIT HYDRAULIC SCHEMATIC STAND ALONE POWER UNIT HYDRAULIC SCHEMATIC COMBINATION POWER UNIT REPLACEMENTPARTS WARRANTY BACK COVER INTRODUCTION Read and understand this manual before attempting to install or operate any DOK LOK vehicle restraint. For best results, have this product serviced by your authorized Rite Hite representative. The STR 4100 DOK LOK vehicle restraint by Rite Hite is intended to provide a safer workplace for workers in shipping and receiving dock areas. The STR 4100 DOK LOK vehicle restraint is a hydraulic restraint device that, when properly installed and operated, retains a secure connection between the truck and dock. Signal lights and signs provide instructions to the truck driver and DOK LOK vehicle restraint operator that a safe condition exists. The DOK LOK vehicle restraint is operated by pressing push buttons on an inside control panel. PRODUCT SPECIFIC WARRANTY Rite Hite warrants the STR 4100 DOK LOK vehicle restraint for five years parts and labor from date of shipment in accordance with Rite Hite's Standard Warranty Policy. NOTICE TO USER Your local Rite Hite representative provides a Planned Maintenance Program (P.M.P.) which can be fitted to your specific operation. Call your local representative or the Rite Hite at The Rite Hite products in this manual are covered by one or more of the following U.S. patents: 5,271,183; 5,323,503; 5,546,623; 5,553,987; 5,582,498; 5,664,930; 5,702,223; 5,762,459 (RE: 37,570); 5,882,167; 6,065,172; 6,070,283; 6,085,375; 6,092,970; 6,106,212; 6,116,839; 6,190,109; 6,220,809; 6,276,016; 6,311,352; 6,318,947; 6,322,310; 6,360,394; 6,368,043; 6,431,819; 6,488,464; 6,499,169; 6,505,713; 6,524,053; 6,634,049; 6,726,432; 6,773,221; 6,832,403; 6,880,301; 6,892,411; 7,032,267; 7,062,814; 7,134,159; 7,213,285; 7,216,391; 7,363,670; 7,380,305; 7,503,089; 7,533,431; 7,546,655; 7,584,517; 7,681,271; 7,841,823; 7,877,831; 7,823,239; 8,006,811; 8,065,770; 8,141,189 and pending U.S and foreign patent applications. RITE HITE, THINMAN TM, SAFE T LIP, HYDRACHEK, WHEEL LOK TM, DOK LOK, DUAL DOK, SAFE T STRUT TM, DOK COMMANDER, JUMBO TM, HYDRA RITE TM, SAFE T GATE, RITE VU TM LIGHTCOMMUNICATIONSYSTEM and SMOOTH TRANSITION DOK SYSTEM TM, are trademarks of Rite Hite. 2 Pub. No November 2012

49 RITE HITE STR 4100 DOK LOK Owner s Manual SAFETYWARNINGS When working with electrical or electronic controls, make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes. DO NOT OPERATE XXXXXXXXXXXX XXXXXXXXXXX FIGURE 1 LOCKOUT/TAGOUT LOCKOUT/TAGOUT PROCEDURES The Occupational Safety and Health Administration requires that, in addition to posting safety warnings and barricading the work area, the power supply has been locked in the OFF position or disconnected. It is mandatory that an approved lockout device is utilized. An example of a lockout device is illustrated. The proper lockout procedure requires that the person responsible for the repairs is the only person who has the ability to remove the lockout device. In addition to the lockout device, it is also a requirement to tag the power control in a manner that will clearly note that repairs are under way and state who is responsible for the lockout condition. Tagout devices have to be constructed and printed so that exposure to weather conditions or wet and damp locations 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 regulation ). Rite Hite also recommends the review and implementation of an entire safety program for the Control of Hazardous Energy (Lockout/Tagout). These regulations are available through OSHA publication This is the highest level statement. Failure to follow the listed instructions will most likely result in severe injury or death. The statements used with this level of warning deal with a safe operating procedure. If the procedure is ignored, the possibility of personal injury may exist. This is a statement of serious hazard. Failure to follow the listed instructions could place the individual at risk of serious injury or death. IMPORTANT is used to draw attention to a procedure that needs to be followed to prevent machine or property damage. Pub. No November

50 RITE HITE STR 4100 DOK LOK Owner s Manual OWNER RESPONSIBILITY 1. The owner should recognize the inherent danger of the interface between dock and transport vehicle. The owner should, therefore, train and instruct operators in the safe use of dock equipment in accordance with the information provided below. The manufacturer shall publish, provide to the initial purchaser, and make the following information readily available to owners: Installation instructions Recommended initial and periodic inspections procedures Maintenance procedures Operating instructions Descriptions or specifications for replaceable or repairable parts Tables identifying the grade (slope) for all variations of length or configuration of the dock equipment, and Information identifying the maximum uncontrolled drop encountered upon sudden removal of support while within the working range of the equipment. It shall be the responsibility of the owner to verify that the material listed in this section has been received and that it is made available for the instruction and training of presonnel entrusted with the use or maintenance of the dock equipment. 2. When a transport vehicle is parked at a loading dock, it is important that the vehicle is relatively perpendicular to the dock face and in close contact with at least one of the dock bumpers. 3. Nameplates, cautions, instructions, and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended. 4. Manufacturer s recommended periodic maintenance and inspection procedures in effect at date of shipment shall be followed, and written records of the performance of these procedures 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 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 manufacturer shall make available replacement nameplates, caution/instruction labels, and operating/maintenance manuals upon request of the owner. The owner shall see that all nameplates, caution/instruction markings or labels are in place and legible, and that the appropriate operating/maintenance manuals are provided to users. 8. Modifications or alterations of dock equipment shall be made only with written permission of the original manufacturer. These changes shall also satisfy all safety recommendations of the original equipment manufacturer for the particular application of the dock equipment. 9. In order to be entitled to the benefits of the standard product warranty, the dock equipment must have been properly installed, maintained and operated within its rated capacities and/or specific design parameters, and not otherwise abused. 10. It is recommended that trailers equipped with air ride suspensions should remove the air from the suspension to minimize trailer bed drop, prior to loading or unloading. 11. When industrial trucks are driven on and off transport vehicles during the loading and unloading operation, the brakes on the transport vehicle shall be applied and wheel chocks or a positive restraining device shall be engaged. 12. In selecting dock equipment, it is important to consider not only present requirements but also future plans or adverse environments. 4 Pub. No November 2012

51 The STR 4100 DOK LOK vehicle restraint is a hydraulic, self aligning restraint device used to secure trucks and semi trailers with an intact Rear Impact Guard (R.I.G.) to the face of a loading dock. In addition this device, when engaged, limits the vertical motion of the trailer when loading and/or unloading. This is achieved by securing the R.I.G. with a hydraulically positioned steel hook, while support cylinders extend under the carriage to limit vertical motion. This prevents forward movement of the truck/trailer that may create an unsafe void between the face of the dock and the rear end of the truck/trailer as a forklift travels from the loading dock onto the trailer; or to create an obstruction noticeable to the truck driver, should the driver accidentally try to pull the truck/trailer away while it is being serviced. The proper or improper activation of the hook and support function are monitored by: VISUAL CONTROL One set of flashing green or red lights located at the inside of the building for the forklift operator, and one set located outside of the building for the truck driver. In addition to the lights, there are three instruction signs. AUDIO CONTROL Ahorn will sound at the inside of the building, warning the forklift operator if there is not R.I.G. present, or if the engagement is improper. In this case, the trailer must be secured by other means (wheel chokes, etc.) prior to servicing trailer. RITE HITE STR 4100 DOK LOK Owner s Manual DEFINITION AND FUNCTION 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 the building and a flashing green light (trailer free to move to or away from the loading dock) at the outside of the building. Once the trailer is parked, the dock attendant will depress the Lock button. This will raise the hook to engage the R.I.G. and simultaneously extend the support cylinders to support the carriage. As soon as the R.I.G. is properly locked with carriage supported, there will be a simultaneous light change the inside will change from red to green flashing (trailer secured and supported) and the outside will change from green to red flashing (do not move trailer). After the service is complete, the dock attendant will have to depress the Unlock button which then will return the hook and support cylinders to their STORED position. A proper hook engagement is achieved when the hook raises unobstructed to fully trap the horizontal cross member of the R.I.G. Assembly. An improper hook engagement is if the horizontal cross member of the R.I.G. is missing, obstructed or it is bent or located so far toward the rear axle of the trailer that it will prevent the free passage of the hook. At this point, the trailer must be secured by other means (example: wheel chocks) in order to become serviceable. Prerequisite for proper barrier engagement is that the trailer is parked firmly against a 4" (trade standard) thick dock bumper. The activation/deactivation is solely controlled from inside of the building by momentarily depressing either the Lock (raise) button or the Unlock (lower) button. The support cylinders will not be engaged without proper hook engagement. If trailer can not be secured, normal vertical motion of the trailer is to be expected. Pub. No November

52 RITE HITE STR 4100 DOK LOK Owner s Manual FEATURES Refer to Figure 2, page 7 for the locations of the following features: R.I.G. Acronym used for the Federally mandated rear impact guard located on the rear of over the road trailers to prevent accidental underride by automobiles. ROLLER TRACK ASSEMBLY Mounted to the loading dock wall to guide the carriage assembly in a vertical plane and transmit the creep or pull out force from a trailer to the loading dock wall. CARRIAGE ROLLER ASSEMBLY Comprised of a steel roller housing, a pre lubricated bearing to allow easy movement of the carriage assembly. CARRIAGE RETURN SPRINGS AND TUBES Bias the carriage assembly to its upward stored position and to maintain contact with the R.I.G. while servicing a trailer. CARRIAGE ASSEMBLY SLOPE EXTENSION Allows trailers with lower R.I.G. s to be serviced by the DOK LOK vehicle restraint. HOOK Entraps R.I.G. to prevent trailer from rolling/creeping away from the dock. HOOK CYLINDER Provides means of moving the hook between its stored and active positions. SUPPORT CYLINDERS Provides a means to support the underside of the carriage, thus supporting the rear end of trailer. SENSING SWITCHES, CONTROL BOX, OUTSIDE LIGHT BOX AND SIGNAGE Combination of these components is used to control the STR 4100 DOK LOK vehicle restraint and provide audio/visual communications to the dock attendant and trailer driver. CARRIAGE ASSEMBLY Sloped front provides self positioning by the R.I.G. and restrains the trailer once the hook has been activated by the dock attendant. 6 Pub. No November 2012

53 RITE HITE STR 4100 DOK LOK Owner s Manual outside signs inside sign light box control box hook cylinder hook carriage assembly power unit sensing switches carriage roller assembly support cylinders return springs and tubes auxillary manifold slope extension support switch roller track assembly base plate assembly FIGURE 2 STR 4100 DOK LOK VEHICLE RESTRAINT FEATURES Pub. No November

54 RITE HITE STR 4100 DOK LOK Owner s Manual OPERATING PROCEDURES Before loading or unloading a vehicle at your loading dock while using a DOK LOK vehicle restraint, always visually inspect to be sure that the barrier blocks the R.I.G. assembly. If a condition occurs that cannot be remedied by backing the trailer firmly against the dock bumpers, secure the trailer by other means. Be sure that the area around the R.I.G. assembly is free of plates or other obstructions. Always operate the DOK LOK vehicle restraint from the top of the dock. Inspect all restraint lights daily to make certain they work properly. Perform maintenance on restraints in accordance with Maintenance on page 12 of this manual. DOK LOK vehicle restraints should be operated only by authorized personnel who have read and understand the Owner s Manual. Call your local representative or Rite Hite at (800) with any questions. FAILURE TO FOLLOW THESE PROCEDURES COULD ALLOW UNEXPECTED TRAILER / LOADING DOCK SEPERATION RESULTING IN DEATH OR SERIOUS INJURY! HANDS OFF Power Moving Components Serious Injury Could Occur Stored Position / Restraint UNLOCKED NO STEP Barrier is in the STORED position. Inside light is flashing red alerting forklift operator unsafe condition exists. Outside light is flashing green alerting truck driver it is safe to back in. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED HORN OVERRIDE LOCK UNLOCK GREEN Inside Lights Outside Lights FIGURE 3 STORED POSITION 8 Pub. No November 2012

55 RITE HITE STR 4100 DOK LOK Owner s Manual Restraint Locking, LOCK Button Pressed Trailer has backed into loading dock and is parked firmly against dock bumpers. Hook rotates from stored position to entrap the R.I.G. while the support cylinders extend to support the carriage. Inside light is steady red alerting the operator that an unsafe condition exists while hook and support cylinders are in transit. Outside light is flashing red alerting truck driver not to move. If trailer can not be restrained due to a lift gate or other obstruction that could become damaged, go to OVERRIDE state. If horn sounds, go to FAULTstate, otherwise go to Restraint LOCKED. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED HORN OVERRIDE LOCK UNLOCK GREEN Inside Lights Outside Lights FIGURE 4 RESTRAINT LOCKING Restraint LOCKED Once the R.I.G. is entrapped by the hook and the carriage is supported by support cylinders, a LOCKED condition exists. Inside light is flashing green alerting the forklift operator a safe condition exists. Outside light is flashing red alerting truck driver not to move. If during loading/unloading the inside light turns red and the horn sounds, press LOCK button to secure the R.I.G. Visually inspect to ensure that the DOK LOK barrier obstructs the R.I.G. of the trailer being serviced before operating the dock leveler. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED HORN OVERRIDE LOCK UNLOCK GREEN Inside Lights Outside Lights FIGURE 5 RESTRAINT LOCKED Pub. No November

56 RITE HITE STR 4100 DOK LOK Owner s Manual Restraint UNLOCKING, UNLOCK Button Pressed Hook travels from the LOCKED position to the STORED position while the support cylinders retract. Inside light is steady red alerting the operator that an unsafe condition exists while hook and support cylinders are in transit. Outside light is flashing red alerting truck driver not to move. If horn sounds go to FAULTstate, otherwise go to STORED. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED HORN OVERRIDE LOCK UNLOCK GREEN Inside Lights Outside Lights FIGURE 6 RESTRAINT UNLOCKING FAULT State From LOCKING State Hook cannot entrap the R.I.G. This could be due to a R.I.G. that is located too far from rear of trailer, bent, obstructed or missing. Inside light is flashing red and horn is pulsing, alerting the forklift operator that the trailer is not locked. Outside light is flashing red alerting the truck driver not to move. The unit will store itself. If the trailer is parked firmly against the dock bumpers go to HORNOVERRIDE state. If not, press UNLOCK to clear the fault, have trailer back up and repeat Restraint LOCKING. FAULT State From UNLOCKING State Hook cannot rotate to the STORED position. The hook could be caught on the R.I.G. or another part of the trailer. Inside light is flashing red and horn is pulsing, alerting the forklift operator that the trailer is not locked. Outside light is flashing red alerting the truck driver not to move. Make sure trailer is parked firmly against the dock bumpers. If not, press LOCK to entrap R.I.G., have trailer back up and repeat Restraint UNLOCKING. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED 1 2 LOCK HORN GREEN 3 HORN OVERRIDE UNLOCK Inside Lights Outside Lights FIGURE 7 FAULT STATE 10 Pub. No November 2012

57 RITE HITE STR 4100 DOK LOK Owner s Manual HORN OVERRIDE State, HORN OVERRIDE Code Entered after Securing Trailer by Alternate Means An alternate means of securing the truck must be used if the hook can not capture the R.I.G. (i.e. wheel chocks). Inside lights are flashing red and green alerting the forklift operator the trailer is secured by other means. Outside light is flashing red alerting the truck driver not to move. To return to STORED, enter the HORN OVERRIDE CODE followed by the UNLOCK button. The support cylinders will not be engaged in HORN OVERRIDE STATE, vertical motion of the trailer is to be expected. NOTE: The unit will continue to store itself (approx. 20 seconds) after the horn has been silenced from the FAULT STATE. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED HORN OVERRIDE LOCK UNLOCK GREEN Inside Lights Outside Lights FIGURE 8 HORN OVERRIDE STATE Pub. No November

58 RITE HITE STR 4100 DOK LOK Owner s Manual MAINTENANCE When working with electrical or electronic controls, make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes. Post safety warnings and barricade work area, at dock level and at ground level, to prevent unauthorized use of the dock position. NOTE: Your local Rite Hite representative provides a Planned Maintenance Program (P.M.P.) which can be fitted to your specific operation. Call your local representative. DAILY 1. Remove debris around DOK LOK vehicle restraint. 2. Verify inside and outside lights are working. 3. Replace damaged or missing light bulbs and lenses. 4. Repair, remount, or replace outside and inside signs as required. 5. Inspect dock bumpers. Four inches (4") of protection is required. Worn, torn, loose or missing bumpers must be replaced. Asafe work place requires all lights and the horn to be working properly. DO NOT use DOK LOK vehicle restraint if parts are broken or missing. When lifting unit use a proper lifting device (ex. crane, jack). Lifting by hand may cause back injury. Maintenance may be required more frequently at loading docks exposed to harsh environments (extreme climates, corrosive chemicals, frequency of usage, etc.). Consult Rite Hite if these conditions exist for accelerated maintenance requirements. NOTE:If a leveler is installed at the STR 4100 DOK LOK vehicle restraint location, it may be necessary to raise the leveler before performing maintenance. Raise the leveler, insert and secure the SAFE T STRUT, and LOCKOUT/ TAGOUT the power source. 180 DAYS 1. Perform all Daily maintenance. 2. Grease rollers at fittings located on the top and bottom axle. Grease hook and support cylinders at fittings. See figure 9. Use Mobilith SHC220 No. 2 grease (or equivalent temperature range lithium based grease). Seven (7) to eight (8) pumps should be used for first 180 day maintenance. Two (2) or three (3) pumps at subsequent 180 Day maintenance intervals. NOTE:Items that use SAE 30 weight oil lubricant only require lubrication every 360 Days. 3. Check that all concrete anchor bolts are torqued to 100 ft lbs. 4. Inspect hydraulic hoses and power unit for signs of leakage. Check oil fluid level, and fill with appropriate fluid as needed. 5. Inspect pit junction and light box. They should be rigidly mounted. If loose or damaged, inspect all wires and wire connections. 6. Inspect switch wires from DOK LOK vehicle restraint to junction box. Look for kinks, crushed areas, etc. 12 Pub. No November 2012

59 RITE HITE STR 4100 DOK LOK Owner s Manual 7. 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. Adrip 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 adhered to the cover with no signs of peeling or bubbling. Repair or replace if worn or damaged. c.for non metalic enclosures, breather vent part number may be installed. The vent is NEMA4X and will not change the enviromental rating of the control box. 8. Perform operational test after all maintenance repairs and adjustments are complete. 360 DAYS MAINTENANCE CONT. 1. Perform daily and 180 days maintenance. 2. Check and tighten control box mounting hardware. SAE 30 Weight Oil Grease Dry Spray Lubricate NOTES: a.use Mobilith SHC220 No. 2 grease (or equivalent temperature range lithium based grease) b.use a dry spray lubricate in slots and on the outside of lower spring tubes as shown. FIGURE 9 LUBRICATION Pub. No November

60 RITE HITE STR 4100 DOK LOK Owner s Manual TROUBLESHOOTING GENERAL DIAGNOSTIC INFORMATION Problem Probable Cause Solution 1.DOK LOK vehicle restraint hook does a. Power source malfunction. a.check power source including building not raise and lights do not flash. circuit breaker, 1Aand 20Afuse on the power module. b. Power module failure. b. Verify the appropriate motor output LED (M1), and SOLLED is lit when the LOCK button or UNLOCK button is pressed. c. Incorrect wiring. c. Verify wiring per Electrical Schematic. 2. DOK LOK vehicle restraint lights are a. Hook needs to be lubicated. a. Lubricate hook shaft. flashing, but hook does not raise/ b. Severed Hose. b. Replace damaged hose as required. lower. c. Power module failure. c. Verify the appropriate LED is lit when the LOCK button or UNLOCK button is pressed. d. No push button inputs. d. Check for defective push button board or ribbon cable. e. Hook Cylinder defective. e. Disconnect cylinder and check extension / retraction without hook attached. f. Incorrect wiring. f. Verify wiring per Electrical Schematic. 3. DOK LOK vehicle restraint is a. Hook Cylinder defective. a. Disconnect cylinder and check operational but hook drops causing extension / retraction without hook lights to change and/or horn to sound attached. while trailer is being serviced. 4. DOK LOK vehicle restraint hook is a. Bulbs burnt out, loose or missing. a. Check all bulbs and replace as operational but all lights are out. required. b. Bad Light Fuse b.replace as required. c. Damaged CPU module. c.if the ISG and OSR LEDs are not flashing while in the locked position or the ISR and OSG LEDs are not flashing while in the UNLOCKED position, replace the CPU module as required. d. Incorrect wiring. d. Verify wiring per Electrical Schematic. 5. DOK LOK vehicle restraint inside red a. Controls are in neutral state. a. Contact your local representative or light and horn are pulsing. Outside red RITE HITE. light is flashing. All buttons do not function. 6. DOK LOK vehicle restraint horn does a. Horn is defective. a.power horn using 12V DC power. If not sound, but lights and hook are horn does not sound, replace as operational. required. 7.DOK LOK vehicle restraint hook is in a. Incorrect wiring stored position with an inside green light. a. Verify wiring of SW1 and SW2 at the control box and outside junction box. 8. DOK LOK vehicle restraint carriage a. Carriage binding in track. a. Check to see if roller track plate is clean does not return to a full up position and rollers are clean, free of debris and lubricated. Use only approved grease to lubricate rollers. b. Damaged roller track plate. b. Verify that the roller track plate is straight and not damaged. c. Broken or weak springs c. Replace as required. d. Improperly shimmed Base Plate d. Shim and adjust as required. 14 Pub. No November 2012

61 RITE HITE STR 4100 DOK LOK Owner s Manual COMPONENT TESTING Mag. Res. Limit Switch Test Procedure (SW1 & SW2) 1. Set multimeter to RX1 scale for Continuity Test. 2. Attach multimeter leads to white and black wires of mag. res. switch connector. You should have: no magnet present no meter reading. magent present a Full Scale meter reading. Mech. Limit Switch Test Procedure (SW3) 1. Set multimeter to RX1 scale for Continuity Test. white black sensing switch magnet FIGURE 10 MAGNETIC RESISTANT LIMIT SWITCH (SW1 & SW2) 2. Attach multimeter leads to white and black wires of limit switch connector. You should have: plunger released no meter reading. plunger depressed a Full Scale meter reading. NOTE:The green (ground) wire of the limit switch does not have to be tested. Acontinuity test lamp may be used instead of a multimeter. fixed guide limit switch body plunger w/roller mounting bolt holes wire harness NOTE:Limit Switch 1 (SW1) and Limit Switch 3 (SW3) are wired in series into the SW1 input on the CPU module. green black white red (not used) Limit Switch and Hook Position Chart Hook Position Limit Switch 1 Lock (SW1) (Mag. Res. Switch) Limit Switch 2 Unlock (SW2) (Mag. Res. Switch) FIGURE 11 MECHANICALLIMIT SWITCH (SW3) Limit Switch 3 Support (SW3) (Mech. Switch) Inside Light Outside Light Horn 1. Stored Off On Open Red Green Off 2. No Hook (No Support) Off Off Open Red Red On 3. Hooked/Support On Off Closed Green Red Off 4. No Hook (Support On) Off Off Closed Red Red On Pub. No November

62 PB1,2&3 SOL2(Combo Only) RITE HITE STR 4100 DOK LOK Owner s Manual COMPONENT TESTING CONT. Vehicle Restraint Motor Test Procedure hydraulic power unit 1. SHORTED: Set multimeter to ohms. a. Take readings between leads M1 to ground/motor casing and COM to ground/motor casing. b. Reading should be Infinite (0) ohms (no needle movement). c.any reading indicates bad motor windings. 2. MECHANICAL BINDING: Motor hums. Motor leads show continuity between all windings. Shaft does not move. multimeter G COM M1 FIGURE 12 MOTOR TEST Restraint State LED Inputs LED Outputs SW1 SW2 LOCK PB UNLOCK PB Stored (Unlocked) F T P F F P F F F F F * T Locking F F M T F P F F T T T F * T Locked T F F P P F F F T F T * T Storing (Unlocking) F F M T F P F F T F T F * T Fault F F P F P F P F F F F * F Horn Silence?? M P P P F F F F F T * T SW1 =MAG RES (SW1 LOCK) + MECH (SW3 SUPPORT)ISR=Inside Red Light SW2=MAG RES (SW2 UNLOCK) ISG=Inside Green Light LOCK PB=Lock Push Button OSR=Outside Red Light UNLOCK PB = Unlock Push Button OSG = Outside Green Light PB1, 2, & 3=Horn Silence Code Push Buttons HORN=Alarm Horn M1=Power Unit Run SOL1=Hook / Support Solenoid SOL2=Leveler Block SOL2 + SOL3 (Combo Only) CR1 = Green Light Interlock Output INPUTFAULT=SW1/SW2 did not sense a safe CR2=Unidox Output LOCK/UNLOCK CR3 = Security System Output ISR T = Steady ON D = Double Pulse F = OFF P = Pulsing/Flashing * = TRUE when Unidox is enabled? = Varies depending on operation M = Lights when button is pressed ISG OSR OSG FIGURE 13 LED STATUS CHART HORN M1 SOL1 CR1 CR2 CR3 16 Pub. No November 2012

63 SETTING HORN OVERRIDE CODE 1. Press and hold DIAGNOSTIC button until horn chirps (approximately three seconds). 2. Enter the factory preset HORN OVERRIDE code: (horn will chirp) 3. Enter the new HORN OVERRIDE code. The code can be one to four numbers in length. 4. Once the new code has been entered, press the LOCK button. 5. Controls reset with new HORN OVERRIDE code enabled. If no buttons are pressed within a five minute period, the controls will automatically retain the previous code. To exit the HORN OVERRIDE code set mode at any time, press the DIAGNOSTIC button. If code has been forgotten, follow the above procedures and enter a new code. RITE HITE STR 4100 DOK LOK Owner s Manual HORN OVERRIDE CODE Diagnostic Button FIGURE 14 DIAGNOSTIC / FILLMODE BUTTON Control Box SETTING HYD. SERVICE / FILL MODE 1. Apply power to the control box and enter fill mode. a. Press and hold Diagnostic/Fill Mode Button on the inside of the control box until horn chirps. See figure 15. DO NOT ENTER TRAILER ENTER TRAILER RED GREEN NOTE: You must wait one minute to exit Service Mode HORN OVERRIDE LOCK UNLOCK b. After horn chirps, press the following buttons in order to enter fill mode. See figure 16. 1b. LOCK 2b. HORN OVERRIDE #2 3b. LOCK Diagnostic / Fill Mode Button FIGURE 15 DIAGNOSTIC / FILLMODE BUTTON c. Controls are now in Fill Mode. Holding the LOCK or UNLOCK Button will run the pump up or down. Press Buttons In The Following Order To Enter Fill Mode 1. LOCK Button 2. HORN OVERRIDE #2 Button 3. LOCK Button FIGURE 16 ENTER FILLMODE 2. Cycle the DOK LOK up and down to remove air from the system. Add remaining hydraulic fluid. Stop cycling once the support cylinders travel up and down the full length of slots without hesitation. 3. Press Diagnostic/Fill Mode Button to exit Fill Mode. NOTE:Must wait one minute to exit Fill Mode. Pub. No November

64 RITE HITE STR 4100 DOK LOK Owner s Manual HOSE ROUTING NOTE: DO NOT Overtighten Hose Fittings! From P Port On Valve Block To P Port On Power Unit NOTE: Stand Alone Power Hoses Are Not Trimable From L Port On Valve Block To L Port On Power Unit FIGURE 17 HOSE ROUTING STAND ALONE POWER UNIT NOTE: DO NOT Overtighten Hose Fittings! (SOL3) RAMP DIVERT Solenoid (SOL1) RAISE Solenoid (SOL 2) LIP BLOCK Solenoid From P Port On Restraint Valve Block To RP Port On Combination Power Unit Valve Block NOTE: Remote Power Hoses Are Trimable, See Installation Manual for Trimming Instructions From L Port On Restraint Valve Block To LP Port On Combination Power Unit Valve Block FIGURE 18 HOSE ROUTING COMBINATION POWER UNIT 18 Pub. No November 2012

65 NOTE: Mounted On STR-4100 Carriage. RITE HITE STR 4100 DOK LOK Owner s Manual VALVE BLOCK ASSEMBIES HL Port - Hook Cylinder Retract HR Port - Hook Cylinder Extend L Port To Power Unit or Combo Valve Block P Port To Power Unit or Combo Valve Block MR Port - Raise Support Cylinder (Left) ML Port - Lower Support Cylinder (Left) ML Port - Lower Support Cylinder (Right) MR Port - Raise Support Cylinder (Right) FIGURE 19 AUXILLARY MANIFOLD ASSEMBLY NOTE: Located Adjacent To Leveler Power Unit. Only On Combination Power Units. (SOL 2) LIP BLOCK Solenoid (SOL 3) RAMP DIVERT Solenoid (SOL 2) LIP BLOCK Solenoid LP Lower Port to STR4 LO Leveler Lip Out Port (SOL 3) RAMP DIVERT Solenoid RP Raise Port to STR4 (SOL 1) RAISE Solenoid NOTE: This Face Towards Front Of Pit T Return to Tank Port FIGURE 20 COMBINATION POWER UNIT VALVE BLOCK ASSEMBLY RO Leveler Ramp Out Port Pub. No November

66 4 AMP RITE HITE STR 4100 DOK LOK Owner s Manual ELECTRICAL SCHEMATIC STAND ALONE POWER UNIT NOTES: 1. Power Supply Disconnect Or Protection Device Supplied At Installation. (By Others) 2. All Incoming Wiring (L1, L2) To Be Minimum #12GA. 60/75 Deg. C Copper Wire Only, Insulated Sufficiently For Incoming Voltage. (See Chart) 3. All Other Wiring To Be #16GA. Minimum 90 Deg. C Copper Wire, Insulated Sufficiently For Incoming Voltage. 4. Class 1 Control Circuit. 5. Use Insulated 1/4 Female Spade Connectors. 6. Installation Per Local Electrical Codes. Refer All Installation And Service To Qualified Personnel. Power Module See Chart For Wire Size To Customer Power Supply 120v, 1PH, LY, 60Hz, 20 Amp. 30 Amp. Rated Fused Disconnect With 20 Amp. Dual Element Time Delay Fusing. (Supplied By Others) (G) (L1) (L2) SCOM 250v. 1A Fast Blow L1 L2 MCOM M1 250v. 20A Slow Blow MCom Motor - 1 H.P. 120v. 1Ph. 50/60 Hz. 9 F.L.A. M1 M (1) SCom ISA2 PUSH BUTTON BOARD R LOCK UNLOCK G R G Inside Lights, Horn and Push Button Wiring Harness HS #1 1 HS #2 HS #3 Orange ISR 12 VDC,.54A Green ISG VDC,.54A Diagnostic / Fill Mode Button + 12VDC + 12VDC Ambr Lt Cntrl OSR Sense OSG Sense GND GND HS #3 HS #2 HS #1 Lock Unlock CPU module 4 Amp Automotive Fuse Red Red Yellow White/Orange White/Green Black Black Violet Brown Gray Blue White ISA PB3 PB2 PB1 LOCK UNLOCK OSG ISR OSR ISG HORN SW2 SW1 +V1 SW1+ SW1- +V2 SW2+ SW2- CR4 CR5 SOL2 OSPWR OSG OSR SOL1 M1 CR3 CR2 CR1 SOL1 SOL2 CR3 CR2 CR1 AUX1 AUX2 AUX3 (2) Sol1 CR3_A CR3_B CR2_A CR2_B CR1_A CR1_B AUX1+ AUX1- AUX2+ AUX2- AUX3+ AUX3- leveler/ overhead door stored interlock (BLK) RAISE SOL1 120 VAC, 0.23 AMPS security system interface output unidox interconnect output green light interlock output Options module unidox interconnect selector switch OFF (WHT) ON H Horn Red +12V White/Black Horn - 12 VDC, 0.03A White/Red Horn + (SW1+) (SW2+) mech./ FA interconnect hydraulic interconnect raise photoeye interconnect white black Support Limit Switch (SW3) (WH) (BLK) N.O. (SW1-) (SW1-) white black red (42) white (41) G Outside Light Power Outside Light Green 12VDC, 2.1A Safe Hook LOCKED Sensor Switch (SW1) Hook UNLOCKED Sensor Switch (SW2) white (40) R Outside Light Red 12VDC, 2.1A LEGEND WIRE SIZE REQUIREMENTS lable LED lamp Wire Run Length denotes field wiring Wire Gauge Size 12GA 10GA 8GA NOTE: Use included female spade connectors for installation. FIGURE 21 ELECTRICAL SCHEMATIC STAND ALONE POWER UNIT 20 Pub. No November 2012

67 4 AMP RITE HITE STR 4100 DOK LOK Owner s Manual ELECTRICAL SCHEMATIC COMBO POWER UNIT NOTES: 1. Power Supply Disconnect Or Protection Device Supplied At Installation. (By Others) 2. All Incoming Wiring (L1, L2) To Be Minimum #12GA. 60/75 Deg. C Copper Wire Only, Insulated Sufficiently For Incoming Voltage. (See Chart) 3. All Other Wiring To Be #16GA. Minimum 90 Deg. C Copper Wire, Insulated Sufficiently For Incoming Voltage. 4. Class 1 Control Circuit. 5. Use Insulated 1/4 Female Spade Connectors. 6. Installation Per Local Electrical Codes. Refer All Installation And Service To Qualified Personnel. NOTE: Attach Leads From Dok-Lok Power To The LOWER Button When Module Combining With A VHL Leveler. ISA2 10FU1 1.0A 250V DUAL ELM TD PUSH BUTTON BOARD R LOCK UNLOCK G R G "RAISE" Leveler Control Box HS #1 1 HS #2 HS #3 LEVELER CONTACTOR (A1) Orange ISR 12 VDC,.54A Green ISG (A2) Inside Lights, Horn and Push Button Wiring Harness VDC,.54A + 12VDC + 12VDC Ambr Lt Cntrl OSR Sense OSG Sense GND GND HS #3 HS #2 HS #1 Lock Unlock H3 (BK) H5A (RD) CPU module 4 Amp Automotive Fuse Red Red Yellow White/Orange White/Green Black Black Violet Brown Gray Blue White PB3 PB2 PB1 LOCK UNLOCK ISA ISR ISG HORN To Customer Power Supply 120v, 1PH, 60Hz, 15 Amp. Fused Disconnect With 1 Amp. Dual Element Time Delay Fusing (Supplied By Others) (G) (L1) (L2) NOTE: Lip Block Solenoid Not Used When Combining Dok-Lok With A VHL Leveler. SCOM CR4 CR5 Diagnostic / Fill Mode Button OSG OSR SW2 SW1 +V1 SW1+ SW1- +V2 SW2+ SW2-250v. 1A Fast Blow SOL2 L1 L2 MCOM M1 OSPWR OSG OSR SOL1 M1 CR3 CR2 CR1 250v. 20A Slow Blow SOL1 SOL2 CR3 CR2 CR1 AUX1 AUX2 AUX3 (2) Sol1 (3) Sol2 (8) Sol3 CR3_A CR3_B CR2_A CR2_B CR1_A CR1_B AUX1+ AUX1- AUX2+ AUX2- AUX3+ AUX3- leveler/ overhead door stored interlock RAISE SOL1 (WKX) (BLK) (WHT) 120 VAC, 0.23 AMPS LIP BLOCK SOL2 (WKV) (BLK) (WHT) 120 VAC, 0.23 AMPS RAMP DIVERT SOL3 (WKC) (BLK) (WHT) 120 VAC, 0.23 AMPS security system interface output unidox interconnect output green light interlock output Options module unidox interconnect selector switch OFF (1) SCom ON H Horn Red +12V White/Black Horn - 12 VDC, 0.03A White/Red Horn + (SW1+) (SW2+) mech./ FA interconnect hydraulic interconnect raise photoeye interconnect white black Support Limit Switch (SW3) (WH) (BLK) N.O. (SW1-) (SW1-) white black red (42) white (41) G Outside Light Power Outside Light Green 12VDC, 2.1A Safe Hook LOCKED Sensor Switch (SW1) Hook UNLOCKED Sensor Switch (SW2) white (40) R Outside Light Red 12VDC, 2.1A LEGEND lable LED lamp denotes field wiring NOTE: Use included female spade connectors for installation. FIGURE 22 ELECTRICAL SCHEMATIC COMBINATION POWER UNIT Pub. No November

68 RITE HITE STR 4100 DOK LOK Owner s Manual HYDRAULIC SCHEMATIC STAND ALONE POWER UNIT HOOK CYLINDER 1.25 x 3 x.5 ROD HR (HOOK RAISE) #4SAE RV Relief Valve, 2000 PSI HL (HOOK LOWER) #4SAE ML (MAIN LOWER) #6SAE CV Check Valve PP Pilot To Open CV Check Valve L (LOWER) #6SAE ML (MAIN LOWER) #6SAE MAIN SUPPORT CYLINDER, LH 3.5 x 9 MR (MAIN RAISE) #6SAE NOTE: THIS HOSE IS A #4SAE HOSE. PCC Pilot To Close Check Valve P (PRESSURE) #6SAE MR (MAIN RAISE) #6SAE AUXILLARY MANIFOLD MOUNTED ON CARRIAGE MAIN SUPPORT CYLINDER, RH 3.5 x 9 #6SAE P (PRESSURE) RAISE (SOL1) L (LOWER) #6SAE HOLDING CHECK VALVE, 50PSI VMS ORIFICE, V 2POS 4WAY SOLENOID RAISE/LOWER SELECTOR SOLENOID IS POWERED DURING LOCKED AND LOCKING STATES. ADJUSTABLE SYSTEM RELIEF, 675 PSI MOTOR: M 120/1/60 RESERVOIR: 1 GALLON VERTICAL & HORIZONTAL MOUNT SCREEN AND MAGNET STAND ALONE POWER UNIT FIGURE 23 HYDRAULIC SCHEMATIC STAND ALONE POWER UNIT 22 Pub. No November 2012

69 RITE HITE STR 4100 DOK LOK Owner s Manual HYDRAULIC SCHEMATIC COMBO POWER UNIT HOOK CYLINDER 1.25 x 3 x.5 ROD HR (HOOK RAISE) #4SAE RV Relief Valve, 2000 PSI HL (HOOK LOWER) #4SAE ML (MAIN LOWER) #6SAE CV Check Valve PP Pilot To Open CV Check Valve L (LOWER) #6SAE ML (MAIN LOWER) #6SAE MAIN SUPPORT CYLINDER, LH 3.5 x 9 MR (MAIN RAISE) #6SAE NOTE: THIS HOSE IS A #4SAE HOSE. PCC Pilot To Close Check Valve P (PRESSURE) #6SAE MR (MAIN RAISE) #6SAE AUXILLARY MANIFOLD MOUNTED ON CARRIAGE MAIN SUPPORT CYLINDER, RH 3.5 x 9 RO (RAMP OUT) #6SAE PCC Pilot To Close Check Valve, 50 PSI RAMP DIVERT (SOL3) RP #6SAE (RAISE PORT).020 Orifice CV Check Valve RAISE (SOL 1) LP (LOWER PORT) #6SAE T (TANK) #6SAE LO (LIP OUT) #4SAE RV Relief Valve, 675 PSI LIP BLOCK (SOL2) RI (RAMP IN) #6SAE LI (LIP IN) #4SAE FIGURE 24 HYDRAULIC SCHEMATIC COMBINATION POWER UNIT COMBINATION POWER UNIT VALVE BLOCK. LOCATED ADJACENT TO LEVELER POWER UNIT Pub. No November

70 RITE HITE STR 4100 DOK LOK Owner s Manual OUTSIDE LIGHT BOX WIRING #40 Wire White Wire Red Wire #42 Wire Red Lamp Red Wire Green Lamp #41 Wire White Wire Light Box Cover FIGURE 25 OUTSIDE LIGHT BOX WIRING 24 Pub. No November 2012

71 RITE HITE STR 4100 DOK LOK Owner s Manual NOTES Pub. No November

72 RITE HITE STR 4100 DOK LOK Owner s Manual CARRIAGE & TRACK REPLACEMENT PARTS 34 NOTE: DECK OF CARRIAGE WELDMENT REMOVED FOR CLARITY Pub. No November 2012

73 RITE HITE STR 4100 DOK LOK Owner s Manual CARRIAGE & TRACK ASSEMBLY PARTS LIST Item Qty Description Part Number 1 1 Base Plate Track Weldment Track Cover Weldment Inch Carriage Weldment Hook Weldment Nose Weldment Upper Spring Tube Compression Spring W/ Mounting Height > Compression Spring W/ Mounting Height >23 and < Compression Spring W/ Mounting Height >21 and < Lower Spring Tube Support Cylinder Hook Cylinder Clevis Pin Upper Spring Tube Clevis Pin Nose Weldment Clevis Pin Hook Weldment Mag. Res Switch Sensor Bracket Magnet High Energy Rubber Lower Magnet High Energy Rubber Upper Auxillary Manifold Complete Patent Decal Carriage Roller Washer 1.5 OD x ID Grease Fitting Flat Washer Washer 1.88 OD x 1.25 ID Lock Washer Cotter Pin Cotter Pin Warning Decal Screw, #6 32 x.599 Pan SST Mag. Res. Switch Nut, #6 32 Nylock SST Cotter Pin,.125Dia. x 2LZP Bolt, HEX UNC x.75 ZP Screw x 2.00 Cap SKTHEX Nut Nylock Bolt, #10 24 x.50 HEX GR5 ZP Split Lock Washer, # Limit Switch, Roller Plunger Screw, SHCS x 1LZP Nut, HEX FLG ZP Hydraulic Elbow Fitting, 90 0 #6 SAE(M) #6 JIC(M) Decal, Serial Number/ Model Clevis Pin Lower Spring Tube, 5.75 x Clevis Pin Hook Cylinder Plug, Male #6 MORB Washer 1.265OD x Washer 1.5OD x 1.063IO Clevis Pin Support Cylinder Lower Pin Pub. No November

74 RITE HITE STR 4100 DOK LOK Owner s Manual HYDRAULIC REPLACEMENT PARTS , 26, Item Qty Description Part Number 1 1 Hook Cylinder Hose Assembly Hook Cylinder HL(Hook Lower) Hose Assembly Hook Cylinder HR (Hook Raise) Hose Assembly Left Side Support Cylinder MR (Main Raise) Hydraulic Fitting Support Cylinders & Power Unit Support Cylinders Hose Assembly Left Side Support Cylinder ML(Main Lower) Hydraulic Fitting Hydraulic Elbow Fitting System Relief Valve Hydraulic Fitting Auxillary Manifold Complete Hose Assembly Solenoid Coil Hydraulic Valve Solenoid Operated Hose Assembly Right Side Support Cylinder MR (Main Raise) Hose Assembly Right Side Support Cylinder ML(Main Lower) Hydraulic Plug Cotter Pin Washer 1.5OD x 1.063ID Clevis Pin Support Cylinder Lower Pin Clevis Pin Hook Cylinder Lower Pin Cotter Pin Stand Alone Power Unit Assy Hydraulic Oil Tank Hydraulic Oil Tank 0 Ring/Seal Hydraulic Oil Tank Dipstick/Breather Cap Pub. No November 2012

75 RITE HITE STR 4100 DOK LOK Owner s Manual HYDRAULIC REPLACEMENT PARTS COMBINATION POWER UNIT VALVE BLOCK PARTS NOTE: THIS FACE TOWARDS FRONT OF PIT Item Qty Description Part Number 1 1 Combination Valve Block Assembly Complete Solenoid Coil Hydraulic Valve WKC SOL Hydraulic Valve WKX SOL Hydraulic Valve WKV SOL Hydraulic Relief Valve Hydraulic Check Valve Hydraulic Check Valve Hirschmann Plug Rect. & Harn. Assy. (Not Shown) Pub. No November

76 RITE HITE STR 4100 DOK LOK Owner s Manual ELECTRICAL REPLACEMENT PARTS M1 SOL2 SOL #14 ga. wire x 5 long with ring terminal existing black wire light base control box Pub. No November 2012

77 RITE HITE STR 4100 DOK LOK Owner s Manual ELECTRICAL REPLACEMENT PARTS LIST Item Qty Description Part Number 1 1 Control box assembly, complete (Consult RITE HITE for specific part) 103.xxx 2 1 Electrical schematic decal (Consult RITE HITE for specific part) 108.xxx 3 2 Inside red LED bulbs Inside green LED bulbs Light bulb (#194 Incandescent) Insulated female terminal 1/4, awg Fuse, 1amp 250volt fast blo Inside signal light, green assembly Inside signal light, green lens Inside signal light, red assembly Inside signal light, red lens Push button module, 5 button includes mounting hardware Combo Power module includes subplate & mounting hardware CPU module includes mounting hardware Options module, not included in STANDARD control box assembly Program configuration decal (Consult RITE HITE for specific part) 107.xxx 15 1 Full Load Amp and Voltage Decal (Consult RITE HITE for specific part) 110.xxx 16 1 Horn, 12VDC Wiring harness Grounding harness Screw, panhead (#10 32 x.250) Lock washer, internal tooth # Screw, round head #8 32 x 1.00 (red light only) Screw, round head #8 32 x Screw, round head #8 32 x.50(green light only) Nut, hex (#8 32) Lock washer, external tooth # Washer, nylon 0.26 ID x 0.75 OD x 0.10 thk Bushing, nylon Common wire, light assembly Outside light box LED, complete Outside light box, complete (Incandescent) Outside light box cover LED, with lamps & lenses Outside light box cover, with lamps & lenses (Incandescent) Screw, round head #6 32 x 3/4" Long Outside red LED bulb Outside green LED bulb Light bulb (GE#1156 Incandescent) Lamp socket assembly Outside light box, NEMA 3R, (without cover) Fuse, 20 amp 250v Fuse, 4 Amp Pub. No November

78 part of the SMOOTH TRANSITION DOK SYSTEM TM This Manual Covers Restraints Built After Serial Numbers: 05GD150001W and up MADE IN U.S.A. PRINTED IN U.S.A. RITE-HITE PRINT SHOP PUBLICATION NO Copyright 2012 NOVEMBER 2012 RITE HITE STR 4100 DOK LOK Owner s Manual MISC. PARTS STR-4100 Dok-Lok Vehicle Restraint Owners Manual MISCELLANEOUS REPLACEMENT PARTS LIST Item Qty Description Part Number 1 1 Interior Warning sign Narrow sign (normal letters) Narrow sign (reverse letters) STR warning decal Cover decal 5 button STR Lockout/tagout warning decal STR 4100 Owner s manual (Publication No. 1244) Pub. No Pub. No November 2012

79 RITE HITE STR 4100 DOK LOK Owner s Manual NOTES Pub. No November

80 RITE HITE STR 4100 DOK LOK Owner s Manual NOTES 34 Pub. No November 2012

81 RITE HITE STR 4100 DOK LOK Owner s Manual NOTES Pub. No November

82 RITE HITE STANDARD WARRANTY Rite Hite warrants that its products will be free from defects in design, materials, and workmanship for a period of 365 days from the date of shipment. All claims for breach of this warranty must be made within 30 days after the defect is or can, with reasonable care, be detected and in no event no more than 30 days after the warranty has expired. In order to be entitled to the benefits of this warranty, the products must have been properly installed, maintained, and operated within their rated capacities and/or specified design parameters, and not otherwise abused. Periodic lubrication and adjustment is the sole responsibility of the owner. This warranty is Rite Hite s exclusive warranty. RITE HITE EXPRESSLY DISCLAIMS ALL IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS. Non standard warranties, if any, must be specified by Rite Hite in writing. In the event of any defects covered by this warranty, Rite Hite will remedy such defects by repairing or replacing any defective equipment or parts, bearing all the costs for parts, labor, and transportation. This shall be the exclusive remedy for all claims whether based on contract, negligence, or strict liability. LIMITATION OF LIABILITY RITE HITE SHALLNOTIN ANYEVENTBE LIABLE FOR ANYLOSS OF USE OF ANYEQUIPMENTOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, WHETHER FOR BREACH OF WARRANTY, NEGLIGENCE, OR STRICT LIABILITY. Global Sales & Service Office: RITE HITE 8900 N. Arbon Drive P.O. Box Milwaukee, Wisconsin Phone: Representatives in all Major Cities

83 P i t m a s t e r u n d e r - l e v e l e r s e a l C o m p l e t e t h e s e a l at y o u r l o a d i n g d o c k. You re already investing in a dock seal or shelter to control the environmental conditions at your dock doors. Why stop at sealing only three sides of the opening? Complete the job by sealing the fourth side with PitMaster TM, the industry s best-selling under-leveler seal. Open leveler pit without PitMaster. Pit sealed with PitMaster. Winner

84 The easy seal for your loading dockʼs 4th side. Dirt. Debris. Pests. Heat. Cold. The many reasons youʼve installed a seal or shelter on your loading dock are the very same reasons you need a PitMaster Under-leveler Seal from Frommelt. The PitMaster seal goes beyond standard dock leveler weather seals to help keep insects, dust and debris out and heating and cooling energy in by closing off the pit and sealing up air gaps where the leveler, the truck, and the dock seal or shelter all meet. Keeps docks cleaner. Helps prevent dust, pests, debris and refuse from collecting in leveler pits. Keeps your dock area and your entire building cleaner. Promotes improved sanitation and industrial hygiene. Without PitMaster. Dirt and debris can easily collect in the dock leveler pit. With PitMaster. The leveler pit stays virtually free of dirt and debris. Seals air gaps and white space with optional corner seals and filler pads. Closes up the gaps at the dock/trailer level that traditional seals and shelters can t seal. Eliminates small openings and white space to help your facility pass AIB inspections. Keeps employees safer, healthier and more comfortable. Shields employees from the elements. Helps prevent rain, cold air, snow and dust from entering your facility. Without PitMaster. This view from inside the dock with the leveler lip on the bed of a trailer clearly shows air gaps and white space at the corners of the leveler. With PitMaster and optional lip corner seals. The same view shows how air gaps and white space have been effectively closed.

85 P i t m a s t e r u n d e r - l e v e l e r s e a l Prevent dramatic heat and energy loss through the dock leveler deck. The front of a typical leveler pit is fully open to the environment outside the building. PitMaster minimizes airflow through openings in the leveler pit. And, it creates an insulating dead-air cavity in the pit, reducing transfer of heat into or out of your facility through the steel leveler deck and gaps around it. The result: Substantial energy savings 24 hours a day, whether or not a trailer is parked at the dock. Without PitMaster. Heating or cooling energy can escape your facility through open spaces around the leveler, plus heat is transferred through the leveler deck itself. With PitMaster and optional lip corner seals. Air trapped by the PitMaster seal creates a pocket of dead air in the leveler pit, which acts as a thermal insulator that reduces heat transfer. Heat losses add up fast. Heating energy lost through open air gaps, and through the leveler deck, can be drastically reduced with PitMaster for savings as high as $900 per year per dock position in colder climates. Ask your Rite-Hite Representative for details and a free loading dock energy cost analysis for your facility. Location Energy Savings* Minneapolis, MN $904 Milwaukee, WI $803 Chicago, IL $604 Denver, CO $534 Trenton, NJ $359 Cincinnati, OH $344 Nashville, TN $272 Dallas, TX $237 Los Angeles, CA $512 Heating only Heating and air conditioning Freezer dock * Typical annual energy savings possible per dock position with PitMaster seal and optional lip corner seals.

86 p i t m a s t e r 2 1. The main sealing curtain made of durable black vinyl is held in place by spring-loaded pivot arms and flexible stays that keep the seal engaged against the leveler and pit sides The header curtain constantly maintains the seal even when the dock leveler is in an above-dock position (up to 3") Optional leveler lip corner seals eliminate the hard-to-seal gaps at the corners of the dock leveler. 4. Optional filler pads (shown with optional bumper covers) close the gaps between the leveler and the dock shelter when a truck is in place. Easy installation. Fits a variety of leveler types with minimal modifications. Installs quickly using common tools. Money-back guarantee. 12-month money-back customer satisfaction guarantee. Simple maintenance. No regular seal maintenance required. Components can be replaced quickly and easily. Curtain is easily moved for dock equipment maintenance or routine pit cleanout with quick-disconnect feature. The full support you know and expect from Frommelt and Rite-Hite. F15PMB0307C 8900 North Arbon Drive Milwaukee, WI USA (414) (800) FAX: (414) Mailing Address: Rite-Hite P.O. Box Milwaukee, WI USA RITE-HITE, PitMaster and Frommelt are trademarks of the RITE-HITE Holding Corporation. RITE-HITE products may be covered by one or more U.S. Patents with other U.S. and foreign patents pending. RITE-HITE reserves the right to make product improvements without prior notice.