AL-900 Dock Leveler Owners Manual

Transcription

1 AL-900 Dock Leveler Owners Manual part of the SMOOTH TRASITIO DOK SYSTEM TM By Rite-Hite MADE I U.S.A. This Manual Covers Dock Levelers Built After Serial umbers: 07DD400623M and up PRITED I U.S.A. RITE-HITE PRIT SHOP PUBLICATIO O MAY 2014

2 enisys AL-900 Dock Leveler Owner s Manual OTES 2 Pub. o May 2014

3 TABLE OF COTETS enisys AL-900 Dock Leveler Owner s Manual OTICE TO USER SAFETY WARIS OWER RESPOSIBILITY OPERATIO ISTRUCTIOS MAITEACE PROCEDURES LEVELER ADJUSTMETS/TROUBLESHOOTI ELECTRICAL WIRI CHARTS ELECTRICAL SCHEMATICS REPLACEMET PARTS WARRATY BACK COVER PRODUCT SPECIFIC WARRATY Rite-Hite warranties the AL9 Dock Leveler for one year parts and labor from date of shipment. With a additional five years parts warranty on the Air Tower, Blower Motor and Hose parts. All warranties are subject to standard limitations on liability. PRODUCT SPECIFIC WARRATY Rite-Hite warrants the AL9 Dock Leveler for one-year parts and labor from date of shipment with an additional fiveyear parts warranty on the Air Tower, Blower Motor and Hose parts in accordance with Rite-Hite's Standard Warranty Policy. OTICE 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 Rite-Hite at The Rite-Hite products in this manual are covered by one or more of the following U.S. patents: 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; 6,089,544; 6,092,970; 6,106,212; 6,116,839; 6,190,109; 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; 6,520,472; 6,524,053; 6,634,049; 6,726,432; 6,773,221; 6,832,403; 6,880,301; 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; 7,823,239; 7,841,823; 7,877,831; 7,914,042; 8,006,811; 8,065,770; 8,141,189; 8,191,194; 8,286,757; 8,287,223; 8,303,235; 8,307,956; 8,443,474; 8,464,384; 8,464,846; 8,465,245 and pending U.S and foreign patent applications. RITE-HITE, THIMA TM, SAFE-T-LIP, HYDRACHEK, WHEEL-LOK TM, DOK-LOK, DUAL-DOK, SAFE-T-STRUT TM, DOK-COMMADER, JUMBO TM, HYDRA-RITE TM, SAFE-T-ATE, RITE- VU TM LIHT COMMUICATIO SYSTEM and SMOOTH TRASITIO DOK SYSTEM TM, are trademarks of Rite-Hite. Pub. o May

4 enisys AL-900 Dock Leveler Owner s Manual SAFETY WARI DO OT 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 FIURE 1 - LOCKOUT/TAOUT LOCKOUT/TAOUT 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. IMPORTAT is used to draw attention to a procedure that needs to be followed to prevent machine damage. 4 Pub. o May 2014

5 enisys AL-900 Dock Leveler Owner s Manual OTHER IMPORTAT OPERATIOAL SAFETY WARIS ever 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. ever 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. ever 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 OT 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. o May

6 enisys AL-900 Dock Leveler Owner s Manual SAFETY DEVICES ever be under the dock leveler platform or lip without: Installing the Maintenance Support. 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. - Then have assistant insert the Maintenance Support over the base located on the leveler s front frame. 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. ISERT ITO CUP - Release the pushbutton on powered levelers allowing the support to rest inside the lip cup 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 Maintenance Support removal, have an assistant raise the leveler to its highest position with lip fully extended. Lift the support off base. Return the Maintenance Support 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 ISERT OTO BASE FIURE 2 - ISTALL MAITEACE SUPPORT 6 Pub. o May 2014

7 enisys AL-900 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. ameplates, 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. OWER RESPOSIBILITY 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. o May

8 enisys AL-900 Dock Leveler Owner s Manual OPERATIO ISTRUCTIOS LEVELERS ORMAL OPERATIO 1. Activate the leveler by pushing and holding the RAISE button until leveler is fully raised and lip is fully extended. See figure 3. BELOW DOCK LOADI OPERATIO 1. Activate the leveler by pushing and holding the RAISE button until leveler is fully raised and lip is fully extended. See figure When lip is fully extended, release RAISE button. If equipped with safety legs, pull and hold the safety leg chain as the leveler lowers automatically onto the truck/trailer bed. See figure 5. Safety Leg Chain FIURE 3 - POWERED DOCK LEVELER 2. When lip is fully extended, release RAISE button. The leveler will automatically lower onto the truck/trailer bed. See figure 4. FIURE 5 - BELOW DOCK OPERATIO (SAFETY LE EQUIPPED SHOW) 3. When loading/unloading is complete, continue with normal operation or return the leveler to stored position. See Storing Leveler. FIURE 4 - ORMAL OPERATIO 3. See Storing Leveler. OTES: 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. 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. 8 Pub. o May 2014

9 DOCK LEVEL (OR LOWER) ED LOADI OPERATIO enisys AL-900 Dock Leveler Owner s Manual OPERATIO ISTRUCTIOS LEVELERS COT. 1. Activate the leveler by pushing and holding the RAISE button until leveler lip clears the lip supports. See figure When loading/unloading is complete, continue with normal operation or return the leveler to stored position. See Storing Leveler. Safety Leg Chain FIURE 8 - ED LOAD OPERATIO (EQUIPPED WITH SAFETY LES) FIURE 6 - ED LOAD OPERATIO - LIP POSITIO STORI 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 9. FIURE 7 - ED LOAD OPERATIO OTE: 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. 2. Release RAISE button and as platform is lowering pull and hold the Safety Leg Chain, if equipped. 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 7 & 8. FIURE 9 - LEVELER STORED Pub. o May

10 enisys AL-900 Dock Leveler Owner s Manual MAITEACE PROCEDURES Read and obey these instructions to prevent personal injury. SUESTED LEVELER MAITEACE Daily 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. OTE: Follow maintenance procedures below as outlined. Include the specific steps for your leveler model. OTE: 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. 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. 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. OTE: 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 EMA 4X and will not change the enviromental rating of the control box. 10. With the leveler supported by the maintenance strut, inspect the air tower and blower for damage. Replace if worn or damaged. 360 Days 1. Perform Daily and 90-Day Maintenance. 2. Check and tighten control box mounting hardware. 90 Days 1. Perform all Daily Maintenance. 2. Clean pit. 3. Inspect lip out mechanism (pins, lip crank, links, chains and shackles). Replace if worn. 4. Lubricate the leveler with the proper lubricants. See figure 10. OTE: Items that use Anti-Seize lubricant only require lubrication every 360 Days. 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. 10 Pub. o May 2014

11 enisys AL-900 Dock Leveler Owner s Manual LUBRICATIO CHART OIL SAE 30 Weight Anti-Seize FIURE 10 - LEVELER LUBRICATIO Pub. o May

12 enisys AL-900 Dock Leveler Owner s Manual LEVELER ADJUSTMETS LIP LATCH BOLT ADJUSTMET The lip latch bolt is factory adjusted. Over time however, if the lip does OT latch when the leveler is fully raised and remain latched as the platform lowers, the lip latch bolt may need to be readjusted. Use the following procedure to readjust the lip latch bolt: 1. Loosen the jam nuts on the lip latch bolt. See figure Turn the bolt clockwise one full turn at a time. See figure 11. Flat On Bolt Head To Be Parallel To Bottom Of Lip Crank Mount. 3. Tighten the jam nuts on the lip latch bolt. 4. Follow normal operating procedures to verify that the lip latch has been adjusted correctly and holds the lip out as the platform lowers. Test unit three times to make sure it latches all three times, if not readjust. OTE: DO OT over adjust the lip latch bolt. When properly adjusted the lip should just latch in. If you have over adjusted the lip may not release, or it will bend the delatch rod over time. Re-adjust bolt until lip no longer latches and then make one full turn of the bolt until lip just latches. LIP STOP BOLT ADJUSTMET 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. 1 1/8 Preset FIURE 11 - LIP LATCH BOLT ADJUSTMET Lip Stop Bolt Lip Centered In Keepers FIURE 12 - LIP STOP BOLT 12 Pub. o May 2014

13 enisys AL-900 Dock Leveler Owner s Manual Problem 1. Platform does not raise 2. Lip will not extend. 3. Lip remains fully or partially extended. 4. Platform does not lower. 5. Platform raises slowly. 6. Lip does not latch. Probable Cause a. Power has been disconnected. b. The blower motor and/or control box has been miswired. c. The pushbutton and/or contact block does not function properly. d. Overload relay tripped. e. The blower motor has failed. f. Check blower and air tower system for damage. a. Debris in lip hinge or lubrication needed. b. Lip out mechanism or below dock actuator is damaged. a. Debris in lip hinge. b. Lip out mechanism or below dock actuator is damaged. c. Lip impacted or bent. a. Debris under platform. a. Air tower system damaged. b. Weight on platform. a. Lip latch adjustment bolt out of adjustment. LEVELER TROUBLESHOOTI Solution a. Verify that power has not been disconnected and that disconnect circuit breaker or fuses are not tripped. b. Verify that the blower motor and/or control box have been wired according to the wiring schematic. c. Replace pushbutton operator and/or contact block. d. Push RESET on overload relay, if applicable. e. Replace Air Tower assy. if necessary. f. Repair or Replace components if necessary. a. Remove dirt, debris and corrosion from the lip hinge and/or lubricate. See maintenance procedures. b. Repair or replace damaged components. a. Remove debris from lip hinge. b. Repair or replace damaged components. c. Lubricate per maintenance procedures or replace lip. a. Remove debris. a. Repair or replace components if necessary. b. Remove weight on platform. a. Readjust lip latch bolt. See Figure 11. Pub. o May

14 enisys AL-900 Dock Leveler Owner s Manual ELECTRICAL WIRI CHARTS Average Motor Loads (Amps) Air Hydraulic Leveler Levelers 3/4 hp 1hp / /A / /A /3 /A /A /3 /A /A /3 /A /A /3 /A /A 1.7 Minimum Wire Size Chart for Various Line Lengths and Line Loads Line Length (In Feet) / watts Air Powered Levelers /1 3/4 hp Hydraulic Levelers /1 1 hp Hydraulic Levelers / watts Air Powered Levelers /1 3/4 hp Hydraulic Levelers /1 1 hp Hydraulic Levelers /3 1hp Hydraulic Levelers /3 1 hp Hydraulic Levelers /3 1 hp Hydraulic Levelers /3 1 hp Hydraulic Levelers Pub. o May 2014

15 enisys AL-900 Dock Leveler Owner s Manual ELECTRICAL SCHEMATICS FROM CUSTOMER MAI POWER & SAFETY PROTECTIO v. 1PH. 60HZ. USE 15.0A DUAL ELEMET TIME DELAY v. 1PH. 60HZ. USE 10.0A DUAL ELEMET TIME DELAY v. 1PH. 50HZ. USE 10.0A DUAL ELEMET TIME DELAY SEE OTE 4 FUSED DISCOECT (BY OTHERS) IF FUSED DISCOECT IS OT PROVIDED BY RITE-HITE PRODUCTS CORPORATIO, FUSED DISCOECT MUST BE PROVIDED BY OTHERS AD ISTALLED PER LATEST EDITIO OF UL508A AD EC REQUIREMETS. SEE OTE 1 L 1 1L1 A BRACH CIRCUIT DISCOECT SHALL BE LOCATED WITHI A 50 FT. RADIUS AD BE VISIBLE FROM THE COTROL BOX LOCATIO. [REFERECE LATEST EDITIO OF EC, SECTIO 430] SEE OTE 1 PIT J-BOX MOTOR J-BOX MOTOR J-BOX "RAISE" T1 T1 T1 MOT MOT PB1 TO DOK-LOK COTROL BOX FOR VEHICLE RESTRAIT ITC. BLOWER MOTOR 1300 WATTS MAXIMUM (SEE MOTOR FLA CHART) 115/1 50/60 Hz ITERMITTET DUTY 1L2 BLOWER MOTOR 1533 WATTS MAXIMUM (SEE MOTOR FLA CHART) /1 50/60 Hz ITERMITTET DUTY OTE: 1. All Incoming Power (From Disconnect to Control Box) and Leveler Motor Field Wiring To Be Minimum #12A./Maximum #10A. 60/75 Deg. C Copper Wire, Insulated Sufficiently For Incoming Voltage. 2. All Control Field Wiring To Be Minimum #14A. 60/75 Deg. C Copper Wire Only, Insulated Sufficiently For Incoming Power. 3. All Internal Control Box Wiring To Be Minimum #16A. 90 Deg. C, Red Copper Wire Unless Otherwise oted, Insulated Sufficiently For Incoming Power. 4. Incoming Power Field Wiring: See Minimum Wire Size Chart. LEED: DEOTES WIRE COECTIOS THRU TERMIAL BLOCK. DEOTES FIELD WIRES. DEOTES WIRE UT COECTIO DEOTES MALE/FEMALE PLU COECTIO FIURE 13 - TYPE 1 COTROL BOX - 120V./ V. 50/60HZ. SILE PHASE SCHEMATIC Pub. o May

16 enisys AL-900 Dock Leveler Owner s Manual ELECTRICAL SCHEMATICS COT. FROM CUSTOMER MAI POWER & SAFETY PROTECTIO v. 1PH. 60HZ. USE 15.0A DUAL ELEMET TIME DELAY v. 1PH. 60HZ. USE 10.0A DUAL ELEMET TIME DELAY v. 1PH. 50HZ. USE 10.0A DUAL ELEMET TIME DELAY SEE OTE 4 FUSED DISCOECT (BY OTHERS) IF FUSED DISCOECT IS OT PROVIDED BY RITE- HITE PRODUCTS CORPORATIO, FUSED DISCOECT MUST BE PROVIDED BY OTHERS AD ISTALLED PER LATEST EDITIO OF UL508A AD EC REQUIREMETS. SEE OTE 1 SEE OTE AMP. 250v. DUAL ELM TIME DELAY H4(RD) 1L1(RD) 10FU1 "RAISE" H4 H4(RD) H5(RD) PB1 1L1 L1 1L1 1L2 (WH) #12A. MIIMUM, 90 C, BLACK #12A. MIIMUM, 90 C, WHITE A BRACH CIRCUIT DISCOECT SHALL BE LOCATED WITHI A 50 FT. RADIUS AD BE VISIBLE FROM THE COTROL BOX LOCATIO. [REFERECE LATEST EDITIO OF EC, SECTIO 430] FOR /1/60, ICOMI POWER AD MOTOR WIRI TERMIATE AT "1L2" TERMIAL. (SEE SPECIFIC SCHEMATIC FOR FURTHER DETAILS) (1) R1-1 SEE OTE 1 JUMPER WIRE MTR RLY H5 H5A H5A(RD) R1 (WH) (6) (5) LS1 "DOOR ITERLOCK" 120 VAC (4) (3).O. SHOW WITH DOOR CLOSED. (4) TO DOK-LOK COTROL BOX FOR VEHICLE RESTRAIT ITC. T1 PIT J-BOX MOTOR J-BOX T1 MOT BLOWER MOTOR 1300 WATTS MAXIMUM (SEE MOTOR FLA CHART) 115/1 50/60 Hz ITERMITTET DUTY MOTOR J-BOX T1 1L2 MOT BLOWER MOTOR 1533 WATTS MAXIMUM (SEE MOTOR FLA CHART) /1 50/60 Hz ITERMITTET DUTY OTE: 1. All Incoming Power (From Disconnect to Control Box) and Leveler Motor Field Wiring To Be Minimum #12A./Maximum #10A. 60/75 Deg. C Copper Wire, Insulated Sufficiently For Incoming Voltage. 2. All Control Field Wiring To Be Minimum #14A. 60/75 Deg. C Copper Wire Only, Insulated Sufficiently For Incoming Power. 3. All Internal Control Box Wiring To Be Minimum #16A. 90 Deg. C, Red Copper Wire Unless Otherwise oted, Insulated Sufficiently For Incoming Power. 4. Incoming Power Field Wiring: See Minimum Wire Size Chart. LEED: DEOTES WIRE COECTIOS THRU TERMIAL BLOCK. DEOTES FIELD WIRES. DEOTES WIRE UT COECTIO DEOTES MALE/FEMALE PLU COECTIO FIURE 14 - TYPE 2 COTROL BOX - 120V./ V. 50/60 HZ. SILE PHASE SCHEMATIC 16 Pub. o May 2014

17 (-) RT (+) FROM CUSTOMER MAI POWER & SAFETY PROTECTIO DEVICE v. 1PH. 60HZ. USE 15.0A DUAL ELEMET TIME DELAY FUSES v. 1PH. 60HZ. USE 10.0A DUAL ELEMET TIME DELAY FUSES SEE OTE 4 enisys AL-900 Dock Leveler Owner s Manual ELECTRICAL SCHEMATICS COT. FUSED DISCOECT (BY OTHERS) IF FUSED DISCOECT IS OT PROVIDED BY RITE-HITE PRODUCTS CORPORATIO, FUSED DISCOECT MUST BE PROVIDED BY OTHERS AD ISTALLED PER LATEST EDITIO OF UL508A AD EC REQUIREMETS. SEE OTE 1 1L1 L1 1L1 1L2 A BRACH CIRCUIT DISCOECT SHALL BE LOCATED WITHI A 50 FT. RADIUS AD BE VISIBLE FROM THE COTROL BOX LOCATIO. [REFERECE LATEST EDITIO OF EC, SECTIO 430] FOR /1/60, ICOMI POWER AD MOTOR WIRI TERMIATE AT "1L2" TERMIAL. (SEE SPECIFIC SCHEMATIC FOR FURTHER DETAILS) PIT J-BOX MOTOR J-BOX MOTOR J-BOX T1 T1 T1 #12A. MIIMUM, 90 C, BLACK 1.0 AMP. 250v. DUAL ELM H3(RD) TIME DELAY 1L1(RD) (WH) H3(RD) H5(RD) "RAISE" 10FU1 H5(RD) H5B(RD) H5 } #12A. MIIMUM, 90 C, WHITE FOR VEHICLE RESTRAIT ITC. TO DOK-LOK COTROL BOX JUMPER TERMIAL BLOCK H5A LS2 "DOOR ITERLOCK" (4) (3).O. SHOW WITH DOOR CLOSED. SEE OTE 1 H5A(RD) (A1) 1MCR 70VA (A2) H5B(RD) (WH) MOT BLOWER MOTOR 1300 WATTS MAXIMUM (SEE MOTOR FLA CHART) 115/1 50/60 Hz ITERMITTET DUTY 1L2 MOT BLOWER MOTOR 1533 WATTS MAXIMUM (SEE MOTOR FLA CHART) /1 50/60 Hz ITERMITTET DUTY OTE: 1. All Incoming Power (From Disconnect to Control Box) and Leveler Motor Field Wiring To Be Minimum #12A./Maximum #10A. 60/75 Deg. C Copper Wire, Insulated Sufficiently For Incoming Voltage. 2. All Control Field Wiring To Be Minimum #14A. 60/75 Deg. C Copper Wire Only, Insulated Sufficiently For Incoming Power. 3. All Internal Control Box Wiring To Be Minimum #16A. 90 Deg. C, Red Copper Wire Unless Otherwise oted, Insulated Sufficiently For Incoming Power. 4. Incoming Power Field Wiring: See Minimum Wire Size Chart. H3(RD) PB1 H4(RD) 3 2 ~ ~ V L S1 1 (WH) TMR1: SILE SHOT LEED: DEOTES WIRE COECTIOS THRU TERMIAL BLOCK. DEOTES FIELD WIRES. DEOTES WIRE UT COECTIO DEOTES MALE/FEMALE PLU COECTIO H4 LS1 "ARTD LIMIT SWITCH" 4(BLK) 7(WHT).O. H FIURE 15 - TYPE 3 COTROL BOX - 120V./240V. 60 HZ. ELECTRICAL SCHEMATIC Pub. o May

18 (-) RT (+) enisys AL-900 Dock Leveler Owner s Manual ELECTRICAL SCHEMATICS COT. FROM CUSTOMER MAI POWER & SAFETY PROTECTIO DEVICE v. 1PH. 50HZ. USE 10.0A DUAL ELEMET TIME DELAY FUSES SEE OTE 4 FUSED DISCOECT (BY OTHERS) IF FUSED DISCOECT IS OT PROVIDED BY RITE-HITE PRODUCTS CORPORATIO, FUSED DISCOECT MUST BE PROVIDED BY OTHERS AD ISTALLED PER LATEST EDITIO OF UL508A AD EC REQUIREMETS. SEE OTE 1 CAUTIO #12A. MIIMUM, 90 C, BLACK 2FU2 2L1 (H1) 1L1 (H3) (H2) TRASFORMER FOR LEVELER COTROLS OLY! DO OT USE TO POWER 10FU1 AUXILIARY EQUIPMET.(X1) L 1 1L1 120v. 2FU2 2L2 (H4) (X2) #12A. MIIMUM, 90 C, WHITE 50VA A BRACH CIRCUIT DISCOECT SHALL BE LOCATED WITHI A 50 FT. RADIUS AD BE VISIBLE FROM THE COTROL BOX LOCATIO. [REFERECE LATEST EDITIO OF EC, SECTIO 430] 1MCR SEE OTE AMP. 250v. DUAL ELM TIME DELAY #12A. MIIMUM, REE T1 TRASFORMER PRIMARY FUSI 1.0 AMP. 600v. CLASS CC REJ DUAL ELM TD PIT J-BOX MOTOR J-BOX T1 1L2 MOT BLOWER MOTOR 1533 WATTS MAXIMUM (SEE MOTOR FLA CHART) /1 50/60 Hz ITERMITTET DUTY OTE: 1. All Incoming Power (From Disconnect to Control Box) and Leveler Motor Field Wiring To Be Minimum #12A./Maximum #10A. 60/75 Deg. C Copper Wire, Insulated Sufficiently For Incoming Voltage. 2. All Control Field Wiring To Be Minimum #14A. 60/75 Deg. C Copper Wire Only, Insulated Sufficiently For Incoming Power. 3. All Internal Control Box Wiring To Be Minimum #16A. 90 Deg. C, Red Copper Wire Unless Otherwise oted, Insulated Sufficiently For Incoming Power. 4. Incoming Power Field Wiring: See Minimum Wire Size Chart. H3(RD) X2(WH) H3(RD) "RAISE" H5(RD) } FOR VEHICLE RESTRAIT ITC. TO DOK-LOK COTROL BOX JUMPER TERMIAL BLOCK H5 H5A H5A(RD) 1MCR 70VA X2(WH) LEED: DEOTES WIRE COECTIOS THRU TERMIAL BLOCK. DEOTES FIELD WIRES. DEOTES WIRE UT COECTIO DEOTES MALE/FEMALE PLU COECTIO H5(RD) H5B(RD) LS2 "DOOR ITERLOCK" (4) (3).O. SHOW WITH DOOR CLOSED. (A1) (A2) H5B(RD) X2(WH) H3(RD) PB1 H4(RD) 3 2 ~ ~ V L S1 1 TMR1: SILE SHOT H4 LS1 "ARTD LIMIT SWITCH" 4(BLK) 7(WHT).O. H FIURE 16 - TYPE 3 COTROL BOX V. 50HZ. SILE PHASE 18 Pub. o May 2014

19 enisys AL-900 Dock Leveler Owner s Manual OTES Pub. o May

20 enisys AL-900 Dock Leveler Owner s Manual REPLACEMET PARTS , Pub. o May 2014

21 enisys AL-900 Dock Leveler Owner s Manual REPLACEMET PARTS LIST Leveler Length Item Qty. Description 6' Long 8' Long 10' Long 1 1 Frame Weldment 673.xxx 673.xxx 673.xxx 2 1 Platform Weldment 436.xxx 436.xxx 436.xxx 3 1 Lip Weldment 421.xxx 421.xxx 421.xxx 4 1 Lip Out Lug/Lever Lip Hinge Pin 6 Wide Lip Hinge Pin 6.5 Wide Lip Hinge Pin 7 Wide Lip Hinge Pin 6 Wide (Stainless Steel) Lip Hinge Pin 6.5 Wide (Stainless Steel) Lip Hinge Pin 7 Wide (Stainless Steel) Tension Pin,.25Dia. x 1.75L Clevis Pin, Headed,.875 x 3.25L roove ZP Clevis Pin, Headed,.875 x 3.25L r (Stainless Steel) Ring, Ext. Retaining,.875OD Bolt, Hex.75-10UC x 3L ZP ut, Hex.75-10UC ZP Bolt Hex.5-13 UC x 1.75L 5 ZP Jam ut.5-13 UC Lip Crank Torsion Spring 180 Deg OD MW Clevis Pin.5 x 4L HD ZP Lip Link Clevis Pin, Headed.5 Dia. 1.75L 1Hole ZP Cotter Pin.125 Dia. x 1L ZP Flat Washer.500 Flat MED ZP Flat Washer.375 Flat MED ZP Chain 7MM r30 LD RT 1300Lb. ZP Chain Shackle, 3/ Air Tower Assy. 120V/1Ph 3Stage Air Tower Assy V/1Ph 3Stage Round.312 Dia. x 46.5L Bar.25 x 1.25 x 9L Hole Hydrachek Bore (1DIA) Washer.547ID 2.25OD.25Thk ZP Bolt UC 3.5L Hex ZP ut uc ylock Jam ZP Clevis Pin.5 x 2.25L Hole ZP Safety Leg 3.06 x 7L Round.5Dia L HR M S-Hook.219 Wire Chain Assembly Lanyard Twist #1/0 ZP Clevis Pin.5 Dia 1.25L Hole ZP Cam MBDC.375 x 4 x 5.88 M Lanyard Assy Air Tower Deep Pit Conversion platform - 4 (DPC Only) 665Dxxx 665Dxxx 665Dxxx 39 1 Maintenance Support Chain Assembly Pub. o May

22 enisys AL-900 Dock Leveler Owner s Manual REPLACEMET PARTS - COT , Pub. o May 2014

23 enisys AL-900 Dock Leveler Owner s Manual REPLACEMET PARTS LIST COT. Leveler Length Item Qty. Description 6' Long 8' Long 10' Long 41 1 Full Range LH (2 Fan) (ot Shown) Full Range LH (3 Fan) Full Range RH (2 Fan) (ot Shown) Full Range RH (3 Fan) (ot Shown) Toeguard Fan 14A x 11 4Hole 1Slot LH Toeguard Fan 14A x 11 4Hole 1Slot RH (ot Shown) Toeguard Fan 14A x 11 3Hole 1Slot LH Toeguard Fan 14A x 11 3Hole 1Slot RH (ot Shown) Toeguard Fan 14A x 11 2Hole 1Slot LH (3 Fan Only) Toeguard Fan 14A x 11 2Hole 1Slot LH (3 Fan Only) Bolt Hex x 1L 5 ZP ylock ut UC ZP Pin Clevis.5 x 2L Hole HD ZP Hook shpng 18/20LP Formed (ot Shown) Cylinder Assembly - Stump Out Weatherseal Insert - PT2-1 (ot Shown) Weatherseal Insert - B1-1 (ot Shown) Washer SAE ZP Washer.75 Split LK Heavy ZP Trigger, ARTD Cam SPL (ARTD Only) Limit Switch Assembly (ARTD Only) Screw 8-32 HD CAP Washer.5 LK Lip Keeper Weldment Formed Operational Sign (ot Shown) Decal Sheet Manufacturing (ot Shown) Decal Sheet Field (ot Shown) Cover - Tub Locator Pub. o May

24 enisys AL-900 Dock Leveler Owner s Manual TYPE 1 COTROL BOX PARTS ISIDE LEFT 5 ISIDE RIHT 7 Back Of Cover Item Qty. Description Part umber 1 1 Control Box Complete 228.xxx 2 1 Control Box Enclosure, 4 x 4 x 2 4XF Push Button 12/ Push Button 4X Control Box Cover Decal, Raise 3 x 3 Hole (30.5MM Oprtr) Decal V/PH/FLA 230.xxx 6 1 Decal UL/ULC Contact Block, O 30.5MM 600V (1.5 HP) Pub. o May 2014

25 enisys AL-900 Dock Leveler Owner s Manual TYPE 2 COTROL BOX PARTS , 17, 18 TOP RITE-HITE CORP. (414) ISIDE LEFT 19, 17, 18 16, 17, ISIDE RIHT Item Qty. Description Part umber 1 1 Control Box Complete 228.xxx 2 1 Control Box Enclosure, 6 x 6 x 4 4XF Push Button Operator (22.5MM) Black, O, 12/ Push Button Operator (22.5MM) Black, O, 4X Control Box Cover Decal, Raise, 4 x 6, 1 Hole (22.5MM Oprtr) Decal V/PH/FLA 230.xxx 6 1 Decal UL/ULC Decal, Fuse Replacement Mounting Latch, 3 Across Contact Block, 1.O. (22.5MM) Terminal Strip Assm., 6PT, 8-14AW Decal Terminal Strip, 6PT 115/1PH Decal Terminal Strip, 6PT 230/1PH Fuse Holder, 1 Pole Fuse 1A 250V 3A Relay, 1P IP (120VAC) Relay, 1P IP (240VAC) AW Female Terminal Insulating Wire Crimp Screw #6-32 x 1, Cap Flat CTSK SLTD ZP ut #6-32, Hex ZP Lock Washer #6 Lock Washer, Ext. Tooth ZP Screw #6-32 x.6, Cap Flat CTSK SLTD ZP Screw #6-32 x.4375, Cap Flat CTSK SLTD ZP Pub. o May

26 (-) (+) RT enisys AL-900 Dock Leveler Owner s Manual TYPE 3 COTROL BOX PARTS 2 3 4, 5, , ,13,14, H4 H4 H5 H5 H5A H5A X2/ X2/ 1L1 1L2 1L1 1L2 L1 L2 L3 19 H4 H ~ ~ V 1 L S OUTSIDE LEFT 30 OUTSIDE RIHT 29 ISIDE LEFT 26 Pub. o May 2014

27 enisys AL-900 Dock Leveler Owner s Manual TYPE 3 COTROL BOX REPLACEMET PARTS LIST Item Qty. Description Part umber 1 1 Control Box Complete 219.xxx 2 1 Control Box Enclosure, 10 x 8 x Control Box Enclosure, 10 x 8 x Control Box Enclosure, 14 x 12 x 8 4X (ot Shown) Push Button Operator (22.5MM) Black, 12/ Push Button Operator (22.5MM) Black, 4X Contact Block Mounting Latch Contact Block, Black, O Contact Block, Black, C Cover Decal round Lug Fuse Holder A Fuse, 250V Slo-Blow, (Installed Without Transformer) Terminal Jumper Red Terminal Block Black Terminal Block, 600V, 50A (1L1/ 1L2) White Terminal Block, 600V, 50A () End Anchor Terminal Block Mounting Din Rail Back Panel, Drilled, 10 x Back Panel, Drilled, 14 x Leveler Motor Contactor Leveler Control Fuse, 1A 250V Dual Elm., 230/1/ Transformer Primary Fuse, 1A CC Rej. Dual Elm., 230/1/ Single Shot Time, ARTD Timer Mounting Bracket Transformer, 50VA 240/480V round Harness Decal Fuse Replacement, 115/230/1/ Decal Fuse Replacement, 230/1/ Decal UL/ULC - Consult Rite-Hite Decal Voltage/Phase/FLA 226.xxx 28 1 Decal Operation Decal Electrical Schematic 225.xxx 30 1 Decal Lockout/Tagout Pub. o May

28 WARRATY enisys Dock Leveler by Rite-Hite Standard Warranty Policy Rite-Hite warrants to and for the sole benefit of the original purchaser that enisys by Rite-Hite (hereinafter "enisys") Dock Levelers shall be free from defects in material and workmanship subject to the following: Length of Time: All products are warranted for a one year period commencing on the earlier date of approved installation or the (30th) day after the date of shipment. This warranty covers the repair or replacement of the defective product or component at Rite-Hite's sole election and expense, including reasonable labor, reasonable travel and freight. Component Scope: The structural components protected by this warranty include the rear frame, deck, lip, front and rear hinge area and working range toe guards on all enisys Dock Levelers. On HL Series dock levelers, all cylinders, pumps, hoses, fittings, electrical motors and control panels are covered. On ML Series mechanical levelers, springs, chains, lip extension mechanism, main counterbalance and ramp control are covered. On AL Series dock levelers, air tower, blower motor, hoses, lip extension mechanism, chains and control panels are covered. 5 year warranty on the air tower, blower motor, and hoses. Repair part freight costs will be borne by Rite-Hite via standard shipping terms. Charges for overnight or special freight requirements will be billed to the end user, eneral Contractor or enisys Representative and must be approved at time of shipment. Warranty claims will not be accepted if the parts and/or assemblies have not been installed on enisys products or the installation has not been carried out in accordance with enisys installation instructions. If a part is replaced during the standard warranty period, it will be covered for the remainder of the warranty period for the dock leveler. The above warranties are in lieu of any other warranties, either expressed or implied, including but not limited to any warranty of merchantability or implied warranty of fitness for a particular application. In no event shall Rite-Hite or any of its subsidiaries be responsible for or liable to anyone, including third parties, for special, indirect, punitive, incidental or consequential damages, even if Rite-Hite Representative has been advised of the possibility of such damages. Such excluded damages include, but are not limited to, loss of goodwill, loss of profits, loss of use, interruption of business, or other similar indirect financial loss. This limited warranty shall be void and of no effect: if product is altered or modified from its original condition as installed or as delivered at or from the factory to the extent that the product defect is the direct result of improper installation, operation beyond capacity, or other than in accordance with enisys instructions, careless or negligent use, or failure to maintain the product as recommended by the enisys owner's manual. com- if Rite-Hite or the enisys Representative is not notified of the defect and such notification failure creates additional ponent or product stress which compounds the cost for defect correction. if the product is not adjusted and lubricated on the intervals and to the extent required in the enisys Owner's Manual. if the product is moved and reinstalled from its original installation point without advising Rite-Hite or a Rite-Hite Representative. By Rite-Hite Arbon Dr. Milwaukee, Wisconsin USA (414)