RHE3 Dock Leveler Installation Manual MADE IN U.S.A. This Manual Covers Dock Levelers Built After Serial Numbers: 07FE160001M and up PRINTED IN U.S.A. RITE-HITE PRINT SHOP PUBLICATION NO. 1222 MAY 2007
NOTES 2 Pub. No. 1222 - May 2007
TABLE OF CONTENTS NOTICE TO USER..........................................................................3 SAFETY WARNINGS........................................................................4 INSTALLATION INSTRUCTIONS...............................................................7 OPTIONAL TRANSITION PLATE INSTALLATION INSTRUCTIONS....................................9 OPTIONAL HYDRAULIC POWER KIT INSTALLATION INSTRUCTIONS..............................10 OPTIONAL TELESCOPING HANDLE INSTALLATION INSTRUCTIONS...............................14 WARRANTY....................................................................BACK COVER 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 414-355-2600. The RITE-HITE products in this manual are covered by one or more of the following U.S. patents: 4,744,121; 4,819,770; 4,843,373; 4,865,507; 4,920,598; 4,995,130; 5,040,258; 5,111,546; 5,212,846; 5,271,183; 5,299,386; 5,311,628; 5,323,503; 5,375,965; 5,440,772; 5,442,825; 5,453,735; 5,531,557; 5,546,623; 5,553,987; 5,582,498; 5,664,930; 5,702,223; 5,762,459 (RE: 37,570); 5,882,167; 5,964,572; 6,010,297; 6,052,268; 6,065,172; 6,070,283; 6,074,157; 6,085,375; 6,092,970; 6,106,212; 6,116,839; 6,190,109; 6,220,809; 6,627,016; 6,238,163; 6,311,352; 6,322,310; 6,360,394; 6,368,043; 6,431,819; 6,488,464; 6,497,076; 6,499,169; 6,505,713; 6,524,053; 6,634,049; 6,654,976; 6,676,360; 6,726,432; 6,773,221; 6,832,403; 6,880,301 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 and SAFE-T-GATE are trademarks of RITE-HITE Corporation. Pub. No. 1222 - May 2007 3
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 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 1910.147). 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 3120. 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. 1222 - May 2007
OTHER IMPORTANT OPERATIONAL SAFETY WARNINGS Never be under the dock leveler platform or lip without: Installing the maintenance strut. Always barricade the dock leveler at ground level and dock level from any form of traffic when maintenance is required. 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. 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. If a malfunction does occur, always call your authorized RITE-HITE service representative immediately. Pub. No. 1222 - May 2007 5
SAFETY DEVICES Never be under the dock leveler platform or lip without: Installing the Maintenance Strut. See right. The operation handle also serves as a maintenance strut preventing the leveler from rotating onto the maintenance personnel. 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. If you are unable to install the Maintenance Support properly, contact your authorized RITE-HITE Service Representative or RITE- HITE Customer Service at 1-414-355-2600. To install the strut: Rotate the leveler to its rearward 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. Remove the clevis pin attaching the lip latch to the underside of the lip. When lifting lip (approx. 110 lbs.) use lifting device (crane). Lifting by hand may cause back injury. Rotate the lip up and over. Place the handle in the socket provided. 6 Pub. No. 1222 - May 2007
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. PREPARATION PRIOR TO INSTALLATION 1. Check pit to insure it meets pit details. If pit does not match pit details, contact your local representative or RITE-HITE before proceeding. NOTE: Unit may not operate properly if pit is not correct. Operating Socket RITE-HITE RHE3 Dock Leveler Installation Manual INSTALLATION INSTRUCTIONS 2. The dock must be clean, straight, and free of protrusions. Adequately sized dock edge steel must be an integral part of the dock or a transition plate with face plate must be utilized. INSTALLATION PROCEDURES 1. Center the leveler in place. The top of faceplate should be 5/16 ± 1/16 below the top surface of dock edge steel (or transition plate if used). 2. Weld the leveler and bumper blocks to dock edge steel and/or transition plate. Use 7018 welding rod. 3. All anchor holes must be anchored with 5/8 x 5L concrete anchor bolts (RH# 65639) or plug welded to dock edge steel. See figure 1. 4. Clean and paint all welded joints. 5. Lubricate dock leveler per lubrication chart. See figure 2. Transition plate must be installed on docks without proper dock-edge steel Top of Faceplate 5/16 ± 1/16 below top of dock or Transition Plate Handle Storage Socket 1/4 3 Each End 1/4 Above each hinge tube welded to the faceplate 1/4 Continuous Bumpers See Step #3 No gap between Faceplate and Bumper Flange Bumper Flange with Anchor Holes 5/16 ±1/16 FLATNESS: ± 1/8 CHANNEL: C8 x 11.5lb/ft Anchor Leg 1/4 x 1-1/2 x 11 steel flat with 90 bend to form 1-3/4 angle 108 10 MAX 1 3/4 RECOMMENDED DOCK EDGE STEEL (Not Supplied By Rite-Hite) FIGURE 1 - INSTALLATION Pub. No. 1222 - May 2007 7
LUBRICATION CHART Lip Lip Hinge (Grease or Oil) Deck Hinge Pin (Grease) Spring Assembly (Grease or Oil) Handle Socket Hinge Pin (Grease) Lip Latch (Grease or Oil) Faceplate Riser (Grease) Lip Stop Maintenance Strut FIGURE 2 - LEVELER LUBRICATION DETAIL 8 Pub. No. 1222 - May 2007
OPTIONAL TRANSITION PLATE INSTALLATION INSTRUCTIONS 108 6ea. Anchor Holes 1) Install 5/8 x 5L Concrete Anchor Bolts (RH # 65639) 2) Grind Head Flush With Transition Plate 3) Weld To Transition Plate 1-1/2 12, 18, or 24 15-7/8 66, 72, 78 or 84 15-7/8 Transition Plate must be installed on docks without proper Dock Edge Steel. (8 Channel with anchor legs on 10 centers) Set Faceplate of leveler 5/16 ± 1/16 below top surface of Dock Edge Steel or Transition Plate 1/4 3 Each End 1/4 Above each Hinge Tube welded to the Faceplate 1/4 Continuous Bumpers Deck A Bumper Flange No gap between Faceplate and Bumper Flange Anchor Holes Lip Faceplate Dock Edge Steel 3/16 21-1/2 for 24 Trans. Plate 15-1/2 for 18 Trans. Plate 9-1/2 for 12 Trans. Plate 2-1/2 1/2 Chamfer Detail A Transition Plate FIGURE 3 - TRANSITION PLATE INSTALLATION Pub. No. 1222 - May 2007 9
OPTIONAL HYDRAULIC POWER KIT INSTALLATION INSTRUCTIONS 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. The Edge of Dock Leveler must be properly installed prior to installation of the hydraulic power kit in accordance with leveler installation instructions. PARTS LIST ITEM PICTORIAL DESCRIPTION QTY A 3/4 x 5 Clevis Pin 1 B 3/4 x 2-3/4 Clevis Pin 2 C Cylinder Bracket 1 The operation handle also serves as a maintenance strut preventing the leveler from rotating onto the maintenance personnel. D 3/4 Plain Washer 3 E Rue Ring Cotter 4 F 3/8 Bolt 2 G Hydraulic Power Unit 1 H Hydraulic Cylinder 1 I Electrical Control Box 1 J Reservoir Breather Cap 1 K Motor Mount Bracket 1 To install the strut: Rotate the leveler to its rearward position. Remove the clevis pin attaching the lip latch to the underside of the lip. When lifting lip (approx. 110 lbs.) use lifting device (crane). Lifting by hand may cause back injury. Rotate the lip up and over. Place the handle in the socket provided. L Lift Arm, Hydraulic 1 PREPARATION PRIOR TO INSTALLATION 1. Verify all components are in the shipping container, If not contact your local representative. 2. Install maintenance strut. 10 Pub. No. 1222 - May 2007
OPTIONAL HYDRAULIC POWER KIT INSTALLATION INSTRUCTIONS CONT. (E) Rue Ring (L) Lift Arm (E) Rue Ring (D) Washer (B) Clevis Pin (C) Cylinder Bracket (K) Motor Mount Bracket FIGURE 4 - LIFT ARM, CYLINDER BRACKET, AND MOTOR MOUNT PLACEMENT INSTALLATION PROCEDURES 1. Remove the existing lift arm from RHE. Be sure to retain the clevis pins and washers. 2. Position the Lift Arm (L) and Cylinder Bracket (C) as shown in figure 4. Reuse the clevis pins and washers with new Rue Rings (E) to pin the Cylinder Bracket (C) and Lift Arm (L) to the leveler. 3. Weld or anchor bolt the cylinder bracket flange to the dock face with 5/8 x 5L concrete anchor bolts. (RH# 65639) 4. Use one 2-3/4 long Clevis Pin (B), one 3/4 Washer (D), and one Rue Ring Cotter (E) to pin the Motor Mount Bracket (K) to the leveler as shown in figure 4. 5. Use one 2-3/4 long Clevis Pin (B), one 3/4 Washer (D), and one Rue Ring Cotter (E) to pin the rod end of the Hydraulic Cylinder (H) to the riser lift arm. See figure 5. 6. Use two 3/8 Bolts (F) to bolt the Hydraulic Power Unit (G) to the mounting bracket (K). See figure 5. NOTE: Ensure hoses are behind the Hydraulic Power Unit (G) next to the faceplate. See figure 5. Hoses Behind Hyd. Power Unit (G) Hyd. Power Unit (D) Washer (B) Clevis Pin (E) Rue Ring (H) Hydraulic Cylinder FIGURE 5 - HYDRAULIC COMPONENT INSTALLATION Pub. No. 1222 - May 2007 11
OPTIONAL HYDRAULIC POWER KIT INSTALLATION INSTRUCTIONS CONT. To Power See Step #8 For Specifications On Fused Disconnect with Lockout/Tagout Device To Power See Step #8 For Specifications On Fused Disconnect with Lockout/Tagout Device (I) Control Box (I) Control Box Approx 5ft Building Floor Approx 5ft Building Floor 21 Min 16 1/2 Junction Box 20 36 1/2 To Motor Hyd. Unit J-Box 8-1/4 Out From Dock Face Junction Box 19 36 1/2 To Motor Junction Box FACE MOUNTED PIT MOUNTED FIGURE 6 - ELECTRICAL ELECTRICAL INSTALLATION PROCEDURES 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. 7. Securely mount the Electrical Control Box (I) on the inside ensuring the operator has a clear view of the dock at all times. See figure 6. 8. Route electrical conduit and wire the system according to the electrical schematic on the inside cover of the Electrical Control Box (I). Check local electrical codes before beginning control box installation. Reference Only - See Control Box Drawing For Complete Fusing Requirements Voltage & Phase 115V (1 Phase) 220V (1 Phase) 208-230V (3 Phase) 460V (3 Phase) Leveler Motor Full Load Amps 5.1 Amps 2.3 Amps 1.1-1.0 Amps 0.5 Amps Branch Circuit Disconnect Fusing Required 10 Amps 5 Amps 3 Amps 2 Amps 0 NOTES: 1) Minimum Wire size - # 14 Gauge Copper (75 C). 2) Properly Ground Disconnect, Motor And Control Box. 3) All Motors Are 1/3 HP. FIGURE 7 - ELECTRICAL REQUIREMENTS 12 Pub. No. 1222 - May 2007
OPTIONAL HYDRAULIC POWER KIT INSTALLATION INSTRUCTIONS CONT. (J) Control Box Up Button (H) Hydraulic Cylinder (K) Breather Cap (E) Rue Ring (D) Washer (A) Clevis Pin FINAL INSTALLATION PROCEDURES 9. Replace the filler hole plug with the Reservoir Breather Cap (K). See figure 8. 10. Re-energize the electrical power. 11. Use the Electrical Control Box (I) to extend the cylinder by pressing and releasing the UP button. Pin the end of the Hydraulic Cylinder (H) to the leveler with the 5 Long Clevis Pin (A) and secure with the 3/4 Washer (D) and Rue Ring (E). See figure 8. 12. Grease the cylinder mount points using the provided grease zerk fittings factory installed into the Hydraulic Cylinder (H). 13. Remove the maintenance strut and return it to its storage place. Re-connect the extension arm to the lip in a reverse procedure from installing the strut. 14. Cycle the leveler several times to verify proper operation of the unit. Contact your local representative if you encounter any problems. FIGURE 8 - FINAL INSTALLATION Pub. No. 1222 - May 2007 13
OPTIONAL TELESCOPING HANDLE INSTALLATION INSTRUCTIONS NOTE: Riser Assembly is part of the RHE Dock Leveler Riser Assembly Riser Socket Lower Tube Handle Stop 3/8 3/16 INSTALLATION PROCEDURES 1. Install Edge Of Dock Leveler per installation instructions. 2. Place Telescopic Handle in Riser Socket. 3. Place Handle Stop over lower tube 3/8 from bottom as shown in figure 9. 4. Weld bottom handle stop in position and paint any welds. FIGURE 9 - TELESCOPING HANDLE INSTALLATION 14 Pub. No. 1222 - May 2007
NOTES Pub. No. 1222 - May 2007 15
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 245020 Milwaukee, Wisconsin 53224 Phone: 414-355-2600 1-800-456-0600 www.ritehite.com Representatives in all Major Cities