RITE-HITE LEVEL-RITE HL-800 Series Manuale utente

LEVEL-RITE®

HL-800 SERIES

HYDRAULIC DOCK LEVELER

Owner’s Manual

PRINTED IN U.S.A. PUBLICATION NO. 1167-R2

RITE-HITE PRINT SHOP 1-414-355-2600 APRIL 2003

By Rite-Hite

THIS MANUAL COVERS LEVELERS

AFTER SERIAL NUMBER M101516

HL-800 HYDRAULIC DOCK LEVELER

2Pub. No. 1167-R2 - April 2003

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PIT DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

HYDRUALIC FLUID CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

ADJUSTMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

PRODUCT INTRODUCTION

The LEVEL-RITE®HL Series Leveler By RITE-HITE®is intended to provide a safer work place for workers in shipping

and receiving dock areas. The HL Series Leveler is a hydraulically operated device that, when properly installed and

operated, provides a safe and secure access between dock and truck. The HL Series Leveler is operated from the top

of the dock.

NOTICE TO USER

Your local RITE-HITE

representative provides a Planned Maintenance Program (P.M.P.) which can be fitted to your

The RITE-HITE

products in this manual are covered by one or more of the following U.S. patents: 4,560,315 (RE:

32,968); 4,570,277; 4,605,353 (RE: 33,154); 4,634,334; 4,692,755; 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; 6,065,172; 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; 6,322,310; 6,311,352; 6,360,394; 6,368,043, 6,431,819;

6,488,464; 6,497,067; 6,499,169; 6,505,713; 6,524,053 and pending U.S. and foreign patent applications. RITE-

HITE

, LEVEL-RITE

, GUARDRITE

, SAFE-T-LIP

, HYDRACHEK

, WHEEL-LOK

, DOK-LOK

, DUAL-DOK

and SAFE-T-GATE

are trademarks of RITE-HITE

Corporation.

specific operation. Call your local representative or the Corporation at 414-355-2600.RITE-HITE

Pub. No. 1167-R2 - April 2003

SAFETY WARNINGS

HL-800 HYDRAULIC DOCK LEVELER

LOCKOUT/TAGOUT PROCEDURES

The Occupational Safety and Health Administration (OSHA) 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 PRODUCTS CORPORATION does not recommend any particular lockout device, but recommends the

utilization of an OSHA approved device (refer to OSHA regulation 1910.147). RITE-HITE PRODUCTS

CORPORATION 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 a statement of serious hazard. Failure to

follow the listed instructions could place the

individual at risk of serious injury or death.

WARNING

This is the highest level statement. Failure to

follow the listed instructions will most likely

result in severe injury or death.

DANGER

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.

CAUTION

IMPORTANT is used to draw attention

to a procedure that needs to be followed to

prevent machine or property damage.

IMPORTANT

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.

WARNING

HL-800 HYDRAULIC DOCK LEVELER

4Pub. No. 1167-R2 - April 2003

NOTES

HL-800 HYDRAULIC DOCK LEVELER

Pub. No. 1167-R2 - April 2003

Pit Details for LEVEL-RITE®by Rite-Hite®

Hydraulic and Mechanical Dock Levelers

Dock Floor

Pit Floor

Dock

Face

1/2" Pitch

Driveway Approach

Dim. A

+1/4-0

Dim. C

1/8

Dim. B

1/8

All Curb Angle

Joints To Be

Welded Securely.

Rear Pit Wall

To Be Plumb.

Reverse Slope Of

1/4" Is Permissible.

Important: Concrete Behind

Pit Steel Must Be Well Vibrated.

8" Recommended Minimum Thickness

For Pit Walls, Pit Floor And Dock Face.

FrontCurbAngleForUnits

MustBe3"x 3"x 3/16"

With1/2"Dia. x 6"Long

ConcreteAnchors

On12"Centers.

Important:

Side Curb

Angles Must

Be 90

Dock Face.

Important: Angle Between

Side And Rear Curb Angles

Must Be 90

Junction Box Location

For HL Series Only

(See Item 6 On Following Page)

See Item 5

On Following Page

See Item 1

On Following Page

See Item 4

On Following Page

See Item 3

On Following Page

See Item 3

On Following Page

See Item 2

On Following Page

See Item 4

On Following Page

6L X 6W 8L X 6W 8L X 7W

63 87 87

74 74 85

19-1/2

PIT DIMENSIONS FOR CAPACITIES: 30K, 35K, 40K

NOMINAL PIT SIZES

PIT LENGTH

PIT WIDTH DIM A

DIM B

DIM C

PIT DEPTH

Figure - 3 Pit Details

HL-800 HYDRAULIC DOCK LEVELER

6Pub. No. 1167-R2 - April 2003

PIT DETAILS CONTINUED

Alternate

Junction Box

And Conduit

Location

4" x 4" x 2" NEMA 4 (By Others)

10"

ITEM 6: JUNCTION BOX LOCATION DIMENSIONS FOR HL SERIES

Preferred

Junction Box

And Conduit

Location

Minimum

1" Dia.

Conduit

Required

14"

27-1/2"

11-3/4"

23-1/2"

20"

7" Typ.

6" Typ.

1-1/4"

Typ.

1/4" Front Curb Angle

To Be Welded To

Mounting Plate

1/2" x 6"

Nelson Stud (16)

Mounting Plate

1/4" x 20" x 23-1/2"

H.R.S.

ITEM 5: RESTRAINT MOUNTING PLATE (OPTIONAL)

Typ.

Restraint Mounting Plate Furnished By General Contractor Or

Available From RITE-HITE at Additional Cost.

ITEM 1, 2, 3, 4: ANCHOR LAYOUT

FOR CURB ANGLES

12" 12"

IMPORTANT: Curb Angles Nelson Studs.

1/2" Dia. 6" Long Located As Shown

12" 12"

CONSTRUCTION NOTES

1. Concrete Behind Pit Steel Must Be Well Vibrated.

2. Rear Pit Wall Must Be Square With Dock Floor.

3. All Curb Angle Joints To Be Welded Securely.

4. 1/2" Pitch Toward Front Of Pit For Drainage.

5. Both Item 4 Bumper Mountings Must Be The

Same Design.

ITEM QTY 6L X 6W 8L X 6W 8L X 7W

1 1 74 74 85

2 1 80 80 91

3 2 60 84 84

4 2 20 20 20

CONTRACTOR'S BILL OF MATERIALS FOR NOMINAL PIT SIZES

DESCRIPTION

FRONT CURB ANGLE

3 X 3 X 3/16

REAR CURB ANGLE

3 X 3 X 3/16

SIDE CURB ANGLE

3 X 3 X 3/16

SIDE VERTICAL ANGLES

3 X 3 X 3/16

Figure - 4 Pit Details

HL-800 HYDRAULIC DOCK LEVELER

Pub. No. 1167-R2 - April 2003

INSTALLATION INSTRUCTIONS

HL800

LEVELER

ASSEMBLY

APPROACH

DOCK

BUMPERS

(2)

DOCK FACE

BRANCH

RITE-HITE)

(SUPPLIED BY

CONTROL BOX

CIRCUIT

ASSEMBLY

CUSTOMER

DISCONNECT.

TYPICAL COMPLETED INSTALLATION

IMPORTANT

DANGER

NEVER BE UNDER THIS LEVELER WITHOUT PLACING

THE MAINTENANCE SUPPORT AS SHOWN IN DIAGRAM.

FOR SUPPORT REMOVAL: RAISE LEVELER TO HIGHEST

POSITION AND TILT SUPPORT TO THE STORED POSITION.

DO NOT USE MAINTENANCE SUPPORT IF DAMAGED.

IF A PROCEDURE IS NOT CLEARLY DEFINED, CONTACT YOUR LOCAL RITE-HITE

REPRESENTATIVE OR RITE-HITE AT 1-414-355-2600 BEFORE PROCEEDING.

Figure - 5 Complete Installation

HL-800 HYDRAULIC DOCK LEVELER

8Pub. No. 1167-R2 - April 2003

INSTALLATION INSTRUCTIONS - CONTINUED

DETAIL "B" - HANDLING PLATE

DETAIL "C"

3/8 X 3

1-1/2

2 REQUIRED. SUPPLIED BY OTHERS.

3/4

DIA

FLAT

1-3/4

ROD, 1 DIA

15°

1-1/2

3-1/2

1. Check pit to ensure it meets RITE-HITE pit details #0108172. If pit does not match pit details, contact your local

representative or RITE-HITE before proceeding.

2. Leave shipping bands on leveler until instructed to remove them.

3. Verify that the leveler voltage matches the voltage supplied at pit. Remove control box from frame if it has not already

been installed.

4. Clean out pit and remove all debris from work area.

5. Handling Plates (see Detail "B") must be inserted into the forward handling holes of the toeguards. See Details "C".

6. Attach lifting chain, lift leveler and position above pit. Lower leveler into pit. See Detail "C".

7. Center leveler in pit so that equal gaps are maintained on each side of leveler. See Detail "D".

8. Push leveler straight back until the front frame angle is flush with the front curb angle. If the pit is not square, push

the leveler straight back until the front frame angle is completely behind the front curb angle by no more than 1/4 inch.

The front frame angle should never extend past the front curb angle. If unit cannot be pushed back far enough, the

back edge of the rear frame angle can be cut off up to 3/8 inch. If trimming back edge of angle does not allow frame

to be positioned properly in pit, contact contact your local representative or RITE-HITE for assistance. Tack weld rear

frame angle to rear curb angle. See Details "D" & "G".

DOCK FACE

PLATFORM

LIP

SIDE CURB ANGLE

PIT FLOOR

PIT SIDE VIEW

FLOOR

DOCK

HANDLING PLATE

BANDS

SHIPPING LEVELER

TOP OF

FRONT CURB ANGLE

LIFTING CHAIN

REAR FRAME

ANGLE

NUT

HANDLING

PLATE

TOEGUARD

FRAME

FRONT

FRAME

ANGLE

REAR CURB

ANGLE

THREADED

X 2 LG.

NUT,

1 DIA

FLAT,

X 8 HRS

WARNING

WHILE WORK IS BEING PERFORMED.

* POST SAFETY WARNINGS AND BARRICADE WORK AREA TO PREVENT UNAUTHORIZED USE OF THE UNIT

* DO NOT POSITION THE LEVELER ON ITS SIDE OR TURN THE LEVELER TOPSIDE DOWN AT ANY TIME.

* ENSURE LIFTING EQUIPMENT IS RATED FOR 3,000 lb. LIFTING CAPACITY OR GREATER.

COMPONENTS MAY RESULT.

PLATFORM WHEN WELDING ON LEVELER FRAME. DAMAGE TO BEARINGS OR OTHER MECHANICAL

* ALWAYS GROUND TO THE FRAME OR FRONT PIT ANGLE WHEN WELDING. DO NOT GROUND TO LEVELER

Figure - 6 Installation

HL-800 HYDRAULIC DOCK LEVELER

Pub. No. 1167-R2 - April 2003

INSTALLATION INSTRUCTIONS - CONTINUED

DETAIL "G"

DETAIL "F"

TOP VIEW OF

LEVELER IN PIT.

DETAIL "D"

DETAIL "J"

9. Check the area between the rear frame and the back of the pit. If a gap exists, place spacers between the rear frame

angle and the rear curb angle. Tack weld spacers to rear frame angle only. See Detail "F".

10. Remove lifting chain from handling plates. See Detail "C".

11. Lift leveler until platform is level with dock floor. Place shims under below dock stop channels, located on frame angle,

and tack to front frame angle. NOTE: For units with 20" lips, lift bottom of front frame angle until it is at 19-1/2"

below dock floor, and add shims. See Detail "K".

12. Remove and discard shipping bands from lip.

13. Place marks on the face of the front frame angle to indicate the frame centerline and the location of each below

dock stop channel. Also, place a mark on the face of the lip to indicate the lip/platform centerline.

14. Shift the front frame angle sideways so that the frame centerline matches up with the lip centerline (using the lines

drawn earlier.) Tack weld front frame angle and shims to front curb angle.

15. Manually raise platform and extend lip. Engage the maintenance support. See Detail "K".

16. Remove handling plates from platform.

1 MAX

CUT

PLACES1/4 TACK

SPACER AS

2 PLACES EACH

FRAME MUST BE IN

CONTACT WITH REAR

CURB ANGLE.

EQUAL GAPS

MUST BE

MAINTAINED

ON EACH

SIDE OF

LEVELER.

1/4 TACK NECESSARY.

FILL GAP BETWEEN REAR FRAME

ANGLE AND REAR CURB ANGLE ON

EACH END WITH A 3" LONG SPACER.

FILL GAP BETWEEN REAR FRAME

ANGLE AND REAR CURB ANGLE AT

CENTER WITH A 6" LONG SPACER.

FILL GAP BETWEEN REAR FRAME

ANGLE AND REAR CURB ANGLE

BEHIND HINGE LUGS. SPACER

MUST SPAN DISTANCE FROM

OUTSIDE TO OUTSIDE OF HINGE

LUGS.

HINGE LUGS

ON EACH

EQUAL GAPS

MAINTAINED

MUST BE

SIDE OF

LEVELER

REAR EDGE OF LEVELER FRAME MUST BE AGAINST REAR

CURB ANGLE. SHIM OR TRIM REAR FRAME ANGLE AS

NECESSARY. IF PIT IS NOT SQUARE, SEE DETAIL "F" & "G".

1/4 TACK

SIDE CURB ANGLE

FRONT CURB ANGLE

PLATFORM REMOVED FOR CLARITY

PORTIONS OF FRAME AND

SHIM SIZE:

4 X 3 X *

QTY 3

2 PLACES

2 SHIMS

UNDER REAR

FRAME

SUPPORTS.

SHIM SIZE:

4 X 3 X *

UNDER

CENTER

REAR FRAME

SUPPORT. MIN.

SHIM SIZE:

4 X 12 X *

REAR CURB

ANGLE

6'UNITS: 40-1/2

8'UNITS: 44-1/2 CENTERED UNDER

FRAME CHANNELS

UNDER RAMP

CYLINDER.

SHIM SIZE:

4 X 12 X *

SHIM PACK

WILL VARY

DEPENDING

HEIGHT OF

ON PIT

DEPTH.

CAUTION

STAND TO ONE SIDE WHEN CUTTING BANDS TO AVOID BEING CUT BY THE BANDS.

SHIPPING BANDS ARE UNDER TENSION. WEAR SAFETY GLASSES AND PROTECTIVE GLOVES.

DANGER

1/4

TACK

NEVER BE UNDER THIS LEVELER WITHOUT PLACING

THE MAINTENANCE SUPPORT AS SHOWN IN DIAGRAM.

FOR SUPPORT REMOVAL: RAISE LEVELER TO HIGHEST

POSITION AND TILT SUPPORT TO THE STORED POSITION.

DO NOT USE MAINTENANCE SUPPORT IF DAMAGED.

Figure - 7 Installation

HL-800 HYDRAULIC DOCK LEVELER

10 Pub. No. 1167-R2 - April 2003

INSTALLATION INSTRUCTIONS - CONTINUED

DETAIL "L"

DETAIL "H"

DETAIL "K"

DETAIL "N"DETAIL "M"

DETAIL "M"

2 PLACES

** WELD TO SPAN

OUTSIDE TO OUTSIDE

OF HINGE LUGS

2 PLACES

EACH

SPACER

CENTERED

SPACER

WHEN NO

EXISTS.

HINGE

LUGS

2 PLACES

POSTS.

REAR FRAME SUPPORT

INSERT SHIMS UNDER

POST

SUPPORT

FLOOR

DOCK

FULL RANGE TOEGUARD

SHIPPING BOLT

LOCATION

MAINTENANCE

SUPPORT

19-1/2

EACH SHIM 1/4

FRONT CURB

ANGLE

FRONT FRAME

ANGLE

SHIM

EACH SHIM

1/4

EACH SHIM 1/4 SHIM

REAR FRAME

ANGLE

EACH SHIM 1/4

1/4

FRONT CURB

ANGLE

FRONT FRAME

ANGLE

EACH SHIM

1/4

EACH SHIM

SHIM

1/4

3 MIN.

1/4

SOME COMPONENTS

REMOVED FOR

CLARITY

FRAME RECESSED

FRAME FLUSH

17. Cut and place shims under the rear frame support posts as necessary. See Detail "J".

18. Cut and place shim(s) between the frame channels and pit floor directly under the ramp cylinder pivot.

Do not weld shims at this time! The frame channels will be level between the rear frame and the ramp

cylinder pivot with the proper shim height. See Detail "J" and "K".

19. Weld all stacked shims together. Weld rear shims to the rear frame. Weld shim(s) to the frame channels

under the ramp cylinder pivot. Weld shims to the front curb angle and front frame angle. See Detail "M"

& "N".

20. Stitch weld the rear frame angle (and the rear spacers if needed) to the rear curb angle. See Detail "H"

& "L". Center a 6 inch weld behind each support post and a 3 inch weld at each end of rear frame angle.

21. Clean and paint all weld and grind marks.

22. Remove front shipping bolt from each full range toeguard. Verify that toeguards move up and down freely.

See Detail "K".

Figure - 8 Installation

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