Dock Leveler Installation Manual - Rite-Hite

Dock Leveler Installation Manual - Rite-Hite
RHV41
Dock Leveler
Installation Manual
part of the SMOOTH TRANSITION DOK SYSTEMTM
MADE IN U.S.A.
This Manual Covers Dock Levelers Built After Serial Numbers:
11JH170001M and up
PRINTED IN U.S.A.
RITE-HITE PRINT SHOP
PUBLICATION NO. 1323
MARCH 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
TABLE OF CONTENTS
NOTICE TO USER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BUMPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LEVELERS ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOTE POWER UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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 at 414-355-2600.
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
®
TM
®
®
TM
pending U.S and foreign patent applications. RITE-HITE , THINMAN , SAFE-T-LIP , HYDRACHEK , WHEEL-LOK ,
®
®
TM
®
TM
TM
®
DOK-LOK , DUAL-DOK , SAFE-T-STRUT , DOK-COMMANDER , JUMBO , HYDRA-RITE , SAFE-T-GATE , RITETM
TM
®
VU LIGHT COMMUNICATION SYSTEM and SMOOTH TRANSITION DOK SYSTEM , are trademarks of Rite-Hite .
2
Pub. No. 1323 - March 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
SAFETY WARNINGS
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.
D
OP O N
ER O T
AT
E
XX
XX XXX
XX XX
XX XX
XX XX
XX X
X
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 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.
Pub. No. 1323 - March 2015
3
RITE-HITE® RHV41 Dock Leveler Installation Manual
OTHER IMPORTANT OPERATIONAL SAFETY WARNINGS
CRUSH HAZARD.
• Keep away from hinge when operating leveler.
• DO NOT operate leveler
with anyone standing in
the path of the leveler.
• Post safety warnings and barricade work area
at dock level and at ground level to prevent
unauthorized use of the dock leveler during
maintenance/service.
• DO NOT service leveler
unless Maintenance Pin
is properly engaged. See
page 6.
• Before beginning any service procedures:
– Position the RHV leveler in the vertical/
stored position.
– Disconnect the power and follow all
LOCKOUT/TAGOUT procedures as stated
on the inside front cover of this manual.
• DO NOT operate leveler without following the
procedure below if the leveler has not been in
service for an extended period of time.
• Procedure for filling cylinder:
– Press and hold the RAISE button (Run
Pump) to operate for (35) seconds
• During installation, anchors must be properly
torqued to obtain the necessary anchoring
strength. DO NOT USE IMPACT DRIVERS.
• DO NOT drive or walk onto truck/trailer until
the truck/trailer is parked against the dock
bumpers and the wheels are chocked or the
DOK-LOK® has been fully engaged and the
lights have changed to GREEN inside and
RED outside.
• NEVER attempt to lift the lip or hold the lip out
by hand. Serious personal injury could occur.
• DO NOT remove lifting equipment until:
a) the main cylinder has been filled.
b) Maintenance Pin has been installed and
engaged.
• ALWAYS check the rigging to make sure that
it is secure before proceeding with lifting the
unit. Never stand under any unit being lifted.
• NEVER remove the wheel chocks until
loading/ unloading is finished and the truck
driver has been given permission to drive
away from the dock or the DOK-LOK® has
been released and the lights have changed to
RED inside and GREEN outside.
4
Pub. No. 1323 - March 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
OTHER IMPORTANT OPERATIONAL SAFETY WARNINGS
• This equipment should not be operated or
serviced except by trained personnel.
• DO NOT ground welding equipment to any
hydraulic cylinder or electrical components.
• DO NOT operate leveler until truck/trailer is
parked against the dock bumpers and the
truck/trailer has been secured.
• DO NOT attach welder ground to leveler
platform when welding on base frame
assembly. Attach welder ground to base frame
assembly only. Damage to bearings or
hydraulic equipment will occur.
• ALWAYS return the leveler platform to the
proper stored position.
• Failure to conduct routine inspections and
maintenance could cause personal injury or
damage to equipment.
• ALWAYS call your authorized RITE-HITE®
Service Representative or RITE-HITE®
(1-800-456-0600) immediately if a malfunction
occurs.
• When drilling holes in the control box, do not
allow the drill to go too deeply into the box.
Damage to the control systems may occur.
• Use a vacuum to remove debris from control
box. NEVER use air to blow debris from
control box.
• DO NOT connect green ground lead into
control box or junction box until all welding
has been completed.
• Check hydraulic fluid level. Deck mounted
power unit has been filled with fluid but
cylinders, hoses and manifold are shipped
dry.
• NOTE — check motor rotation. Jog the motor
until rotation has been determined. DO NOT
run the motor in reverse because this will
damage the motor and power unit.
• Make sure that the cylinder clevis and the rod
will not contact either the rear header or frame
clevis during operation.
• DO NOT force valve adjustment screws
against internal stops. Damage will occur to
the valve.
• If a procedure is not clearly defined in this
manual, contact your authorized RITE-HITE®
Service Representative or RITE-HITE® at
1-800-456-0600 before proceeding.
Pub. No. 1323 - March 2015
5
RITE-HITE® RHV41 Dock Leveler Installation Manual
OTHER IMPORTANT OPERATIONAL SAFETY WARNINGS
Never be in the path of the dock leveler platform
without:
• Raising the platform by pressing and holding
RAISE button. Raise platform to its highest
position until the lip is fully extended. Release
RAISE button.
• Turning off, locking out and tagging out the
power to the control box.
• Barricading the dock leveler from any form of
traffic.
• Engage the Maintenance Pin. See Figure 2.
• If you are unable to engage the Maintenance
Pin, contact your authorized RITE-HITE®
Service Representative or RITE-HITE® at
1-800-456-0600.
Post safety warnings and barricade work area
at dock level and at ground level to prevent
unauthorized use of the dock leveler during
maintenance/service.
TO ENGAGE:
• Press RAISE Button Until Platform
Stops Moving.
• Remove Linch Pin And Maintenance Pin
From Bracket On Platform.
• Insert Maintenance Pin Into Tilt Back Rod
And Secure With Linch Pin. Snap Wire
Must Be Engaged On Pin.
CRUSH HAZARD
• DO NOT operate
leveler with anyone
standing in the path
of the leveler.
• Access Brace is
NOT a substitute
for the integral
Maintenance
Support System.
Maintenance Pin In
Engaged Position
TO DISENGAGE:
• Press RAISE Button Until Platform
Stops Moving.
• Remove Linch Pin And Maintenance Pin
From Tilt Back Rod.
• Insert Maintenance Pin Into Storage Plate
And Secure With Linch Pin. Snap Wire
Must Be Engaged On Pin.
Leveler Stored
Brace Engaged
Leveler Stored
Brace Disengaged
Maintenance Pin
In Stored Position
FIGURE 2 - MAINTENANCE SUPPORT SYSTEM
6
Pub. No. 1323 - March 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
INSTALLATION PROCEDURES
DO NOT disengage Maintenance Pin until
hydraulic system has been purged of air.
• DO NOT ground welding equipment to any
hydraulic cylinder or electrical components.
• DO NOT attach welder ground to leveler
platform when welding on base frame
assembly. Attach welder ground to base
frame assembly only. Damage to bearings or
hydraulic equipment will occur.
CRUSH HAZARD.
• DO NOT remove lip out
bracket from underside of
lip.
• DO NOT connect green ground lead into
control box or junction box until all welding
has been completed.
• Check hydraulic fluid level.
• NOTE — check motor rotation. Jog the
motor until rotation has been determined.
DO NOT run the motor in reverse because
this will damage the motor and power unit.
• Follow all electrical LOCKOUT/TAGOUT
procedures as stated on the inside front cover
of this manual.
• Post safety warnings and barricade work area
at dock level and at ground level to prevent
unauthorized use of the RHV before full
installation has been completed.
• If a procedure is not clearly defined in this
manual, contact RITE-HITE® at 1-800-4560600 before proceeding.
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.
2. Remove paint from top rear of transition flange on
rear frame and rear pit steel in areas to be welded.
See figure 5.
NOTE: Minimum electrode must be 1/8", 7018 or
better.
Pub. No. 1323 - March 2015
7
RITE-HITE® RHV41 Dock Leveler Installation Manual
INSTALLATION INSTRUCTIONS
Leveler Width
ALWAYS check the rigging to make sure that it
is secure before proceeding with lifting the unit.
Never stand under any unit being lifted.
Rear Of Leveler To Be Pushed Against Rear
Pit Steel Along Entire Width Of Leveler.
INSTALLATION PROCEDURES
1. Check to ensure support bars are flush within 1/16”.
2. Attach lifting chains, lift leveler and position above pit.
Lower leveler into pit. Support bars at top rear of
leveler must rest on top of rear pit steel. See Figures
3 & 4.
NOTES:
a. Rear edge of leveler must be in contact with pit wall.
b. Ensure leveler is centered in pit or door opening and
is parallel to sides of pit or square with rear pit wall.
See figure 3.
Spacing **
** Spacing
Dock Opening
** Spacing On Each Side Of Leveler To Be Equal Within 1/2”.
FIGURE 3 - CENTERING LEVELER IN PIT
1/16"
Max. Gap
1/16"
Max.
Gap
Rear Support Angles.
• Must Rest On Top Of Rear Pit Steel.
• Must Be Flush Within 1/16”.
• DO NOT Remove Until Leveler Frame Has
Been Welded To Rear Pit Steel.
Lifting Chain
2X (1 Each End) Weld End
Plates To Rear Pit Steel.
Continuous Pit Only.
Toe Guard
IMPORTANT: For Remote Power Unit Applications,
Connect Hydraulic Hoses To Power Unit
BEFORE Raising Platform.
NOTE: Continuous Pit Installation Shown
Leveler In Pit Resting
On Read Support Bars
And Wood Legs.
FIGURE 4 - SETTING LEVELER INTO PIT
8
Pub. No. 1323 - March 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
INSTALLATION INSTRUCTIONS CONTINUED
Weld Each Chamfer Area On
Rear Frame Angle Rear Edge
Rear Pit Steel
2X 3” Centered
Behind Hinges
22”
CL
3” Min.
Each End
For straight pits and Tee pits
weld both ends of transition
plate to side pit steel.
4 1/2”
ATTENTION!
No welds on ends of rear
transition when installed in a
closed-sided pit with a shrink
compensated specialty floor
Leveler
Frame
(Overhead View)
Rear Support Angles
Weld Detail - Rear Frame To Pit Steel
FIGURE 5 - REAR FRAME WELDS
3. Apply ground clamp to rear frame or rear pit steel
prior to welding.
4. Secure rear of leveler in place. Be sure to remove
excess weld spatter. See figure 5.
NOTE: For Straight Pits and T-Pits
a. Do not weld ends of rear frame to side pit steel with a
shrink compensated specialty floor. See figure 5.
Turn in Set Screws Until They
Are Flush With Transition Plate
And Rear Header. Discard Rear
Support Angles and Nuts.
NOTE: For Continuous Pits
a. Fully weld end plates at each end of rear frame to
rear pit steel. See figure 4.
5. Remove support angles from top rear of leveler,
discard angles and nuts. Turn in set screws until they
are flush with top of leveler. See figure 6.
a. Level platform in all directions.
b. Measure and scribe the location of lip keepers along
leading edge of lip. See figure 7.
7. Locate and install bumpers and bumper brackets.
See page 14.
6. Measure and scribe location of lip keepers.
Level Line
Represents
Dock Height.
FIGURE 6 - AFTER WELDING
Platform MUST BE Level
In All Directions.
Lip
Length
+ 5/8"
Measure And Scribe Line To
Represent Top Of Lip Keepers.
DO NOT Remove
Lip Shipping Support
Bracket From Lip Cylinder.
60" Centered In Pit
Or Dock Opening
Measure And Scribe Lines Representing
The Center Line Of Lip Keepers.
FIGURE 7 - INSTALL LIP KEEPERS
Pub. No. 1323 - March 2015
9
RITE-HITE® RHV41 Dock Leveler Installation Manual
INSTALLATION INSTRUCTIONS CONTINUED
11. Install danger tag (ships attached to linch pin) to hole
in end of linch pin with wire tie. See figure 9, detail B.
NOTE: DO NOT remove lifting equipment at this time.
BEFORE raising platform connect hydraulic
hoses to remote power unit! Failure to do so will
result in leveler damage.
12. Ensure there are no gaps greater than 1/8 inch from
the RHV back plate (where weld slots are) and the
embedded channel.
13. Weld rear frame back plate to pit channels as shown.
See figure 8.
8. If applicable, follow remote power unit installation
procedures at this time. See page 17.
14. Weld top and sides of lip keepers to front pit steel.
See figure 9.
15. Torque ALL anchor bolts on lip keeper mounting
60 Ft.Lbs.
When lifting leveler lip use lifting device (ex.
crane, jack). Lifting by hand may cause back
injury.
16. Check leveler tilt back. See page 15.
9. Hook lifting chain to bottom edge of front header in a
minimum of two (2) places. See figure 9.
17. Apply touch up paint to all grind and weld areas.
Includes rear frame to rear pit steel and lip keeper
mounting plates to front pit steel.
10. Manually raise leveler to vertical position and install
Maintenance Pin. See page 7.
Each End Of
Back Plate
.25
x
x
x
x
x
x
xxxx
xxxx
16” Ref.
7.25” Ref.
CL
x
x
x x x x x x x xx
Conduit Stub
xxxx
xxxx
xxxx
xxxx
xxxx
xxxx
x
xxxx
x x x xx x x x x x x x
x
x
xxxx x
xxxx x
x
x
Embedded
Channel
Welds
Weld Detail Two - Rear Frame To Pit Steel
FIGURE 8 - REAR FRAME BACK PLATE WELDS
10
Pub. No. 1323 - March 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
INSTALLATION INSTRUCTIONS CONTINUED
Install Maintenance Pin Immediately After Leveler
Is Raised To Vertical Position. Secure Danger Tag,
With Wire Tie, To Hole In Linch Pin.
.25”
Linch Pin
14X Slots
In Back Plate
Maintenance
Pin
DAN
GER
Tilt-Back Rod
CRUS
H HA
ZA
RD
DO
MAINT NOT RE
MOVE
EN
THE ANCE PIN
MA
HAS IN CYLIN UNTIL
BEEN
DE
FILLE R
FILL
D
MAIN
CYLIN
1) PR
DER:
ESS
TO OP RAISE
(RUN
SECO ERATE
PUMP
NDS. FOR
)
(35)
2) INS
TA
3) RE LL SOLE
NOID
MOVE
COIL
MAINT
4) LO
ENAN
WE
CE PIN
FOR R AND
(1) CY RAISE
LEVE
CLE.
5) DIS
LER
CA
COMP RD TH
LETIO IS TAG
UP
N.
ON
Wire Tie
Danger Tag
Detail B
1/4”
1/4”
1/4”
2X
Detail A
2X
Remove Shipping Legs
Lip Out Bracket.
DO NOT Remove
Until Main Cylinder
Has Been Filled.
Detail C
Lifting Chains Must Be
Hooked To Bottom
Of Front Header To
Raise Leveler To
Vertical Position
Details A & B
NOTE: Continuous Pit Installation Shown
Detail C
FIGURE 9 - UNIT RAISED INSTALLATION
Pub. No. 1323 - March 2015
11
RITE-HITE® RHV41 Dock Leveler Installation Manual
INSTALLATION INSTRUCTIONS CONTINUED
Control Box Assembly
Supplied By Rite-Hite
60” Ref.
NOTES:
For Continuous Pit (Shown):
Control Box Mast Required.
Supplied By Others.
For Square or T-Type Pits:
Mount On Building Wall.
Detail A
Conduit - See Pit
Construction Details.
Weatherproof
Junction Box
4” x 4” Minimum.
Supplied By Others.
4 lb-ft
maximum
torque on nut.
Over
tightening will
damage the
valve/coil!
Detail A
FIGURE 10 - CONTROL BOX MOUNTING
12
Pub. No. 1323 - March 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
INSTALLATION INSTRUCTIONS CONTINUED
ELECTRICAL INSTALLATION
CRUSH HAZARD.
• DO NOT remove Maintenance
Pin until the main cylinder has
been filled.
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.
CONTROL BOX AND CONDUIT
INSTALLATION PROCEDURES.
19. Install the control box on a wall adjacent to the
overhead door at approximately 48" above the floor
level. See Figure 10.
20. Drill a hole for the power supply conduit (by others) in
the bottom of the control box. All holes drilled
through the control box must be through the
bottom of the box.
• The control box and all wiring should be
installed by a qualified electrician in
accordance with all national and local
electrical codes.
• If rigid conduit is installed, bonding must be
maintained between conduit connections by
using ground bushings and a jumper wire.
Install per local electrical codes. Refer all
installation and service to qualified personnel.
When in doubt, call your local RITE-HITE
representative or RITE-HITE at 888-456-3625.
• When drilling holes in the box, DO NOT allow
the drill to go too deeply into the box.
Damage to the control systems may occur.
• DO NOT turn control box upside down to drill
any access holes. Cover internal electrical
components prior to drilling - this will prevent
debris from contacting the internal electrical
components.
• Remove all debris from box using a shop
vacuum. NEVER use air to blow debris from
the control box.
18. Complete electrical installation per schematics.
NOTE: Schematics are located inside control box.
Grounding Electrode System must conform to
the latest addition of the National Electrical Code
(NFPA 70), where applicable, and/or local
electrical
codes.
Grounding
Electrode
Conductors must be connected where indicated,
and where required.
Control Box Installation Guidelines - Temperature
controlled applications.
a. Conduit should be routed to enter through the
bottom or side of the enclosure.
NOTE: A drip leg may be needed if the conduit is
filling with water.
b. Seal the conduit in any location where the conduit
transitions temperature zones that may produce
condensation.
c. Spacers should be installed between the enclosure
and the wall to provide tempature insulation and air
flow.
21. Press RAISE button (run pump) to operate for (35)
seconds.
Pub. No. 1323 - March 2015
13
RITE-HITE® RHV41 Dock Leveler Installation Manual
INSTALLATION INSTRUCTIONS CONTINUED
22. Install solenoid coil. See figure 10, Detail A.
25. Discard control box tag at this time.
23. Remove Maintenance Pin, lifting equipment and Lip
Out Bracket at this time.
26. Leveler is preadjusted from the factory. Operate
leveler several times to verify proper operation.
Adjustments may be needed to insure proper
operation, adjust as needed. See pages 16 & 17.
24. Lower and raise leveler for (1) cycle.
Route new 168L
harness across
unit to existing
junction box.
Pit Floor
OR run harness through rear frame
cutting off excess cord as required.
Existing HDVHL
Junction Box
FIGURE 11 - 6’L HDVHL REPLACEMENT HARNESS
NOTE:
For 6’L Rite-Hite replacement units, the standard 31” long control/power harness is replaced with a special 168” long
since existing junction box on pit floor is on opposite side of new power unit.
Route new harness across unit or through rear hinge weldment, as shown in Figure 11, to junction box location.
Attaching harness to platform securely with wire ties (by others).
14
Pub. No. 1323 - March 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
BUMPER INSTALLATION
LAMINATED BUMPER INSTALLATION
(Standard)
NOTE: Complete installation instructions are supplied
in the anchor kit.
1. Tack weld each bumper into position as shown in
figure 12.
4. Secure other end of each bumper with concrete
anchor bolts. Torque each bolt to 100 ft-lbs.
2. Each bumper should be secured with two 3/4 inch
concrete anchor bolts that are a minimum of 5-1/4
inch long. (Ref. Rawl anchor 6954 - supplied by
others.)
5. Weld the bumper side plate to the front vertical pit
angle.
6. Clean and paint all weld and grind marks.
3. Using bumper mounting holes as a guide drill two 3/4
inch holes per bumper that are approximately 1/2
inch deeper than the bolt length that will be used.
Dock Bumper
1/4"
Dock Floor
Leveler Lip
Side Of Leveler Pit
Typ. 2 Places
1/4"
1/4"
Min. 3/4” x 5-1/4” Concrete Anchors
(Supplied By Others)
Anchor Bolts
FIGURE 12 - BUMPER INSTALLATION
• DO NOT ground welding equipment to any
hydraulic cylinder or electrical components.
• DO NOT attach welder ground to leveler
platform when welding on base frame
assembly. Attach welder ground to base
frame assembly only. Damage to bearings or
hydraulic equipment will occur.
Bumper Support Bracket
For Use On “ Continuous ”
And “ T” Type Pits Only.
Typ. 2 Places
1/4"
• DO NOT connect green ground lead into
control box or junction box until all welding
has been completed.
• If a procedure is not clearly defined in this
manual, contact RITE-HITE® at 1-800-4560600 before proceeding.
Pub. No. 1323 - March 2015
FIGURE 13 - “CONTINUOUS” AND “T” TYPE PITS
15
RITE-HITE® RHV41 Dock Leveler Installation Manual
LEVELER ADJUSTMENTS
CRUSH HAZARD.
• DO NOT operate leveler
with anyone standing in
the path of the leveler.
• DO NOT service leveler
unless Maintenance Pin
is properly engaged. See
page 6.
4' Level or plumb line
• Before beginning any service procedures:
– Position the RHV leveler in the vertical/
stored position.
– Disconnect the power and follow all
LOCKOUT/TAGOUT procedures as stated
on the inside front cover of this manual.
Turn adjustment nut to adjust
leveler tilt back
48.00"
Do not use a level or plumb line longer than 4'.
LEVELER TILT BACK ADJUSTMENT
NOTE: This adjustment must be completed for all
units. However, when multiple levelers are being
installed, it is recommended that the tilt back
adjustment be the same on each unit so that the
units are uniform in function and appearance.
1. Restore power. Press the RAISE button so that the
leveler is in the “full back, over center” position.
2-1/2"
+/- 1/2"
FIGURE 14 - TILT BACK SETTING
2. Check that the leveler is tilted back the proper
distance using a 4' level or plumb line held plumb.
Place the level against the platform and flush with
dock floor. See figure 14.
3. Adjust the tilt back, if necessary, by adjusting the
nut on the leveler tilt back rod. See figure 13.
4. Repeat Steps 1 through 3 until tilt back adjustment
is correct.
16
Pub. No. 1323 - March 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
LEVELER ADJUSTMENTS CONTINUED
Counterbalance
Valve (CB)
DO NOT force valve adjustment screws against
internal stops. Damage will occur to the valve.
This equipment should not be operated or
serviced except by trained personnel.
COUNTERBALANCE VALVE ADJUSTMENT
1. Initial adjustment.
NOTE: This adjustment must be completed before
fine adjustment.
a. From the fully raised position, lower the platform to
45° above dock height. See figure 15. The platform
should completely stop moving and the lip should
retract.
FIGURE 16 - COUNTERBALANCE VALVE
2. Fine adjustment.
NOTE: This adjustment must be completed after
initial adjustment.
a. Return the platform to the fully raised position then
lower the platform to dock height. See figure 17. The
platform should hold that position until someone
stands on the platform near the lip.
FIGURE 17 - LEVELER AT DOCK HEIGHT
45°
FIGURE 15 - LEVELER AT 45 DEGREES
b. If the platform continues to move downward, raise the
platform and engage the Maintenance Pin. See page
6. Loosen the lock nut on counterbalance valve while
holding adjusting screw with a hex key wrench. See
figure 16. Rotate the adjustment screw 1/8 of a turn
clockwise. Tighten locknut while holding adjustment
screw. Disengage Maintenance Pin and verify step
#1A performance. If ok, proceed to step 2. If not,
repeat step #1B.
Pub. No. 1323 - March 2015
b. If the empty platform does not hold at dock height
position, rotate the adjustment screw another 1/8 of a
turn clockwise as described in step #1B.
c. If the platform does not easily break and lower to
below dock level, raise platform and engage the
Maintenance Pin. See page 6. Loosen the lock nut on
the counterbalance valve while holding the adjusting
screw with a hex key wrench. See figure 16. Rotate
the adjustment screw 1/16 of a turn counterclockwise.
Tighten locknut while holding the adjusting screw.
Disengage Maintenance Pin and verify that both
steps #1 and #2 have been met. Repeat if necessary.
17
RITE-HITE® RHV41 Dock Leveler Installation Manual
REMOTE POWER UNIT INSTALLATION
Quick connect ends, DO NOT trim!
FIGURE 18 - LEVELER HOSES FOR REMOTE POWER UNIT
REMOTE POWER UNIT
Orient power unit
assembly as shown
making sure the
manifold(s) are above
the power unit.
BEFORE raising platform connect hydraulic
hoses to remote power unit! Failure to do so will
result in leveler damage.
Connect STR4 hoses as
supplied from lock and
trim as needed. Follow
instructions for re-using
supplied fittings.
1. Mount power unit in the proper location. Be sure the
manifold(s) are above the power unit. See figure 19.
Route lock hose to
VBR and trim as
needed. Follow
instructions for
re-using supplied
fittings.
2. Cut hose to required length using a fine tooth
hacksaw. Clean hose bore after cutting. See figure
20.
Route hoses to
leveler and trim as
necessary. Follow
instructions for reusing supplied
fittings.
FIGURE 19 - REMOTE POWER UNIT ORIENTATION
18
Clean hose bore
after cutting
FIGURE 20 - CUT HOSE TO LENGTH
Pub. No. 1323 - March 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
REMOTE POWER UNIT INSTALLATION CONTINUED
3. Liberally lubricate hose cover with heavy weight oil.
Place socket in vise and turn hose into socket
counterclockwise until it bottoms out. When
assembling long lengths of hose, it may be necessary
to put hose in vise just tight enough to prevent from
turning, and screw socket onto the hose
counterclockwise until it bottoms out. See figure 21.
FIGURE 21 - INSTALL SOCKET
4. Liberally lubricate nipple threads and inside of hose
using heavy weight oil.
5. Screw nipple clockwise into socket and hose. Leave
1/32 to 1/16 inch clearance between nipple hex and
socket. See figure 22.
FIGURE 22 - INSTALL NIPPLE
6. Blow out hose assembly with clean compressed air
before routing hose.
7. Route hoses between leveler and power unit.
8. Leveler is preadjusted from the factory. Operate
leveler several times to verify proper operation.
Adjustments may be needed to insure proper
operation, adjust as needed. See pages 15 & 16.
Pub. No. 1323 - March 2015
19
RITE-HITE® RHV41 Dock Leveler Installation Manual
ACCESS BRACE INSTALLATION
ACCESS BRACE
1. A 4" clear space is needed on each side of platform.
2. Assemble Access Brace components as shown in
figure 23 (washers, collar, cotter pin, Access Brace).
Make certain the Access Brace is stamped with the
correct pit depth prior to installation.
3. Right side installation shown in figure 23. If left side
installation is desired, install all components on
opposite side by flipping over Access Brace
components with holes facing opposite direction.
4. Add shim to pit floor if gap is greater than 3/4".
20
Pub. No. 1323 - March 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
ACCESS BRACE INSTALLATION CONTINUED
COLLAR
COTTER PIN
WASHER
A
TOEGUARD
ACCESS BRACE
A
ACCESS BRACE
SECTION A-A
BRACE SHIM
REQUIRED ONLY FOR
GAPS GREATER THEN 3/4"
3/4" MAX
PIT FLOOR
SHIM THICKNESS AS
REQUIRED FOR GAP
LESS THEN 3/4"
6"
2X
11/16"
6"
3"
3/4"
4 1/2"
BRACE SHIM DETAIL
SUPPLIED BY OTHERS
2X PER SHIM
5/8" ANCHOR BOLTS
SUPPLIED BY OTHERS
RIGHT SIDE
INSTALLATION SHOWN
FIGURE 23 - ACCESS BRACE INSTALLATION
Pub. No. 1323 - March 2015
21
RITE-HITE® RHV41 Dock Leveler Installation Manual
NOTES
22
Pub. No. 1323 - March 2015
RITE-HITE® RHV41 Dock Leveler Installation Manual
NOTES
Pub. No. 1323 - March 2015
23
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. Nonstandard 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
INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, WHETHER FOR BREACH OF WARRANTY,
NEGLIGENCE, OR STRICT LIABILITY.
National 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
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising