RITE-HITE Hydra-Rite RHH-4000 Owner's Manual
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RITE-HITE Hydra-Rite RHH-4000 Owner's Manual

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RHH-4000 Hydra-Rite
This Manual Covers Dock Levelers Built After Serial Numbers:
13GD480708M and up
PRINTED IN U.S.A.
RITE-HITE
PRINT SHOP
Dock Leveler
Owners Manual
part of the SMOOTH TRANSITION DOK SYSTEM
TM
/ Base
RHH HYDRA-RITE
TM
Dock Leveler Shown
TM
MADE IN U.S.A.
PUBLICATION NO. 1210
APRIL 2016

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  • Page 1 Owners Manual RHH HYDRA-RITE Dock Leveler Shown part of the SMOOTH TRANSITION DOK SYSTEM MADE IN U.S.A. This Manual Covers Dock Levelers Built After Serial Numbers: 13GD480708M and up PRINTED IN U.S.A. PUBLICATION NO. 1210 RITE-HITE PRINT SHOP APRIL 2016...
  • Page 2 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual NOTES Pub. No. 1210 - April 2016...

  • Page 3: Table Of Contents

    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: 5882167, 6065172, 6070283, 6085375, 6092970, 6106212, 6116839, 6190109, 6276016, 6311352, 6318947, 6322310, 6360394, 6368043, 6431819, 6488464, 6524053, 6726432,...

  • Page 4: Safety Warnings

    ® 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).
  • Page 5 • 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.
  • Page 6 Release the safety clip and remove retaining pin. Lift strut off base, and remove from lip. Return the Safe-T-Strut to the proper storage position. • If you are unable to install the Safe-T-Strut properly, contact your authorized RITE-HITE ® Service ® Representative or RITE-HITE Customer Service at 1-414-355-2600.

  • Page 7: Owner Responsibility

    Planned Maintenance Program (P.M.P.). As part of this provided below. The manufacturer shall publish, provide to the service, your local RITE-HITE ® representative will do all initial purchaser, and make the following information readily routine maintenance, lubrication, and adjustments.

  • Page 8: Operation Instructions

    RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual OPERATION INSTRUCTIONS POWERED LEVELERS NORMAL OPERATION See Storing Leveler. NOTES: Activate the leveler by pushing and holding the RAISE button until leveler is fully raised and lip is fully extended. See figure 3.
  • Page 9 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual OPERATION INSTRUCTIONS POWERED LEVELERS CONT. DOCK LEVEL (OR LOWER) END LOADING OPERA- NOTES: TION a. Some levelers may be equipped with a two button control box. If so, release RAISE and LIP EXTEND buttons Activate the leveler by pushing and holding the RAISE button b.
  • Page 10 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual OPERATION INSTRUCTIONS POWERED LEVELERS CONT. STORING LEVELER To store the leveler, push and hold the RAISE button until leveler is about 6 inches above dock level and lip is fully pendant. Release RAISE button. Leveler will lower to dock level with lip resting in the lip supports.

  • Page 11: Maintenance Procedures

    10. With the leveler supported by the Safe-T-Strut, check hydraulic SUGGESTED LEVELER MAINTENANCE fluid level in tank. Add fluid if necessary. Use only Rite-Hite approved hydraulic fluids. NOTE: Follow maintenance procedures below as outlined.
  • Page 12 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual RHH HYDRA-RITE LUBRICATION CHART NOTE: Only if grease zerks are present. OIL SAE 30 Weight Grease - Moly Based Dry Spray Lubricant NOTE: Inside and Under Slots ® On Safe-T-Lip NOTE: Check Hydraulic Fluid level.
  • Page 13 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual RHH BASE LUBRICATION CHART NOTE: Only if grease zerks are present. OIL SAE 30 Weight Grease - Moly Based Dry Spray Lubricant NOTE: Inside and Under Slots On Safe-T-Lip ® NOTE: Check Hydraulic Fluid level.

  • Page 14: Leveler Adjustments / Troubleshooting

    RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC LEVELER ADJUSTMENTS HYDRAULIC POWERED LEVELER ADJUSTMENTS ARTD ADJUSTMENTS: • Shuttle valve is factory adjusted and sealed. ARTD Limit Switch Cam • Adjustments to be completed by trained technician only. NOTE: Before continuing be sure the lip stop bolt is properly adjusted.
  • Page 15 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC LEVELER ADJUSTMENTS CONT. SEQUENCE VALVE ADJUSTMENT (Controls Lip Extension) NOTE: Check oil level before making any adjustments. If the lip begins to extend at any time before the platform has fully raised, the Sequence Valve setting is too low.
  • Page 16 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC LEVELER ADJUSTMENTS CONT. ARTD ADJUSTMENTS: ARTD Limit Switch Cam NOTE: Before continuing be sure the lip stop bolt is properly • Flow Control valve is factory adjusted. adjusted. See page 13. • Adjustments to be completed by trained technician only.
  • Page 17 Press RAISE button and run the platform up until the lip extends. To Lip To Ramp Cylinder Cylinder Pilot-To-Close System Relief Valve Check Valve: (Set at 1,250 PSI. Do NOT adjust Base: 8:1 without permission from Rite-Hite) HydraRite: 17:1 IFC/ESB Sequence Option Valve Port Pilot-To-Open HYDRARITE Check Valve (3:1)
  • Page 18 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC POWERED LEVELER TROUBLESHOOTING Problem Probable Cause Solution 1. Platform does not raise a. Power has been disconnected. a. Verify that power has not been disconnected. Verify that disconnect circuit breaker or fuses are not tripped.

  • Page 19: Hydraulic Schematic

    RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC SCHEMATIC (HALDEX POWER UNIT) Power Unit Assembly Velocity Fuse 140-170 Motor Optional 8 GPM Micron 3450 RPM 2W N.O. Valve “RAMP” Strainer For IFC Port Pump 3.6 GPM @ 250 PSI Adj. Shuttle Valve.
  • Page 20 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC SCHEMATIC (BUCHER POWER UNIT) DECK PORT PORT SEQUENCE VALVE .047 IFC/ESB 950 PSI VALVE (OPTIONAL) 2 PSI LIP CYLINDER FLOW CONTROL 1.5" X 6" S.A. RAMP SYSTEM RAMP CYLINDER RELIEF 2.5" X 13.62" S.A. (6') 1250 PSI 2.5"...
  • Page 21 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual LED STATUS CHART - STANDALONE PIT DOCK LEVELER RITE-HITE PRODUCTS CORP. INPUTS OUTPUTS OUTPUTS STANDALONE CONTROLS RELAY TERMINAL BLOCK NO. J9.2 J11.2 J11.1 J9.1 J16.4 J16.3 J16.1 J10.3 J10.1-2 J2.3 J2.3 LEVELER CONTROL BOARD LEDs...
  • Page 22 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual LED STATUS CHART - DOK-COMMANDER PIT DOCK LEVELER MICRO CONTROL BOARD POWER LEVELER AUX BOARD RITE-HITE PRODUCTS CORP. INPUTS OUTPUTS BOARD OUTPUTS RELAY DOK-COMMANDER CONTROLS FIELD PUSH BUTTONS TERMINAL BLOCK NO. J14.4 J14.2 J14.3...

  • Page 23: Electrical Wiring Charts

    RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual ELECTRICAL WIRING CHARTS MOTOR CONNECTION DETAIL / FLA HALDEX BASE BUCHER BASE HALDEX HYDRARITE BUCHER HYDRARITE 1 PH CONNECTON DETAIL 3 PH CONNECTON DETAIL P1 P2 T3 T5 T2 T4 T8 P1 P2 T3 T5 T2 T4 T8...

  • Page 24: Electrical Schematics

    A BRANCH CIRCUIT DISCONNECT SHALL BE LOCATED WITHIN A 50 FT. RADIUS IF FUSED DISCONNECT IS AND BE VISIBLE FROM THE CONTROL NOT PROVIDED BY RITE-HITE BOX LOCATION. [REFERENCE LATEST PRODUCTS CORPORATION, EDITION OF NEC, SECTION 430] FUSED DISCONNECT MUST...
  • Page 25 1. INSTALL PER LOCAL ELECTRICAL CODES. REFER ALL INSTALLATION AND LEGEND: SERVICE TO QUALIFIED PERSONNEL. LS2 PROVIDED BY RITE-HITE WITH LEVELER FOR ARTD. DENOTES WIRE CONNECTIONS THRU TERMINAL BLOCK. 2. ALL INCOMING POWER (FROM DISCONNECT TO CONTROL BOX) AND 8. DISCONNECT NOTES: DENOTES FIELD WIRES.
  • Page 26 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual ELECTRICAL SCHEMATIC CONT. DETAIL A - DIP SWITCH SETTINGS FACTORY POSITION FUNCTION CONTROLLED 1 (DOWN) (DIP SWITCH 1 NOT USED) 2 (UP) GREEN LIGHT ITL/ITC (DOWN - IF REQUIRED/UP TO DISABLE) 3 (UP)
  • Page 27 7. LS1 PROVIDED BY OTHER FOR OVERHEAD DOOR INTERLOCK (OPEN). 9. DISCONNECT NOTES: SERVICE TO QUALIFIED PERSONNEL. LS2 PROVIDED BY RITE-HITE WITH LEVELER FOR ARTD. -FUSED DISCONNECT IS NOT PROVIDED BY RITE-HITE PRODUCTS 2. ALL INCOMING POWER (FROM DISCONNECT TO CONTROL BOX) AND 8.
  • Page 28 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual ELECTRICAL SCHEMATIC CONT. DETAIL A - DIP SWITCH SETTINGS FACTORY POSITION FUNCTION CONTROLLED 1 (DOWN) (DIP SWITCH 1 NOT USED) 2 (UP) GREEN LIGHT ITL/ITC (DOWN - IF REQUIRED/UP TO DISABLE) 3 (UP)
  • Page 29 7. LS1 PROVIDED BY OTHER FOR OVERHEAD DOOR INTERLOCK (OPEN). SERVICE TO QUALIFIED PERSONNEL. -FUSED DISCONNECT IS NOT PROVIDED BY RITE-HITE PRODUCTS LS2 PROVIDED BY RITE-HITE WITH LEVELER FOR ARTD. 2. ALL INCOMING POWER (FROM DISCONNECT TO CONTROL BOX) AND CORPORATION.
  • Page 30 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual ELECTRICAL SCHEMATIC CONT. DETAIL A - DIP SWITCH SETTINGS DETAIL D - LEVELER MOTOR WIRING (BASE) FACTORY POSITION FUNCTION CONTROLLED OVERLOAD PROTECTION PROVIDED 1 (DOWN) (DIP SWITCH 1 NOT USED) BY BRANCH CIRCUIT FUSES...
  • Page 31 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual ELECTRICAL SCHEMATIC CONT. DETAIL E - CONTROL TRANSFORMER WIRING TRANSFORMER PRIMARY FUSING 2FU1 2FU2 1.0 AMP. 600v. CLASS CC REJ DUAL ELM TD 230v. H2(VT) H3(BL) H1(BN) H4(OR) 230V 60VA TRANSFORMER 120v. X1(RD)

  • Page 32: Replacement Parts

    RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual REPLACEMENT PARTS - BASE UNIT Pub. No. 1210 - April 2016...
  • Page 33 Full Range RH (2Fan) Units W/O ADS 418.102 418.103 418.104 418.105 Full Range RH (3Fan) Units With ADS 420.101 420.103 NOTE: Lip Spool Module part numbers above apply to most levelers. If you are not sure, contact Rite-Hite before ordering. Pub. No. 1210 - April 2016...
  • Page 34 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual REPLACEMENT PARTS - BASE UNIT Pub. No. 1210 - April 2016...
  • Page 35 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual REPLACEMENT PARTS LIST - BASE UNIT Leveler Length Item Qty. Description 6' Long 8' Long 10' Long 12' Long Toeguard Fan 14GA X 11 4Hole 1 Slot LH 411.100 411.101 563.100 563.101 Toeguard Fan 14GA X 11 4Hole 1 Slot RH 411.100...
  • Page 36 Push Button N12/N4 57075 Push Button N4X 118316 Control Box Cover Decal, Raise 3 x 3 Hole (30.5MM Oprtr) 117414 Decal V/PH/FLA 230dxxx Decal UL/ULC - Consult RITE-HITE Contact Block, NO 30.5MM 600V (1.5 HP) 118315 Pub. No. 1210 - April 2016...
  • Page 37 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual NOTES Pub. No. 1210 - April 2016...
  • Page 38 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual REPLACEMENT PARTS - HYDRA-RITE UNIT Pub. No. 1210 - April 2016...
  • Page 39 Full Range LH (2FAN) Units W/O ADS 417.102 417.103 417.104 417.105 Full Range LH (3FAN) Units With ADS 419.102 419.103 NOTE: Lip Spool Module part numbers above apply to most levelers. If you are not sure, contact Rite-Hite before ordering. Pub. No. 1210 - April 2016...
  • Page 40 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual REPLACEMENT PARTS - HYDRA-RITE UNIT Pub. No. 1210 - April 2016...
  • Page 41 128121 128121 128121 128121 Washer Flat 1.125ID 1.75OD .1406THK ZP 139809 139809 139809 139809 NOTE: Lip Spool Module part numbers above apply to most levelers. If you are not sure, contact Rite-Hite before ordering. Pub. No. 1210 - April 2016...
  • Page 42 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC REPLACEMENT PARTS - HYDRA-RITE (HALDEX POWER UNIT) Lip Cylinder Port TOP VIEW SIDE VIEW Main Cylinder Port 19 20 NOTE: 4 Lb-ft max torque on solenoid valve steam nut (ref. item #31),...
  • Page 43 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC REPLACEMENT PARTS LIST - HYDRA-RITE - (HALDEX POWER UNIT) Leveler Length Item Qty. Description 6’ Long 8’ Long 10’ Long 12’ Long Power Unit - 120/240 Single Phase 126501 126501 126501 126501...
  • Page 44 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC REPLACEMENT PARTS - BASE (HALDEX POWER UNIT) Lip Cylinder Port TOP VIEW SIDE VIEW Main Cylinder Port 19 14 NOTE: 4 Lb-ft max torque on solenoid valve steam nut (ref. item #24),...
  • Page 45 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC REPLACEMENT PARTS LIST - BASE UNIT (HALDEX POWER UNIT) Leveler Length Item Qty. Description 6’ Long 8’ Long 10’ Long 12’ Long Power Unit - 120/240 Single Phase 126498 126498 126498 126498...
  • Page 46 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC REPLACEMENT PARTS - HYDRA-RITE (BUCHER POWER UNIT) Pub. No. 1210 - April 2016...
  • Page 47 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC REPLACEMENT PARTS LIST - HYDRA-RITE - (BUCHER POWER UNIT) Leveler Length Item Qty. Description 6’ Long 8’ Long 10’ Long 12’ Long Power Unit 115/230v 1ph 141170 141170 141170 141170 Power Unit 208-230/380-460v 3ph...
  • Page 48 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC REPLACEMENT PARTS - BASE (BUCHER POWER UNIT) 5, 14 Pub. No. 1210 - April 2016...
  • Page 49 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual HYDRAULIC REPLACEMENT PARTS LIST - BASE - (BUCHER POWER UNIT) Leveler Length Item Qty. Description 6’ Long 8’ Long 10’ Long 12’ Long Power Unit 115/230v 1ph 141167 141167 141167 141167 Power Unit 208-230/380-460v 3ph...
  • Page 50 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual AUTOMATIC RETURN TO DOCK PARTS - HYDRA-RITE 9 11 Leveler Length Item Qty. Description 6' Long 8' Long 10' Long 12' Long Lip Cylinder, Single Acting 119291 119291 119291 119291 Clevis Pin, 1.00Dia. x 3.625L ZP...
  • Page 51 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual AUTOMATIC RETURN TO DOCK PARTS - BASE 11 10 12 13 Leveler Length Item Qty. Description 6' Long 8' Long 10' Long 12' Long Lip Cylinder, Single Acting 102239 102239 102239 102239 Clevis Pin, .75Dia. x 3.75L CRM...
  • Page 52 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual ENDLOAD LEG OPTION PARTS Item Qty. Description Part Number Endload Leg Assembly - Hydrarite 121708 Endload Leg Assembly - Base 121850 Lanyard Chain Assembly 147L 510d123 Lever Weldment 121902 Spacer Tube 2.75L 477d108...
  • Page 53 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual SAFE-T-LIP (2-3-2) ASSEMBLY PARTS Leveler Hydraulics Item Qty. Description RHH(Base) RHH(HydraRite) See Description Below Safe-T-Lip Plate Square Ends 684dxxx 684dxxx TAPERED Ends (Shown) 685dxxx 685dxxx Notched Ends 686dxxx 686dxxx Shoulder Bolt - 1.125Dia...
  • Page 54 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual SAFE-T-LIP (1-5-1) ASSEMBLY PARTS PRIOR TO SERIAL NUMBER 11GD480214M Item Qty. Description Part Number Safe-T-Lip Assembly 396dxxx Spool Module Consult Factory Shoulder Bolt 1” Dia. x .66L 119920 Pub. No. 1210 - April 2016...
  • Page 55 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual NOTES Pub. No. 1210 - April 2016...
  • Page 56 EXTEND KEYED OPTION TO STORE LEVELER LIP EXTEND BELOW DOCK ENDLOADING MOMENTARY PAUSE WARNING WARNING RITE-HITE PRODUCTS CORP. MILWAUKEE WI 53223 1-800-456-0600 PRODUCTS CORP. Milwaukee, Wisconsin 53223 (800) 456-0600 EXTERIOR DECAL NOTE: 1. PLACE ITEM 310 IN UPPER PORTION OF ENCLOSURE WHEN ITEM 309 IS NOT PRESENT.
  • Page 57 Standard Leveler Control Board, Including Fuse 144574-883D100 Leveler control board with Program Options, Blank (Consult Rite-Hite for specific part number) 144555-xxx Leveler control board with Program Options, Including Fuse (Consult Rite-Hite for specific part number) 144574-xxx Leveler circuit board cover 146552...
  • Page 58 EXTEND KEYED OPTION TO STORE LEVELER LIP EXTEND BELOW DOCK ENDLOADING MOMENTARY PAUSE WARNING WARNING RITE-HITE PRODUCTS CORP. MILWAUKEE WI 53223 1-800-456-0600 PRODUCTS CORP. Milwaukee, Wisconsin 53223 (800) 456-0600 EXTERIOR DECAL NOTE: 1. PLACE ITEM 310 IN UPPER PORTION OF ENCLOSURE WHEN ITEM 309 IS NOT PRESENT.
  • Page 59 RITE-HITE ® RHH-4000 Dock Leveler Owner’s Manual ELECTRICAL REPLACEMENT PARTS LIST - CONTINUED Item Qty. Description Part Number Selector switch, keyed (If equipped) 149175 Standoff, Male/Female, #6-32, 2.5" length 133365 Screw, round head, #6-32, 0.25" length 133366 Lock washer, #6 51826 Standoff, Male/Female, #6-32, 2.5"...
  • Page 60 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 ®...

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