RITE-HITE GENISYS AL-900 Owner's Manual
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RITE-HITE GENISYS AL-900 Owner's Manual

RITE-HITE GENISYS AL-900 Owner's Manual

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AL-900
Dock Leveler
Owner 's Manual
part of the SMOOTH TRANSITION DOK SYSTEM
TM
By Rite-Hite
This Manual Covers Dock Levelers Built After Serial Numbers:
07DD400623M and up
Publication: AMEN00044 2017-01-27

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Summary of Contents for RITE-HITE GENISYS AL-900

  • Page 1 AL-900 Dock Leveler Owner ’s Manual part of the SMOOTH TRANSITION DOK SYSTEM By Rite-Hite This Manual Covers Dock Levelers Built After Serial Numbers: 07DD400623M and up Publication: AMEN00044 2017-01-27...
  • Page 2 GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27...
  • Page 3 414-355-2600. ® 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, 6773221, 6832403, 6880301, 7032267, 7062814, 7213285, 7216391, 7363670,...

  • Page 4: Safety Warnings

    RITE-HITE ® 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 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.
  • Page 5 GENISYS AL-900 Dock Leveler Owner’s Manual OTHER IMPORTANT OPERATIONAL SAFETY WARNINGS NEVER be under the dock leveler platform or lip ALWAYS barricade the dock leveler at ground without: level and dock level from any form of traffic when maintenance is required.
  • Page 6 GENISYS AL-900 Dock Leveler Owner’s Manual OTHER IMPORTANT OPERATIONAL SAFETY WARNINGS NEVER be under the dock leveler platform or lip • Post warnings and barricades at dock level and without: at drive level to indicate that work is being done around and under the leveler platform.

  • Page 7: Owner Responsibility

    GENISYS AL-900 Dock Leveler Owner’s Manual OWNER RESPONSIBILITY 1. The owner should recognize the inherent danger of Dock equipment that is structurally damaged shall be the interface between dock and transport vehicle The removed from service, inspected by a manufacturer’s...

  • Page 8: Operating Procedures

    GENISYS AL-900 Dock Leveler Owner’s Manual OPERATING PROCEDURES NORMAL OPERATION BELOW DOCK LOADING OPERATION 1. Activate the leveler by pushing and holding the 1. Activate the leveler by pushing and holding the RAISE button until leveler is fully raised and lip is fully RAISE button until leveler is fully raised and lip is fully extended.
  • Page 9 GENISYS AL-900 Dock Leveler Owner’s Manual OPERATING PROCEDURES CONT. DOCK LEVEL (OR LOWER) END LOADING 3 When loading/unloading is complete, continue with normal operation or return the leveler to stored position OPERATION See Storing Leveler 1. Activate the leveler by pushing and holding the RAISE button until leveler lip clears the lip supports See figure 6.

  • Page 10: Maintenance

    GENISYS AL-900 Dock Leveler Owner’s Manual MAINTENANCE 9. Inspect all conduit boxes, control boxes and electrical connections for damage Repair or replace if worn or damaged NOTE: If control box has evidence of condensation ALWAYS read and obey these instructions to prevent a Inspect conduit Conduit should be routed to enter personal injury.
  • Page 11 GENISYS AL-900 Dock Leveler Owner’s Manual MAINTENANCE CONT. OIL SAE 30 Weight Anti-Seize FIGURE 10 - LEVELER LUBRICATION Stops for side Tub opening on Leveler Frame. Attach chain assembly to d-rings on Tub, both sides Stops for side Tub opening on Leveler Frame.
  • Page 12 GENISYS AL-900 Dock Leveler Owner’s Manual LEVELER ADJUSTMENTS LIP LATCH BOLT ADJUSTMENT The lip latch bolt is factory adjusted Over time however, if the lip does NOT latch when the leveler is fully raised and remain latched as the platform lowers, the lip latch bolt...
  • Page 13 GENISYS AL-900 Dock Leveler Owner’s Manual LEVELER TROUBLESHOOTING Problem Probable Cause Solution Platform does not raise. No power Check the main power supply Check fuses in the control box and disconnect Check wiring The blower motor and/or control box has been mis-wired...
  • Page 14 GENISYS AL-900 Dock Leveler Owner’s Manual LED STATUS CHARTS PIT DOCK LEVELER LEVELER CONTROL BOARD LEVELER AUX BOARD RITE-HITE PRODUCTS CORP. INPUTS OUTPUTS OUTPUTS PUSH STANDALONE CONTROLS BUTTONS 12VDC TERMINAL BLOCK NO. J9.2 J11.2 J11.1 J9.1 J16.4 J10.3 J10.1-2 J2.3 J2.3...
  • Page 15 GENISYS AL-900 Dock Leveler Owner’s Manual ELECTRICAL WIRING CHARTS Motor FLA  Minimum Wire Size (AWG) Chart  Ratings &  for Various Line Lengths and Line  Connection  Loads Detail     Line Length (ft) 0‐50 51‐100 101‐150 151‐200 110‐120/1/60/1300W 13.3 208‐240/1/60/1533W AL‐800/900 MOTOR SIZE 1533W 110‐120/1/60 13.3 208‐240/1/50/60 DOCK LEVELER MOTOR FLA RATINGS HALDEX BUCHER CONN  CONN  BASE DETAIL DETAIL 110‐120/1/60 .75HP/10 1HP/11.2...

  • Page 16: Electrical Schematics

    GENISYS AL-900 Dock Leveler Owner’s Manual ELECTRICAL SCHEMATICS FROM CUSTOMER MAIN POWER & SAFETY PROTECTION 110-120v. 1PH. 60HZ. USE 15.0A DUAL ELEMENT TIME DELAY 208-240v. 1PH. 60HZ. USE 10.0A DUAL ELEMENT TIME DELAY 208-240v. 1PH. 50HZ. USE 10.0A DUAL ELEMENT TIME DELAY...
  • Page 17 7. LS1 PROVIDED BY OTHER FOR OVERHEAD DOOR INTERLOCK (OPEN). 1. INSTALL PER LOCAL ELECTRICAL CODES. REFER ALL INSTALLATION AND LEGEND: LS2 PROVIDED BY RITE-HITE WITH LEVELER FOR ARTD. SERVICE TO QUALIFIED PERSONNEL. DENOTES WIRE CONNECTIONS THRU TERMINAL BLOCK. 2. ALL INCOMING POWER (FROM DISCONNECT TO CONTROL BOX) AND 8.
  • Page 18 GENISYS AL-900 Dock Leveler Owner’s Manual ELECTRICAL SCHEMATICS 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) OVERHEAD DOOR INTERLOCK...
  • Page 19 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 20 GENISYS AL-900 Dock Leveler Owner’s Manual ELECTRICAL SCHEMATICS 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) OVERHEAD DOOR INTERLOCK...
  • Page 21 GENISYS AL-900 Dock Leveler Owner’s Manual NOTES Publication: AMEN00044 2017-01-27...

  • Page 22: Replacement Parts

    GENISYS AL-900 Dock Leveler Owner’s Manual REPLACEMENT PARTS REPLACEMENT PARTS AL9 - Parts Publication: AMEN00044 2017-01-27...
  • Page 23 GENISYS AL-900 Dock Leveler Owner’s Manual REPLACMENT PARTS LIST Leveler Length Item Qty. Description 6’ Long 8’ Long 10’ Long Frame Weldment 673 xxx 673 xxx 673 xxx Platform Weldment 436 xxx 436 xxx 436 xxx Lip Weldment 421.xxx 421.xxx 421.xxx...
  • Page 24 GENISYS AL-900 Dock Leveler Owner’s Manual REPLACEMENT PARTS CONT. AL9 - Parts Publication: AMEN00044 2017-01-27...
  • Page 25 GENISYS AL-900 Dock Leveler Owner’s Manual REPLACMENT PARTS LIST CONT. Leveler Length Item Qty. Description 6’ Long 8’ Long 10’ Long Maintenance Support 413.105 413.105 413.102 Chain Assembly 117395 117395 117395 Full Range LH (2 Fan) (Not Shown) 417.102 Full Range LH (3 Fan) 419.101...
  • Page 26 GENISYS AL-900 Dock Leveler Owner’s Manual TYPE 1 CONTROL BOX PARTS INSIDE RIGHT INSIDE LEFT Back Of Cover Item Description Part Number Control Box Complete 228.xxx Control Box Enclosure, 4 x 4 x 2 N4XF 117342 Push Button Operator (30.5MM) Black, NO, N12/N4 (AB: 800T-A2D1M) 117352 Push Button Operator (30.5MM) Black, NO, N4X (AB: 800H-AR2D1M)
  • Page 27 GENISYS AL-900 Dock Leveler Owner’s Manual NOTES Publication: AMEN00044 2017-01-27...
  • Page 28 GENISYS AL-900 Dock Leveler Owner’s Manual TYPE 2 CONTROL BOX PARTS DOCK LEVELER RAISE OPERATIONAL INSTRUCTIONS PLATFORM RAISE & LIP EXTEND KEYED OPTION TO STORE LEVELER BELOW DOCK ENDLOADING WARNING WARNING RITE-HITE PRODUCTS CORP. MILWAUKEE WI 53223 1-800-456-0600 PRODUCTS CORP.
  • Page 29 Standard Leveler Control Board, Blank 144555-883D100 Standard Leveler Control Board, Including Fuse 144574-883D100 Leveler control board with Program Options, Blank (Consult Rite-Hite for specific part 144555-xxx number) Leveler control board with Program Options, Including Fuse (Consult Rite-Hite for specific 144574-xxx...
  • Page 30 GENISYS AL-900 Dock Leveler Owner’s Manual TYPE 2 CONTROL BOX PARTS - CONTINUED DOCK LEVELER RAISE OPERATIONAL INSTRUCTIONS PLATFORM RAISE & LIP EXTEND KEYED OPTION TO STORE LEVELER BELOW DOCK ENDLOADING WARNING WARNING RITE-HITE PRODUCTS CORP. MILWAUKEE WI 53223 1-800-456-0600 PRODUCTS CORP.
  • Page 31 GENISYS AL-900 Dock Leveler Owner’s Manual TYPE 2 CONTROL BOX REPLACMENT PARTS LIST - CONTINUED Item 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 32: Warranty

    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.

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