RITE-HITE Genisys HL-900 Owner's Manual
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RITE-HITE Genisys HL-900 Owner's Manual

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This Manual Covers Dock Levelers Built After Serial Numbers:
13GD480708M and up
PRINTED IN U.S.A.
RITE-HITE
PRINT SHOP
HL-900
Dock Leveler
Owners Manual
part of the SMOOTH TRANSITION DOK SYSTEM
By Rite-Hite
TM
MADE IN U.S.A.
PUBLICATION NO. 1213
APRIL 2016

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  • Page 1 HL-900 Dock Leveler Owners Manual part of the SMOOTH TRANSITION DOK SYSTEM MADE IN U.S.A. By Rite-Hite This Manual Covers Dock Levelers Built After Serial Numbers: 13GD480708M and up PRINTED IN U.S.A. PUBLICATION NO. 1213 RITE-HITE PRINT SHOP APRIL 2016...
  • Page 2 Genisys HL-900 Dock Leveler Owner’s Manual NOTES Pub. No. 1213 - 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

    Genisys HL-900 Dock Leveler Owner’s Manual SAFETY WARNING 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. 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.
  • Page 5 Genisys HL-900 Dock Leveler Owner’s Manual OTHER IMPORTANT OPERATIONAL SAFETY WARNINGS Never be under the dock leveler platform or lip without: Always barricade the dock leveler at ground level and dock level from any form of traffic when maintenance is required.
  • Page 6 Genisys HL-900 Dock Leveler Owner’s Manual SAFETY DEVICES Never be under the dock leveler platform or lip without: • Post warnings and barricades at dock level and at drive level to indicate that work is being done around • Installing the Maintenance Strut. See below right. This and under the leveler platform.

  • Page 7: Owner Responsibility

    Genisys HL-900 Dock Leveler Owner’s Manual OWNER RESPONSIBILITY The owner should recognize the inherent danger of the As with any piece of machinery, dock equipment requires routine interface between dock and transport vehicle. The owner maintenance, lubrication, and adjustments. Your local...

  • Page 8: Operation Instructions

    Genisys HL-900 Dock Leveler Owner’s Manual OPERATION INSTRUCTIONS 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. a. Levelers without Automatic Return to Dock (ARTD) If the...
  • Page 9 Genisys HL-900 Dock Leveler Owner’s Manual OPERATION INSTRUCTIONS CONT. DOCK LEVEL (OR LOWER) END LOADING NOTES: OPERATION 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: Maintenance Procedures

    Genisys HL-900 Dock Leveler Owner’s Manual MAINTENANCE PROCEDURES 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. Read and obey these instructions to prevent personal a.
  • Page 11 Genisys HL-900 Dock Leveler Owner’s Manual MAINTENANCE PROCEDURES OIL SAE 30 Weight NOTE: Check Hydraulic Fluid level. FIGURE 8 - HYDRAULIC POWERED LEVELER LUBRICATION Pub. No. 1213 - April 2016...

  • Page 12: Hydraulic Leveler Adjustments/Troubleshooting

    Genisys HL-900 Dock Leveler Owner’s Manual LEVELER ADJUSTMENTS HYDRAULIC LEVELER ADJUSTMENTS OPTIONAL ARTD ADJUSTMENTS: ARTD Limit Switch Cam NOTE: NOTE: Before continuing be sure the lip stop bolt is properly The adjustments listed below are factory averages, field adjusted. See figure 9.
  • Page 13 Genisys HL-900 Dock Leveler Owner’s Manual LEVELER ADJUSTMENTS CONT. Optional Infinite Lip Ramp Cylinder Port Control (IFC), Emergency Stop (ESB) Lip Cylinder Port Port Adjustable Sequence Valve Adjustable Pilot Shuttle Operated Check Valve Valve System Pilot To Close Relief Check Valve...
  • Page 14 Genisys HL-900 Dock Leveler Owner’s Manual LEVELER ADJUSTMENTS CONT. SEQUENCE VALVE ADJUSTMENT (CONTROLS LIP EXTENSION) Note: • Check oil level before making any adjustments. • Sequence valve is factory sealed. Adjustments to be completed by trained technician only. When the leveler is fully raised and the lip does not extend, the Sequence Valve is set too high.
  • Page 15 Genisys HL-900 Dock Leveler Owner’s Manual LEVELER ADJUSTMENTS CONT. To Lip Cylinder To Ramp Cylinder System Relief Valve Pilot To Close (Set at 1,250 PSI. Do NOT adjust Check Valve (8:1) without permission from Rite-Hite) Sequence IFC/ESB Valve Option Port...
  • Page 16 Genisys HL-900 Dock Leveler Owner’s Manual LEVELER ADJUSTMENTS CONT. SEQUENCE VALVE ADJUSTMENT (Controls Lip Extension) NOTE: Check oil level before making any adjustments. NOTE: Sequence valve is factory set. Adjustments to be completed by trained technician only. When the leveler is fully raised and the lip does not extend, the Sequence Valve is set too high.
  • Page 17 Genisys HL-900 Dock Leveler Owner’s Manual 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 18: Hydraulic Leveler - Hydraulic Schematic

    Genisys HL-900 Dock Leveler Owner’s Manual HYDRAULIC SCHEMATIC Power Unit Assembly Velocity Fuse 6 GPM (6’) 140-170 Motor 2.5 GPM (8’) Optional 5 GPM (10’ & 12”) Micron 3450 RPM 2W N.O. Valve “RAMP” Strainer For IFC Port Pump 1.1 GPM @ 750 PSI Adj.
  • Page 19 Genisys HL-900 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 20 Genisys HL-900 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 DOK-COMMANDER CONTROLS FIELD PUSH BUTTONS RELAY TERMINAL BLOCK NO. J14.4 J14.2 J14.3 MEMBRANEMEMBRANE J7.8...

  • Page 21: Electrical Wiring Charts

    Genisys HL-900 Dock Leveler Owner’s Manual ELECTRICAL WIRING CHARTS MOTOR CONNECTION DETAIL / FLA HALDEX BUCHER 1 PH CONNECTON DETAIL 3 PH CONNECTON DETAIL P1 P2 T3 T5 T2 T4 T8 P1 P2 T3 T5 T2 T4 T8 IF ROTATION IS WRONG REVERSE T5/5 AND T8/8...

  • Page 22: Electrical Schematics

    Genisys HL-900 Dock Leveler Owner’s Manual ELECTRICAL SCHEMATIC 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 23 7. LS1 PROVIDED BY OTHER FOR OVERHEAD DOOR INTERLOCK (OPEN). 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 24 Genisys HL-900 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) OVERHEAD DOOR INTERLOCK...
  • Page 25 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 26 Genisys HL-900 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) OVERHEAD DOOR INTERLOCK...
  • Page 27 7. LS1 PROVIDED BY OTHER FOR OVERHEAD DOOR INTERLOCK (OPEN). 1. INSTALL PER LOCAL ELECTRICAL CODES. REFER ALL INSTALLATION AND -FUSED DISCONNECT IS NOT PROVIDED BY RITE-HITE PRODUCTS LS2 PROVIDED BY RITE-HITE WITH LEVELER FOR ARTD. SERVICE TO QUALIFIED PERSONNEL.
  • Page 28 Genisys HL-900 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 BY BRANCH CIRCUIT FUSES 1 (DOWN) (DIP SWITCH 1 NOT USED)
  • Page 29 Genisys HL-900 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) X2(WH)

  • Page 30: Replacement Parts

    Genisys HL-900 Dock Leveler Owner’s Manual REPLACEMENT PARTS REPLACEMENT PARTS LIST Leveler Length and Capacity Item Qty. Description 6' Long 8' Long 10' Long 12' Long Frame HL9/RHH40 361.___ 361.___ 361.___ 361.___ Platform 401.___ 401.___ 401.___ 401.___ Lip Weldment 421.___ 421.___...
  • Page 31 Genisys HL-900 Dock Leveler Owner’s Manual REPLACEMENT PARTS LIST CONTINUED Leveler Length and Capacity Item Qty. Description 6' Long 8' Long 10' Long 12' Long See Page 38-41 Power Unit Pin Clevis HD .875 X 3.25L ZP 129307 129307 129307 129307 Pin Clevis HD .875 X 3.25L ZP (Stainless Steel)
  • Page 32 Genisys HL-900 Dock Leveler Owner’s Manual TYPE 1 CONTROL BOX PARTS INSIDE RIGHT INSIDE LEFT Back Of Cover Item Qty. Description Part Number Control Box Complete 228.xxx Control Box Enclosure, 4 x 4 x 2 N4XF 117342 Push Button N12/N4...
  • Page 33 Genisys HL-900 Dock Leveler Owner’s Manual Pub. No. 1213 - April 2016...
  • Page 34 Genisys HL-900 Dock Leveler Owner’s Manual CONTROL BOX PARTS DOCK LEVELER RAISE OPERATIONAL INSTRUCTIONS PLATFORM RAISE & LIP 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.
  • Page 35 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 36 Genisys HL-900 Dock Leveler Owner’s Manual TYPE 3 CONTROL BOX PARTS CONT. DOCK LEVELER RAISE OPERATIONAL INSTRUCTIONS PLATFORM RAISE & LIP 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.
  • Page 37 Genisys HL-900 Dock Leveler Owner’s Manual CONTROL BOX REPLACEMENT PARTS LIST CONT. Item Qty. Description Part Number 0.5A fuse, 5mm x 20mm 145216 1A fuse, CC, Dual element time delay 66003 0.5A fuse, CC, Dual element time delay 66005 0.4A fuse, CC, Dual element time delay...
  • Page 38 Genisys HL-900 Dock Leveler Owner’s Manual HYDRAULIC REPLACEMENT PARTS (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), over tightening may cause...
  • Page 39 Genisys HL-900 Dock Leveler Owner’s Manual HYDRAULIC REPLACEMENT PARTS LIST (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 Power Unit - 240/380 - 415/480 Three Phase...
  • Page 40 Genisys HL-900 Dock Leveler Owner’s Manual HYDRAULIC REPLACEMENT PARTS - BASE (BUCHER POWER UNIT) 5, 14 Pub. No. 1213 - April 2016...
  • Page 41 Genisys HL-900 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 42 Genisys HL-900 Dock Leveler Owner’s Manual OPTIONAL AUTOMATIC RETURN TO DOCK PARTS (ARTD) 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 43 Genisys HL-900 Dock Leveler Owner’s Manual NOTES Pub. No. 1213 - April 2016...

  • Page 44: Warranty

    Length of Time: All products are warranted for a one year period commencing on the earlier date of approved installation or the (30th) day after the date of shipment. This warranty covers the repair or replacement of the defective product or component at Rite-Hite's sole election and expense, including reasonable labor, reasonable travel and freight.

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13gd480708m

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