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

Dock leveler
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Genisys™ HL-900 Dock Leveler
Owner's Manual
NOTICE TO USER                        2
SAFETY                                4
COMPONENTS                          6
Motor FLA/Connection Detail                 7
Type 1 Control Box: 120V/208-240V, 50/60HZ
Single Phase                             8
Wiring: 115V Single Phase                   9
Wiring: 230V Single Phase                 11
Wiring: 3 Phase                          13
Standard                                16
Below Dock Loading                      16
Storing Leveler                           17
MAINTENANCE                         18
Planned Maintenance                     19
Lubrication                              20
Leveler Adjustments                       20
Hydraulic Schematic                      25
TROUBLESHOOTING                    26
HL-900                                 28
Type 1 Control Box                        31
Control Box                             32
Haldex Power Unit                        34
Bucher Power Unit                        36
Decals                                 39
WARRANTY                            40
Model: HL-900
Publication: AMEN00160 2021-08-17
Language: English

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Summary of Contents for RITE-HITE Genisys HL-900

  • Page 1: Table Of Contents

    Genisys™ HL‑900 Dock Leveler Owner's Manual NOTICE TO USER                        2 SAFETY                                4 COMPONENTS                          6 ELECTRICAL Motor FLA/Connection Detail                 7...

  • Page 2: Notice To User

    The English version of this manual shall prevail over any error in, or conflicting interpretation of, any translations. Rite-Hite reserves the right to substitute and/or modify parts and drawings If separate prints are included with the unit, they supersede those contained in the manual...
  • Page 3 Your local Rite-Hite representative offers owners the option of a Planned Maintenance Program (PMP) As part of this service, your local Rite-Hite representative will do all routine maintenance, lubrication, and adjustments Publication: AMEN00160 2021‑08‑17...

  • Page 4: Safety

    ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual SAFETY Safety Identifications Lockout Procedure Barricade work area and post safety warnings DANGER Power supply and control must: • Be disconnected or locked in OFF position Indicates a hazardous situation which, if not using a lockout device approved by local avoided, will result in death or serious injury.
  • Page 5 If you are unable to install the maintenance strut properly, contact your authorized Before starting installation or maintenance, check Rite-Hite Service Representative or Rite-Hite and follow the safety procedures of the facility technical support at (US) 888-456-3625, where the dock leveler is being installed.

  • Page 6: Components

    ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual COMPONENTS <HL9 ‑ COMPONENTS‑210706.PDF> A Lip Weldment F Ramp Cylinder K Maintenance Strut B Lip Hinge Pin G Lip Cylinder L Velocity Fuse C Lip Lug H Frame M Lip Keeper D Platform...

  • Page 7: Electrical

    (25 mm (25 mm (25 mm (25 mm NOTE: For line lengths over 200 ft (61 m), contact your local Rite-Hite representative 3 PH CONNECTION DETAIL 1 PH CONNECTION DETAIL Haldex If rotation is wrong, reverse T5/5 and T8/8 Bucher...

  • Page 8: Single Phase

    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 9: Wiring: 115V Single Phase

    Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual ELECTRICAL Wiring: 115V Single Phase For field wiring and "Motor FLA/Connection Detail" go to page Figure 4 Publication: AMEN00160 2021‑08‑17...
  • Page 10 ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual ELECTRICAL Wiring: 115V Single Phase Continued <HL9 115V SCHEMATIC_UPDATED 2016‑6‑9.PDF> Figure 5 Publication: AMEN00160 2021‑08‑17...

  • Page 11: Wiring: 230V Single Phase

    Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual ELECTRICAL Wiring: 230V Single Phase For field wiring and "Motor FLA/ Connection Detail" go to page Figure 6 Publication: AMEN00160 2021‑08‑17...
  • Page 12 ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual ELECTRICAL Wiring: 230V Single Phase Continued <HL9 230V 1PH SCHEMATIC_UPDATED 2016‑6‑9.PDF> Figure 7 Publication: AMEN00160 2021‑08‑17...

  • Page 13: Wiring: 3 Phase

    Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual ELECTRICAL Wiring: 3 Phase FOR LEVELER MOTOR WIRING CONTACT RITE-HITE FOR TRANSFORMER WIRING CONTACT RITE-HITE FOR MOTOR CONTACTOR WIRING CONTACT RITE-HITE Figure 8 Publication: AMEN00160 2021‑08‑17...
  • Page 14 ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual ELECTRICAL Wiring: 3 Phase Continued For field wiring and "Motor FLA/Connection Detail" go to page Figure 9 Publication: AMEN00160 2021‑08‑17...
  • Page 15 Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual ELECTRICAL Wiring: 3 Phase Continued <HL9 3PH SCHEMATIC_UPDATED 210706.PDF> Figure 10 Publication: AMEN00160 2021‑08‑17...

  • Page 16: Operation

    ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual OPERATION STATE POSITION Standard 1 Activate the leveler by pushing and holding the RAISE button until leveler is fully raised and lip is fully extended NOTE: Some levelers may be equipped with a 2...

  • Page 17: Dock Level (Or Lower) End Loading

    Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual OPERATION STATE POSITION Dock Level (Or Lower) End Loading 1 Activate the leveler by pushing and holding the RAISE button until leveler is fully raised and lip begins to extend Some levelers may be equipped with a...

  • Page 18: Maintenance

    NOTICE the underside of lip NOTE: If you are unable to install the maintenance Contact Rite-Hite if loading docks are exposed to strut properly, contact your authorized Rite-Hite harsh environments (extreme climates, corrosive Service Representative or Rite-Hite Technical Support chemicals, high usage, etc) More frequent...

  • Page 19: Planned Maintenance

    With the leveler supported by the maintenance strut, check hydraulic fluid level in tank. Add fluid if necessary. Use only   – Rite‑Hite approved hydraulic fluids. STANDARD: 108303 – Mil 5606 Fluid (quart/red in color) OPTIONAL: 119181 – Rite-Hite Biodegradable Fluid (quart/light blue in color)  Check and tighten control box mounting hardware – – Publication: AMEN00160 2021‑08‑17...

  • Page 20: Lubrication

    ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual MAINTENANCE Lubrication = Oil SAE 30 Weight Check hydraulic fluid level. <HL9 - Maint-02262020pdf> Figure 11 Leveler Adjustments The adjustments shown are factory averages Field DANGER adjustment may be necessary None of the adjustments will...
  • Page 21 Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual MAINTENANCE Leveler Adjustments Continued Lip Stop Bolt ARTD Limit Switch Cam (Optional) Shown with lip pendant and lip stop bolt adjusted Front Washer ARTD Cam Front Washer ARTD Cam Lip Stop Bolt...
  • Page 22 ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual MAINTENANCE Leveler Adjustments Continued Hydraulic Valves (Haldex Power Unit) Haldex Power Unit End Head Optional Infinite Lip Ramp Cylinder Port Control (IFC), Emergency Stop (ESB) port Lip Cylinder Port Sequence Valve Pilot Operated...
  • Page 23 Flow Control Valve Check Valve (3:1) Lock Nut Lock Nut Ramp Ramp Pilot-To-Close Pilot to Close Check Valve (3:1) Check Valve (3:1) *DO NOT adjust the system relief valve (set at 1,250 PSI) without permission from Rite-Hite Figure 15 Publication: AMEN00160 2021‑08‑17...
  • Page 24 ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual MAINTENANCE Leveler Adjustments Continued Hydraulic Valves (Bucher Power Unit) Continued The flow control valve (Figure 15 on page 23) controls The sequence valve (Figure 15 on page 23) controls the leveler's descent...

  • Page 25: Hydraulic Schematic

    Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual MAINTENANCE Hydraulic Schematic Haldex Power Unit Power Unit Assembly Velocity Fuse 6 GPM (6’) 140-170 Motor 25 GPM (8’) Optional Micron 3450 RPM 5 GPM (10’ & 12”) 2W NO Valve Strainer “RAMP”...

  • Page 26: Troubleshooting

    ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual TROUBLESHOOTING PROBLEM PROBABLE CAUSE REMEDY Platform does not raise Power has been disconnected Make sure that power has not been disconnected Verify that disconnect circuit breaker or fuses are not tripped The motor is not wired correctly...

  • Page 27: Led Status Chart - Standalone Controls

    Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual TROUBLESHOOTING LED Status Chart – Standalone Controls LEVELER CONTROL BOARD LEVELER AUX BOARD INPUTS OUTPUTS OUTPUTS ? = Varies (depending on operation) FIELD PUSH BUTTONS 12VDC RELAY 12VDC F = Off ITL = Interlock input on...

  • Page 28: Parts

    ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual PARTS HL‑900 <HL9 ‑ PARTS‑05152020.PDF> Publication: AMEN00160 2021‑08‑17...
  • Page 29 Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual PARTS HL‑900 Continued PART # LEVELER LENGTH AND CAPACITY DESCRIPTION 6FT LONG 8FT LONG 10FT LONG 12FT LONG Frame HL9/RHH40 573XXX 573XXX 573XXX 573XXX Platform 401XXX 401XXX 401XXX 401XXX Lip Weldment 421XXX...
  • Page 30 ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual PARTS HL‑900 Continued PART # LEVELER LENGTH AND CAPACITY DESCRIPTION 6FT LONG 8FT LONG 10FT LONG 12FT LONG Toeguard Fan 14GA X 11 3Hole 1 Slot LH 896100 896101 899100 899101 Toeguard Fan 14GA X 11 3Hole 1 Slot RH...

  • Page 31: Type 1 Control Box

    Control Box Cover Decal, Raise 3 x 3 Hole 0117414 (305MM Oprtr) Decal V/PH/FLA 230xxx Decal UL/ULC – Consult Rite-Hite – Contact Block, NO 305MM 600V (15 HP) 0118315 NOTE: For ordering purposes, the leading "0" or "00" may need to be dropped from Part Number (eg "0054321" could be "54321" or "0123456" could be "123456")...

  • Page 32: Control Box

    ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual PARTS Control Box EXTERIOR DECAL NOTE: 1 Place item 310 in upper portion of enclosure when item 309 is not present INTERIOR DECAL NOTE: 1 Item 302, 303, and 304 place in available space on rear of...
  • Page 33 Fuse 883D100 05A fuse, CC, Dual element time delay 0066005 Leveler control board with Program 144555-xxx Options, Blank (Consult Rite-Hite for 04A fuse, CC, Dual element time delay 0066006 specific part number) Mushroom stop button 0125163 Leveler control board with Program...

  • Page 34: Haldex Power Unit

    ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual PARTS Haldex Power Unit Lip Cylinder Port TOP VIEW SIDE VIEW Main Cylinder Port 19 14 <PUPARTS4.EPS> IFC/ESB Parts Breakdown (Optional) Side View Tank End View NOTE: 4 lb-ft max torque on solenoid valve...
  • Page 35 Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual PARTS Haldex Power Unit Continued PART # LEVELER LENGTH DESCRIPTION 6FT LONG 8FT LONG 10FT LONG 12FT LONG Power Unit – 120/240 Single Phase 0126498 0126498 0126498 0126498 Power Unit – 240/380 – 415/480 Three Phase...

  • Page 36: Bucher Power Unit

    ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual PARTS Bucher Power Unit Publication: AMEN00160 2021‑08‑17...
  • Page 37 Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual PARTS Bucher Power Unit Continued PART # LEVELER LENGTH DESCRIPTION 6FT LONG 8FT LONG 10FT LONG 12FT LONG Power Unit 115/230V 1ph 0156693 0156693 0156693 0156693 Power Unit 208-230/380-460v 3ph 0156694 0156694...

  • Page 38: Automatic Return To Dock (Artd) (Optional)

    ® Genisys™ HL-900 Dock Leveler Rite-Hite Owner's Manual PARTS Automatic Return to Dock (ARTD) (Optional) 11 10 12 13 <ARTD‑RHH(B)1.EPS> PART # LEVELER LENGTH DESCRIPTION 6FT LONG 8FT LONG 10FT LONG 12FT LONG Lip Cylinder, Single Acting 0102239 0102239 0102239...

  • Page 39: Decals

    Rite-Hite ® Genisys™ HL-900 Dock Leveler Owner's Manual PARTS Decals <DECALVIEWHL9‑03122020.PDF> DESCRIPTION PART # Warning ARTD Decal 0148720-01* Danger Crush Hazard Maint Support 0148720-02* Warning Trained Personnel Decal 0128121-02** Genisys Logo Decal 0128121-03** Made in USA Decal 0128121-04** *Part of decal sheet 148720 and are purchased together under this part number...
  • Page 40 Product claimed to be defective and shall, at Rite-Hite's option, either (x) grant Rite-Hite or its agent access to Owner's premises for the purpose of repairing or replacing the Product or (y)

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