RITE-HITE LEVEL-RITE HL-800 Series Manual
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RITE-HITE LEVEL-RITE HL-800 Series Manual

RITE-HITE LEVEL-RITE HL-800 Series Manual

Hydraulic dock leveler
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HYDRAULIC DOCK LEVELER
THIS MANUAL COVERS LEVELERS
AFTER SERIAL NUMBER M101516
PRINTED IN U.S.A.
RITE-HITE PRINT SHOP
LEVEL-RITE
HL-800 SERIES
Owner's Manual
1-414-355-2600
®
By Rite-Hite
PUBLICATION NO. 1167-R2
®
APRIL 2003

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Summary of Contents for RITE-HITE LEVEL-RITE HL-800 Series

  • Page 1 ® LEVEL-RITE HL-800 SERIES HYDRAULIC DOCK LEVELER ® By Rite-Hite THIS MANUAL COVERS LEVELERS AFTER SERIAL NUMBER M101516 Owner’s Manual PRINTED IN U.S.A. PUBLICATION NO. 1167-R2 RITE-HITE PRINT SHOP 1-414-355-2600 APRIL 2003...

  • Page 2: Table Of Contents

    PRODUCT INTRODUCTION The LEVEL-RITE ® HL Series Leveler By RITE-HITE ® is intended to provide a safer work place for workers in shipping and receiving dock areas. The HL Series Leveler is a hydraulically operated device that, when properly installed and operated, provides a safe and secure access between dock and truck.
  • Page 3 RITE-HITE PRODUCTS 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 PRODUCTS CORPORATION also recommends the review and implementation of an entire safety program for the Control of Hazardous Energy (Lockout/Tagout).
  • Page 4 HL-800 HYDRAULIC DOCK LEVELER NOTES Pub. No. 1167-R2 - April 2003...

  • Page 5: Pit Details

    HL-800 HYDRAULIC DOCK LEVELER Pit Details for LEVEL-RITE ® by Rite-Hite ® Hydraulic and Mechanical Dock Levelers Important: Angle Between See Item 3 Side And Rear Curb Angles On Following Page Must Be 90 Junction Box Location See Item 2...
  • Page 6 Location Location Restraint Mounting Plate Furnished By General Contractor Or ¨ Available From RITE-HITE at Additional Cost. 4" x 4" x 2" NEMA 4 (By Others) Figure - 4 Pit Details CONTRACTOR'S BILL OF MATERIALS FOR NOMINAL PIT SIZES ITEM...

  • Page 7: Installation Instructions

    POSITION AND TILT SUPPORT TO THE STORED POSITION. DO NOT USE MAINTENANCE SUPPORT IF DAMAGED. IMPORTANT IF A PROCEDURE IS NOT CLEARLY DEFINED, CONTACT YOUR LOCAL RITE-HITE REPRESENTATIVE OR RITE-HITE AT 1-414-355-2600 BEFORE PROCEEDING. Figure - 5 Complete Installation Pub. No. 1167-R2 - April 2003...
  • Page 8 * DO NOT POSITION THE LEVELER ON ITS SIDE OR TURN THE LEVELER TOPSIDE DOWN AT ANY TIME. * ENSURE LIFTING EQUIPMENT IS RATED FOR 3,000 lb. LIFTING CAPACITY OR GREATER. 1. Check pit to ensure it meets RITE-HITE pit details #0108172. If pit does not match pit details, contact your local representative or RITE-HITE before proceeding.
  • Page 9 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED 9. Check the area between the rear frame and the back of the pit. If a gap exists, place spacers between the rear frame angle and the rear curb angle. Tack weld spacers to rear frame angle only. See Detail "F". 10.
  • Page 10 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED 17. Cut and place shims under the rear frame support posts as necessary. See Detail "J". 18. Cut and place shim(s) between the frame channels and pit floor directly under the ramp cylinder pivot. Do not weld shims at this time! The frame channels will be level between the rear frame and the ramp cylinder pivot with the proper shim height.
  • Page 11 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED FOR LEVELERS WITH SELF FORMING PANS Figure - 9 Installation Pub. No. 1167-R2 - April 2003...
  • Page 12 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED FOR LEVELERS WITH SELF FORMING PANS Figure - 10 Installation Pub. No. 1167-R2 - April 2003...
  • Page 13 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED FOR LEVELERS WITH SELF FORMING PANS Figure - 11 Installation Pub. No. 1167-R2 - April 2003...
  • Page 14 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED FOR LEVELERS WITH SELF FORMING PANS Figure - 12 Installation Pub. No. 1167-R2 - April 2003...
  • Page 15 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED FOR LEVELERS WITH SELF FORMING PANS Figure - 13 Installation Pub. No. 1167-R2 - April 2003...
  • Page 16 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED FOR LEVELERS WITH SELF FORMING PANS Figure - 14 Installation Pub. No. 1167-R2 - April 2003...
  • Page 17 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED ELECTRICAL INSTALLATION Figure - 15 Electrical Installation Pub. No. 1167-R2 - April 2003...
  • Page 18 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED ELECTRICAL INSTALLATION Figure - 16 Electrical Installation Pub. No. 1167-R2 - April 2003...
  • Page 19 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED COMPLETION BUMPER INSTALLATION MOLDED BUMPER (STANDARD) 1. With a bumper positioned as shown in Detail "R" (top is inline with dock surface and one side is even with the edge of the pit), mark the hole centers. 2.
  • Page 20 HL-800 HYDRAULIC DOCK LEVELER INSTALLATION INSTRUCTIONS - CONTINUED COMPLETION LIP SUPPORT INSTALLATION (20" LIPS ONLY) 1. Raise leveler and engage maintenance support. 2. Remove lip supports from front frame angle (right side). 3. Disengage maintenance support and lower leveler to below dock position. 4.

  • Page 21: Hydrualic Fluid Check

    HL-800 HYDRAULIC DOCK LEVELER HYDRAULIC FLUID CHECK CHECK HYDRAULIC OIL LEVEL D A N G E R I M P O R T A N T V e r i f y p r o p e r h y d r a u l i c f l u i d l e v e l b e f o r e NEVER go under the hydraulic leveler platform o p e r a t i n g l e v e l e r or lip without engaging the maintenance...

  • Page 22: Operating Instructions

    HL-800 HYDRAULIC DOCK LEVELER OPERATING INSTRUCTIONS WARNING Read and obey these instructions to prevent personal injury. • DO NOT operate leveler with anyone standing on, or in front of lip. • DO NOT stand on moving leveler. • DO NOT operate leveler until truck/trailer is parked against the dock bumpers and the truck/ trailer Figure 20 has been secured.
  • Page 23 HL-800 HYDRAULIC DOCK LEVELER OPERATING INSTRUCTIONS - CONTINUED Below Dock Loading Operation 1. Push and hold RAISE button until leveler is fully raised and lip begins to extend. See Figure 20. 2. When lip extends about 2”, release RAISE button. The leveler will lower to the below dock position with the lip positioned between the face of the loading dock and the truck/trailer bed.

  • Page 24: Maintenance Procedures

    HL-800 HYDRAULIC DOCK LEVELER MAINTENANCE PROCEDURES 3. Lubricate the unit with the proper lubricants. See Figure 25. WARNING 4. Inspect structure, hinge pins, clevis pins and cotter pins for abnormal wear. 5. With the leveler supported by the Maintenance • Post safety warnings and barricade work area, Support, check hydraulic oil level in tank.

  • Page 25: Troubleshooting

    HL-800 HYDRAULIC DOCK LEVELER TROUBLESHOOTING Problem Probable Cause Solution 1. Platform does not raise (motor not a. Power has been disconnected. a. Verify that power has not been running). disconnected. Verify that disconnect circuit breakers or fuses are not tripped. b.
  • Page 26 HL-800 HYDRAULIC DOCK LEVELER TROUBLESHOOTING - CONTINUED Problem Probable Cause Solution 3. Leveler runs continuously when a. ARTD cam is out of adjustment a. Readjust ARTD cam. power is turned on. or damaged. b. The ARTD system has failed. b. Verify that ARTD and restrictor limit switches are functional.
  • Page 27 HL-800 HYDRAULIC DOCK LEVELER TROUBLESHOOTING - CONTINUED Problem Probable Cause Solution 6. Platform does not lower. a. Hydraulic fluid level is low. a. Check oil level when the unit is held open with the maint. support. See Figure 19. Refill if necessary. Do not exceed maximum oil level indicated by the “Oil Level”...
  • Page 28 HL-800 HYDRAULIC DOCK LEVELER TROUBLESHOOTING - CONTINUED Problem Probable Cause Solution 10.Lip does not store or store properly e. Valve failures on power unit e. Inspect, test and replace the in lip supports. - Continued endhead. adjustable sequence valve if necessary.

  • Page 29: Adjustment Procedures

    HL-800 HYDRAULIC DOCK LEVELER ADJUSTMENT PROCEDURES ADJUSTMENTS Restrictor Limit Switch NOTE: This limit switch restricts how high the platform is allowed The adjustments listed below are factory averages, field to rise during ARTD operation. The restrictor limit switch adjustment may be necessary. None of the adjustments is factory adjusted to allow the leveler to raise 5"-12"...
  • Page 30 HL-800 HYDRAULIC DOCK LEVELER ADJUSTMENT PROCEDURES - CONTINUED VIEWED FROM TANK END .035" ADJUSTABLE ORIFICE PLUG PILOT TO SEQUENCE CLOSE CHECK VALVE VALVE PILOT OPERATED CHECK VALVE ADJUSTABLE ADJUSTABLE RELIEF VALVE SHUTTLE ANTI-CAVITATION VALVE CHECK VALVE Figure 28 - Power Unit End Head D A N G E R •...

  • Page 31: Electrical Schematics

    HL-800 HYDRAULIC DOCK LEVELER ELECTRICAL SCHEMATICS Figure - 30 Electrical Schematics Pub. No. 1167-R2 - April 2003...
  • Page 32 HL-800 HYDRAULIC DOCK LEVELER ELECTRICAL SCHEMATICS Figure - 31 Electrical Schematics Pub. No. 1167-R2 - April 2003...
  • Page 33 HL-800 HYDRAULIC DOCK LEVELER ELECTRICAL SCHEMATICS Figure - 32 Electrical Schematics Pub. No. 1167-R2 - April 2003...
  • Page 34 HL-800 HYDRAULIC DOCK LEVELER ELECTRICAL SCHEMATICS Figure - 33 Electrical Schematics Pub. No. 1167-R2 - April 2003...
  • Page 35 HL-800 HYDRAULIC DOCK LEVELER ELECTRICAL SCHEMATICS Figure - 34 Electrical Schematics Pub. No. 1167-R2 - April 2003...

  • Page 36: Hydraulic Schematic

    HL-800 HYDRAULIC DOCK LEVELER HYDRAULIC SCHEMATICS POWER UNIT ASSEMBLY VELOCITY FUSE FILTER MOTOR 6 GPM (6') OPTIONAL 3450 RPM 2.5 GPM (8') 2W N.O. VALVE MICRON "RAMP" FOR IFC PORT ANTI-CAVITATION PUMP CHECK 1.4 GPM VALVE @ 880 PSI ADJ SHUTTLE P.T.C.

  • Page 37: Replacement Parts

    HL-800 HYDRAULIC DOCK LEVELER FRAME REPLACEMENT PARTS - DRAWING Parts List - Frame Assembly - 6’ Long Item Description Frame HL800 111609 111609 111610 Pin Rear Hinge 107929 107929 107928 Pin Cotter .188 DIA. x 1.50L ZP 51907 51907 51907 BSHG Machine 1.5 od x 1 id x .134 thk ZP 51730 51730...
  • Page 38 HL-800 HYDRAULIC DOCK LEVELER PLATFORM REPLACEMENT PARTS - DRAWING Pub. No. 1167-R2 - April 2003...
  • Page 39 HL-800 HYDRAULIC DOCK LEVELER PLATFORM REPLACEMENT PARTS Platform Assembly - 6’ Long Item Description Platform HL8 107651 107652 107653 Lip 16L HL8 107678 107684 107690 Lip 18L HL8 107679 107685 107691 Lip 20L HL8 107680 107686 107692 Pin LP HNG 1 x 35.25L 50785 50785 50785...
  • Page 40 HL-800 HYDRAULIC DOCK LEVELER CONTROL BOX REPLACEMENT PARTS - NON- METALLIC Parts List - Control Box Components (Non Metallic) Item Description 115V 115V 230V 230V 208-230V 460V 1PH OPT 1PH OPT Control Box Assembly (complete) 114.100 114.104 114.101 114.105 114.102 114.103 Enclosure NEMA 4 3.5 x 7 x 4.25 1PB 109016...
  • Page 41 HL-800 HYDRAULIC DOCK LEVELER CONTROL BOX REPLACEMENT PARTS - STEEL GRAY Parts List - Control Box Components (Steel Grey) 208-230V 460V Item Description Control Box Assembly (Complete) 53.102 53.103 Enclosure NEMA 12 10 x 8 x 6 103308 103308 Panel 10 x 8 x 6 100222 100222 Decal, Voltage/Phase/FLA...
  • Page 42 HL-800 HYDRAULIC DOCK LEVELER HYDRAULIC REPLACEMENT PARTS Parts List - Hydraulic Components 6’ Long 8’ Long Item Description Units Units Ramp Cylinder 108925 108924 Lip Cylinder 102239 102239 Power Unit HL8 115/230/1 113248 113248 Power Unit HL8 208-230/460/3 113252 113252 Velocity Fuse .5NPT 8MJ 108958 108959...
  • Page 43 HL-800 HYDRAULIC DOCK LEVELER OPTIONAL ARTD REPLACEMENT PARTS Item Description Units ARTD Sub-Assembly, Includes Items 3 & 9-15 (Does Not Include Clylinder) 109046 Shoulder Bolt 104394 Guide Rod 100132 Clevis Pin W/Washer 102311 Cotter Pin 51903 Spacer Tube 100131 U-Bolt 2 ID x 3.25 x .25-20 Thread 100130 Nut .25-20 UNC HEX 51524...
  • Page 44 HL-800 HYDRAULIC DOCK LEVELER WEATHER SEAL REPLACEMENT PARTS DECK PLATE DECK PLATE TOEGUARD TOEGUARD REAR WEATHERSEAL Parts List - Hydraulic Components Item Description 6L x 6W 8L x 6W 8L x 7W Channel 108079 108080 108080 Insert 108081 108082 108082 Screw Self Drill 1L 58117 58117...
  • Page 45 HL-800 HYDRAULIC DOCK LEVELER NOTES Pub. No. 1167-R2 - April 2003...
  • Page 46 HL-800 HYDRAULIC DOCK LEVELER NOTES Pub. No. 1167-R2 - April 2003...

  • Page 47: 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.
  • Page 48 ® By Rite-Hite 8900 N. Arbon Dr. Milwaukee, Wisconsin 53223 USA (414)355-2600...

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