Railcar Ramp
Vertical Hydraulic
Dock Leveler
Installation and Operation Manual
Printed in U.S.A.
Copyright 1997
Publication No. 1134
April 1998
OWNER RESPONSIBILITY
(The following responsibilities for owners of loading dock equipment are set forth in the American National
Standard for Safety Performance and Testing of Dock Leveling Services MH30.1-1993 and are repeated here for
the convenience of owners and operators of this equipment.)
The owner’s responsibilities include the following:
The owner should recognize the inherent danger of the
interface between dock and transport vehicle. The owner
should, therefore, train and instruct operators in the safe
use of dock leveling devices in accordance with information provided in Section 4.1.2.
When a transport vehicle is positioned as closely as
practicable to a dock leveling device, there shall be at
least 4" (100 mm) of overlap between the front edge of
the lip and the edge of the floor or sill of the transport
vehicle.
Nameplates, cautions, instructions, and posted warnings
shall not be obscured from the view of operating or
maintenance personnel for whom such warnings are
intended.
Manufacturer’s recommended periodic maintenance and
inspection procedures in effect at date of shipment shall
be followed, and written records of the performance of
these procedures should be kept.
Dock leveling devices that are structurally damaged or
have experienced a sudden loss of support while under
load, such as might occur when a transport vehicle is
pulled out from under the dock leveling device, shall be
removed from service, inspected by the manufacturer’s
authorized representative, and repaired as needed
before being placed back in service.
The manufacturer shall supply replacement nameplates,
caution or instruction labels, and operating and maintenance manuals upon request of the owner. The owner
shall see that all nameplates and caution and instruction
markings or labels are in place and legible and that the
appropriate operating and maintenance manuals are
provided to users.
When industrial trucks are driven on and off transport
vehicles during the loading and unloading operation, the
brakes on the transport vehicle shall be applied and
wheel chocks or positive restraints that provide the
equivalent protection of wheel chocks engaged.
NOTE
The MH30 Committee recognizes the devices intended
to secure a transport vehicle to a loading dock by
mechanical means. However, no standards currently
exist for the strength, construction or attachment of the
underride guard on a transport vehicle.* It is therefore
recommended that users of such positive restraint
devices review:
• The means of attachment to the transport vehicle
• The strength of the overall connection
• The proper coordination of the actuation of devices
with any signaling system used
• The need to use wheel chocks
In selecting dock leveling devices, it is important to consider not only present requirements but also future plans
or adverse environments.
* Since ANSI MH30.1-1993 was adopted, the National
Highway Traffic Safety Administration has adopted
standards for the strength, construction, or attachment
of the underride guard on a transport vehicle. See Part
571.232 of the Federal Motor Vehicle Safety Standard.
Nevertheless, it is still important to follow the requirements of this note.
Modifications or alterations of dock leveling devices shall
be made only with written permission of the original
manufacturer. These changes shall be in conformance
with all applicable provisions of this standard and shall
be at least as safe as the equipment was before modification. These changes shall also satisfy all safety recommendations of the original equipment manufacturer
for the particular application of the dock leveler.
i
Pub. No. 1134 — April 1998
SAFETY SIGNAL WORD DEFINITIONS
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury. This signal word is to be limited
to the most extreme situations.
Indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury. Is also used to alert against
unsafe practices.
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
Is used to draw attention to a procedure that
needs to be followed to prevent machine or
property damage.
Pub. No. 1134 — April 1998
ii
GENERAL SAFETY WARNINGS
LOCKOUT/TAGOUT PROCEDURES
When working with electrical or electronic controls, make sure that the power source has
been locked out and tagged according to OSHA
regulations and approved local electrical codes.
The Occupational Safety and Health Administration requires that, in addition to posting safety warnings and barricading
the work area and loading docks, the power supply has been locked in the OFF position or disconnected. It is mandatory that an approved lockout device is utilized. An example of a lockout device is illustrated. The proper lockout procedure requires that the person responsible for the repairs is the only person who has the ability to remove the lockout
device.
In addition to the lockout device, it is also a requirement to tag the power control in a manner that will clearly note that
repairs are under way and state who is responsible for the lockout condition. Tagout devices have to be constructed
and printed so that exposure to weather conditions or wet and damp locations will not cause the tag to deteriorate or
become unreadable.
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.
DO NOT ground welding equipment to any
hydraulic cylinder or electrical components. DO
NOT attach welder ground to leveler platform
when welding lower frame support shims into
position. Damage to bearings or hydraulic
equipment will occur. Attach welder ground to
base frame assembly only.
iii
Pub. No. 1134 — April 1998
TABLE OF CONTENTS
DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
INTRODUCTION
The purpose of the Railcar Ramp hydraulic leveler is to safely and reliably bridge the gap between the loading dock
and the railcar. This RITE-HITE® dock leveler Model Railcar Ramp is hydraulically operated. There are no
chains/cables to pull or handles to lift. The only energy required of the dock attendant is to push and hold the LOWER
button on the control box allowing the unit to descend to the railcar floor. After loading or unloading is complete, the
dock attendant needs only to push and hold the RAISE button on the control box for the Railcar Ramp hydraulic leveler
to raise back to the vertical stored and locked position. A 1 horsepower unit requiring a 30 amp. circuit delivers
hydraulic oil to a non-regenerative hydraulic system and assures leak-proof operation. The ramp is raised by a 3-1/2"
I.D. hydraulic cylinder. Hydraulic pump/motor and plumbing are mounted under the platform.
Pub. No. 1134 — April 1998
iv
DEFINITIONS
LIP
MAIN LIFTING CYLINDER
The lip is the extendible portion of the dock leveler which
provides a bridge from the platform to the bed of the box
car. The leveler lip features seamless steel tube lip hinges.
The main lifting cylinder is a double acting hydraulic piston
of heavy duty construction grade, non-adjustable, with a
3-1/2" diameter piston and a 1-1/2" diameter rod. When
the power unit is energized, the cylinder extends, lifting
the platform.
PLATFORM
The platform, along with the lip, provides the main bridge
between the dock and the box car. It is hinged at the
rear of the subframe, and automatically adjusts with the
position of the box car. The platform is constructed in a
four-sided box structure with a bridge bar at the header
cutout. When in the vertical stored position, the platform
is securely held in place by the hydraulic system or by
the maintenance strut. Additional details on the maintenance strut are given later.
LIP CYLINDER
The lip cylinder is a single-acting hydraulic piston of
heavy duty construction grade, non-adjustable with a
2-1/2" diameter piston and a 1" diameter rod. When the
power unit is energized, the cylinder extends, lifting the
lip. When power is removed, the lip’s weight compresses
the cylinder, allowing the lip to fall back to the pendant
position.
END LOAD ARMS
POWER UNIT
The end load arms provides support in an end load condition when the lip is not used. The major components of
the end load assembly are two ramp support arms, one
on either side of the platform. In an end load condition,
the operator loosens the support arm lock on the platform allowing the ramp support arm to be pulled out. To
secure the ramp support arm at the needed length, the
support arm lock is tightened. When loading or unloading is complete, the support arm lock is loosened and
the ramp support arms are slid back inside the runoff
guards; they can be secured in place by tightening the
support arm lock.
The power unit for the Railcar Ramp hydraulic leveler is
an electro-hydraulic motor which pumps hydraulic fluid to
the ramp lifting cylinder. The power unit package consists of a 1 hp 120V or 240V single phase electric motor,
a 1.35 GPM gear pump, a 1.5 gallon capacity hydraulic
fluid reservoir, and all valving.
CARRIAGE ASSEMBLY
The carriage assembly attaches the platform to the track
assembly. The carriage assembly consists of the horizontal carriage and a number of horizontal and vertical
rollers to allow smooth movement of the Railcar Ramp
hydraulic leveler along the track assembly.
TRACK ASSEMBLY
NOTE
When adding oil, use only MIL-H-5606 or equal.
VALVE BLOCK ASSEMBLY
The valve block assembly consists of a metal block with
attached valves which control the hydraulics of the
Railcar Ramp.
SAFETY STOP SYSTEM
The hydraulic system has an emergency flow control
stopping valve (velocity fuse) that prevents the leveler
from “free-falling” if a hose should be damaged and
loose pressure. The valve is in line with the hydraulic
hose at the ramp lifting cylinder.
The track assembly consists of a ten foot section furnished by RITE-HITE®. The track assembly allows the
carriage assembly to move freely left and right for proper
railcar loading and unloading.
Pub. No. 1134 — April 1998
1
MAINTENANCE STRUT
CONTINUOUS RAIL APPLICATION
The Railcar Ramp hydraulic leveler is shipped with its own
maintenance strut. This maintenance strut is inserted
between the inside of the platform and the rear curb angle
of the pit. The maintenance strut increases the level of
safety for workers when installing equipment or performing routine maintenance, and must be used every time
service is being performed on the unit.
When more than (1) mounting rail section is used. This
type is only applicable with straight track applications.
Please note, continuous rail section must be requested
when the order for the unit is entered. This will ensure
the ends are beveled for field welding.
FIXED APPLICATION
SKEWED DECK
Railcar ramp does not move side to side in mounting rail
section.
The length of deck is a different dimension on the left
side versus the right side to compensate for curve track
applications.
MOVEABLE APPLICATION
CARRIAGE WINDOWS
Access holes in carriage for weld-on applications which
are installed in pit type applications.
STRAIGHT TRACK
When the railroad track and mounting rail section are
parallel within ±1" over 90° (45' to the left and right of the
door center line).
CURVE TRACK
Railcar ramp moves or slides to the left or right in mounting rail section(s).
EMBEDDED (STANDARD RAIL SECTION)
When the rail section is embedded into concrete at the
top edge of the dock face. This method is shipped standard with all Railcar Ramp hydraulic leveler applications
and is preferred. Please note, for “F” and “L” capacity
units, this application is required. When these capacities
are used with “existing” applications, the end user is
required to remodel the dock face with an embedded
rail section.
When the railroad track and mounting rail section are not
within ±1" over 90° (45' to the left and right of the door
center line).
WELD-ON
ACTUAL CENTERLINE DIMENSION
The rail section is welded to a minimum size 15" “C”
channel complying with RITE-HITE®’s specifications.
See Figure 10.
The measurement from the top of the dock edge of the
nearest rail, plus 2' 4-1/4".
EFFECTIVE CENTERLINE DIMENSION
The calculated dimension to determine fabrication
requirements of the platform length based upon one
or all of the following: Fixed or movable application,
recessed dimensions, capacities and curve track
application.
2
Option 1
Option 2
The mounting rail section is welded to existing curb steel
that has a vertical leg which measures 5" to 10" in size.
Please note, if replacing an existing Railcar Ramp
hydraulic leveler, an approach plate may be required.
Pub. No. 1134 — April 1998
INSTALLATION INSTRUCTIONS
Follow all electrical LOCKOUT/TAGOUT procedures as stated on page iii of this manual.
1.
2.
Post safety warnings and barricade work
area, at dock level and at ground level, to
prevent unauthorized use of the Railcar
Ramp Leveler before full installation has
been completed.
Be sure to follow these caution notes when
installing your Railcar Ramp Leveler.
2.
DO NOT ground welding equipment
to any hydraulic cylinder or electrical
components.
3.
DO NOT attach welder ground to leveler
platform when welding on base frame
assembly. Attach welder ground to base
frame assembly only. Damage to bearings
or hydraulic equipment will occur.
4.
DO NOT connect green ground lead until
all welding has been completed.
5.
Unit is shipped filled with hydraulic oil.
Verify oil level before operating.
Pub. No. 1134 — April 1998
NOTE – check motor rotation. Jog the
motor until rotation has been determined.
Do Not run the motor in reverse because
this will burn out the motor and hydraulic
pump unit.
7.
If a procedure is not clearly defined in this
manual, contact RITE-HITE Corporation at
414-355-2600 before proceeding.
INITIAL INSTALLATION
1.
Verify that the rail assembly channel is level,
plumb, and even with the dock floor. If the rail
assembly does not meet specifications, contact the
RITE-HITE Corporation for further instructions.
2.
Remove shipping bands and inspect the unit for
damaged or missing parts. If any are noticed, contact the RITE-HITE Corporation.
3.
Verify that available voltage and phase is the same
as specified on the hydraulic pump/motor specification plate.
4.
Make sure that the lifting unit, or picker crane, is
capable of lifting a minimum of 3,000 lbs.
DO NOT REMOVE SAFETY-LOCK PIN until
hydraulic system has been filled and
purged of air. See page 11, “Initial Start-up.”
1.
6.
3
STANDARD EMBEDDED RAIL
1.
Using a lift truck or picker crane, attach lifting
device via chain through lifting angles, located
under the platform. See Figures 1 and 2.
Crane
Always double check the rigging to make sure
that it is secure and balanced before proceeding with the lift. Never stand under any unit
being lifted.
2.
Lifting Angle
The Rail Car Ramp leveler fits onto a rail curb angle
that is embedded into the concrete at the edge of
dock with one or both ends of the rail open.
To lift and install the Rail Car Ramp, follow these
steps:
FIGURE 1
a. Secure chains to the lifting angles under the
platform.
3.
b. From the rail road track side move leveler and
carriage assembly to the end of the rail. Slide
the carriage rollers into the rail. See Figure 3.
c. Move and slide the carriage slowly insuring
leveler does not bind on rail until complete carriage and rollers are engaged in the track.
Place a bar (1/4" x 2" x 8") or two end stops
(1/4" x 2" x 2") across both ends of the rail insuring
both rails are properly stopped. Weld stops to rail
to keep the leveler from accidentally being pushed
off the rail.
C
L
! CAUTION
“THIS EQUIPMENT SHOULD NOT BE OPERATED
OR SERVICED EXCEPT BY TRAINED PERSONNEL.
LIKE MANY OTHER PIECES OF EQUIPMENT, IT
CAN CAUSE INJURIES IF IT IS NOT HANDLED
PROPERLY.” FOR ASSISTANCE CONTACT THE
RITE-HITE CORPORATION (414) 355-2600
DANGER
DO NOT STAND
ON THIS SIDE OF
DOCK LEVELER!!
LEVELER SWINGS
DOWN TOWARD YOU
HYDRAULIC
DOCK LEVELER
BY
MILW., WIS. (414) 3552600
FIGURE 2
4
Pub. No. 1134 — April 1998
To
p
Of
Do
ck
FIGURE 3
The Railcar Ramp hydraulic leveler is held in
the vertical position by a safety restraint pin
located in the lower right hand corner of the
platform assembly. See Figure 4. DO NOT
remove this pin or warning tag until instructed
to do so.
Platform
DO NOT REMOVE SAFETY
PIN UNTIL SYSTEM HAS
BEEN PROPERLY FILLED
WITH HYDRAULIC FLUID
(SEE INSTRUCTIONS)
Rear
Hinge
Frame
Safety
Restraint
Pin
FIGURE 4
Pub. No. 1134 — April 1998
5
Platform
Safety Lock
Pin Storage
Hole
Cotter Pin
Hinge Pin
Washer
Carriage Assembly
FIGURE 5
WELD-ON TRACK ASSEMBLY
1.
Separate the platform from the frame carriage
to make the installation of the Weld-On track
assembly easier. See Figure 5.
2.
Place the frame carriage rollers into the track angles
and slide the frame until it is centered on the track
assembly. Clamp the frame carriage to the roller track
assembly to prevent any movement when lifting.
3.
With proper overhead lifting equipment, attach the
lifting equipment to the frame carriage and track
assembly. Position on dock face so that the top
edge of the frame carriage assembly is flush and
level with the top of the dock surface. Tack weld
several holes at each end to hold in place before
fully plug welding the roller track assembly. See
Figure 6.
6
4.
After correctly positioning the roller track assembly,
plug weld the outer-most holes before removing the
clamp from the frame carriage, allowing the frame
carriage to be moved laterally (side to side).
5.
Move the frame carriage all the way over to one
side of the track. See Figure 7. Plug weld all
exposed holes in the roller track. Move the frame
carriage slowly to the opposite side of the track,
plug welding all holes exposed by the carriage
“windows” as the frame carriage is moved from one
side to the other. Once the frame carriage is all the
way over to the opposite side of what was welded,
plug weld the remaining exposed holes.
Pub. No. 1134 — April 1998
Crane
FIGURE 6
(Carriage "Windows")
(Carriage "Windows")
FIGURE 8
FIGURE 7
6.
If this is a Weld-On application where the bottom
row of holes will use concrete anchors, use the
roller plate as a drilling template to drill out ALL
anchor holes. Use Rawl “Rawl-Bolt” #6987
0.625 x 6" LG Flat Head concrete anchors (supplied by others). Tighten all anchors to 100 ft. lbs.
torque unless otherwise specified.
7.
Weld across the entire length of roller track.
8.
Remove all weld spatter and residue from track
angle surfaces and remove all concrete dust and
debris if concrete anchoring was used.
9.
Using proper overhead lifting equipment, reattach
the platform to the frame carriage. Extend the ramp
cylinder piston rod and align with the mounting hole
in the lower pivot weldment and install the pivot pin.
See Figures 8 and 9.
Pub. No. 1134 — April 1998
7
Safety Lock
Pin Storage
Hole
Platform
Platform
Cotter Pin
Safety Lock
Hinge Pin
Washer
Carriage Assembly
Carriage Assembly
FIGURE 9
8
Pub. No. 1134 — April 1998
FIXED APPLICATION – WELD-ON/BOLT-ON
3.
For additional information on Fixed Application Installation
Instructions, see the detail drawings provided with the
Railcar Ramp hydraulic leveler.
With proper overhead lifting equipment, attach a
lifting clamp to the extended lip, or use lifting
angles on the underside of the platform.
4.
Using proper overhead lifting equipment, reattach
the platform to the frame carriage. Extend the ramp
cylinder piston rod and align with the mounting hole
in the lower pivot weldment and install the pivot pin.
See Figures 8 and 9.
1.
Locate the frame assembly at the 0.25" below dock
edges dimension. Tack weld in place. See Figure 10.
2.
Weld all plug welds and across the top surface, and
along the ends and bottom. See Figures 10 and 11.
Weld-On Style Rear Frame
Building
Wall
Vertical Straightness
0.125" Over Entire Length
Mounting Channel
Flatness 0.125"
.25
Platform
Full Weld
4
Safety Lock
Pin Storage
Hole
Cotter Pin
Hinge Pin
Pit Length +- 0.25"
Over Entire Width
24"
Minimum
Washer
NOTE: DO NOT INSTALL
If Pit And Angle Tolerances
Are Not As Shown.
Hinge Plate Is Easiest To Install
If The Ends Are Secured First.
Secure The Center Next And Stagger
The Weld Sequence Between The
Right And Left Of The Centerline.
1.38
All Holes
FIGURE 10
Remove All Welding
Residue Break All Sharp
Corners After Welding
0.25"
Full Weld
.25
.25
1.688
+.031
-.000
.25
Both Ends
10.00
3-5
.25
27 Places
Dimensions Shown In Inches
Unless Otherwise Specified.
Pub. No. 1134 — April 1998
FIGURE 11
9
Incoming Power From Customers
Fused Disconnect (Supplied By Others)
(Wire Size Per Chart)
Hydraulic
Incoming Power From Customers
Fused Disconnect (Supplied By Others)
(Wire Size Per Chart)
Hydraulic
Control Box
Control Box
G
3
X2
2
L1L2 L3
G
3
L2
2
L1L2 L3
G
2**
X2**
3**
G*
G
T2*
T1*
T1
T2
T3
G
3
X2
2
Field Wiring
(By Others)
( * ) Min #8 Gage Wire
( ** ) Min #14 Gage Wire
Wire Nut
Conn. (Typ.)
Field Wiring
(By Others)
G
3
L2
2
( * ) Min #10 Gage Wire
( ** ) Min #14 Gage Wire
To Motor
J-BOX
To Motor
J-BOX
To Sol. Coil
“RAMP”
To Sol. Coil
“LIP”
To Sol. Coil
“RAMP”
To Sol. Coil
“LIP”
BLK
YLW
BLK
YLW
Junction Box (On Pit Floor Or On
Remote Power Unit Platform.) (Supplied
And Installed By Others.)
Junction Box (On Pit Floor Or On
Remote Power Unit Platform.) (Supplied
And Installed By Others.)
Typical Three Phase
Typical Single Phase
One Leveler
Per Overload
Protection
Device. [Ref.
N.E.C. 1990
Para. 430-110
(B)(C)] Consult
Local Code
Fused Power
Disconnect
(Required)
(By Others)
Wire Size Chart
Voltage
&
Phase
Distance From Door To
Power Disconnect
0-100' 100-200'
120V 1 Phase #8 Gage #8 Gage
240V 1 Phase #10 Gage #10 Gage
240V 3 Phase #10 Gage #10 Gage
480V 3 Phase #10 Gage #10 Gage
200'+
#6 Gage
#8 Gage
#10 Gage
#10 Gage
Rigid Conduit
(By Others)
Solenoid
Control
Valve
Hydraulic Power Unit
FIGURE 12 — WIRING DIAGRAMS
10
3
2**
L2**
3**
G*
T3*
T2*
T1*
Wire Nut
Conn. (Typ.)
2
L2
2L1
1L1
3
T1
T2
T1 T2 T3
2
X2
2X1
1X1
T1T2T3
Hydraulic
Control Box
(By RITE-HITE®)
Hirschmann
Conn. Cords
Motor
Junction
Box
SO Cord (Supplied By RITE-HITE®)
AI-1605
Pub. No. 1134 — April 1998
CONTROL BOX INSTALLATION
When working with electrical or electronic
controls, make sure that the power source has
been locked out and tagged according to OSHA
regulations and approved local electrical codes.
Breather
System Relief
Shuttle Valve
Fill Port
IMPORTANT - CHECK OIL
LEVEL BEFORE MAKING
ANY ADJUSTMENTS - ADD
MIL-H5606 HYDRAULIC
FLUID ONLY.
Control
Box
Sight Glass
Dock
Floor
48"
FIGURE 14 — HYDRAULIC OIL FILLING
6"
24"
1.
Install the control box as indicated in Figure 13.
2.
Connect wiring to the control panel and the Railcar
Ramp hydraulic leveler as indicated in Figure 12.
3.
Install junction box or connect main power.
4.
Manually extend the Ramp Cylinder until the cylinder rod clevis aligns with the embedded frame
channel clevis. Loosen the locking bolt on the cylinder rod clevis if it is required to adjust the cylinder
clevis either higher or lower for alignment. Rotate
the clevis end to adjust. See Figure 17.
Junction Box
FIGURE 13
Make sure that the electrical power has been
locked out and the power source tagged before
proceeding with the installation.
NOTE
When the leveler is in the vertical stored position
there should be approximately .062" minimum clearance between the hydraulic cylinder rod and the
notch in the rear header assembly. See Figure 15.
There should be a 3" offset to assure a safe vertical
storage position. See Figure 16.
5.
Post safety warnings and barricade work area, at
dock level and at ground level to prevent unauthorized use of the RCR during maintenance/
service.
Pub. No. 1134 — April 1998
Insert the clevis pin. Secure the clevis pin with the
thrust washers and cotter keys.
11
(Viewed From Above)
Deck
0.062 Min.
FIGURE 17 — CLEVIS ADJUSTMENT
Cylinder Rod
Rear Header
FIGURE 15 — CYLINDER ROD CLEARANCE
HYDRAULIC SYSTEM START-UP
DO NOT operate leveler with anyone standing
in front of the leveler.
This equipment should not be operated or serviced except by trained personnel.
Service
Strut
Stored
Position
Keep away from hinge when operating leveler.
Service
Strut
Service
Position
1.
The leveler ships with oil stored within the hydraulic
reservoir.
Locate the yellow plastic plug which is inserted in the
breather port. Remove and discard this plug ONLY
after unit has been installed and is vertically stored.
3"
2.
Install the breather assembly into the breather port.
See Figure 18.
FIGURE 16 — VERTICAL STORAGE POSITION
12
Pub. No. 1134 — April 1998
(55299)
Lip Fall
Pressure
Compensated
Flow Control
55253
Counterbalance
Valve
A
B
Cyl. Rod
MILWAUKEE, WI
(414) 355-2600
PART #6624
A
6680
Main Valve
Block Assembly
B
System
Relief
55024
Breather
Plug
IMPORTANT - CHECK OIL
LEVEL BEFORE MAKING
ANY ADJUSTMENTS - ADD
MIL-H5606 HYDRAULIC
FLUID ONLY.
Lip Fall
Relief Valve
Counterbalance Valve
TOP VIEW
56303
Lip Out
Relief Valve
(Fixed)
VIEW A-A
5
CB
CORPORATION
Ramp Four Way Valve
Lip Three Way Valve
LIP
! CAUTION
“THIS EQUIPMENT SHOULD NOT BE OPERATED
OR SERVICED EXCEPT BY TRAINED PERSONNEL.
LIKE MANY OTHER PIECES OF EQUIPMENT, IT
CAN CAUSE INJURIES IF IT IS NOT HANDLED
PROPERLY.” FOR ASSISTANCE CONTACT THE
RITE-HITE CORPORATION (414) 355-2600
RAMP
55184
55186
Four Way Two Position Three Way Two Position
Lip Solenoid Valve
Lip Solenoid Valve
(55261 Coil)
(55261 Coil)
Lip Out
Relief Valve
Lip (Base)
BASE
10
55146
Shuttle
Valve
C1
55311
Check Valve
70 PSI
(Optional
55313 90 PSI)
T
P
Tank
VIEW B-B
BOTTOM VIEW
FIGURE 18 — HYDRAULIC VALVE ADJUSTMENT
Cap Nut
Pressure
SEE AI-1757
Gaps Must Be Equal
Adjusting Screw
Gap
O-ring
(In Recess)
Gap
Locknut
FIGURE 19
Pub. No. 1134 — April 1998
13
3.
From dock level, push the leveler against the safety
lock pin.
4.
Have an assistant press and hold the RAISE button
on the control box until the platform moves back
towards the vertical stored position. This indicates
that the main cylinder has been filled with oil.
Continue to hold the RAISE button until the lip fully
extends, indicating that the lip cylinder has been
filled with oil, and release the RAISE button.
7.
AIR PURGING PROCEDURE
DO NOT operate leveler with anyone standing
in front of the leveler.
If the main cylinder does not begin to extend
within five seconds release the RAISE button,
the pump/motor is running in reverse. Review
the electrical wiring diagram and reverse motor
leads (3 phase only).
5.
6.
Check the fluid level in the reservoir. Add more
hydraulic fluid until the proper level is noted at
the sight glass. Do not overfill the reservoir, fluid
will leak out of the breather port when the unit is
lowered into the service position, if overfilled.
See Figure 14.
Inspect the sight glass on the hydraulic reservoir.
See Figure 14. The oil level should be visible. If
not, temporarily install a 45° street elbow and using
a funnel, fill the reservoir with oil until the level is
visible in the sight glass. Use only MIL-H-5606.
This equipment should not be operated or serviced except by trained personnel.
Press and hold the RAISE button until the Lip
Cylinder fully extends.
Keep away from hinge when operating leveler.
Make sure that the electrical power has been
locked out and the power source tagged before
proceeding with the installation.
Post safety warnings and barricade work area, at
dock level and at ground level to prevent unauthorized use of the RCR during maintenance/
service.
14
1.
Open overhead door.
2.
Locate the Service Strut device stored under the
leveler body. See Figures 16 and 20. Insert the
Service Strut in the proper position.
3.
Remove the Safety Lock Pin and indicator tag.
Install the Safety Lock Pin and indicator tag through
the hole on the leveler frame and secure with the
cotter key, for storage. See Figure 9.
4.
Remove and store Service Strut device.
5.
Press and hold the LOWER button on the control
panel until the leveler is at about a 30° angle. Return
the leveler to the normal raised/stored position.
6.
Repeat Step 5 five more times, each time allowing
the platform to drop slightly lower before raising it
up again.
Pub. No. 1134 — April 1998
NOTE
A slight bouncing of the platform may be noticed until
all of the air is purged from the hydraulic system.
7.
Return the platform to the fully raised position and
once again lower it to the horizontal stored position.
In the process of lowering the unit, release the
LOWER button. The leveler platform should immediately stop and hold that position. If it does not,
repeat Steps 5 and 6.
8.
Return the platform to the fully raised position, with
the lip extended. Insert the Service Strut. Recheck
the reservoir and fill as needed. Recheck all hoses
and fittings for leaks.
DOWNWARD “FLOAT” ADJUSTMENT
DO NOT operate leveler with anyone standing
in front of the leveler.
This equipment should not be operated or serviced except by trained personnel.
Keep away from hinge when operating leveler.
1.
Press and hold the LOWER button until the platform is at the horizontal (dock level) position.
Release the button to stop the downward movement. The leveler should hold that position.
2.
Walk out to the front of the leveler platform. The
platform should drop VERY slowly.
3.
If the leveler fails either or both of these tests press
and hold the RAISE button to return the platform to
the vertical stored position.
IMPORTANT:
EN
G
FU AG
LL E S
Y ER
TO V
TH ICE
IS S
PO TR
IN UT
T
EN
G
FU AG
LL E S
Y ER
TO V
TH ICE
IS S
PO TR
IN UT
T
Service Strut Must Be
Placed Over Leveler Hinge
Or Damage May Occur To
Deck Of Unit.
Frame Hinge
Plate
FIGURE 20 — SERVICE STRUT
Pub. No. 1134 — April 1998
15
4.
Insert the service strut.
5.
Locate Counterbalance Valve. See Figure 21.
Rotate the adjustment screw 1/8 of a turn and
retest the leveler.
OPERATIONAL TESTS
AND VALVE TRIM ADJUSTMENTS
C.W. — Decreases downward float speed
C.C.W. — Increases downward float speed
6.
Repeat Steps 1 through 5 until the leveler operates
properly.
7.
When the testing is complete, tighten the lock nut
on the adjustment screw.
NOTE
All valves have been set at the factory. If any adjustments are required, the instructions for valve setting will
indicate the number of revolutions to turn the set screw
for the proper setting.
DO NOT force valve adjustment screws against
internal stops. Damage will occur to the valve.
(55299)
Lip Fall
Pressure
Compensated
Flow Control
55253
Counterbalance
Valve
A
B
Cyl. Rod
MILWAUKEE, WI
(414) 355-2600
PART #6624
A
6680
Main Valve
Block Assembly
B
System
Relief
55024
Breather
Plug
IMPORTANT - CHECK OIL
LEVEL BEFORE MAKING
ANY ADJUSTMENTS - ADD
MIL-H5606 HYDRAULIC
FLUID ONLY.
Lip Fall
Relief Valve
Counterbalance Valve
TOP VIEW
56303
Lip Out
Relief Valve
(Fixed)
VIEW A-A
5
CB
CORPORATION
Ramp Four Way Valve
Lip Three Way Valve
LIP
! CAUTION
“THIS EQUIPMENT SHOULD NOT BE OPERATED
OR SERVICED EXCEPT BY TRAINED PERSONNEL.
LIKE MANY OTHER PIECES OF EQUIPMENT, IT
CAN CAUSE INJURIES IF IT IS NOT HANDLED
PROPERLY.” FOR ASSISTANCE CONTACT THE
RITE-HITE CORPORATION (414) 355-2600
RAMP
55184
55186
Four Way Two Position Three Way Two Position
Lip Solenoid Valve
Lip Solenoid Valve
(55261 Coil)
(55261 Coil)
Lip Out
Relief Valve
Lip (Base)
BASE
10
55146
Shuttle
Valve
C1
55311
Check Valve
70 PSI
(Optional
55313 90 PSI)
T
P
Tank
VIEW B-B
FIGURE 21 — HYDRAULIC VALVE ADJUSTMENT
16
Pressure
BOTTOM VIEW
SEE AI-1757
Pub. No. 1134 — April 1998
SHUTTLE VALVE ADJUSTMENT
INSTRUCTIONS
The shuttle valve is adjusted at RITE-HITE® prior to
shipment. The adjustment procedures given here are
intended to be instructions for RITE-HITE® representatives only, and for service parts reference.
1.
Remove the cap nut. See Figure 22.
DO NOT operate leveler with anyone standing
in front of the leveler.
Do not lose the O-ring.
2.
Loosen the locknut.
3.
Adjust the valve to the factory setting. See Figure 22.
Turn the valve in 1/8 increments. The increments
may be either clockwise or counterclockwise to trim
the adjustment.
4.
When the adjustment is complete, tighten the locknut.
5.
Reinstall the cap nut.
This equipment should not be operated or serviced except by trained personnel.
Keep away from hinge when operating leveler.
NOTE
Make sure the O-ring is in recess to prevent damage to
the O-ring.
Cap Nut
Gaps Must Be Equal
Adjusting Screw
Gap
O-ring
(In Recess)
Gap
Locknut
FIGURE 22
Pub. No. 1134 — April 1998
17
OPERATING INSTRUCTIONS
VERTICAL STORED POSITION
1. Do not operate the leveler with anyone or
anything standing on or in front of the
leveler.
2. The Railcar Ramp hydraulic leveler should
never be allowed to descend unless there is
a railcar in position to stop the downward
travel of the extended lip or the extended
ramp support arms.
3. Always operate the Railcar Ramp hydraulic
leveler from the top of the dock.
4. Do not raise the Railcar Ramp hydraulic leveler with anyone or anything on top of the
ramp.
5. Visually verify that the service strut is properly in place whenever the Railcar Ramp
hydraulic leveler is in the vertically stored
position.
6. Always use both support arms, in locked
position, for end loading.
7. Always clean and lubricate every 90 days.
8. Always inspect the leveler daily before use
to insure that there are no broken or worn
parts which could cause injury to personnel
or equipment damage.
9. Always call your local authorized RITEHITE ® representative or the RITE-HITE
Corporation at 1-800-456-0600 immediately
when a leveler malfunction occurs.
10. Keep all parts of the body away from moving parts.
11. Always store the leveler in the vertical position with the service strut in place.
18
The Railcar Ramp hydraulic leveler should never be kept
in the vertical stored position for any length of time when
the lip is pendant and the service strut is not in place. An
accidental impact could start the leveler downward. The
unit can be stored with the ramp support arms extended.
STANDARD OPERATING
1.
Remove the maintenance strut and store for future
use. See Figure 20.
2.
Press and hold the LOWER button until the lip
rests on the railcar floor. See Figure 23.
3.
When loading or unloading is finished, press and
hold the RAISE button until the Railcar Ramp
hydraulic leveler raises to the fully upright position
and the lip fully extends. See Figure 24.
NOTE
If the Railcar Ramp hydraulic leveler is to be left in the
vertical stored position for a prolonged period of time, it
is recommended that the service strut be inserted.
4.
Insert the service strut at the end of each shift or
workday. See Figure 20.
END LOAD OPERATION
Do not overextend support arms, indicated by
the yellow point.
1.
Loosen both support arm locking lugs and extend
both left and right hand support arms. Then tighten
both support arm locking lugs.
2.
Press and hold the LOWER button until the platform is at about 45°. Release the LOWER button.
See Figure 25.
Pub. No. 1134 — April 1998
LATERAL MOVEMENT
3.
Allow the platform to stay in this position until the
lip falls to the pendant position.
4.
Press and hold the LOWER button until the support
arms rest on the floor of the railcar.
5.
As soon as end loading has been completed, reset
the RCR for standard operation. Make sure to
retract and secure both support arms.
6.
Press and hold the RAISE button until the leveler
has returned to the vertical stored position.
Move unit only when in vertical stored position.
1.
Remove and store the service strut.
2.
Push the Railcar Ramp hydraulic leveler from side
to side to align with door opening.
3.
Lower platform to loading/unloading position.
HYDRAULIC DOCK LEVELER
Press And Hold
Lower Button
Press & hold “LOWER” button
until lip rests on rail car bed.
“LOWER”
To stop leveler ramp movement,
Release button.
“RAISE”
Press & hold “RAISE” button
to raise platform. Hold button
until lip is fully extended in
vertical position.
Press & hold “LIP OUT” button
to extend lip.
“LIP OUT”
WARNING
!
DANGER
DO NOT drive on leveler, when “END LOADING”
without endload supports extended, locked &
positioned on the rail car bed.
END LOADING:
1.) Extend ENDLOAD supports and lock in place.
2.) Position platform at 45° by pressing“LOWER”
push button. Release button and lip will fall.
3.) Press “LOWER” button to lower platform to
rail car bed.
LATERAL MOVEMENT:
1.) Pull unit back towards dock until balanced on
railers, push unit to move side to side.
2.) Track section must be cleaned regularly to prevent
obstruction of rollers for free movement.
3.) NEMER Use a froktruck to position unit laterally
damage to equipment will occur and leveler repairs
will not be covered under warranty.
MILWAUKEE, WISCONSIN
(414)355-2600
64161
!
DISCONNECT POWER before opening this panel.
DO NOT operate leveler with anyone standing on
or in front of leveler.
DO NOT operate with load on leveler.
ALWAYS return leveler to the stored (vertical)
position.
FIGURE 23
Pub. No. 1134 — April 1998
19
HYDRAULIC DOCK LEVELER
Press & hold “LOWER” button
until lip rests on rail car bed.
“LOWER”
To stop leveler ramp movement,
Release button.
Press And Hold
Raise Button
Press & hold “RAISE” button
to raise platform. Hold button
until lip is fully extended in
vertical position.
“RAISE”
Press & hold “LIP OUT” button
to extend lip.
“LIP OUT”
!
END LOADING:
WARNING
DANGER
DO NOT drive on leveler, when “END LOADING”
without endload supports extended, locked &
positioned on the rail car bed.
1.) Extend ENDLOAD supports and lock in place.
2.) Position platform at 45° by pressing“LOWER”
push button. Release button and lip will fall.
3.) Press “LOWER” button to lower platform to
rail car bed.
LATERAL MOVEMENT:
1.) Pull unit back towards dock until balanced on
railers, push unit to move side to side.
2.) Track section must be cleaned regularly to prevent
obstruction of rollers for free movement.
3.) NEMER Use a froktruck to position unit laterally
damage to equipment will occur and leveler repairs
will not be covered under warranty.
MILWAUKEE, WISCONSIN
(414)355-2600
64161
!
DISCONNECT POWER before opening this panel.
DO NOT operate leveler with anyone standing on
or in front of leveler.
DO NOT operate with load on leveler.
ALWAYS return leveler to the stored (vertical)
position.
FIGURE 24
20
Pub. No. 1134 — April 1998
Press And Hold Lower Button Until
Platform Is At About 45°, Then Release.
Allow Lip To Fall To Pendant Position.
HYDRAULIC DOCK LEVELER
Press & hold “LOWER” button
until lip rests on rail car bed.
“LOWER”
To stop leveler ramp movement,
Release button.
“RAISE”
Press & hold “RAISE” button
to raise platform. Hold button
until lip is fully extended in
vertical position.
Press & hold “LIP OUT” button
to extend lip.
“LIP OUT”
WARNING
!
DANGER
DO NOT drive on leveler, when “END LOADING”
without endload supports extended, locked &
positioned on the rail car bed.
END LOADING:
1.) Extend ENDLOAD supports and lock in place.
2.) Position platform at 45° by pressing“LOWER”
push button. Release button and lip will fall.
3.) Press “LOWER” button to lower platform to
rail car bed.
LATERAL MOVEMENT:
1.) Pull unit back towards dock until balanced on
railers, push unit to move side to side.
2.) Track section must be cleaned regularly to prevent
obstruction of rollers for free movement.
3.) NEMER Use a froktruck to position unit laterally
damage to equipment will occur and leveler repairs
will not be covered under warranty.
MILWAUKEE, WISCONSIN
(414)355-2600
64161
!
DISCONNECT POWER before opening this panel.
DO NOT operate leveler with anyone standing on
or in front of leveler.
DO NOT operate with load on leveler.
ALWAYS return leveler to the stored (vertical)
position.
HYDRAULIC DOCK LEVELER
Press & hold “LOWER” button
until lip rests on rail car bed.
“LOWER”
To stop leveler ramp movement,
Release button.
“RAISE”
Press & hold “RAISE” button
to raise platform. Hold button
until lip is fully extended in
vertical position.
Press & hold “LIP OUT” button
to extend lip.
“LIP OUT”
WARNING
!
DANGER
DO NOT drive on leveler, when “END LOADING”
without endload supports extended, locked &
positioned on the rail car bed.
END LOADING:
1.) Extend ENDLOAD supports and lock in place.
2.) Position platform at 45° by pressing“LOWER”
push button. Release button and lip will fall.
3.) Press “LOWER” button to lower platform to
rail car bed.
LATERAL MOVEMENT:
1.) Pull unit back towards dock until balanced on
railers, push unit to move side to side.
2.) Track section must be cleaned regularly to prevent
obstruction of rollers for free movement.
3.) NEMER Use a froktruck to position unit laterally
damage to equipment will occur and leveler repairs
will not be covered under warranty.
MILWAUKEE, WISCONSIN
(414)355-2600
64161
!
DISCONNECT POWER before opening this panel.
DO NOT operate leveler with anyone standing on
or in front of leveler.
DO NOT operate with load on leveler.
ALWAYS return leveler to the stored (vertical)
position.
HYDRAULIC DOCK LEVELER
Press & hold “LOWER” button
until lip rests on rail car bed.
“LOWER”
To stop leveler ramp movement,
Release button.
“RAISE”
Press & hold “RAISE” button
to raise platform. Hold button
until lip is fully extended in
vertical position.
Press & hold “LIP OUT” button
to extend lip.
“LIP OUT”
WARNING
!
DANGER
DO NOT drive on leveler, when “END LOADING”
without endload supports extended, locked &
positioned on the rail car bed.
END LOADING:
1.) Extend ENDLOAD supports and lock in place.
2.) Position platform at 45° by pressing“LOWER”
push button. Release button and lip will fall.
3.) Press “LOWER” button to lower platform to
rail car bed.
LATERAL MOVEMENT:
1.) Pull unit back towards dock until balanced on
railers, push unit to move side to side.
2.) Track section must be cleaned regularly to prevent
obstruction of rollers for free movement.
3.) NEMER Use a froktruck to position unit laterally
damage to equipment will occur and leveler repairs
will not be covered under warranty.
MILWAUKEE, WISCONSIN
(414)355-2600
64161
!
DISCONNECT POWER before opening this panel.
DO NOT operate leveler with anyone standing on
or in front of leveler.
DO NOT operate with load on leveler.
ALWAYS return leveler to the stored (vertical)
position.
FIGURE 25
Pub. No. 1134 — April 1998
21
OPTIONAL EQUIPMENT
REMOTE MOUNT POWER UNIT
1.
The remote mounted pump/motor is the same as
the platform mounted unit. Longer hoses have
been provided for this type of installation.
See Figure 26.
2.
Mount the pump/motor mounting plate to the wall
by the best possible means. NAILS ARE NOT AN
ACCEPTABLE MEANS OF INSTALLATION.
3.
Attach the pump/motor to the mounting plate.
4.
Connect to power supply as indicated in the standard installation instructions.
5.
With the leveler vertically stored by the lifting
device, fill the reservoir will additional MIL-H-5606
hydraulic fluid. Due to additional length of the
hoses, this style of installation will require more
hydraulic fluid. The correct level is indicated by the
sight glass on the reservoir.
6.
Follow the remainder of standard installation
instructions.
22
Pub. No. 1134 — April 1998
Secure Pump Mounting Plate
To Wall By Best Possible Means.
Nails Are Not Acceptable.
From Incoming
Power Source.
120V 1 Phase 60 Hz.
30A Min. Circuit Breaker
208/240V 1 Phase 60 Hz.
20A Min. Circuit Breaker.
240/480V 3 Phase 60 Hz.
20A Min. Circuit Breaker
Min. Wire Size Dependant
On Distance Run From
Customers Fused Power
Disconnect.
For Refrigerated Warehouse Application, Route
Conduit Through Bottom Of Control Box. If Entry
Through The Top Is Required The Conduit Opening
Must Be Sealed With Silicone Sealant.
Hydraulic VHL Control Box
(Supplied By RITE-HITE®)
Edge Of Door, Wall Or Outside
Surface Of Shelter (If Equipped)
Hirschmann
Conn. Cords
Liquidtight
! CAUTION
“THIS EQUIPMENT SHOULD NOT BE OPERATED
OR SERVICED EXCEPT BY TRAINED PERSONNEL.
LIKE MANY OTHER PIECES OF EQUIPMENT, IT
CAN CAUSE INJURIES IF IT IS NOT HANDLED
PROPERLY.” FOR ASSISTANCE CONTACT THE
RITE-HITE CORPORATION (414) 355-2600
DANGER
DO NOT STAND
ON THIS SIDE OF
DOCK LEVELER!!
LEVELER SWINGS
DOWN TOWARD YOU
HYDRAULIC
DOCK LEVELER
Secure Control
Box To Wall By
Best Possible
Means. Nails Are
Not Acceptable.
BY
MILW., WIS. (414) 3552600
84*
Junction Box
48
Approx.
For Incoming Power
0.50" Min. Electrical Conduit
Unless Otherwise Specified
By Local And/Or Building
Codes (By Others)
Secure Hoses To Wall
With Conduit Clamps.
(Supplied By Others)
Dock
Floor
Seal Conduit Openings
(Both Ends) With
Silicone Sealant.
PVC Must Extend
Above Pit Floor 2"
3" PVC
Dimensions Shown In Inches
Unless Otherwise Specified
Approach
*Hose Lengths Are Calculated For A Pump Mounting
Height Of 84" And 3" PVC Routing As Shown. Other
Height Variations And/Or Different Conduit Routing
May Require Custom Hoses.
C
L
Suggested Conduit Routing
FIGURE 26
Pub. No. 1134 — April 1998
23
MAINTENANCE
MAINTENANCE PROCEDURES
Daily
1. Make sure that the electrical power has been
locked out and tagged out before proceeding with any maintenance work.
2. Post safety warnings and barricade the work
area at dock level and at ground level to prevent unauthorized use of the Railcar Ramp
hydraulic leveler during maintenance.
3. Verify that the Service Strut has been properly inserted before beginning any maintenance work.
1.
Clean the track and the area surrounding the
Railcar Ramp hydraulic leveler.
2.
Verify proper operation.
90 Days
1.
Perform all Daily maintenance.
2.
Lubricate all wear points with oil or grease as
indicated.
3.
Check the hydraulic reservoir for proper fluid level.
4.
Check all hydraulic hoses, cylinders, and fittings for
leaks or wear.
5.
Check all hardware to make sure that it is tight.
Make sure that all cotter pins are not worn, damaged, or missing.
LUBRICATION
Depending on the dock leveler application and for proper
operation of your Railcar Ramp hydraulic leveler, cleaning and lubrication should follow a 90 day cycle. See
Figure 28. Perform all maintenance before making any
adjustments.
Before beginning this procedure make sure that
the Service Strut has been inserted properly.
See Figure 20.
1.
Remove all debris from the dock leveler and the
surrounding area. Make certain that the hinges, lip,
and platform are kept clean.
2.
Lubricate the leveler rear hinges, lower cylinder
pivot pin, upper cylinder pivot pin, and lip cylinder
pivots with SAE-30 oil every 90 days.
3.
360 Days
1.
Perform all daily and 90 Day maintenance.
2.
Inspect hydraulic oil. If dirty, drain and fill with
MIL-H-5606 hydraulic fluid.
NOTE
Frequency of maintenance may need to change if
equipment is installed in an extremely dusty or hot
environment.
3.
Verify the back-tilt of the leveler when in the
vertical stored position. Adjust as required to
obtain proper back-tilt.
4.
Carriage Roller Track “Gap”. If gap exceeds 1", carriage must be raised and inspected. See Figure 27.
1" Max.
Lubricate lip hinges with heavy duty grade moly
grease every 90 days.
FIGURE 27
24
Pub. No. 1134 — April 1998
LUBRICATION
2
2
2
2
2
1
2
2
2
2
2
2
2
2
2
1 – SAE 30 Oil
2 – Moly Based Grease
1
2
1
1
1
1
1
FIGURE 28
Pub. No. 1134 — April 1998
25
TROUBLESHOOTING
DO NOT operate leveler with anyone standing
in front of the leveler.
Keep away from hinge when operating leveler.
This equipment should not be operated or serviced except by trained personnel.
Problem
Cause
Remedy
1. Unit will not operate.
a. No power.
a. Check the main power supply.
b. Fuses blown.
b. Check fuses in main control box.
c. Is the voltage/motor
phase correct?
c. Check power requirements.
d. Is motor wired correctly?
d. Check wiring. See pages 10, 24 and 35.
a. Improper maintenance.
a. Perform all required maintenance, see Maintenance
Procedures.
b. Hydraulic system.
b. Check to make sure that the hydraulic pump
has power.
c. Hose leak.
c. Check hoses, valves, and fittings for leaks.
d. Solenoid valves are
not opening.
d. Verify that the solenoids are magnetized. If not, verify
wiring and/or replace solenoid coil.
e. Pump runs slowly.
e. Replace pump/motor assembly.
a. No power.
a. Check main power supply.
Check fuses in the control box.
b. Improper maintenance.
b. Perform all required maintenance, see Maintenance
Procedures.
c. Counterbalance valve is
not adjusted properly
(velocity fuse lockup).
c. Verify counterbalance valve setting. See pages 16 and 17.
Check shuttle valve adjustment. See page 18.
d. Hydraulic system.
d. Check to make sure that the hydraulic pump
has power. Check hoses, valves, and fittings for leaks.
Replace pump/motor assembly.
a. Improper maintenance.
a. Perform all required maintenance, see Maintenance
Procedures.
Check shuttle adjustment.
b. Lip cylinder binding.
b. Check for debris, replace lip cylinder.
c. Lip bent.
c. Contact the RITE-HITE Corporation at 1-800-456-0600.
a. Improper maintenance.
a. Perform all required maintenance, see Maintenance
Procedures.
Increase pressure on counterbalance valve.
See pages 16 and 17.
b. Lip too long for unit.
b. Replace check valve with 70 psi or 90 psi valve.
2. Unit functions slowly.
3. Functions stop during cycle.
4. Lip falls too slowly or not
at all.
5. Lip falls too fast.
26
Pub. No. 1134 — April 1998
TROUBLESHOOTING
DO NOT operate leveler with anyone standing
in front of the leveler.
Keep away from hinge when operating leveler.
This equipment should not be operated or serviced except by trained personnel.
Problem
Cause
Remedy
6. Platform falls too slowly.
a. Improper maintenance.
a. Perform all required maintenance, see Maintenance
Procedures.
Verify that the solenoids are properly adjusted.
b. Shuttle valve is not
adjusted properly.
b. See “Shuttle Valve Adjustment Instructions”
on page 18.
c. Counterbalance valve not
adjusted properly.
c. Locate counterbalance valve, rotate adjust
screw 1/8 turn CCW and test. Retest as needed.
a. Improper maintenance.
a. Perform all required maintenance, see Maintenance
Procedures.
b. Counterbalance valve not
adjusted properly.
b. Locate counterbalance valve, rotate adjust screw
1/8 turn CW and test. Repeat test until platform fall is
within specifications. See pages 16 and 17.
7. Platform falls too quickly.
Does not stop at any position
(too much float).
8. Platform drops suddenly
and then will not operate.
9. Lip falls immediately when
LIP OUT button is pressed.
Contact the RITE-HITE Corporation. Check the velocity
fuse for a jammed poppet.
a. Button not making contact
with contact block, motor is
not energizing.
a. Replace contact block on button.
Check motor for operation.
10. Unit raises when either the
LOWER or RAISE buttons are
pressed.
a. 4-way solenoid is not
shifting.
a. Check solenoid coil for magnetism/operation.
Check valve for debris by removing from valve block
and plunging valve. Replace valve assembly.
11. Unit raises when LIP OUT
button is pressed.
a. Lip Out 3-way valve is not
energizing.
b. Leakage past valves.
a. Verify wiring of solenoids.
b. Check solenoid coil. Replace assembly.
12. When pressing the LOWER
button, the lip extends only,
and when pressing the
LIP OUT button, the unit
lowers.
a. Lip Out 3-way valve is
energizing when the
LOWER button is
pressed. The 4-way valve
is energizing when the
LIP OUT button is
pressed.
a. Check wiring of #2 and #3 solenoid wires
in control and junction boxes.
13. Solenoids have power and
operate, but motor doesn’t run.
a. Overload relay tripped.
b. Improper electrical hookup.
a. Reset or replace overload relay.
b. Verify motor wiring. See pages 10, 24 and 35.
Pub. No. 1134 — April 1998
27
SCHEMATIC 120V 1 PHASE
From Customer Main Power &
Safety Protection Device
120V 1 Phase 60 Hz.
(Disconnect Provided By Installer)
L1
G
One Leveler
Per Overload
Protection
Device. [Ref.
N.E.C. 1990
Para. 430-110
(C)] Consult
Local Code
L2
Use #8 Gage Wires
MCR T1
L1
Motor
Thermal O/L
P2
P1
M
MCR T2
L2
T2
G
MOTOR – 1 H.P.
@ 3450 R.P.M.
120V 1 Phase 60 Hz.
With Thermal O/L
Door Interlock
Limit Switch (Optional)
L2
L2
O/L
2L1
“LOWER”
Fuse (3 AG Slow Blow)
0.5A, 250V
MCR
1L1
L1
Jumper (Remove Jumper
When Installing Limit Switch)
1L1
Four Way Valve Solenoid
120V, 0.2A
3 3
L2
3
L2
1PB
Motor Name Plate
P1- Line
“RAISE”
120V 1 Phase
1L1
P2
T8
1
1
2PB
Wire Nut
“LIP OUT”
T3
1L1
T2
T5
1
Lip Out Solenoid
120V, 0.2A
Line
T4
2
1L1
Motor Connections
120V 1 Phase
2
L2
3PB
Denotes Wire Connections
Thru Terminal Block
28
L2
4283
Pub. No. 1134 — April 1998
SCHEMATIC 240V 1 PHASE
From Customer Main Power &
Safety Protection Device
240V 1 Phase 60 Hz.
(Disconnect Provided By Installer)
G
A (L1) B (L1) L2
Use #10 Gage Wires
120V
240V
One Leveler
Per Overload
Protection
Device. [Ref.
N.E.C. 1990
Para. 430-110
(C)] Consult
Local Code
MCR T1
Motor
Thermal O/L
P2
P1
L1
M
MCR T2
T2
G
Motor – 1 H.P.
@ 3450 R.P.M.
240V 1 Phase 60 Hz.
With Thermal O/L
Door Interlock
Limit Switch (Optional)
L2
L2
O/L
L1
“LOWER”
Fuse (3 AG Slow Blow)
0.5A, 250V
MCR
2L1
1L1
Jumper (Remove Jumper
When Installing Limit Switch)
1L1
Four Way Valve Solenoid
120V, 0.2A
3 3
L2
3
L2
1PB
Motor Name Plate
P1- Line
“RAISE”
240V 1 Phase
1L1
P2 - Wire Nut
1
1
2PB
T8
T3
“LIP OUT”
Wire Nut
1L1
T2
1
Lip Out Solenoid
120V, 0.2A
T5
Line
2
1L1
T4
Motor Connections
240V 1 Phase
2
L2
3PB
Denotes Wire Connections
Thru Terminal Block
Pub. No. 1134 — April 1998
L2
4282
29
SCHEMATIC 240V 3 PHASE
From Customer Main Power &
Safety Protection Device
240V 3 Phase 60 Hz.
(Disconnect Provided By Installer)
G
L1 L2 L3
Use #12 Gage Wires
One Leveler Per
Overload Protection
Device.
[Ref. N.E.C. 1990 Para.
430-110 (C)]
Consult Local Code
L1
L2
MCR 1 O/L
T1
MCR 2 O/L
T2
MCR 3 O/L
L3
T3
SET @ 3.8A
H1
H3 H2
H4
CAUTION!!!
50 VA
Transformer
M
G
Motor – 1 H.P.
@ 3450 R.P.M.
240V 3 Phase 60 Hz.
Transformer Primary
Fusing. 1.0A, 600V
Class CC With Rejection
Feature (Typ. Two Places)
X2
X1
X2
Fuse (3 AG Slow Blow)
0.5A, 250V
2X1
Door
Interlock
“LOWER”
Limit Switch
(Optional)
1X1
1X1
O/L
MCR
1
Four Way Valve Solenoid
120V, 0.2A
3 3
X2
Jumper (Remove Jumper
When Installing Limit Switch)
1X1
1
X2
1PB
“RAISE”
1X1
1
2
3
7
8
9
4
5
6
1
1
2PB
“LIP OUT”
1X1
1
Connect T1, T2, T3 To
Terminals 1, 2, 3. If Rotation
Is Wrong, Reverse Any Two Lines.
Lip Out Solenoid
120V, 0.2A
1X1
Motor Connections
240V 3 Phase
2
2
X2
3PB
Denotes Wire Connections
Thru Terminal Block
30
X2
4281
Pub. No. 1134 — April 1998
SCHEMATIC 480V 3 PHASE
From Customer Main Power &
Safety Protection Device
480V 3 Phase 60 Hz.
(Disconnect Provided By Installer)
G
L1 L2 L3
Use #12 Gage Wires
20A Circuit
One Leveler Per
Overload Protection
Device.
[Ref. N.E.C. 1990 Para.
430-110 (C)]
Consult Local Code
L1
L2
MCR 1 O/L
T1
MCR 2 O/L
T2
MCR 3 O/L
L3
T3
SET @ 1.9A
H3 H2
H1
H4
CAUTION!!!
50 VA
Transformer
M
G
Motor – 1 H.P.
@ 3450 R.P.M.
480V 3 Phase 60 Hz.
Transformer Primary
Fusing. 0.5A, 600V
Class CC With Rejection
Feature (Typ. Two Places)
X2
X1
X2
Fuse (3 AG Slow Blow)
0.5A, 250V
2X1
Door
Interlock
“LOWER”
Limit Switch
(Optional)
1X1
1X1
O/L
MCR
1
Jumper (Remove Jumper
When Installing Limit Switch)
1X1
3
Four Way Valve Solenoid
120V, 0.2A
3
X2
3
X2
1PB
“RAISE”
1
1X1
1
2
3
7
8
9
4
5
6
2PB
“LIP OUT”
1X1
1
Connect T1, T2, T3 To
Terminals 1, 2, 3. If Rotation
Is Wrong, Reverse Any Two Lines.
Motor Connections
480V 3 Phase
2
1X1
2
Lip Out Solenoid
120V, 0.2A
X2
3PB
Denotes Wire Connections
Thru Terminal Block
Pub. No. 1134 — April 1998
X2
4280
31
HRCR, 3 P.B.
Motor 115/230V 1 Phase
1 H.P.@ 3450 R.P.M.
M
OR
Motor 240/480V 3 Phase
1 H.P.@ 3450 R.P.M.
1.5
G.P.M
Power Unit
System Relief
1500 P.S.I. - (120V 1 Phase)
1500 P.S.I. - (480V 3 Phase)
Shuttle
Valve
30 P.S.I.
Ramp
Port
Suction
Port
Velocity Fuse
(Base)
(P)
“RAISE”
Ramp
(Rod)
Ramp
Cylinder
“LOWER”
1.75 G.P.M.
1000
P.S.I.
(T)
P.C. Flow
Control
Three Way
Two Position
Solenoid Valve
(Lip)
Four Way
Two Position
Solenoid Valve
(Ramp)
Manifold Valve Ass’y.
Hydraulic
Counterbalance
Relief
(Lip Out)
Lip Cylinder
4355
32
Pub. No. 1134 — April 1998
WIRING 1 PHASE
Solenoids (Supplied By RITE-HITE®)
120V, 2A
120V/240V Power
“LIP” “FOUR WAY”
(See Proper Schematic,
120V Shown)
L1
L2
Limit Switch (Optional)
B
1 (ORG)
2L11L1 2 L2 3 C
L2 (WHT)
L1 (RED)
3
E
A1
1
(BLK)
NOTE:
Power Supply
Disconnect Or
Protection Device
Supplied At Installation. Use 60°/75°
Copper Wire Only.
1
3
1L1
L1 L2 L3
C
LOWER
L1
1
2 L2 (WHT)
1L1
1
A2
To Motor
RAISE
2L1
2
1
2L1
1
1L1
1L1
LIP OUT
Wiring Diagram
(120V Shown)
8627/8628
WIRING 3 PHASE
480V/240V Power
(See Proper Schematic,
480V Shown)
Solenoids (Supplied By RITE-HITE®)
120V, 2A
NOTE:
Power Supply Disconnect
Or Protection Device Supplied
At Installation. Use 60°/75°
Copper Wire Only.
“LIP” “FOUR WAY”
L1 L2 L3
Limit Switch (Optional)
1 (ORG)
1X1 2X1
2 X2 3
3
1
1X1
A1
X2 (WHT)
L1 L2 L3
LOWER
2
1
1
C
A2
A2
(BLK)
(BLK)
95 96 97 98
T1
T2
1X1
(BLK)
480V
(BLK)
(H4)
(H1)
(X2) 120V
T3
(X1)
RAISE
1
2
1X1
LIP OUT
X2 (WHT)
2X1
To Motor
Pub. No. 1134 — April 1998
Wiring Diagram
(480V Shown)
1X1
8629/8630
33
LIP AND PLATFORM PARTS
2
3
4
6
1
11
5
8
2
3
7
10
4
9
37 R.H.
38 L.H.
10
11
39
3
13
18
19
20
21
23
22
12
4
14
36
34
35
33
3
24
17
16
15
30
4
31
27
26
28
25
L Model Only
34
33
36
32
29
Pub. No. 1134 — April 1998
LIP AND PLATFORM PARTS LIST
8' 7" Long to 9' 4" Long
Item
Qty.
9' 4" Long and Greater
Description
6' W
6-1/2' W
7' W
7-1/2' W
8' W
8-1/2' W
6' W
6-1/2' W
7' W
7-1/2' W
8' W
8-1/2' W
1
1
1
1
1
1
1
1
1
1
Lip 16" Capacity (D)
Lip 18" Capacity (D)
Lip 20" Capacity (D)
Lip 16" Capacity (F)
Lip 18" Capacity (F)
17116
17117
17118
17134
17135
17119
17120
17121
17137
17138
17122
17123
17124
17140
17141
17125
17126
17127
17143
17144
17128
17129
17130
17146
17147
17131
17132
17133
17149
17150
17116
17117
17118
17134
17135
17119
17120
17121
17137
17138
17122
17123
17124
17140
17141
17125
17126
17127
17143
17144
17128
17129
17130
17146
17147
17131
17132
17133
17149
17150
1
1
1
1
2
1
1
1
1
2
Lip 20" Capacity (F)
Lip 16" Capacity (L)
Lip 18" Capacity (L)
Lip 20" Capacity (L)
Clevis Pin
17136
—
—
—
52518
17139
—
—
—
52518
17142
—
—
—
52518
17145
—
—
—
52518
17148
—
—
—
52518
17151
—
—
—
52518
17136
—
—
—
52518
17139
—
—
—
52518
17142
17152
17153
17154
52518
17145
17155
17156
17157
52518
17148
17158
17159
17160
52518
17151
17161
17162
17163
52518
3
4
5
6
6
4
1
1
Cotter Pin
Washer
Clevis Nut (5/16" – 18 UNC)
Clevis Bolt
(5/16" – 18 UNC x 2-1/2" Long)
51909
51721
51535
51631
51909
51721
51535
51631
51909
51721
51535
51631
51909
51721
51535
51631
51909
51721
51535
51631
51909
51721
51535
51631
51909
51721
51535
51631
51909
51721
51535
51631
51909
51721
51535
51631
51909
51721
51535
51631
51909
51721
51535
51631
51909
51721
51535
51631
7
8
8
8
9
2
2
2
1
Lip Cylinder
Lip Hinge Pin Capacity (D)
Lip Hinge Pin Capacity (F)
Lip Hinge Pin Capacity (L)
Platform Capacity (D)
01380
59466
59472
—
17167
01380
59467
59473
—
17168
01380
59468
59474
—
17169
01380
59469
59475
—
17170
01380
59470
59476
—
17171
01380
59471
59477
—
17172
01380
59466
59472
—
17173
01380
59467
59473
—
17174
01380
59468
59474
59478
17175
01380
59469
59475
59479
17176
01380
59470
59476
59480
17177
01380
59471
59477
59481
17178
Platform Capacity (F)
Platform Capacity (L)
0.25 x 1" Roll Pin
Grease Fitting
17179
—
52805
51169
(12)
17180
—
52805
51169
(14)
17181
—
52805
51169
(14)
17182
—
52805
51169
(16)
17183
—
52805
51169
(18)
17184
—
52805
51169
(18)
17185
—
52805
51169
(12)
17186
—
52805
51169
(14)
17187
17191
52805
51169
(14)
17188
17192
52805
51169
(16)
17189
17193
52805
51169
(18)
17190
17194
52805
51169
(18)
Ramp Cylinder Ass’y. 12" Stroke
(Includes 3 and 13 through 17)
8' 7" Long to 8' 10-7/8" Long
Ramp Cylinder Ass’y. 16" Stroke
(Includes 3 and 13 through 17)
8' 11" Long and Greater
06618
06618
06618
06618
06618
06618
—
—
—
—
—
—
06634
06634
06634
06634
06634
06634
06634
06634
06634
06634
06634
06634
9
9
10
11
1
1
2
See
P/N
12
1
12
1
13
14
14
15
16
1
1
1
1
1
Top Pin
Bottom Pin (D) and (F)
Bottom Pin (L)
Clevis
Clevis Nut (7/16" – 14 UNC)
52649
52667
—
55256
51544
52649
52667
—
55256
51544
52649
52667
—
55256
51544
52649
52667
—
55256
51544
52649
52667
—
55256
51544
52649
52667
—
55256
51544
52649
52667
—
55256
51544
52649
52667
—
55256
51544
52649
52667
52649
55256
51544
52649
52667
52649
55256
51544
52649
52667
52649
55256
51544
52649
52667
52649
55256
51544
17
1
58106
58106
58106
58106
58106
58106
58106
58106
58106
58106
58106
58106
18
2
58100
58100
58100
58100
58100
58100
58100
58100
58100
58100
58100
58100
19
2
Clevis Bolt
(7/16" – 14 UNC x 2-1/2" Long)
Valve Block Mounting Bolt
(1/4" x 20 UNC x 4" Long)
Lockwasher (1/4")
20
21
1
2
22
23
2
2
24
24
25
1
1
1
51800
51800
51800
51800
51800
51800
51800
51800
51800
51800
51800
51800
Valve Block
Pump Mounting Bolt
(3/8" – 16 UNC x 1" Long)
Pump Mounting Washer (3/8")
Pump Mounting Lockwasher (3/8")
06680
51600
06680
51600
06680
51600
06680
51600
06680
51600
06680
51600
06680
51600
06680
51600
06680
51600
06680
51600
06680
51600
06680
51600
51700
51805
51700
51805
51700
51805
51700
51805
51700
51805
51700
51805
51700
51805
51700
51805
51700
51805
51700
51805
51700
51805
51700
51805
Power Unit 1 Phase, 1 Hp
Power Unit 3 Phase, 1 Hp
Power Unit Mounting Bracket
(L) Only
06681
06682
—
06681
06682
—
06681
06682
—
06681
06682
—
06681
06682
—
06681
06682
—
06681
06682
—
06681
06682
—
06681
06682
17206
06681
06682
17206
06681
06682
17206
06681
06682
17206
Pub. No. 1134 — April 1998
35
LIP AND PLATFORM PARTS
2
3
4
6
1
11
5
8
2
3
7
10
4
9
37 R.H.
38 L.H.
10
11
39
3
13
18
19
20
21
23
22
12
4
14
36
34
35
33
3
24
17
16
15
30
4
31
27
26
28
25
L Model Only
36
33
36
32
29
Pub. No. 1134 — April 1998
LIP AND PLATFORM PARTS LIST
8' 7" Long to 9' 4" Long
Item
Qty.
9' 4" Long and Greater
Description
26
2
Power Unit Bracket Bolt
(L) Only
Power Unit Bracket Washer
(L) Only
Power Unit Bracket Lock Nut
(L) Only
27
2
28
2
29
30
31
32
33
1
1
1
1
See
P/N
Service Strut
Junction Box
Safety Pin and Chain
Safety Pin Warning Sign
Cotter Pin 1-1/2" Long and
(D) and (F)
33
See
P/N
See
P/N
See
P/N
Cotter Pin 1-1/2" Long (L)
6' W
6-1/2' W
7' W
7-1/2' W
8' W
8-1/2' W
6' W
6-1/2' W
7' W
7-1/2' W
8' W
8-1/2' W
—
—
—
—
—
—
—
—
51602
51602
51602
51602
—
—
—
—
—
—
—
—
51700
51700
51700
51700
—
—
—
—
—
—
—
—
51564
51564
51564
51564
01618
01618
01618
01618
01618
01618
01618
01618
01618
01618
01618
01618
10843-14 10843-14 10843-14 10843-14 10843-14 10843-14 10843-14 10843-14 10843-14 10843-14 10843-14 10843-14
01619
59155
51907
(8)
01619
59155
51907
(8)
01619
59155
51907
(8)
01619
59155
51907
(8)
01619
59155
51907
(8)
01619
59155
51907
(10)
01619
59155
51907
(8)
01619
59155
51907
(8)
01619
59155
51907
(8)
01619
59155
51907
(8)
01619
59155
51907
(8)
01619
59155
51907
(10)
—
—
—
—
—
—
—
—
Rear Hinge Pin
(D) and (F)
Rear Hinge Pin (L)
52630
(4)
—
52630
(4)
—
52630
(4)
—
52630
(4)
—
52630
(4)
—
52630
(6)
—
52630
(4)
—
52630
(4)
—
51907
(14)
52630
(4)
59482
(6)
51907
(14)
52630
(4)
59482
(6)
51907
(14)
52630
(4)
59482
(6)
51907
(18)
52630
(6)
59482
(8)
See
P/N
See
P/N
See
P/N
Rear Hinge Bushing
(D) and (F)
Rear Hinge Bushing (L)
52339
(4)
—
52339
(4)
—
52339
(4)
—
52339
(4)
—
52339
(4)
—
52339
(6)
—
52339
(4)
—
52339
(4)
—
Washer (D) and (F)
51730
(9)
51730
(9)
51730
(9)
51730
(9)
51730
(9)
51730
(13)
51730
(9)
51730
(9)
52339
(4)
52339
(6)
51730
(9)
52339
(4)
52339
(6)
51730
(9)
52339
(4)
52339
(6)
51730
(9)
52339
(6)
52339
(8)
51730
(13)
WASHER (L)
—
—
—
—
—
—
—
—
37
37
37
SEE
P/N
1
1
1
RUN-OFF GUARD RH (D)
RUN-OFF GUARD RH (F)
RUN-OFF GUARD RH (L)
17207
17211
—
17207
17211
—
17207
17211
—
17207
17211
—
17207
17211
—
17207
17211
—
17209
17213
—
17209
17213
—
51730
(13)
17209
17213
17213
51730
(13)
17209
17213
17213
51730
(13)
17209
17213
17213
51730
(17)
17209
17213
17213
38
38
38
39
1
1
1
2
Run-off Guard LH (D)
Run-off Guard LH (F)
Run-off Guard LH (L)
“T” Bolt
17208
17212
—
17200
17208
17212
—
17200
17208
17212
—
17200
17208
17212
—
17200
17208
17212
—
17200
17208
17212
—
17200
17210
17214
—
17200
17210
17214
—
17200
17210
17214
17214
17200
17210
17214
17214
17200
17210
17214
17214
17200
17210
17214
17214
17200
34
34
35
35
36
36
Pub. No. 1134 — April 1998
37
CARRIAGE ASSEMBLY PARTS
L
Capacity
(8 Mtg. Holes)
1
D-F
Capacity
(4 Mtg. Holes)
2
3
L
Capacity
(8 Mtg. Holes)
4
D-F
Capacity
(4 Mtg. Holes)
5
L
Capacity
(40 Mtg. Holes)
D-F
Capacity
(22 Mtg. Holes)
6
7
38
Pub. No. 1134 — April 1998
CARRIAGE ASSEMBLY PARTS LIST
8' 7" Long to 8' 10-7/8" Long
Item
Qty.
8' 11" Long and Greater
Description
6' W
6-1/2' W
7' W
7-1/2' W
8' W
8-1/2' W
6' W
6-1/2' W
7' W
7-1/2' W
8' W
8-1/2' W
52309
52309
52309
52309
52309
52309
52309
52309
52309
52309
52309
52309
1
8
Vertical Roller 1-3/4" Dia.
(D) and (F)
1
10
Vertical Roller 1-3/4" Dia. (L)
52309
52309
52309
52309
52309
52309
52309
52309
52309
52309
52309
52309
2
4
Horizontal Roller 3" Dia.
(D) and (F)
52307
52307
52307
52307
52307
52307
52307
52307
52307
52307
52307
52307
2
8
Horizontal Roller 3" Dia. (L)
52307
52307
52307
52307
52307
52307
52307
52307
52307
52307
52307
52307
3
1
Frame Carriage — No Windows
17241
17242
17243
17244
17245
17246
17000
17001
17002
17003
17004
17005
3
1
Frame Carriage — No Windows
9' 4" and Greater (L)
—
—
—
—
—
—
—
—
17012
17013
17014
17015
4
1
Frame Carriage with Windows
(D) and (F)
17247
17248
17249
17250
17251
17252
17006
17007
17008
17009
17010
17011
4
1
Frame Carriage with Windows
9' 4" and Greater (L)
—
—
—
—
—
—
—
—
17016
17017
17018
17019
5
1
Weld-on Fixed Frame
(D) and (F)
17215
17216
17217
17218
17219
17220
17221
17222
17223
17224
17225
17226
5
1
Weld-on Fixed Frame
9' 4" and Greater (L)
—
—
—
—
—
—
—
—
17233
17234
17235
17236
6
1
Weld-on/Bolt-on Track
(D) and (F)
81974
81974
81974
81974
81974
81974
81974
81974
81974
81974
81974
81974
6
1
Weld-on/Bolt-on Track
9' 4" and Greater (L)
10803
10803
10803
10803
10803
10803
10803
10803
10803
10803
10803
10803
7
1
Railcar Track Decal
64113
64113
64113
64113
64113
64113
64113
64113
64113
64113
64113
64113
Pub. No. 1134 — April 1998
39
HYDRAULIC COMPONENTS PARTS
3
2
1
12,13,14
10,11
12,14
13,14
15,16
4
4
4
CORPORATION
MILWAUKEE, WI
(414) 355-2600
PART #6624
17
Black
17
1
18
4
19
20
5
Yellow
6
20
24
7
8
4
3
9
23
22
40
21
Pub. No. 1134 — April 1998
HYDRAULIC COMPONENTS PARTS
Model
Item
Qty.
Description
8' 7" to 8'10-7/8"
8' 11" to 9' 4" Long
9' 4" Long and Greater
06680
01380
55024
55000
06625
06680
01380
55024
55000
06625
06680
01380
55024
55000
06625
1
2
3
4
5
1
1
2
6
1
Solenoid Valve Block Assembly (Reference Only)
Lip Cylinder (Reference Only)
Breather
Swivel Elbow
Velocity Fuse
6
7
8
9
10
1
1
1
1
1
Ramp Cylinder (Reference Only)
Hydraulic Hose
Hydraulic Hose
Swivel
Pressure Compensated Flow Control Valve
06618
06281-34
06281-34
55282
55299
06634
06281-34
06281-34
55282
55299
06634
06281-29
06281-26
55282
55299
11
12
13
14
15
1
1
1
2
1
Counterbalance Valve
3-Way Solenoid Valve
4-Way Solenoid Valve
Encapsulated Coil
Black Harness 33" Long
55253
55186
55184
55261
08639-33
55253
55186
55184
55261
08639-33
55253
55186
55184
55261
08639-33
16
17
18
19
20
1
3
1
1
2
Yellow Harness 33" Long
Female Swivel Fitting
Lip Out Relief Valve
Hydraulic Hose
Hydraulic Hose
08640-33
55013
55303
06281-50
06281-26
08640-33
55013
55303
06281-50
06281-26
08640-33
55037
55303
06281-36
06281-16
21
21
22
23
23
1
1
1
1
1
Power Unit (Reference Only) 1 Phase, 1 Hp
Power Unit (Reference Only) 3 Phase, 1 Hp
Sight Glass
Power Unit Harness 1 Phase 24" Long
Power Unit Harness 3 Phase 24" Long
06681
06682
55318
08638
08637
06681
06682
55318
08638
08637
06681
06682
55318
08638
08637
24
24
24
1
1
1
Check Valve 70 PSI (Standard)
Check Valve 90 PSI
Check Valve 35 PSI
55311
55313
55319
55311
55313
55319
55311
55313
55319
Pub. No. 1134 — April 1998
41
CONTROL BOX PARTS 1 PHASE
3
4
2
5
6 7 8 9
10
12,13
12,14
11
1
12,13
15
16
Item
Qty.
1
2
3
4
5
1
1
1
1
1
6
7
8
9
10
42
Description
17
18
Part Number
120V
240V
Control Box – Complete
NEMA 12 Enclosure 10" x 8" x 6"
Amp and Voltage Decal
Plug-in Jumper
Terminal Block
15790
55595
59041
57281
07164
15791
55595
59041
57281
07164
1
1
1
1
1
Dual Element Fuse
Fuse Holder
Ground Lug Decals
Ground Lug
Contactor
55766
55886
59069
55902
57067
55766
55886
59069
55902
57067
11
12
13
14
15
1
3
2
1
1
Fuse Replacement Decal
Black Pushbutton
Contact Block N.O.2
Contact Block N.O.1
Operation Decal
59152
57075
57091
57077
64161
59152
57075
57091
57077
64161
16
17
18
19
1
1
1
1
Corrosion Retard Pad
Warning Decal
Wiring Diagram Decal
Voltage, Phase, FLA Decal (Not Shown)
55561
59170
04283
59120
55561
59170
04282
59120
Pub. No. 1134 — April 1998
CONTROL BOX PARTS 3 PHASE
3
4
2
5
6 7
8
15,16
1
15,17
9
15,16
10
11
14 13
Item
Qty.
1
2
3
4
5
1
1
1
1
1
6
7
8
9
10
12
Description
18
19
20
21
Part Number
240V
480V
Control Box – Complete
NEMA 12 Enclosure 10" x 8" x 6"
Amp and Voltage Decal
Plug-in Jumper
Terminal Block
15792
55595
54069
57281
07164
15793
55595
54069
57281
07164
1
1
1
1
1
Ground Lug Decal
Ground Lug
Contactor
O/L Relay
Fuse Replacement Decal
59170
55902
57066
57069
59153
59170
55902
57066
57068
59153
11
12
13
14
15
1
2
1
1
3
Fuse Block
Rejection Type Fuse
Dual Element Fuse
Transformer
Black Pushbutton
57561
57867
55766
57559
57075
57561
57860
55766
57559
57075
16
17
18
19
20
2
1
1
1
1
Contact Block N.O.2
Contact Block N.O.1
Operation Decal
Corrosion Retard Pad
Warning Decal
57091
57077
64161
55561
59170
57091
57077
64161
55561
59170
21
22
1
1
Wiring Diagram Decal
Voltage, Phase, FLA Decal (Not Shown)
04281
59120
04280
59120
Pub. No. 1134 — April 1998
43
DECALS
1
2
3
! CAUTION
“THIS EQUIPMENT SHOULD NOT BE OPERATED
OR SERVICED EXCEPT BY TRAINED PERSONNEL.
LIKE MANY OTHER PIECES OF EQUIPMENT, IT
CAN CAUSE INJURIES IF IT IS NOT HANDLED
PROPERLY.” FOR ASSISTANCE CONTACT THE
RITE-HITE CORPORATION (414) 355-2600
BY
6
9
NEVER PLACE
LOAD ONTO
PLATFORM WITHOU
THE
T SUPPORT
OR ENDLOAD
BY LIP
ARMS ON RAILCA
R
MILW., WIS. (414) 3552600
IN FRONT OF LEVELER
WHEN OPERATING
WARNING
DO NOT STAND
ON THIS SIDE OF
DOCK LEVELER!!
LEVELER SWINGS
DOWN TOWARD YOU
! CAUTION
KEEP AWAY FROM HINGE
WHEN OPERATING LEVELER
DO NOT STAND
!
DANGER
8
HYDRAULIC
DOCK LEVELER
4
CORPORATION
MILWAUKEE, WI
(414) 355-2600
PART #6624
6
ENGAGE SERVICE STRUT
FULLY TO THIS POINT
5
4355
7
Item
Qty.
1
2
3
4
5
1
1
1
1
1
Warning Decal
Caution Decal
Logo Decal
Valve Decal
Important Decal
54029
59055
54148
59150
59065
6
7
8
9
10
2
1
2
2
1
Service Strut Decal
Decal
Caution Decal
Warning Decal
Serial Number Decal (Not Shown)
59151
59149
54046
64175
54000
44
Description
Part Number
Pub. No. 1134 — April 1998
RITE-HITE CORPORATION STANDARD WARRANTY
RITE-HITE Corporation warrants that its products will be free from defects in design, materials, and workmanship for a period of 365 days from the date of shipment. All claims for breach of this warranty must be made
within 30 days after the defect is or can, with reasonable care, be detected and in no event no more than 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 exclusive warranty. RITE-HITE CORPORATION EXPRESSLY DISCLAIMS ALL IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS. Non-standard warranties, if any, must be specified by RITE-HITE Corporation in writing.
In the event of any defects covered by this warranty, RITE-HITE Corporation will remedy such defects by
repairing or replacing any defective equipment or parts, bearing all the costs for parts, labor, and transportation. This shall be the exclusive remedy for all claims whether based on contract, negligence, or strict liability.
LIMITATION OF LIABILITY
RITE-HITE CORPORATION SHALL NOT IN ANY EVENT BE LIABLE FOR ANY LOSS OF USE OF ANY
EQUIPMENT OR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, WHETHER FOR BREACH
OF WARRANTY, NEGLIGENCE, OR STRICT LIABILITY.
National Sales & Service Office:
RITE-HITE Corporation
8900 N. Arbon Drive
P.O. Box 23043
Milwaukee, Wisconsin 53223
Phone: 414-355-2600
Representatives in all Major Cities