RITE-HITE DOK-LOK RHR-600, Owner'S Manual

Page 1: ...Model RHR 600 DOK LOK Printed in U S A Publication No 1158 2001 RITE HITE Corp August 2001 Owner s Manual Serial No RHR001000 and UP DL0001 0 ...

Page 2: ...s The RITE HITE products in this manual are covered by one or more of the following U S patents 4 379 354 4 443 150 4 472 099 4 560 315 RE 32 968 4 605 353 RE 33 154 4 634 334 4 692 755 4 843 373 5 212 846 5 297 921 5 375 965 5 453 735 5 531 557 5 553 987 5 582 498 5 664 930 5 702 223 5 762 459 5 882 167 5 964 572 6 010 297 6 074 157 6 092 970 6 106 212 6 116 839 6 190 109 and pending U S and fore...

Page 3: ...LOK vehicle restraint For best results have this product serviced by your authorized RITE HITE representative The RHR 600 DOK LOK vehicle restraint by RITE HITE is intended to provide a safer workplace for workers in shipping and receiving dock areas The RHR 600 DOK LOK vehicle restraint is an electro mechanical restraint device that when properly installed and operated retains a secure connection...

Page 4: ...procedures should be kept 5 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 6 The manufactur...

Page 5: ...ck attendant will have to depress the UNLOCK button which then will return the hook to its lower stored position A proper hook engagement is achieved when the hook raises unobstructed to fully trap the horizontal cross member of the R I G Assembly An improper hook engagement is if the horizontal cross member of the R I G is missing obstructed or it is bent or located so far toward the rear axle of...

Page 6: ...6 RITE HITE RHR 600 DOK LOK Owner s Manual Figure 2 RHR 600 DOK LOK Features ...

Page 7: ... to Figure 26 and Figure 27 Install Roller Track Plate The RHR 600 DOK LOK vehicle restraint is shipped assembled The track roller plate must be disassembled from the DOK LOK vehicle restraint to begin installation To disassemble 1 Remove motor cover 2 Remove spring cover and springs Refer to Figure 4 3 Remove nuts from spring bar 4 Roll DOK LOK vehicle restraint out of roller track plate Be caref...

Page 8: ...g a necessary lip guide Anchor Installation Instructions 1 Put roller track plate in place 2 Drill hole of 5 8 diameter and minimum of 4 5 8 deep Clean out hole 3 Insert anchor and drive flush with roller track plate making certain that the threaded wedge is put in first Do not disassemble anchor prior to installation 4 Install all anchors and torque to 100 ft lbs NOTE 1 For site specific installa...

Page 9: ...ctly onto concrete block or brick dock face NOTE 4 Figure 6 When welding DOK LOK vehicle restraint disconnect power and ground leads to DOK LOK vehicle restraint and leveler NOTE 5 Figure 6 Due to actual conditions total mounting height may be different Refer to RITE HITE Application Guidelines for actual mounting height Special Application Installation NOTE 1 Figure 9 Shim as required behind trac...

Page 10: ...oked into one 1 20 amp branch circuit breaker per the 1999 National Electrical Code Paragraph 430 53 When in doubt call your RITE HITE representative or RITE HITE at 800 456 0600 The DOK LOK vehicle restraint assembly includes a 63 long flexible wiring harness Also provided are the control box with lights and the outside signal light box The outside junction box conduit fittings and wire are provi...

Page 11: ...ol box All signs must be installed NOTE 1 Figure 11 Some docks may have dock truck seals or shelters installed or planned which are larger than standard Outside light sign location and mounting should be studied before proceeding to avoid interference NOTE 2 Figure 11 If required for special reasons signs may be trimmed for fit NEVER cut or eliminate sign letters words NOTE 3 Figure 11 Attach sign...

Page 12: ...11 for motor and limit switch cord routing and wire harness installation instructions NOTE 3 Figure 12 AC motor rating 1 4 HP 120V 1PH 60 Hz 5 2A F L A reversible intermittent duty NOTE 4 Figure 12 If outside lights do not work check connections of wires 40 41 and 42 NOTE 5 Figure 12 SAFETY EARTH GROUND required Figure 12 Installation Wiring Diagram See NOTE 5 See NOTE 4 See NOTE 3 See NOTE 1 ...

Page 13: ...RITE HITE RHR 600 DOK LOK Owner s Manual 13 Electrical Schematic Standard Figure 13 Electrical Schematic Standard ...

Page 14: ...14 RITE HITE RHR 600 DOK LOK Owner s Manual Electrical Schematic Optional Figure 14 Electrical Schematic Optional ...

Page 15: ...r firmly against the dock bumpers secure the trailer by other means Be sure that the area around the R I G assembly is free of plates or other obstructions Always operate the DOK LOK vehicle restraint from the top of the dock Inspect all restraint lights and horns daily to make certain they work properly Perform maintenance on restraints in accordance with Maintenance page 19 of this manual DOK LO...

Page 16: ...ULT otherwise go to Restraint LOCKED Restraint LOCKED Once the R I G is entrapped by the hook a locked condition exists Inside light is flashing green alerting the forklift operator a safe condition exists Outside light is flashing red alerting truck driver not to move If during loading unloading the inside light turns red and the horn sounds press LOCK button to secure the R I G Figure 16 Restrai...

Page 17: ...t operator that the trailer is not locked Outside light is flashing red alerting the truck driver not to move If the trailer is parked firmly against the dock bumpers go to HORN OVERRIDE If not press UNLOCK to clear the fault have trailer back up and repeat Restraint LOCKING FAULT State From UNLOCKING State Hook cannot rotate to the STORED position The hook could be caught on the R I G or another ...

Page 18: ...e means of securing the truck must be used i e wheel chocks Inside lights are flashing red and green alerting the forklift operator the trailer is secured by other means Outside light is flashing red alerting the truck driver not to move To return to STORED press the HORN OVERRIDE button followed by the UNLOCK button Figure 20 HORN OVERRIDE State ...

Page 19: ...ons 5 Check that all concrete anchor bolts are torqued to 100 ft lbs 6 Inspect flexible electrical harness from DOK LOK vehicle restraint to junction box Look for kinks crushed areas etc 7 Perform operational test after all maintenance repairs and adjustments are complete 8 Inspect dock bumpers Four inches 4 of protection is required Worn torn loose or missing bumpers must be replaced 360 Days 1 P...

Page 20: ... loosen the four 4 motor mounting bolts 2 Pry the motor assembly forward in the slotted holes until the chain is tight with proper alignment between sprockets Hold in this position and tighten the four 4 motor mounting bolts to 105 in lbs in increments of 10 in lbs Tighten in pattern shown See Figure 21 3 Test for proper chain alignment 4 Close the motor enclosure When working with electrical or e...

Page 21: ...ower module failure Verify the appropriate LED is lit when the LOCK button or UNLOCK button is pressed No push button inputs Check for defective push button board or ribbon cable Drive motor defective Check motor Figure 22 page 22 Repair or replace as required Incorrect wiring Verify wiring per Electrical Schematic Standard Figure 13 page 13 and Electrical Schematic Optional Figure 14 page 14 3 DO...

Page 22: ...ce as required Damaged CPU module LED labeled HORN should be flashing while in FAULT state If not replace CPU module as required Incorrect wiring Verify wiring per Electrical Schematic Standard Figure 13 page 13 and Electrical Schematic Optional Figure 14 page 14 7 DOK LOK vehicle restraint inside red light and horn double pulse Limit switch fault Power must be cycled to clear fault Check LS1 limi...

Page 23: ...B and C of limit switch connector You should have plunger released no meter reading plunger depressed a Full Scale meter reading NOTE The green ground wire of the limit switch does not have to be tested A continuity test lamp may be used instead of a multimeter Figure 23 Limit Switch Test and Limit Switch and Hook Position Chart Figure 24 LED Status Chart ...

Page 24: ... G locknut with gasket limit switch LS2 motor motor LS1 LS2 45 45 G 1 13 2 G 1 2 G 3 1 15 G G 120V 1 Phase Power Low Voltage 12V Power 12 CARRIAGE SHOWN 44 44 43 43 plug 13 G A B C D A B C D 3 1 15 limit switch LS1 g r e e n r e d white black green orange white black green blue orange black b l u e b l a c k r e d b l a c k DL0021 0 ...

Page 25: ...RITE HITE RHR 600 DOK LOK Owner s Manual 25 Notes ...

Page 26: ...26 RITE HITE RHR 600 DOK LOK Owner s Manual Replacement Parts Standard RHR 600 Parts 12 Carriage Figure 26 RHR 600 Standard Carriage Exploded View ...

Page 27: ...crew 35 27 tooth 56177 20 1 Chain 56175 21 8 Serrated flange whiz nut 3 8 16NC 51564 22 2 Bearing 6085 23 4 Carriage roller 15782 24 1 Carriage 106699 25 6 Carriage bolt 3 8 16NC x 1 long 58022 26 1 Conduit nipple 18204 27 1 Locknut 55791 28 1 Hook shaft 54987 29 1 Conduit bushing 57978 30 1 Harness cord grip 3 4 x 11 16 13 16 66082 31 1 Harness locknut with gasket 55877 32 1 Motor assembly includ...

Page 28: ...28 RITE HITE RHR 600 DOK LOK Owner s Manual Optional RHR 600 Parts 9 Carriage Figure 27 Optional RHR 600 9 Carriage Exploded View ...

Page 29: ...6085 23 4 Carriage roller 15782 24 1 Carriage 106700 25 6 Carriage bolt 3 8 16NC x 1 long 58022 26 1 Conduit nipple 18204 27 1 Locknut 55791 28 1 Hook shaft 54987 29 1 Conduit bushing 57978 30 1 Harness cord grip 3 4 x 11 16 13 16 66082 31 1 Harness locknut with gasket 55877 32 1 Motor assembly includes Item 33 106708 33 1 Wire tie motor and limit switch 18548 34 1 Lower spring bar mounting plate ...

Page 30: ...30 RITE HITE RHR 600 DOK LOK Owner s Manual Electrical Replacement Parts Figure 28 RHR 600 Electrical Replacement Parts ...

Page 31: ...ons module not included in STANDARD control box assembly 105448 14 1 Program configuration decal Consult RITE HITE for specific part 107 xxx 15 1 Full Load Amp and Voltage Decal Consult RITE HITE for specific part 110 xxx 16 1 Horn 12VDC 57383 17 1 Wiring harness 105460 18 1 Grounding harness 105456 19 4 Screw panhead 10 32 x 250 105455 20 4 Lock washer internal tooth 10 51828 21 1 Screw round hea...

Page 32: ...29 RHR 600 Miscellaneous Replacement Parts Item Qty Description Part Number 1 1 Interior Warning sign 56095 2 1 Narrow sign normal letters 56112 3 1 Narrow sign reverse letters 56113 4 1 RHR warning decal 105428 5 1 Cover decal 3 button 105423 6 1 Lockout tagout warning decal 105430 7 1 Owner s manual Publication No 1158 ...

Page 33: ...RITE HITE RHR 600 DOK LOK Owner s Manual 33 Notes ...

Page 34: ...34 RITE HITE RHR 600 DOK LOK Owner s Manual Notes ...

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Page 36: ...ty RITE HITE EXPRESSLY DISCLAIMS ALL IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS Non standard warranties if any must be specified by RITE HITE in writing In the event of any defects covered by this warrranty RITE HITE will remedy such defects by repairing or replacing any defective equipment or parts bearin all the costs for parts labor and transportation Thi...