RITE-HITE Genisys AL-900 Owner's Manual

30, GENISYS AL-900 Dock Leveler Owner’s Manual 30 Publication: AMEN00044 2017-01-27 KEYED OPTION ON OFF 1 3 J6 1 2 DOCK LEVELER RAISE EXTERIOR DECAL NOTE: 1. PLACE ITEM 310 IN UPPER PORTION OF ENCLOSURE WHEN ITEM 309 IS NOT PRESENT. INTERIOR DECAL NOTE: 1. ITEM 302, 303, AND 304 PLACE IN AVAILABLE SPACE ON REAR OF ENCLOSURE COVER. 2. ITEM 305, AND 306 ARE NOT SHOWN. APPLY IN AVAILABLE SPACE IN ENCLOSURE COVER OR TUB. PRODUCTS CORP. Milwaukee, Wisconsin 53223 (800) 456-0600 PLATFORM RAISE & LIP…

15, GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27 15 ELECTRICAL WIRING CHARTS MotorFLA Ratings& Connection Detail 0‐50 51‐100 101‐150 151‐200 110‐120/1/60/1300W 13.3 12866 208‐240/1/60/1533W 6.7 14 14 12 10 MinimumWireSize(AWG)Chart forVariousLineLengthsandLine Loads LineLength(ft) FLA AL9 MOTORSIZE 1533W 110‐120/1/60 13.3 208‐240/1/50/60 6.7 HALDEX BU…

29, GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27 29 Item Qty Description Part Number 1 1 Control box assembly, Complete (Consult Rite-Hite for specic part number) 873.xxx 102 1 Push button, black 146827 103 1 Push button, red 146829 201 1 Pre-drilled control box sub panel 144763 202 1 Standard Leveler Control Board, Blank 144555-883D100 Standard Leveler Control Board, Including Fuse 144574-883D100 Leveler control board with Program Options, Blank (Consult Rite-Hite for specic part n…

4, GENISYS AL-900 Dock Leveler Owner’s Manual 4 Publication: AMEN00044 2017-01-27 FIGURE 1 - LOCKOUT/TAGOUT LOCKOUT/TAGOUT PROCEDURES The Occupational Safety and Health Administration requires that, in addition to posting safety warnings and barricading the work area, 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 locko…

11, GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27 11 FIGURE 10 - LEVELER LUBRICATION OIL SAE 30 Weight Anti-Seize FIGURE 11 - TUB PLACEMENT Attach chain assembly to d-rings on Tub, both sides. Stops for side Tub opening on Leveler Frame. MAINTENANCE CONT. Stops for side Tub opening on Leveler Frame. …

32, Genisys Dock Leveler by Rite-Hite Standard Warranty Policy Rite-Hite warrants to and for the sole benet of the original purchaser that Genisys by Rite-Hite (hereinafter “Genisys”) Dock Levelers shall be free from defects in material and workmanship subject to the following: Length of Time: All products are warranted for a one year period commencing on the earlier date of approved installation or the (30th) day after the date of shipment. This warranty covers the repair or replacement of the defective product or component at Rite-Hite’s…

10, GENISYS AL-900 Dock Leveler Owner’s Manual 10 Publication: AMEN00044 2017-01-27 MAINTENANCE ALWAYS read and obey these instructions to prevent personal injury. • Post safety warnings and barricade work area, at dock level and at ground level, to prevent unauthorized use of the dock position before maintenance has been completed. • Make sure to install the maintenance support strut before proceeding with any repair work. SUGGESTED LEVELER MAINTENANCE NO…

8, GENISYS AL-900 Dock Leveler Owner’s Manual 8 Publication: AMEN00044 2017-01-27 NORMAL OPERATION 1. Activate the leveler by pushing and holding the RAISE button until leveler is fully raised and lip is fully extended. See gure 3. FIGURE 3 - POWERED DOCK LEVELER 2. When lip is fully extended, release RAISE button. The leveler will automatically lower onto the truck/trailer bed. See gure 4. FIGURE 4 - NORMAL OPERATION 3. See Storing Leveler. NOTES: a. Levelers without Automatic Return to Dock (ARTD) If the truck/trailer dep…

14, GENISYS AL-900 Dock Leveler Owner’s Manual 14 Publication: AMEN00044 2017-01-27 LED STATUS CHARTS PIT DOCK LEVELER RITE-HITE PRODUCTS CORP. STANDALONE CONTROLS PUSH BUTTONS 12VDC ARTD INPUT COMBINED POWER UNIT INPUT [CMBD PU] GREEN LIGHT TO OPERATE LEVELER INPUT [GLT ITL] [SEE DIP SWITCH #2] OVERHEAD DOOR OPEN INTERLOCK INPUT [OHD ITL] [SEE DIP SWITCH #3] RAISE PUSH BUTTON MOTOR CONTACTOR OUTPUT [LVLR CONTR] 12VDC POWER SUPPLY OK LEVELER SOLENOID #1 - LIP OUT (K1) [STANDARD] LEVELER SOLENOID #1 - LIP OUT (K1) [E-STOP EQUIPPED] AUX BOARD …

19, RITE-HITE Genisys AL-900 GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27 19 ELECTRICAL SCHEMATICS CONT. LEGEND: DENOTES WIRE CONNECTIONS THRU TERMINAL BLOCK. DENOTES FIELD WIRES. DENOTES WIRE NUT CONNECTION. DENOTES MALE/FEMALE PLUG CONNECTOR. LEVELER POWER CB J11 1 1 JP1 1 JP2 1 J2 TERM1 SP1 DIAG U14 SW1 J4 J1 J3 1 RESET J10 J8 +12VDC LD7 LD9 J6 LD14 LD8 LOWER E-STOP LIP OUT RAISE 1 1 LVLR CONTACTOR (J10-3) OHD ITL (J9-1) ARTD (J9-2) GLT ITL (J11-1) CMBD PU (J11-2) FH1…

28, GENISYS AL-900 Dock Leveler Owner’s Manual 28 Publication: AMEN00044 2017-01-27 TYPE 2 CONTROL BOX PARTS KEYED OPTION ON OFF 1 3 J6 1 2 DOCK LEVELER RAISE EXTERIOR DECAL NOTE: 1. PLACE ITEM 310 IN UPPER PORTION OF ENCLOSURE WHEN ITEM 309 IS NOT PRESENT. INTERIOR DECAL NOTE: 1. ITEM 302, 303, AND 304 PLACE IN AVAILABLE SPACE ON REAR OF ENCLOSURE COVER. 2. ITEM 305, AND 306 ARE NOT SHOWN. APPLY IN AVAILABLE SPACE IN ENCLOSURE COVER OR TUB. PRODUCTS CORP. Milwauk…

31, GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27 31 Item Qty Description Part Number 602 1 Selector switch, keyed (If equipped) 149175 701 4 Standoff, Male/Female, #6-32, 2.5" length 133365 702 4 Screw, round head, #6-32, 0.25" length 133366 703 4 Lock washer, #6 51826 704 4 Standoff, Male/Female, #6-32, 2.5" length 133365 705 4 Screw, round head, #6-32, 0.25" length 13…

25, GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27 25 REPLACMENT PARTS LIST CONT. Item Qty. Description Leveler Length 6’ Long 8’ Long 10’ Long 39 1 Maintenance Support 413.105 413.105 413.102 40 1 Chain Assembly 117395 117395 117395 41 1 Full Range LH (2 Fan) (Not Shown) 417.102 - - 1 Full Range LH (3 Fan) - 419.101 419.102 42 1 Full Range RH (2 Fan) (Not Shown) 418.102 - - 1 Full Range RH (3 Fan) (Not Shown) - 420.100 420.101 43 1 Toeguard Fan 14Ga. X 11 4Hol…

24, RITE-HITE Genisys AL-900 GENISYS AL-900 Dock Leveler Owner’s Manual 24 Publication: AMEN00044 2017-01-27 REPLACEMENT PARTS CONT. 54 5 31 31 36 35 38 33 32 39 20 18 18 4 49 15 22 21 22 7 8 5 6 6 9 10 AL9 - Parts 53 66 40 62 55 43 44 65 45 , 46 41 14 42 58 56 20 16 48 15 28 27 19 16 19 17 25 47 18 30 46 13 26 29 27 19 19 14 24 37 23 34 50 42 3 2 51 1 11 12 14 25 63 64 57 52 19 18 47 …

5, GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27 5 OTHER IMPORTANT OPERATIONAL SAFETY WARNINGS NEVER be under the dock leveler platform or lip without: • Installing the Safe-T-StrutTM or other supporting device. • If lip needs to be extended, follow procedures shown under Safety Devices on the following page. • Turning OFF power to the control box. • Locking out and tagging out the main po…

26, GENISYS AL-900 Dock Leveler Owner’s Manual 26 Publication: AMEN00044 2017-01-27 TYPE 1 CONTROL BOX PARTS INSIDE LEFT 6 7 1 3 4 5 INSIDE RIGHT 2 Back Of Cover Item Qty Description Part Number 1 1 Control Box Complete 228.xxx 2 1 Control Box Enclosure, 4 x 4 x 2 N4XF 117342 3 1 Push Button Operator (30.5MM) Black, NO, N12/N4 (AB: 800T-A2D1M) 117352 1 Push Button Operator (30.5MM) Black, NO, N4X (AB: 800H-AR2D1M) 117…

20, GENISYS AL-900 Dock Leveler Owner’s Manual 20 Publication: AMEN00044 2017-01-27 COM 1 654 23 BK 635241 OR BRRDYE LD14 LIP OUT RAISE LOWER E-STOP LD13 LD12 LD11 DETAIL B - DISCREET INPUTS PUSHBUTTONS X2 SCALE DOWN UP DETAIL A - DIP SWITCH SETTINGS SW1 FACTORY POSITION FUNCTION CONTROLLED 1 (DOWN) (DIP SWITCH 1 NOT USED) 2 (UP) GREEN LIGHT ITL/ITC (DOWN - IF REQUIRED/UP TO DISABLE) 3 (UP) OVERHEAD DOOR INTERLOCK (DOWN - IF EQUIPPED/UP TO DISABLE) "A" AA NOTE: RESTRAINT ITL/ITC OPT…

6, GENISYS AL-900 Dock Leveler Owner’s Manual 6 Publication: AMEN00044 2017-01-27 OTHER IMPORTANT OPERATIONAL SAFETY WARNINGS NEVER be under the dock leveler platform or lip without: • Installing the Maintenance Support. See below right. This can be done with the assistance of another person by: - Raise leveler until platform reaches its highest position and lip extends. Continue to maintain this position. - Then have assistant insert th…

17, RITE-HITE Genisys AL-900 GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27 17 ELECTRICAL SCHEMATICS CONT. (COM) (LSOL1/J23) (N) LIP-OUT LSOL1 CIRCUIT G 120VAC, 0.3 AMPS 7(BK) X2(WH) "LIP OUT" SOLENOID (SOL1) (ARTD/J92) (COM) ARTD CIRCUIT ARTD LIMIT SWITCH (LS2) N.O. 4(BK) 12(WH) G (ARTD/J92) LEGEND: DENOTES WIRE CONNECTIONS THRU TERMINAL BLOCK. DENOTES FIELD WIRES. DENOTES WIRE NUT CONNECTION. DENOTES MALE/FEMALE PLUG CONNECTOR. LEVELER POWER CB J11 1 1 JP1 1 JP2 1 J2 TERM1 SP1 DIAG U14 SW1 J4 J1 J3 1 RESET …

9, GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27 9 DOCK LEVEL (OR LOWER) END LOADING OPERATION 1. Activate the leveler by pushing and holding the RAISE button until leveler lip clears the lip supports. See gure 6. FIGURE 6 - END LOAD OPERATION - LIP POSITION FIGURE 7 - END LOAD OPERATION 2. Release RAISE button and as platform is lowering pull and hold the Safety Leg Chain, if eq…

3, RITE-HITE Genisys AL-900 GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27 3 TABLE OF CONTENTS Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Owner Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Maintenance . . . . . . …

16, GENISYS AL-900 Dock Leveler Owner’s Manual 16 Publication: AMEN00044 2017-01-27 ELECTRICAL SCHEMATICS DENOTES MALE/FEMALE PLUG CONNECTION DENOTES WIRE CONNECTIONS THRU TERMINAL BLOCK. DENOTES WIRE NUT CONNECTION DENOTES FIELD WIRES. PB1 FOR VEHICLE RESTRAINT ITC. TO DOK-LOK CONTROL BOX "RAISE" 208-240v. 1PH. 60HZ. USE 10.0A DUAL ELEMENT TIME DELAY 208-240v. 1PH. 50HZ. USE 10.0A DUAL ELEMENT TIME DELAY FROM CUSTOMER MAIN POWER & SAFETY PR…

13, RITE-HITE Genisys AL-900 GENISYS AL-900 Dock Leveler Owner’s Manual Publication: AMEN00044 2017-01-27 13 Problem Probable Cause Solution 1. Platform does not raise. a. No power. b. The blower motor and/or control box has been mis-wired. c. The pushbutton and/or contact block does not function properly. d. Overload tripped. e. The blower motor has failed. f. Check air tower assembly for damage. a. Check the main power supply. Check fus…

1, RITE-HITE Genisys AL-900 AL-900 Dock Leveler Owner’s Manual By Rite-Hite This Manual Covers Dock Levelers Built After Serial Numbers: 07DD400623M and up Publication: AMEN00044 2017-01-27 part of the SMOOTH TRANSITION DOK SYSTEM TM …