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RITE-HITE APB-1000 Manual
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RITE-HITE APB-1000 Manual

RITE-HITE APB-1000 Manual

Hydraulic dock leveler
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APB-1000
Hydraulic Dock Leveler
Owner's Manual
Printed in U.S.A.
Publication No. 1120-R5
Copyright 1997, 2000
June 2000

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Summary of Contents for RITE-HITE APB-1000

  • Page 1 APB-1000 Hydraulic Dock Leveler Owner’s Manual Printed in U.S.A. Publication No. 1120-R5 Copyright 1997, 2000 June 2000...
  • Page 2 RITE-HITE does not recommend any particular lockout device, but recommends the utilization of an OSHA approved ® device (refer to OSHA regulation 1910.147). RITE-HITE ® 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.
  • Page 3 SAFE-T-STRUT Post warnings and barricades at dock level and at drive level that work is being done around Never be under the APB-1000 platform or lip and under the leveler platform. Lockout and without: tagout power to the APB-1000 dock leveler and •...

  • Page 5: Table Of Contents

    DEFINITION OF FEATURES ON THE APB-1000 ........

  • Page 7: Definition Of Features On The Apb-1000

    DEFINITION OF FEATURES ON THE APB-1000 Front Lip Assist Lip Crank Rear Ramp Lip Hinge Weldment Hydrachek Spring Platform Hinge Pins Lip Stop Bolt Lip Connecting Link Subframe Lip Keepers Rear Front Snubbing Cable Return Spring Rear Nut MECHANICAL COMPONENTS...
  • Page 8 “free-falling” in emergency conditions. The valve is in line with the hydraulic oil hose at the ramp lifting SUBFRAME cylinder. The subframe of the APB-1000 supports the platform and protects the motor and the hydraulic fluid reservoir. See Figure 11, page 13 for location of ™...

  • Page 9: Installation Instructions

    PRIOR TO INSTALLATION Verify pit dimensions to certified pit drawings. Read and study the Pit Details on page 4. Leave shipping bands in place on the APB-1000 until you are instructed to remove them. Cover cylinder with flame retardant covering Clean pit of all debris.
  • Page 10 If you require an alternate pit design, it will be the responsibility of your contractor to design a pit in accordance with federal, state, and local codes. For more information, contact your local RITE-HITE ®...
  • Page 11 By Others. Conduit By Others. Junction Box 4" x 4" x 2" NEMA 4 (By Others), Minimum 3/4" Diameter Conduit Required. Pushbutton Control Box NEMA 12 ® (Supplied By RITE-HITE 48" 3/4"Diameter Minimum Conduit Unless Otherwise Pit Floor Specified 10"...
  • Page 12 INSTALLATION DETAILS 8" Flat Mat’l.: 3/8" x 3" x 8" Long H.R.S. 2" Dia. NOTE: Installation May Be Done 3" From Dock Floor Or Driveway. 2-1/2" 1" Handling Top Of Plate Shipping Top Of Leveler Bands Leveler 1-3/4" Motor 15° 1"...
  • Page 13 ELECTRICAL INSTALLATION DETAILS WIRE SIZES/GAGE CHART Distance in Feet Between Leveler’s Control Box and Power Source (Circuit Breaker) Phase/Voltage For 3/4 HP Units 0 – 100 100 – 200 200+ Single Phase 120 Volts 12 Ga. Wire 10 Ga. Wire 10 Ga.
  • Page 14 Weld front shims, full, to front frame angle and Remove shipping bolts from the full-range toe- curb steel. Weld shims under cylinder mount. guards. Remove shipping hooks from the front of Place (5) 3/8" x 6" long welds at rear curb steel the frame angle (only used with 18"...

  • Page 15: Operating Instructions

    FIGURE 6 — LOWER LEVELER broken or worn parts which could cause injury to personnel or damage to equipment. 7. If a malfunction does occur, always call your authorized RITE-HITE ® service repre- sentative. Pub. No. 1120-R5 — June 2000...
  • Page 16 To retract and store the lip while the truck remains Push and hold the RAISE button on the control in position, jog (push and release) the RAISE box until the leveler is about 10" to 12" above dock button just long enough for the lip to fold clear of level.

  • Page 17: Optional Equipment

    1. DO NOT walk on the lip. the lip keepers. 2. DO NOT use a forklift truck to lower the In the APB-1000, two limit switches and a recycle flag leveler. make up the automatic return to dock assembly. LS1 is the restrictor limit switch and LS2 is the automatic return to dock limit switch.
  • Page 18 OVERHEAD DOOR INTERLOCK The design uses a limit switch mounted on the door track. The switch is closed only when the door has been AND SAFETY SWITCH (Optional) opened, enabling the leveler RAISE button. If the switch The function of the overhead door interlock is to provide is open, no power will be available to the dock leveler protection for overhead doors working in conjunction control box.

  • Page 19: Maintenance

    Be sure to check the hydraulic fluid and all moving parts, as well as each lip, lip push- level when servicing your APB-1000 leveler. When rod assembly, and ramp spool (hinge tube). Do not adding fluid to the hydraulic system, only use MIL-H-5606 lubricate cylinder pins with oil.
  • Page 20 ADJUSTMENTS Table 1 — Pin Center Dimensions Capacity Lip Length 16" 7/8" – 1" 7/8" – 1" 5/8" – 3/4" 1. Always clean and lubricate leveler and lip 18" 7/8" – 1" 5/8" – 3/4" 3/8" – 1/2" hinge prior to attempting any adjustments. 20"...
  • Page 21 Lip Crank Lip Crank Link (Boomerang) Pivot Pin Center Distance Straight Link Edge FIGURE 12 — TOGGLE LINKAGE ADJUSTMENT Lip Assist Lip Assist Lip Assist Spring Jam Nut Adjustment Nut Increase (CCW) Decrease Decrease (CW) (CCW) Increase (CW) Spacer Rear Rear Adjustment FIGURE 13 —...
  • Page 22 AUTOMATIC RETURN TO DOCK (Optional If the leveler is not raising high enough, see Figure 17. Moving the plate forward (towards the front of the pit) will ARTD) LIMIT SWITCH ADJUSTMENTS cause LS2 to be activated for a longer period of time. Ensure lip is adjusted properly before proceeding.
  • Page 23 Recycle Limit Switch Flag Mounting Plate Limit Switch LS2 (ARTD) Lip Fully 3" Extended 6" Lip Fall Should Initiate Between Lip In The 3 And 6 Inches Pendant Position FIGURE 15 — ARTD LIMIT SWITCH (LS2) ADJUSTMENT Bracket Welded Bracket Welded Lip Fully To Underside Lip Fully...
  • Page 24 ELECTRICAL DETAILS NO NC NO NC (WHT. W/ (WHT. W/ Red End) Red End) T1/P1 (BLK.) (BLK.) (GRN.) (GRN.) LS1 Restrictor Limit Switch LS2 ARTD Limit Switch (LS1) (LS2) Restrictor Automatic Limit Switch Lip Hinge Return To Dock Rear Ramp (Optional) Platform Limit Switch...
  • Page 25 ELECTRICAL SCHEMATIC 120V From Customer Main Power & Safety Protection Device 120V 1 PH 50/60 Hz. (Fused Disconnect Supplied By Others) (Must Use Either 20 Amp Dual Element Fuse Or 20 Amp Inverse Time Circuit Breaker). One Leveler Per Overload Protection Device. (Ref.
  • Page 26 ELECTRICAL SCHEMATIC 240V From Customer Main Power & Safety Protection Device 240V 1 PH 50/60 Hz. L1 L2 (Fused Disconnect Supplied By Others) (Must Use Either 10 Amp Dual Element Fuse Or 15 Amp Inverse Time Circuit One Leveler Per Overload Protection Device. Breaker).
  • Page 27 2. Optional Recycle Limit Switch LS1 Is Automatically Operated By The Location Of The Hydraulic Cylinder. This In Turn Controls Flow To LS2 Which Is Operated By The Lip Assist Push Rod Assy. Both Switches Are 1 HP Rated (APB-1000 Only). 3. For Field Wiring See Dwg. #AI-1839. 4424 FIGURE 23 —...
  • Page 28 2. Optional Recycle Limit Switch LS1 Is Automatically Operated By The Location Of The Hydraulic Cylinder. This In Turn Controls Flow To LS2 Which Is Operated By The Lip Assist Push Rod Assy. Both Switches Are 1 HP Rated (APB-1000 Only). 3. For Field Wiring See Dwg. #AI-1839. 4425 FIGURE 24 —...
  • Page 29 HYDRAULIC SCHEMATIC (3/4 HP 120/240V, 1 Phase) Pressure Motor 120/240V 1 PH Filter Return 3/4 HP @ 3450 R.P.M. 149 Micron Ramp Port 1.40 GPM @ 880 P.S.I. Ramp Cylinder 1.4 GPM Velocity Fuse Adjustable Adjustable 6' Unit = 3.5 GPM System Shuttle Valve Relief...

  • Page 30: Troubleshooting

    Do not risk voiding the warranty by tampering with the equipment. Before attempting any troubleshooting pro- cedures, verify that the APB-1000 has been properly lubricated, and that all debris on, 1. Block off leveler area to all forms of around, or under the unit has been removed.
  • Page 31 Problem Probable Cause Remedy 1. The leveler does not function. a. The system breaker has a. Check that the breaker is rated for been tripped. the proper amperage. b. The RAISE pushbutton is not b. Make sure that the pushbutton working properly.
  • Page 32 Problem Probable Cause Remedy 6. Lip remains fully extended. a. Lip assist rod is not a. Verify that the toggle linkage is adjusted properly. properly adjusted. For more information, see page 14. b. Binding in the lip hinge. b. Remove any debris from the lip hinge.
  • Page 33 Problem Probable Cause Remedy 11. Unit will not recycle. a. Power is disconnected. a. Verify that power has not been disconnected. b. Damaged limit switch wand b. Verify that both limit switch wands or wands. are straight and undamaged. Repair or replace as needed.

  • Page 34: Replacement Parts

    FRAME REPLACEMENT PARTS Pub. No. 1120-R5 — June 2000...
  • Page 35 Rear Weatherseal Foam 51155 51155 51155 51155 51155 51155 Rear Stabilizer Rod 51424 51473 51425 51424 51473 51425 † Part numbers are not available at time of printing. Consult your local RITE-HITE ® representative. Pub. No. 1120-R5 — June 2000...
  • Page 36 PLATFORM REPLACEMENT PARTS 6 ft. leveler with optional ARTD shown. 4 L.H. 5 R.H (Not Shown) 6 L.H. 7 R.H (Not Shown) 8 L.H. 9 R.H. (Not Shown) Optional 27* 26* * Optional Pub. No. 1120-R5 — June 2000...
  • Page 37 PLATFORM REPLACEMENT PARTS LIST Item # Quantity Description 6'W x 6'L 6-1/2' W x 6'L 7'W x 6'L 6'W x 8'L 6-1/2'W x 8'L 7'W x 8'L Lip B+ Model 16" 16427 16430 16433 16427 16430 16433 Lip B+ Model 18" 16428 16431 16434...
  • Page 38 PLATFORM REPLACEMENT PARTS (continued) 6 ft. leveler with optional ARTD shown. 4 L.H. 5 R.H (Not Shown) 6 L.H. 7 R.H (Not Shown) 8 L.H. 9 R.H. (Not Shown) Optional 27* 26* * Optional Pub. No. 1120-R5 — June 2000...
  • Page 39 PLATFORM REPLACEMENT PARTS LIST Item # Quantity Description 6'W x 6'L 6-1/2' W x 6'L 7'W x 6'L 6'W x 8'L 6-1/2'W x 8'L 7'W x 8'L Flat Washer 1/4" 51734 51734 51734 51734 51734 51734 Oversize Flat Washer 1/4" 51737 51737 51737...
  • Page 40 HYDRAULIC COMPONENTS PARTS 10, 11 *Optional Item # Quantity Description Part No. Main Cylinder 6696 Important Oil Decal 59065 Breather Cap 55024 Clevis Pin 6-1/4" Long (Reference) 52649 Clevis Pin 3-1/2" Long (Reference) 52644 Cotter Pin 1-1/2" Long (Reference) 51907 90°...
  • Page 41 Control Box Housing and Hardware 65849 Pushbutton 17688 “RAISE” Decal 64194 Switch 25 Amp 17687 APB-1000 Operation Sign 68067 NOTE: All previous style control boxes and components are superseded by Control Box P/N 17684. Pub. No. 1120-R5 — June 2000...
  • Page 42 TABLED LIP ASSIST SPRING AND HYDRACHEK COMBINATIONS (See Key Below) Lip Length Lip Length Lip Length Cap: Unit Size: Cap: Unit Size: Cap: Unit Size: 16" 18" 20" 16" 18" 20" 16" 18" 20" Spring 52011 52014 52041 52011 52014 52041 52011 52014...
  • Page 44 RITE-HITE ® in writing. In the event of any defects covered by this warranty, RITE-HITE ® 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.