RITE-HITE Hydraulic Rail Car Owner's manual

Railcar Ramp

Vertical Hydraulic

Dock Leveler

Installation and Operation Manual

Printed in U.S.A. Publication No. 1134

iPub. No. 1134 — April 1998

OWNER RESPONSIBILITY

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 informa-

tion 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 mainte-

nance 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.

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 modifi-

cation. These changes shall also satisfy all safety rec-

ommendations of the original equipment manufacturer

for the particular application of the dock leveler.

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 con-

sider 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 require-

ments of this note.

(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.)

Pub. No. 1134 — April 1998 ii

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.

iii Pub. No. 1134 — April 1998

GENERAL SAFETY WARNINGS

LOCKOUT/TAGOUT PROCEDURES

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 manda-

tory that an approved lockout device is utilized. An example of a lockout device is illustrated. The proper lockout proce-

dure 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 imple-

mentation of an entire safety program for the Control of Hazardous Energy (Lockout/Tagout). These regulations are

available through OSHA publication 3120.

When working with electrical or electronic con-

trols, make sure that the power source has

been locked out and tagged according to OSHA

regulations and approved local electrical codes.

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.

Pub. No. 1134 — April 1998 iv

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 1

LIP

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.

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 mainte-

nance strut are given later.

END LOAD ARMS

The end load arms provides support in an end load con-

dition 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 plat-

form 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 unload-

ing 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.

CARRIAGE ASSEMBLY

The carriage assembly attaches the platform to the track

assembly. The carriage assembly consists of the hori-

zontal 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

The track assembly consists of a ten foot section fur-

nished by RITE-HITE®. The track assembly allows the

carriage assembly to move freely left and right for proper

railcar loading and unloading.

MAIN LIFTING CYLINDER

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.

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.

POWER UNIT

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 con-

sists 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.

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.

DEFINITIONS

2Pub. No. 1134 — April 1998

MAINTENANCE STRUT

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 perform-

ing routine maintenance, and must be used every time

service is being performed on the unit.

SKEWED DECK

The length of deck is a different dimension on the left

side versus the right side to compensate for curve track

applications.

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

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).

ACTUAL CENTERLINE DIMENSION

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.

CONTINUOUS RAIL APPLICATION

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

Railcar ramp does not move side to side in mounting rail

section.

MOVEABLE APPLICATION

Railcar ramp moves or slides to the left or right in mount-

ing 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 stan-

dard 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.

WELD-ON

Option 1

The rail section is welded to a minimum size 15" “C”

channel complying with RITE-HITE®’s specifications.

See Figure 10.

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 3

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, con-

tact the RITE-HITE Corporation.

3. Verify that available voltage and phase is the same

as specified on the hydraulic pump/motor specifica-

tion plate.

4. Make sure that the lifting unit, or picker crane, is

capable of lifting a minimum of 3,000 lbs.

INSTALLATION INSTRUCTIONS

1. 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.

2. DO NOT REMOVE SAFETY-LOCK PIN until

hydraulic system has been filled and

purged of air. See page 11, “Initial Start-up.”

Follow all electrical LOCKOUT/TAGOUT proce-

dures as stated on page iii of this manual.

1. 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.

6. 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.

4Pub. No. 1134 — April 1998

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.

2. 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:

a. Secure chains to the lifting angles under the

platform.

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 car-

riage and rollers are engaged in the track.

3. 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.

Crane

Lifting Angle

FIGURE 1

Always double check the rigging to make sure

that it is secure and balanced before proceed-

ing with the lift. Never stand under any unit

being lifted.

C

L

DANGER

DO NOT STAND

ON THIS SIDE OF

DOCK LEVELER!!

LEVELER SWINGS

DOWN TOWARD YOU

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

MILW., WIS. (414) 3552600

BY

HYDRAULIC

DOCK LEVELER

FIGURE 2

Pub. No. 1134 — April 1998 5

Top Of Dock

FIGURE 3

DO NOT REMOVE SAFETY

PIN UNTIL SYSTEM HAS

BEEN PROPERLY FILLED

WITH HYDRAULIC FLUID

(SEE INSTRUCTIONS)

Safety

Restraint

Rear

Hinge

Frame

Platform

FIGURE 4

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.

6Pub. No. 1134 — April 1998

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.

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.

Cotter Pin

Hinge Pin

Washer

Platform

Safety Lock

Pin Storage

Hole

Carriage Assembly

FIGURE 5

Pub. No. 1134 — April 1998 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 (sup-

plied 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.

Crane

FIGURE 8

FIGURE 6

(Carriage "Windows")

FIGURE 7

8Pub. No. 1134 — April 1998

Cotter Pin

Hinge Pin

Washer

Platform

Safety Lock

Pin Storage

Hole

Safety Lock

Carriage Assembly Carriage Assembly

Platform

FIGURE 9

Pub. No. 1134 — April 1998 9

FIXED APPLICATION – WELD-ON/BOLT-ON

For additional information on Fixed Application Installation

Instructions, see the detail drawings provided with the

Railcar Ramp hydraulic leveler.

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.

3. 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.

Weld-On Style Rear Frame

1.38

4.25 Full Weld

All Holes

Mounting Channel

Flatness 0.125"

Vertical Straightness

0.125" Over Entire Length

Pit Length 0.25"

Over Entire Width

+

-

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.

Building

Wall

24"

Minimum

Cotter Pin

Hinge Pin

Washer

Platform

Safety Lock

Pin Storage

Hole

FIGURE 10

0.25"

Remove All Welding

Residue Break All Sharp

Corners After Welding

1.688

10.00

+.031

-.000

.25

Full Weld

27 Places

.25

Both Ends

.25

3-5

Dimensions Shown In Inches

Unless Otherwise Specified.

FIGURE 11

10 Pub. No. 1134 — April 1998

#10 Gage #10 Gage

#10 Gage

480V 3 Phase

Incoming Power From Customers

Fused Disconnect (Supplied By Others)

(Wire Size Per Chart) Hydraulic

Control Box

G

3

L2

2

L1L2 L3

T1T2T3

T1*

T2*

G*

3**

L2**

2**

T1

T2

L2

2

3

G

(*) Min #8 Gage Wire

(** ) Min #14 Gage Wire Field Wiring

(By Others)

Wire Nut

Conn. (Typ.)

Wire Nut

Conn. (Typ.)

To Motor

J-BOX

To Sol. Coil

“RAMP”

To Sol. Coil

“LIP”

Junction Box (On Pit Floor Or On

Remote Power Unit Platform.) (Supplied

And Installed By Others.)

BLK

YLW

Typical Single Phase

23

G

Incoming Power From Customers

Fused Disconnect (Supplied By Others)

(Wire Size Per Chart) Hydraulic

Control Box

G

3

X2

2X1

1X1

X2

2L1

1L1

L2

2

L1L2 L3

T1 T2 T3

T1*

T2*

T3*

G*

3**

X2**

2**

T1

T2

T3

X2

2

3

G

(*) Min #10 Gage Wire

(** ) Min #14 Gage Wire Field Wiring

(By Others)

To Motor

J-BOX

To Sol. Coil

“RAMP”

To Sol. Coil

“LIP”

Junction Box (On Pit Floor Or On

Remote Power Unit Platform.) (Supplied

And Installed By Others.)

BLK

YLW

Typical Three Phase

Rigid Conduit

(By Others)

Hirschmann

Conn. Cords

Solenoid

Control

Valve

Hydraulic Power Unit

Motor

Junction

Box

Hydraulic

Control Box

(By RITE-HITE®)

SO Cord (Supplied By RITE-HITE®)

Fused Power

Disconnect

(Required)

(By Others)

One Leveler

Per Overload

Protection

Device. [Ref.

N.E.C. 1990

Para. 430-110

(B)(C)] Consult

Local Code

23

G

120V 1 Phase

240V 1 Phase

0-100'

#8 Gage

#10 Gage

240V 3 Phase

100-200' 200'+

Wire Size Chart

Voltage

&

Phase

#10 Gage

#8 Gage

#10 Gage

#6 Gage

#8 Gage

Distance From Door To

Power Disconnect

FIGURE 12 — WIRING DIAGRAMS AI-1605

Pub. No. 1134 — April 1998 11

CONTROL BOX INSTALLATION

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 cylin-

der rod clevis aligns with the embedded frame

channel clevis. Loosen the locking bolt on the cylin-

der 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.

NOTE

When the leveler is in the vertical stored position

there should be approximately .062" minimum clear-

ance 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. Insert the clevis pin. Secure the clevis pin with the

thrust washers and cotter keys.

Post safety warnings and barricade work area, at

dock level and at ground level to prevent unau-

thorized use of the RCR during maintenance/

service.

Make sure that the electrical power has been

locked out and the power source tagged before

proceeding with the installation.

Junction Box

Control

Box

Dock

Floor

24"

48"

6"

FIGURE 13

System Relief

Sight Glass

Shuttle Valve

Fill Port

Breather

IMPORTANT - CHECK OIL

LEVEL BEFORE MAKING

ANY ADJUSTMENTS - ADD

MIL-H5606 HYDRAULIC

FLUID ONLY.

FIGURE 14 — HYDRAULIC OIL FILLING

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.

12 Pub. No. 1134 — April 1998

HYDRAULIC SYSTEM START-UP

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.

2. Install the breather assembly into the breather port.

See Figure 18.

Deck

Rear Header Cylinder Rod

0.062 Min.

(Viewed From Above)

FIGURE 15 — CYLINDER ROD CLEARANCE

3"

Service

Strut

Stored

Position

Service

Strut

Service

Position

FIGURE 16 — VERTICAL STORAGE POSITION

FIGURE 17 — CLEVIS ADJUSTMENT

DO NOT operate leveler with anyone standing

in front of the leveler.

This equipment should not be operated or ser-

viced except by trained personnel.

Keep away from hinge when operating leveler.

Pub. No. 1134 — April 1998 13

RAMP

LIP5

CB

BASE

10

PT

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

A

AB

B

VIEW A-A

TOP VIEW

BOTTOM VIEW

Pressure

Tank

Lip Three Way Valve

Ramp Four Way Valve

Counterbalance Valve

56303

Lip Out

Relief Valve

(Fixed)

6680

Main Valve

Block Assembly

(55299)

Lip Fall

Pressure

Compensated

Flow Control

55186

Three Way Two Position

Lip Solenoid Valve

(55261 Coil)

Lip Fall

Relief Valve

55253

Counterbalance

Valve

55184

Four Way Two Position

Lip Solenoid Valve

(55261 Coil)

Lip Out

Relief Valve

Cyl. Rod

55146

Shuttle

Valve

CORPORATION

MILWAUKEE, WI

(414) 355-2600

PART #6624

55024

Breather

Plug

VIEW B-B

C1

55311

Check Valve

70 PSI

(Optional

55313 90 PSI)

Lip (Base)

System

Relief

IMPORTANT - CHECK OIL

LEVEL BEFORE MAKING

ANY ADJUSTMENTS - ADD

MIL-H5606 HYDRAULIC

FLUID ONLY.

FIGURE 18 — HYDRAULIC VALVE ADJUSTMENT SEE AI-1757

Gap Gap

Locknut

Cap Nut

O-ring

(In Recess)

Adjusting Screw

Gaps Must Be Equal

FIGURE 19

14 Pub. No. 1134 — April 1998

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.

5. 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.

6. Press and hold the RAISE button until the Lip

Cylinder fully extends.

7. 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.

AIR PURGING PROCEDURE

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.

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).

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 unau-

thorized use of the RCR during maintenance/

service.

DO NOT operate leveler with anyone standing

in front of the leveler.

This equipment should not be operated or ser-

viced except by trained personnel.

Keep away from hinge when operating leveler.

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RITE-HITE Hydraulic Rail Car Owner's manual

RITE-HITE Hydraulic Rail Car Owner's manual

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