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RITE-HITE Dok-Lok STR-4100 - User Manual

RITE-HITE Dok-Lok STR-4100
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STR-4100 Dok-Lok
®
Vehicle Restraint
Installation Manual
This Manual Covers Restraints Built After Serial Numbers:
08EE400001W and up
PRINTED IN U.S.A.
RITE-HITE PRINT SHOP
PUBLICATION NO. 1243
APRIL 2008
MADE IN U.S.A.
part of the SMOOTH TRANSITION DOK SYSTEM
TM
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Summary

Introduction

Notice to User

Provides information on Planned Maintenance Program and contact details.

Safety Warnings

Lockout;Tagout Procedures

Details OSHA requirements for locking out power sources during maintenance.

Safety Devices

Critical Safety Actions

Lists essential safety measures when working under the dock leveler platform.

Power Moving Component Warning

Warns about potential injury from moving components during operation.

Work Area Warnings and Barricades

Advises posting warnings and barricades to indicate ongoing work.

STR-4100 DOK-LOK Installation

Pre-Installation Safety and Requirements

Emphasizes safety precautions and a 4" bumper requirement before installation.

Six-Step Installation Procedure

Outlines the six key steps for installing the DOK-LOK restraint.

Inspect DOK-LOK Materials

Instructions for opening, inspecting, and reporting any damage or shortage.

Mounting Location and Guidelines

Specifies the mounting height and refers to site-specific guidelines.

Installation Notes and Considerations

Provides specific notes on shims, lights, hydraulic levelers, track centering, and approach.

Installation - Anchor Track

Anchor Track Installation

Details the process of anchoring the track using concrete anchors.

Pre-Welding Safety Precautions

Advises disconnecting power and ground before welding.

Welding Ventilation Caution

Warns against welding in enclosed areas without proper ventilation.

Weld Track Installation

Describes the welding steps for the track and mentions reinstallation considerations.

Welding Notes and Guidelines

Provides notes on avoiding direct concrete block installation, disconnecting power, mounting height, shims, and electrode type.

Positioning and Securing DOK-LOK Assembly

Position DOK-LOK Assembly into Track

Details steps for attaching lifting chains, positioning, and centering the assembly.

Shimming for Declined and Inclined Approaches

Illustrates and explains how to shim the base plate for declined and inclined approaches.

Completing Mechanical Installation

Describes anchoring the base plate to the approach.

Positioning and Securing Notes

Notes on base plate squaring, shim placement, cylinder looseness, and cotter pins.

Hydraulic Installation

Hydraulic Installation

Details drilling holes, routing hoses, securing hoses, filling the reservoir, and electrical connections.

Hydraulic Hose Routing Details

Hose Routing for Stand Alone Power Unit

Illustrates hydraulic hose connections for a stand-alone power unit.

Hose Routing for Combination Power Unit

Illustrates hydraulic hose connections for a combination power unit.

Sign and Electrical Component Mounting

Sign and Electrical Component Mounting Diagram

Diagram showing dimensions and placement for inside/outside signs and control box.

Control Box Fill Mode Operation

Entering Diagnostic;Fill Mode

Explains how to enter the diagnostic or fill mode using the control box button.

Entering Fill Mode Sequence

Details the button sequence required to enter the fill mode.

Fill Mode Operations and Air Removal

Describes operations within fill mode, including pump control and air removal.

Exiting Fill Mode

Instructions on how to exit the fill mode after completion.

Special Application Installation Items

Concrete Pad Approach Requirements

Details requirements for concrete pads on non-concrete approaches.

Installation for Recessed and Protruding Levelers

Recessed Leveler Installation

Details modifications for installing on recessed levelers.

Protruding Leveler Installation

Details shimming and modifications for protruding levelers.

Back View for Anchor and Plate Installation

Provides back views for embedded plate and anchor installations.

Installation with Permanent Wheel Risers

Spacer Fabrication for Wheel Risers

Details fabrication of support spacers for permanent wheel risers.

Spacer Installation with Wheel Risers

Describes welding and anchoring the support spacer to the base plate.

Wheel Riser Installation Notes

Notes on channel size, end plate sizing, and consulting factory for site-specific spacers.

Installation with Trench Drain

Trench Drain Installation Procedure

Explains embedding PVC pipe in concrete for drainage with trench drains.

Optional Power Unit Mounting Location

Optional Hydraulic Installation Diagram

Diagram showing optional mounting location and protection for hoses/wires.

Optional Mounting Location Guidelines

Provides guidelines for protecting hoses and wires for optional mounting.

RITE-HITE Standard Warranty

Limitation of Liability

States limitations on RITE-HITE's liability for loss of use or damages.

National Sales & Service Office Information

Provides contact details for RITE-HITE's National Sales & Service Office.

Summary

Introduction

Notice to User

Provides information on Planned Maintenance Program and contact details.

Safety Warnings

Lockout;Tagout Procedures

Details OSHA requirements for locking out power sources during maintenance.

Safety Devices

Critical Safety Actions

Lists essential safety measures when working under the dock leveler platform.

Power Moving Component Warning

Warns about potential injury from moving components during operation.

Work Area Warnings and Barricades

Advises posting warnings and barricades to indicate ongoing work.

STR-4100 DOK-LOK Installation

Pre-Installation Safety and Requirements

Emphasizes safety precautions and a 4" bumper requirement before installation.

Six-Step Installation Procedure

Outlines the six key steps for installing the DOK-LOK restraint.

Inspect DOK-LOK Materials

Instructions for opening, inspecting, and reporting any damage or shortage.

Mounting Location and Guidelines

Specifies the mounting height and refers to site-specific guidelines.

Installation Notes and Considerations

Provides specific notes on shims, lights, hydraulic levelers, track centering, and approach.

Installation - Anchor Track

Anchor Track Installation

Details the process of anchoring the track using concrete anchors.

Pre-Welding Safety Precautions

Advises disconnecting power and ground before welding.

Welding Ventilation Caution

Warns against welding in enclosed areas without proper ventilation.

Weld Track Installation

Describes the welding steps for the track and mentions reinstallation considerations.

Welding Notes and Guidelines

Provides notes on avoiding direct concrete block installation, disconnecting power, mounting height, shims, and electrode type.

Positioning and Securing DOK-LOK Assembly

Position DOK-LOK Assembly into Track

Details steps for attaching lifting chains, positioning, and centering the assembly.

Shimming for Declined and Inclined Approaches

Illustrates and explains how to shim the base plate for declined and inclined approaches.

Completing Mechanical Installation

Describes anchoring the base plate to the approach.

Positioning and Securing Notes

Notes on base plate squaring, shim placement, cylinder looseness, and cotter pins.

Hydraulic Installation

Hydraulic Installation

Details drilling holes, routing hoses, securing hoses, filling the reservoir, and electrical connections.

Hydraulic Hose Routing Details

Hose Routing for Stand Alone Power Unit

Illustrates hydraulic hose connections for a stand-alone power unit.

Hose Routing for Combination Power Unit

Illustrates hydraulic hose connections for a combination power unit.

Sign and Electrical Component Mounting

Sign and Electrical Component Mounting Diagram

Diagram showing dimensions and placement for inside/outside signs and control box.

Control Box Fill Mode Operation

Entering Diagnostic;Fill Mode

Explains how to enter the diagnostic or fill mode using the control box button.

Entering Fill Mode Sequence

Details the button sequence required to enter the fill mode.

Fill Mode Operations and Air Removal

Describes operations within fill mode, including pump control and air removal.

Exiting Fill Mode

Instructions on how to exit the fill mode after completion.

Special Application Installation Items

Concrete Pad Approach Requirements

Details requirements for concrete pads on non-concrete approaches.

Installation for Recessed and Protruding Levelers

Recessed Leveler Installation

Details modifications for installing on recessed levelers.

Protruding Leveler Installation

Details shimming and modifications for protruding levelers.

Back View for Anchor and Plate Installation

Provides back views for embedded plate and anchor installations.

Installation with Permanent Wheel Risers

Spacer Fabrication for Wheel Risers

Details fabrication of support spacers for permanent wheel risers.

Spacer Installation with Wheel Risers

Describes welding and anchoring the support spacer to the base plate.

Wheel Riser Installation Notes

Notes on channel size, end plate sizing, and consulting factory for site-specific spacers.

Installation with Trench Drain

Trench Drain Installation Procedure

Explains embedding PVC pipe in concrete for drainage with trench drains.

Optional Power Unit Mounting Location

Optional Hydraulic Installation Diagram

Diagram showing optional mounting location and protection for hoses/wires.

Optional Mounting Location Guidelines

Provides guidelines for protecting hoses and wires for optional mounting.

RITE-HITE Standard Warranty

Limitation of Liability

States limitations on RITE-HITE's liability for loss of use or damages.

National Sales & Service Office Information

Provides contact details for RITE-HITE's National Sales & Service Office.

Overview

The STR-4100 Dok-Lok is a hydraulic vehicle restraint system designed to enhance safety in shipping and receiving dock areas. Its primary function is to secure a truck to the loading dock, preventing unexpected trailer movement during loading and unloading operations. This is achieved through a robust hydraulic restraint device that, when properly installed and operated, maintains a secure connection between the truck and the dock. The system incorporates signal lights and signs to provide clear instructions to both the truck driver and the Dok-Lok operator, indicating safe conditions and operational status. Operation of the restraint is managed via push buttons on an inside control panel.

Function Description:

The STR-4100 Dok-Lok is a hydraulic vehicle restraint that physically engages with a truck's Rear Impact Guard (RIG) or other suitable trailer component to prevent premature departure or "creep" away from the dock. The system is designed to be installed on the dock face, typically at 27 inches off the approach, though specific application guidelines may dictate variations. Once a truck is positioned at the dock, the operator activates the restraint from the inside control panel. The hydraulic arm extends and engages the truck's RIG, holding it firmly in place. Signal lights (red/green) on both the inside and outside of the dock communicate the restraint's status to the dock personnel and the truck driver, ensuring that all parties are aware of when it is safe to enter or exit the trailer, or when the truck is secured. The system is part of the "SMOOTH TRANSITION DOK SYSTEM™," suggesting integration with other dock equipment for a seamless operation.

Important Technical Specifications:

  • Mounting Height: The Dok-Lok vehicle restraint is typically installed onto the dock face at 27 inches off the approach. Adjustments may be necessary based on "RITE-HITE Installation/Application Guidelines," with a maximum of 1 inch allowed between the bottom of the track and the approach.
  • Anchoring: Installation involves either welding to an embedded steel plate or using concrete anchors provided, in conjunction with welding to pit steel and a leveler frame.
  • Anchor Hole Specifications: For concrete anchoring, holes should be 5/8" diameter and a minimum of 4-1/2" deep. Anchors must be torqued to 100 ft-lbs.
  • Welding: When welding, a minimum electrode of 1/8", 7018 or better is recommended. All holes in contact with embedded mounting plates must be either plug welded or anchored.
  • Shims: If shims are required for inclined or declined approaches, they must be the full length of the roller track mounting plate and base plate, projecting 1/8" from the outside edge of the base plate and welded into place.
  • Concrete Pad Requirement: The approach must be concrete, or a concrete pad must be present where the base plate is installed. For approaches made of materials other than concrete, a concrete pad is required, with a minimum thickness of 10 inches.
  • Power Unit Mounting: The hydraulic power unit can be mounted in various locations, with specific guidelines for hose and wire protection. Hoses and wires should be protected by channels or other devices that do not project more than 3 inches off the dock face and extend down to 8 inches off the approach.
  • Control Box: The system is operated via an inside control panel with push buttons for "LOCK," "UNLOCK," "HORN OVERRIDE #2," and a "Diagnostic / Fill Mode Button."
  • Hydraulic Fluid: The power unit reservoir must be filled with the supplied hydraulic fluid.
  • Electrical Connections: All electrical installations should follow the provided schematics, located inside the control box. Power, ground, and limit switch wires should be disconnected from the junction box before welding and reconnected afterward.

Usage Features:

  • Ease of Operation: The Dok-Lok is operated by pressing push buttons on an inside control panel, simplifying the process for dock personnel.
  • Visual Communication: Signal lights and signs (inside and outside, including mirror image for truck drivers) provide clear instructions and status updates, enhancing safety awareness.
  • Hydraulic System: The hydraulic mechanism ensures a strong and reliable restraint force, adapting to various trailer types and conditions.
  • Fill Mode: A "Fill Mode" is available for initial setup and maintenance, allowing the hydraulic system to be cycled up and down to remove air and ensure proper fluid levels.
  • Horn Override: The control panel includes a "HORN OVERRIDE #2" button, indicating a feature to manage audible alerts, likely for specific operational scenarios.
  • Adaptability: The restraint can be installed on docks with or without levelers and can accommodate inclined or declined approaches with the use of shims.
  • Optional Wheel Risers: The manual provides instructions for installation with permanent wheel risers, including fabrication details for support spacers.
  • Trench Drain Compatibility: Guidelines are provided for installation with trench drains, requiring an embedded PVC pipe in concrete for drainage if the drain is below the base plate.

Maintenance Features:

  • Planned Maintenance Program (P.M.P.): RITE-HITE offers a P.M.P. through local representatives, which can be tailored to specific operations, ensuring regular upkeep and optimal performance.
  • Lockout/Tagout Procedures: The manual emphasizes strict adherence to OSHA-approved lockout/tagout procedures when working with electrical or electronic controls and during maintenance under the dock leveler platform. This includes disconnecting power, using approved lockout devices, and tagging controls to prevent accidental activation.
  • Safe-T-Strut Support: When working under the dock leveler platform or lip, it is mandatory to install a Safe-T-Strut or other manufacturer-approved supporting device, turn off power to the control box, and lockout/tagout the leveler.
  • Hose Routing: Hydraulic hoses are routed to prevent damage, coiled, and secured to the inside dock wall, facilitating inspection and replacement if needed.
  • Hydraulic Fluid Management: The system requires filling the power unit reservoir with hydraulic fluid, and the fill mode assists in bleeding air from the system, which is a key maintenance step.
  • Regular Inspections: The installation process itself includes steps for inspecting materials for damage or shortages, implying the importance of regular checks for operational integrity.
  • Troubleshooting (Implied): The "Diagnostic / Fill Mode Button" on the control panel suggests built-in diagnostic capabilities to assist with troubleshooting and maintenance.
  • Documentation: The provision of detailed schematics inside the control box is a valuable maintenance feature, aiding in electrical and hydraulic system diagnosis and repair.

RITE-HITE Dok-Lok STR-4100 Specifications

General IconGeneral
BrandRITE-HITE
ModelDok-Lok STR-4100
CategoryAutomobile Accessories
LanguageEnglish

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