RITE-HITE Dok-Lok STR-4100 User manual

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 SYSTEMTM

2Pub. No. 1243 — April 2008
RITE-HITE®STR-4100 DOK-LOK®Installation Manual
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL APPLICATION INSTALLATION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BACK COVER
TABLE OF CONTENTS
INTRODUCTION
Read and understand this manual before attempting to install or operate any DOK-LOK vehicle restraint. For best
results, have this product serviced by your authorized RITE-HITE representative. The STR-4100 DOK-LOK vehicle
restraint by RITE-HITE is intended to provide a safer workplace for workers in shipping and receiving dock areas. The
STR-4100 DOK-LOK vehicle restraint is a hydraulic restraint device that, when properly installed and operated, retains
a secure connection between the truck and dock. Signal lights and signs provide instructions to the truck driver and
DOK-LOK vehicle restraint operator that a safe condition exists. The DOK-LOK vehicle restraint is operated by
pressing push buttons on an inside control panel.
NOTICE TO USER
Your local RITE-HITE®representative provides a Planned Maintenance Program (P.M.P.) which can be fitted to your
specific operation. Call your local representative or the RITE-HITE®Corporation at 414-355-2600.
The RITE-HITE®products in this manual are covered by one or more of the following U.S. patents: 4,865,507;
4,920,598; 4,995,130; 5,040,258; 5,271,183; 5,323,503; 5,375,965; 5,440,772; 5,442,825; 5,531,557; 5,546,623;
5,553,987; 5,582,498; 5,664,930; 5,702,223; 5,762,459 (RE: 37,570); 5,882,167; 5,964,572; 6,010,297; 6,052,268;
6,065,172; 6,070,283; 6,074,157; 6,085,375; 6,092,970; 6,106,212; 6,116,839; 6,190,109; 6,220,809; 6,627,016;
6,238,163; 6,311,352; 6,318,947; 6,322,310; 6,360,394; 6,368,043; 6,431,819; 6,488,464; 6,497,076; 6,499,169;
6,505,713; 6,524,053; 6,634,049; 6,654,976; 6,676,360; 6,726,432; 6,773,221; 6,832,403; 6,880,301; 7,032,267;
7,062,814; 7,134,159; 7,213,285; 7,216,391 and pending U.S and foreign patent applications.
RITE-HITE®, LEVEL-RITE®, THINMANTM, SAFE-T-LIP®, HYDRACHEK®, WHEEL-LOKTM, DOK-LOK®, DUAL-DOK®,
SAFE-T-STRUTTM, DOK-COMMANDER®, JUMBOTM, HYDRA-RITETM, SAFE-T-GATE®, and SMOOTH TRANSITION
DOK SYSTEMTM, are trademarks of RITE-HITE®Corporation.

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RITE-HITE®STR-4100 DOK-LOK®Installation Manual
SAFETY WARNINGS
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 lockout device is illustrated. The proper lockout
procedure 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 implementation of an entire safety program for the Control of Hazardous Energy (Lockout/Tagout). These
regulations are available through OSHA publication 3120.
This is the highest level statement. Failure to
follow the listed instructions will most likely
result in severe injury or death.
IMPORTANT is used to draw attention
to a procedure that needs to be followed to
prevent machine or property damage.
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.
This is a statement of serious hazard. Failure to
follow the listed instructions could place the
individual at risk of serious injury or death.
The statements used with this level of
warning deal with a safe operating
procedure. If the procedure is ignored, the
possibility of personal injury may exist.
LOCKOUT/TAGOUT

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RITE-HITE®STR-4100 DOK-LOK®Installation Manual
SAFETY DEVICES
• Post warnings and barricades at dock level
and at drive level to indicate that work is
being done around and under the leveler
platform.
INSTALL SAFE-T-STRUT SUPPORT
Power Moving Components
Serious Injury Could Occur
HANDS
OFF
NO
STEP
Never be under the dock leveler platform or lip
without:
• Installing the Safe-T-Strut or other
manufacturer approved supporting device.
• Turning off power to the control box.
• Lockout/Tagout power to the leveler, as
shown under Safety Warnings on page 3.

A DOK-LOK vehicle restraint may be installed on docks
with or without levelers. Consult RITE-HITE for proper
application.
Follow the six (6) step installation procedure below:
1. Inspect DOK-LOK materials.
2. Anchor or Weld track.
3. Position DOK-LOK assembly into track.
4. Hydraulic installation.
5. Electrical component and sign installation.
6. Test operation.
INSPECT DOK-LOK MATERIALS
Open and inspect all materials. Immediately report any
damage or material shortage. Study component
assemblies and determine their proper locations.
Install DOK-LOK vehicle restraint onto dock face at 27
inches off of the approach, unless otherwise noted in the
“RITE-HITE Installation/Application Guidelines”, at the
specified location by welding to an embedded steel plate
or by using the concrete anchors provided in conjunction
with welding to pit steel and a leveler frame. The track
will need to be trimmed if the mounting height is less than
26 inches. A maximum of 1 inch is allowed between the
bottom of the track and the approach.
For site specific installation information refer to RITE-
HITE Installation/Application Guidelines provided with
DOK-LOK vehicle restraint. If the recommended
mounting height cannot be achieved call your RITE-HITE
Representative or RITE-HITE at [phone].
NOTES:
a. Some levelers may be slightly recessed or protruding
within pit. A shim must be inserted between the roller
track plate and the leveler front subframe and then
must be welded in place. See page 13, figure 12.
b. If the dock conditions DO NOT allow lights and signs
to be mounted in full view of the forklift and/or truck
trailed drivers, consult the factory.
c. If the DOK-LOK is installed with a hydraulic leveler,
verify that the leveler’s recycle function has not been
adversely affected.
d. Track MUST be centered. Offset track installations
ARE NOT allowed. If there is existing anchor hole
interference call your RITE-HITE Representative or
RITE-HITE Customer Service at [phone].
e. Approach must be concrete or there must be a
concrete pad where the base plate is installed. See
page 12.
STR-4100 DOK-LOK INSTALLATION
When lifting carriage use a proper lifting device
(ex. crane, jack). Lifting by hand may cause back
injury.
Whether there is a leveler or not, 4" bumper
protection is required. DO NOT install a DOK-
LOK vehicle restraint on docks without 4"
bumper protection.
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RITE-HITE®STR-4100 DOK-LOK®Installation Manual
Never be under the dock leveler platform or lip
without:
• Installing the Safe-T-Strut or other
manufacturer approved supporting device.
• Turning off power to the control box.
• Lockout/Tagout power to the leveler, as
shown under Safety Warnings on page 3.

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RITE-HITE®STR-4100 DOK-LOK®Installation Manual
INSTALLATION CONT.
ANCHOR TRACK
1. Put DOK-LOK vehicle restraint track in place.
2. Drill holes of 5/8" diameter and minimum of 4-1/2"
deep. Clean out holes.
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. Torque all anchors to 100 ft-lbs.
5. Remove track cover plate and weld top of track to
leveler front frame angle and/or pit steel. WELD TRACK
If the installation being worked on is a “reinstallation”
electrical connections must be disconnected prior to
welding. Make sure to LOCKOUT/TAGOUT the power at
the fused disconnect, then remove sensing switch
connections from control box. Once all welding
procedures have been completed, reconnect all wires.
1. Put DOK-LOK vehicle restraint track in place.
2. Plug weld all holes that are in contact with
embedded mounting plate. All holes must be either
plug welded or anchored.
3. Remove track cover plate and weld top of track to
leveler front frame angle and/or pit steel.
NOTES:
a. Figure 2 – Never install DOK-LOK vehicle
restraint directly onto concrete block or brick
dock face.
b. Figure 2 – When welding DOK-LOK vehicle
restraint, disconnect power and ground leads to
leveler.
c. Figure 2 – Due to actual conditions, total
mounting height may be different. Refer to RITE-
HITE Application Guidelines for actual mounting
height.
d. If shims are required, shims must be the full length
of the roller track mounting plate and base plate.
See page 13.
e. Minimum electrode must be 1/8", 7018 or better.
DO NOT weld in enclosed areas without proper
ventilation.
BEFORE WELDING:
It is recommended that all power, ground and
limit switch wires are disconnected from the
sensor wires at the junction box. When welding
has been completed, reverse the above process.
Concrete anchors are provided with each
STR-4100 DOK-LOK vehicle restraint. You must
install an anchor in each roller track plate hole
except those plug-welded to embedded steel.
FIGURE 1 - ANCHOR INSTALLATION
Attach Lifting Chains
Pit Front
Curb Angle
Concrete
Dock Face
Approach
5/8” Dia. Concrete
Anchors Are Required
Wherever A Plug Weld
Is Not Possible
1/4”
Across Top
Of Track

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RITE-HITE®STR-4100 DOK-LOK®Installation Manual
POSITION DOK-LOK ASSEMBLY INTO
TRACK
1. Attach lifting chains to each side of DOK-LOK
carriage. See figure 2.
2. Lift DOK-LOK and position above the DOK-LOK
track.
3. Lower DOK-LOK into track until base plate is resting
on the approach.
4. Center DOK-LOK in track.
5. If approach is inclined, shim as shown in figure 3.
6. If approach is declined, shim as shown in figure 3.
NOTES:
a. Base plate must be square to track.
b. Shims must be placed under each cylinder and/or
spring tube. Shims should project 1/8” from outside
edge of base plate and welded into place.
c. Cylinder should be loose. No bind cotter pins.
7. Anchor both sides of Base Plate to approach. See
figure 4.
INSTALLATION CONT.
FIGURE 4 - COMPLETING MECHANICAL INSTALLATION
Attach Lifting Chains
Leveler Front
Curb Angle
Embedded Mounting
Plate or Dok-Lok
Bracket
Approach
5/8” Dia. Concrete
Anchors Are Required
Wherever A Plug
Weld Is Not Possible
Typ. (8) Places
Typ.
Both Sides
1/4”
1/4”
Across Top
Of Track
Anchor Base Plate To Approach With 5/8” Dia.
Concrete Anchors. Typical Both Sides.
FIGURE 2 - WELDING INSTALLATION
1/4”
Shim to Base Plate
Approach
3-5/16”
90°
1/4”
Shim to Base Plate
Approach
3-5/16”
90°
Inclined Approach
Declined Approach
FIGURE 3 - SHIM BASE PLATE
See Note
See Note

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RITE-HITE®STR-4100 DOK-LOK®Installation Manual
HYDRAULIC INSTALLATION
1. Drill two holes through the dock wall for hydraulic
hoses to pass through. Make sure holes are free of
debris or sharp edges prior to passing hoses
through wall. Conduit may be required in some
applications to protect hoses.
2. Route hoses from DOK-LOK, through dock wall and
connect to power unit. Make sure hoses are capped
to keep out debris. See figures 5, 6 & 7.
NOTE: For optional power unit mouting location.
See page 16.
3. Secure hoses to dock face to prevent possible
damage. Any extra hosing should be coiled and
secured to the inside dock wall below the power
unit.
4. Fill power unit reservoir using the supplied hydraulic
fluid.
5 Complete electrical installation per schematics.
NOTE: Schematic’s are located inside control box.
INSTALLATION CONT.
Hydraulic Power Unit
Pass Hoses Through Wall
Using Conduit As Required
Wire Power Unit
Into Control Box
Outside Electrical
Junction Box
Three Sensor Wires
Hydraulic Hoses Secured
To Dock Face
Pit Center Line
Dock Floor
Approach
Control Box
FIGURE 5 - HYDRAULIC INSTALLATION

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RITE-HITE®STR-4100 DOK-LOK®Installation Manual
INSTALLATION CONT.
From PPort On Restraint Valve Block
To RP Port On Combination Power Unit Valve Block
From LPort On Restraint Valve Block
To LP Port On Combination Power Unit Valve Block
WKV (SOL 2)
LIP BLOCK
Solenoid
WKX (SOL1)
RAISE
Solenoid
WKC (SOL3)
RAMP DIVERT
Solenoid
FIGURE 7 - HOSE ROUTING - COMBINATION POWER UNIT
From LPort On Valve Block
To LPort On Power Unit
From PPort On Valve Block
To PPort On Power Unit
FIGURE 6 - HOSE ROUTING - STAND ALONE POWER UNIT
NOTE: DO NOT Overtighten Hose Fittings!
NOTE: DO NOT Overtighten Hose Fittings!

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RITE-HITE®STR-4100 DOK-LOK®Installation Manual
INSTALLATION CONT.
FIGURE 8 - SIGN AND ELECTRICAL COMPONENT MOUNTING
Edge of Door or
Outside Surface of
Shelter (If Equipped)
Inside Sign
Control Box
15” Ref.
48” Approx.
18” Ref.
Pit Center Line
Dock Floor
Approach
58” ± 1”
15”
48” Ref.
Outside Sign
(Normal Image) 80”
96”
Outside Sign
(Mirror Image)
32” Approx.
Hydraulic Power Unit
Outside Light Box
1”