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Blue Giant Airbag Dock Leveler Owner's Manual

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ACTUAL PRODUCT MAY NOT APPEAR EXACTLY AS SHOWN
WARNING
Do not operate or service this product unless you have
read and fully understand the entire contents of this
manual. Failure to do so may result in property damage,
bodily injury or death.
STARTING FROM MARCH, 2014 / SERIAL # 386771-1
OWNER'S MANUAL
AIRBAG DOCK LEVELER
ISSUE DATE: FEBRUARY 1, 2016, REV.2 (PART # 038-880E)
WITH CONTROLS

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  • Page 1 OWNER’S MANUAL AIRBAG DOCK LEVELER WITH CONTROLS ACTUAL PRODUCT MAY NOT APPEAR EXACTLY AS SHOWN WARNING Do not operate or service this product unless you have read and fully understand the entire contents of this manual. Failure to do so may result in property damage, bodily injury or death.

  • Page 2: Table Of Contents

    FUNCTIONAL DESCRIPTION DEPLOYING THE DOCK LEVELER STORING THE DOCK LEVELER BELOW LEVEL / END LOADING CHECKLIST - AIRBAG DOCK LEVELER - OPERATOR AND PLANNED MAINTENANCE PROGRAM 10.0 RECOMMENDED SPARE PARTS 10.1 OPTIONAL SUPPORT COMPONENTS 11.0 DECAL IDENTIFICATION AND LOCATION 12.0 EQUIPMENT COMPONENT ILLUSTRATIONS 12.1 COMPONENTS AS SHIPPED CHECK LIST...
  • Page 3 AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL TABLE OF CONTENTS CONT'D. 12.8 CONTROLS 13.0 DOCK LEVELER TROUBLESHOOTING 14.0 WIRING DIAGRAMS 14.1 SP1 WIRING DIAGRAM—110–130V SINGLE PHASE 14.2 SP1 WIRING DIAGRAM—208–240V SINGLE PHASE 15.0 ALTERNATIVE CONTROL STATION OPTIONS 15.1 SP2 CONTROLS 15.2 BLUE GENIUS™ CONTROLS 15.3 BLUE GENIUS™...

  • Page 4: About The Airbag Dock Leveler With Controls

    Blue Giant a global leader in the design, manufacture, and distribution of loading dock systems. Supported by a minimum of six heavy-duty U-beams, the airbag dock leveler has a high-volume, low-pressure (HVLP) air lifting system that is both easy and ergonomic to operate. When activated via the single push-button control station, the air bag inflates, raising the deck and deploying the lip.

  • Page 5: Introduction

    2.1 WARRANTY INFORMATION The following is a quick reference to important procedures that Thank you for purchasing Blue Giant products. We appreciate must be followed while using the Loading Dock Equipment. It is your business, and are confident that our product will serve you for not intended to cover, or suggest that it does cover, all procedures many years to come.

  • Page 6: Owner's Responsibility

    11. If, at the request of the owner, Blue Giant does not supply training dock personnel how to use the equipment safely and all or some of the dock equipment power unit and/or control effectively.

  • Page 7: Operator's Manual Safety Message Color Identification

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 3.0 OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION This manual includes color-coded safety messages that clarify instructions and specify areas where potential hazard exists. To prevent the possibility of equipment damage and serious injury or death, please observe strictly the instructions and warnings contained in the messages.

  • Page 8: Lockout / Tagout Procedure And Rules

    The machine or equipment power supply shall be locked in the OFF position or disconnected from the energy source. Blue Giant strongly recommends that only OSHA-approved lockout devices and procedures be utilized. The energy isolating device must bear a prominent warning tag indicating that work is being done on the equipment and the name of the authorized employee responsible for the lockout.

  • Page 9: Control Station Operation

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 5.0 CONTROL STATION OPERATION 5.1 BUTTON FUNCTION INDEPENDENT TYPE CONTROL STATION ‘UP’ button activates the dock leveler when pressed and held. Controls one individual dock leveler only, equipped with a constant- pressure ‘UP’ button.

  • Page 10: Maintenance Stand Set-Up

    Do not attempt to apply the maintenance stand until the deck and lip are both fully deployed. CAUTION Use of a secondary safety stand (Blue Giant Part # 796-710) in conjunction with the maintenance stand is strongly recommended. This dock comes with a one-piece maintenance stand that must be used during under-dock inspections or repairs / maintenance.

  • Page 11: Maintenance

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 7.0 MAINTENANCE 7.3 ROUTINE SERVICING AND MAINTENANCE Regular maintenance and care of the dock leveler is very important WARNING for cost and operation efficiency and more importantly; operator safety. A faulty dock leveler is a potential source of danger to the Do not operate and/or service this dock leveler until you operator, and to other personnel working near it.

  • Page 12: Operating Instructions

    Do not operate this leveler unless you have been trained Supported by a minimum of six heavy-duty U-beams, the Airbag Dock Leveler has a high-volume, low-pressure air lifting system that presents an and authorized to do so, and have read and understood all eco-friendly alternative to oil-powered hydraulics.

  • Page 13: Deploying The Dock Leveler

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL STANDARD OPERATION PROCEDURES 8.2 DEPLOYING THE DOCK LEVELER Raise the dock leveler by pushing the ‘UP’ button. If the button is still being pressed while the dock is in its fully raised position, the lip will then deploy.

  • Page 14: Below Level / End Loading

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 8.4 BELOW LEVEL / END LOADING 1. After the truck has been chocked and / or restrained in place, hold the control station’s ‘UP’ button until the lip clears the night lock by approximately 6-10".

  • Page 15: Checklist - Airbag Dock Leveler - Operator And Planned Maintenance Program

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 9.0 CHECKLIST - AIRBAG DOCK LEVELER - OPERATOR AND PLANNED MAINTENANCE PROGRAM INSPECTED BY: DATE: SERIAL #: DOOR #: Forward this checklist to the person responsible for dock equipment maintenance. See Section 1.1 "Owner's Purchase Record" for Date in Service.

  • Page 16: Recommended Spare Parts

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 10.0 RECOMMENDED SPARE PARTS 10.0 RECOMMENDED SPARE PARTS REPLACEMENT PARTS AIRBAG DOCK LEVELER REPLACEMENT PARTS AIRBAG DOCK LEVELER ITEM # PART # DESCRIPTION ITEM # PART # DESCRIPTION REQ’D REQ’D 26-011298 Push Rod, Lip Deploy...

  • Page 17: Optional Support Components

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 10.0 RECOMMENDED SPARE PARTS CONT'D. 10.1 OPTIONAL SUPPORT COMPONENTS 10.0 RECOMMENDED SPARE PARTS 10.1 OPTIONAL SUPPORT COMPONENTS REPLACEMENT PARTS FOR AIRBAG DOCK LEVELER OPTIONAL SUPPORT COMPONENTS FOR AIRBAG DOCK LEVELER ITEM # PART# DESCRIPTION ITEM # PART#...

  • Page 18: Decal Identification And Location

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 11.0 DECAL IDENTIFICATION AND LOCATION WARNING SAFETY INSTRUCTIONS CONSIGNES DE SÉCURITÉ DANGER DANGER OPERATION 7. Stay clear of hinges, front, and sides of moving dock leveler. FONCTIONNEMENT 7. Rester loin des pentures et du devant et côtés du niveleur en mouvement.

  • Page 19: Equipment Component Illustrations

    Only for the Airbag Dock Leveler Supported by a minimum of six heavy-duty U-beams, the Airbag Dock Leveler has a high-volume, low-pressure air lifting system that presents an eco-friendly alternative to oil-powered hydraulics. When activated via the Single Push Button control station, the air bags in k to lower smoothly onto the trailer bed.

  • Page 20: Mechanical Assembly

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 12.2 MECHANICAL ASSEMBLY 20 ISSUE DATE: FEBRUARY 1, 2016 REV.2 (PART # 038-880E)
  • Page 21 AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 12.2 MECHANICAL ASSEMBLY NOTE DESCRIPTION NOTE NOTE DESCRIPTION NOTE  Lip Deployment Assembly Includes parts highlighted Maintenance Stand  Includes parts highlighted Assembly  Fall Safe Legs Assembly Includes parts highlighted ITEM QTY. PART NO.

  • Page 22: Airbag And Platform Assembly

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 12.3 AIRBAG AND PLATFORM ASSEMBLY AIR BAG & PLATFORM ASSY - BLOWER MOTOR INCL. 29 25 115V 230V SIZE SIZE (LONG) (LONG) PART NO. PART NO. 26-013427 26-013427-1 26-013429 26-013429-1 26-012963 26-012963-1 26-014280 26-014280-1...

  • Page 23: Deck Size And Capacities

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 12.5 LIP SIZE AND CAPACITIES 12.4 DECK SIZE AND CAPACITIES PART NO. CAPACITY PART NO. DECK SIZE DECK LENGTH CAPACITY MODEL WIDTH (NOMINAL) AB with DLB AB with DLB 30,000 lb 13,636 kg AB6006-30...

  • Page 24: Frame Size

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 12.6 FRAME SIZE PART NO. PART NO. DECK SIZE DECK SIZE LENGTH LENGTH (NOMINAL) (NOMINAL) AB with DLB AB with DLB AB6006 AB6610 16" 406mm 26-011887-1 26-013863-1 16" 406mm 26-011559 26-013998 6' x 6' 6' 6"...

  • Page 25: Controls

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 12.8 CONTROLS 5.28" (135mm) 7.94" (202mm) DISCONNECT POWER .75" BEFORE OPENING. READ AND FULLY UNDERSTAND (19mm) THE OWNER’S MANUAL BEFORE OPERATING THIS PRODUCT. 3.47" 5.81" 1.94" (88mm) (148mm) (49mm) Front View Side View Bottom View...

  • Page 26: Dock Leveler Troubleshooting

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 13.0 DOCK LEVELER TROUBLESHOOTING WARNING Do not attempt to install, make repairs or adjustments. Only a trained and authorized service technician should perform the installation process. Contact your local dealer or distributor for assistance.

  • Page 27: Wiring Diagrams

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 14.1 SP1 WIRING DIAGRAM—110–130V SINGLE PHASE ISSUE DATE: FEBRUARY 1, 2016 REV.2 (PART # 038-880E)

  • Page 28: Sp1 Wiring Diagram-208-240V Single Phase

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 14.2 SP1 WIRING DIAGRAM—208–240V SINGLE PHASE 28 ISSUE DATE: FEBRUARY 1, 2016 REV.2 (PART # 038-880E)

  • Page 29: Alternative Control Station Options

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 15.0 ALTERNATIVE CONTROL STATION OPTIONS Control station upgrades are available for enhanced equipment operation. The SP2 controls an independent dock leveler via a constant pressure “I” (UP) button and has a running timer that shuts down the motor after a specific interval to prevent excessive motor activity.

  • Page 30: Blue Genius™ Controls

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 15.2 BLUE GENIUS™ CONTROLS Wiring Diagram Enclosed Fuse Holder 3 Fuse Holder 1 Fuse Holder 2 ITEM PART NO. DESCRIPTION COMPLETE CONTROL STATION ASSEMBLY - ITEM 1 (Example BGGE01115F) 026-G030 Ribbon Cable ITEM SINGLE PHASE ◊...

  • Page 31: Sp2 Wiring Diagram-115V Single Phase

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 15.4 SP2 WIRING DIAGRAM—115V SINGLE PHASE ISSUE DATE: FEBRUARY 1, 2016 REV.2 (PART # 038-880E)

  • Page 32: Sp2 Wiring Diagram-230V Single Phase

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 15.5 SP2 WIRING DIAGRAM—230V SINGLE PHASE 32 ISSUE DATE: FEBRUARY 1, 2016 REV.2 (PART # 038-880E)

  • Page 33: Blue Genius™ Gold Wiring Diagram-115V Single Phase

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 15.6 BLUE GENIUS™ GOLD WIRING DIAGRAM—115V SINGLE PHASE ISSUE DATE: FEBRUARY 1, 2016 REV.2 (PART # 038-880E)

  • Page 34: Blue Genius™ Gold Wiring Diagram-230V Single Phase

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 15.7 BLUE GENIUS™ GOLD WIRING DIAGRAM—230V SINGLE PHASE 34 ISSUE DATE: FEBRUARY 1, 2016 REV.2 (PART # 038-880E)

  • Page 35: Optional Exterior Traffic Light / Mirror Image Sign

    AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL 15.8 OPTIONAL EXTERIOR TRAFFIC LIGHT / MIRROR IMAGE SIGN Slim-build LED traffic lights and mirror image drive warning sign improve loading dock safety. ¼" (6.35 mm) ½" 5" (127 mm) (12.7 mm) 11.875" 1/2" (12.7 mm) 4"...
  • Page 36 Corporate 85 Heart Lake Road South USA 6350 Burnt Poplar Road Brampton, ON, Canada L6W 3K2 Greensboro, NC 27409 t 905.457.3900 f 905.457.2313 www.BlueGiant.com If calling within North America: t 1.800.668.7078 f 1.888.378.5781 © Copyright Blue Giant Equipment Corporation 2016...

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