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U-SERIES VERTICAL STORING DOCK LEVELER
with BLUE GENIUS
TM
INSTALLATION & OWNER'S MANUAL
DO NOT INSTALL, OPERATE OR SERVICE THIS PRODUCT UNLESS YOU HAVE READ AND
FULLY UNDERSTOOD THE ENTIRE CONTENTS OF THIS MANUAL. FAILURE TO DO SO MAY
RESULT IN PROPERTY DAMAGE, BODILY INJURY OR DEATH.
CONTROLS
U-Series Vertical Storing Dock Leveler with Blue Genius™ Controls
Issue Date: October 30, 2012. REV.3 (Part# 038-722E)
BLUE GENIUS
WARNING
SERIES
TM
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Summary of Contents for Blue Giant U Series
- Page 1 U-SERIES VERTICAL STORING DOCK LEVELER BLUE GENIUS SERIES with BLUE GENIUS CONTROLS INSTALLATION & OWNER’S MANUAL WARNING DO NOT INSTALL, OPERATE OR SERVICE THIS PRODUCT UNLESS YOU HAVE READ AND FULLY UNDERSTOOD THE ENTIRE CONTENTS OF THIS MANUAL. FAILURE TO DO SO MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY OR DEATH.
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Page 2: Table Of Contents
TABLE OF CONTENTS ABOUT THE VERTICAL STORING DOCK LEVELER....................1 1.1 Owner’s Purchase Record............................1 INTRODUCTION................................2 2.1 Warranty Information..............................2 2.2 Exclusion of Liability..............................2 2.3 Manufacturer’s Note..............................2 OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION..............3 3.1 Operational Safety Warnings............................ 3 LOCKOUT / TAGOUT PROCEDURE AND RULES....................... -
Page 3: About The Vertical Storing Dock Leveler
ABOUT THE VERTICAL STORING DOCK LEVELER The Blue Giant U-Series Vertical Storing Dock Leveler provides a complete energy efficient seal. The dock is stored in the vertical position inside the building, allowing the overhead door to close completely, which reduces door damage, prevents energy loss and debris entry, and improves security levels. -
Page 4: Introduction
WARRANTY INFORMATION Thank you for purchasing Blue Giant products. We appreciate your business, and are confident that our product will serve you for many years to come. In the event that you experience a problem with our product, our Warranty Center is here to support the Blue Giant Product(s) that you have purchased. -
Page 5: Operator's Manual Safety Message Color Identification
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION Safety signs and messages are inserted in this manual to identify specific areas where potential hazards exist and advise when special precautions should be taken. To safeguard against personal injury (possibly leading to death) and equipment damage, know and understand the meaning of these instructions, signs, and messages. -
Page 6: Lockout / Tagout Procedure And Rules
The machine or equipment power codes. supply shall be locked in the OFF position or disconnected from the energy source. Blue Giant® strongly recommends that only OSHA-approved lockout devices be utilized. The energy isolating device must bear a prominent... -
Page 7: Maintenance Strut Setup
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS MAINTENANCE STRUT SETUP Never work in the path of the dock leveler platform without engaging the maintenance strut. If you are unable to successfully engage the device, contact your authorized service representative or the manufacturer. Post safety warnings and barricade work area at dock level and at ground level to prevent unauthorized use of the dock leveler during maintenance/service. -
Page 8: Standalone Vs Dock Arrangement (Installation Pictorial)
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS STANDALONE VS DOCK ARRANGEMENT NEW CONSTRUCTION (VS DOCK): SOLENOID VALVE DRILL ONE HOLE THROUGH THE WALL TO THE OUTSIDE FOR THE L.E.D OUTSIDE WIRING TRAFFIC LIGHTS (OPTIONAL). POWER PACK RUN ONE 1 1/2” I.D. CONDUIT FROM CONTROL STATION TO THE I/O BOX (ABOVE THE REMOTE I/O BOX POWER PACK) FOR THE COMMUNICATION CABLES, OUTSIDE TRAFFIC LIGHTS BLUE GENIUS... -
Page 9: Installation Instructions
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS INSTALLATION INSTRUCTIONS The rear frame assembly must be separated from the dock leveler deck and must be poured into place when the floor slab concrete is poured. Concrete strength is to be a minimum of 3,000 PSI, poured to a minimum thickness of 12” in all areas adjacent to the rear frame assembly. -
Page 10: Deck Installation
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS INSTALLATION INSTRUCTIONS Deck Installation 7. Line the rod eye up with the clevis holes in the rear frame. 8. Secure the cylinder pin with split pins. 1. Using slings rated for a minimum capacity of 3000 lbs, (1500 9. -
Page 11: Test Operation
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATING INSTRUCTIONS TEST OPERATION With the overhead door open, test operate the Vertical Storing Dock Leveler as follows to ensure that all functions are operating correctly and adjustments are properly set. Never allow a transporter vehicle to depart when the deck is fully deployed with the lip resting on the surface of the transporter vehicle load bed. -
Page 12: Control Station Operation
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS CONTROL STATION OPERATION CONTROL STATION TYPE - Independent Vertical Dock Leveler YELLOW LIGHT (Proceed With Caution) Caution... -
Page 13: Operating Instructions
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATING INSTRUCTIONS 10.3 Starting Procedure WARNING The operating instructions in this manual include references Do not install, operate and/or service this leveler unless to the advanced communication lights package (control you have been trained and authorized to do so, and have station and traffic lights.) This is an optional feature and may read and understood all of the safety information and... -
Page 14: Returning Dock Leveler To The Stored Position
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATING INSTRUCTIONS WARNING MENU DISPLAY SCREEN: The transport vehicle should never be allowed to depart D e c k D e p l o y e d ES C with the lip plate resting on the load bed. SE L En te r 10.6... - Page 15 U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATING INSTRUCTIONS MENU DISPLAY SCREEN: L i p R a i s i n g D e c k R a i s i n g Deck Lowering Deck Deployed Ent er Do Not Gre en Ent er On...
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Page 16: Maintenance
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS MAINTENANCE The Maintenance strut must be in place before commencing Do not operate and/or service this dock leveler until you have read maintenance procedures. and understood all of the safety information and instructions contained herein and on the dock leveler. -
Page 17: Pm Checklist- Dock Equipment
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS 11.7 PM CHECK LIST - DOCK EQUIPMENT P M C H E C K L I S T – DOCK EQUIPMENT Customer S W O # Location Cust. Contact Date Inspected By Barricade Work Area C L E A N C H E C K / A D J U S T / L U B E... -
Page 18: Parts Illustration- Vertical Loading Dock
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS PARTS ILLUSTRATION - VERTICAL STORING DOCK 16" 20" 18"... -
Page 19: Component List- Vertical Loading Dock
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS COMPONENT LIST - VERTICAL STORING DOCK ITEM QTY. PART NO. DESCRIPTION 200-02545 16" Lip Weld 200-02545-1 18" Lip Weld 200-02545-2 20" Lip Weld ITEM QTY. PART NO. DESCRIPTION ITEM QTY. PART NO. DESCRIPTION 23-003600 Back Frame Weld... -
Page 20: Recommended Spare Parts
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS RECOMMENDED SPARE PARTS Part # Description Qty Req'd 23-003585 SERVICE STAND 23-003570 SWIVEL LEVELING MTG **HARDWARE REQ'D:** QTY: 6 Spring Pin, Part # 013-127 * Complements for Hydraulics (Lip Cylinder) * Part # Description Qty Req'd... -
Page 21: Vertical Storing Dock Leveler Power Pack
VERTICAL STORING DOCK LEVELER POWER PACK LIP SOLENOID (Hydraulic Connection) VIEW SHOWN WITHOUT BRACKET LIP (Hydraulic Connection) DECK UP (Hydraulic Connection) TOP VIEW DECK DOWN (Hydraulic Connection) DECK SOLENOID BLUE GIANT MODEL NO. PART NO. SIDE LEFT SERIAL NO. BLUEGIANT.COM VIEW MOTOR WIRING RELIEF VALVE 19 1/16"... -
Page 22: Shipment Kit- Vertical Storing Dock
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS SHIPMENT KIT - VERTICAL STORING DOCK # on Diagram Part Name Part Number 3/16 DIA. SPRING PIN X 1.50 013-027 SERVICE STAND 23-003585 PIVOT PIN 23-003324 CYLINDER PIN 200-02704-1 SWIVEL LEVELING MTG. 23-003570 PIN (SERVICE STAND) 23-003586... -
Page 23: Troubleshooting
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS TROUBLESHOOTING Only a trained and authorized service technician should perform repairs and adjustments. Contact your local dealer or distributor for assistance. PROBLEM PROBLEM CAUSE 1. Incorrect motor rotation Deck will not raise when the A. - Page 24 U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS TROUBLESHOOTING Only a trained and authorized service technician should perform repairs and adjustments. Contact your local dealer or distributor for assistance. PROBLEM PROBLEM CAUSE Deck rises partially and then 1. Low hydraulic oil in reservoir. stops.
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- Page 27 U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS NOTES...
- Page 28 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 2013...
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