Blue Giant BLUE GENIUS SERIES Installation & Owner's Manual
Hydraulic dock leveler with blue genius control station
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A-SERIES HYDRAULIC DOCK LEVELER
with BLUE GENIUS
TM
DO NOT INSTALL, 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.
A-Series Hydraulic Dock Leveler with Blue Genius
CONTROL STATION
INSTALLATION &
OWNER'S MANUAL
Applies to Serial Numbers 369651 and up.
BLUE GENIUS
WARNING
TM
Controls. Issue Date: September 25, 2012. Rev.5 (Part#038-726E)
SERIES
TM
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Summary of Contents for Blue Giant BLUE GENIUS SERIES
- Page 1 A-SERIES HYDRAULIC DOCK LEVELER BLUE GENIUS SERIES with BLUE GENIUS CONTROL STATION INSTALLATION & OWNER’S MANUAL WARNING DO NOT INSTALL, 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.
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Page 2: Table Of Contents
TABLE OF CONTENTS ABOUT THE A-SERIES HYDRAULIC DOCK LEVELER with BLUE GENIUS CONTROLS........1.1 Owner’s Purchase Record............................INTRODUCTION ................................. 2.1 Warranty Information............................. 2.1 Exclusion of Liability.............................. 2.2 Manufacturer's Note.............................. OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION..............3.1 Operational Safety Warnings..........................LOCKOUT / TAGOUT PROCEDURE AND RULES..................... STANDALONE DOCK ARRANGEMENT ........................ -
Page 3: About The A-Series Hydraulic Dock Leveler With Blue Genius
CONTROLS The Blue Giant A-Series Hydraulic Dock Leveler is a high performance system. I-beams welded at dynamic impact points guarantee sturdy deck support. It is designed to tilt up to 4” (102 mm) on either side, allowing full width contact between the lip and the truck bed and preventing damage to forks, tires, steering system, and load. -
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
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS 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 6: Lockout / Tagout Procedure And Rules
The and approved local electrical codes. 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 be utilized. -
Page 7: Standalone Dock Arrangement
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS STANDALONE DOCK ARRANGEMENT NEW CONSTRUCTION (FH DOCK): 1. DRILL ONE HOLE THROUGH THE WALL TO THE OUTSIDE A FOR THE L.E.D COMMUNICATION LIGHTS (OPTIONAL). BLUE GENIUS CONTROL STATION 2. RUN ONE 1/2” I.D. CONDUIT FROM CONTROL STATION TO THE DOCK JUNCTION BOX (MOUNTED &... -
Page 8: Weld Installation Pictorial
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS WELD INSTALLATION PICTORIAL WELD INSTALLATION PICTORIAL FORK LIFT TRUCK HANDLING SLING HANDLING STITCH WELD 1/4" 6” SHIM BOTH SIDES 5" X 5" - 127mm x 127 mm DOCK LEVELER BASE FRAME SHIM BOTH SIDES SHIM 4"... -
Page 9: Dock Leveler Installation Instructions
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS DOCK LEVELER INSTALLATION INSTRUCTIONS WARNING WIDTH Do not install, operate and/or service this leveler until you LENGTH have read and understood all of the safety information and instructions contained herein and on the leveler. Do not work under or around leveler being installed without first placing adequate barriers to positively prevent vehicle traffic from entering the work area. -
Page 10: Installation Inspection
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS DOCK LEVELER INSTALLATION INSTRUCTIONS 10. Mount Blue Genius Control Station assembly in a suitable location. Mount power unit in a suitable location if REAR FRAME applicable (remote power pack). UPPER REAR PIT ANGLE 11. -
Page 11: Electrical And Hydraulic Installation
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS ELECTRICAL AND HYDRAULIC INSTALLATION DO NOT WIRE HIGH AND LOW VOLTAGES IN THE SAME CONDUIT. High voltage range is 115V and up. Lower voltages include the communication and solenoid wiring as well as the I/O. During installation, place adequate barriers to prevent vehicle traffic from entering the work area, and follow proper lockout / tagout procedures. -
Page 12: Control Station Operation
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS CONTROL STATION OPERATION CONTROL STATION TYPE - Independent Hydraulic Dock Leveler Blue Genius SCROLL ‘UP’ ESCAPE MENU SCREEN SELECT SCROLL ‘DOWN’ RED LIGHT (Do Not Enter) Do Not Enter YELLOW LIGHT (Proceed With Caution) Caution GREEN LIGHT (Enter On Green) -
Page 13: Operating Instructions
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATING INSTRUCTIONS Do not operate this leveler unless you have been trained Secure the transport vehicle with a vehicle restraint, wheel chocks or other method before commencing traffic across the dock leveler. and authorized to do so, and have read and understood all of the safety information and instructions contained herein. -
Page 14: Deploying The Dock (Deck Button Only- Method 1)
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATING INSTRUCTIONS 10.4 Deploying the Dock (Deck Button 10.3 Deploying the Dock (Deck Button and Lip Buttons- Method 2) Only- Method 1) 1. After the truck has been secured, raise the dock leveler by 1. -
Page 15: Storing The Dock Leveler
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATING INSTRUCTIONS 10.5 Storing the Dock Leveler en iu s lu e To return the dock leveler to the stored position, touch and Ent er Do Not Cau tion hold the ‘Deck’ button. The outside traffic light (optional) Gre en Ent er On... -
Page 16: Auto-Return Activate / Deactivate
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATING INSTRUCTIONS Optional Alarm WA R N I N G ALARM WILL SOUND AS LEVELER Au t o Pa r k i n x x RETURNS TO THE STORED POSITION IN AUTO RETURN MODE. e n iu s ES C lu e... -
Page 17: Maintenance
A-SERIES HYDRAULIC 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 18: Pm Checklist
A-SERIES HYDRAULIC 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 19: Hydraulic Cylinders
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS HYDRAULIC CYLINDERS 12.1 HYDRAULIC DECK LIFTING CYLINDER ITEM PART NUMBER GENERAL DESCRIPTION --------------- ------------- 788-635-1 Deck Lifting Cylinder – (6’ & 8’ Long Docks) --------------- ------------- 788-636-1 Deck Lifting Cylinder – (10’ & 12’ Long Docks) --------------- ------------- 036-205... -
Page 20: Leveler Hydraulic Hoses
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS LEVELER HYDRAULIC HOSES NOTE: Illustration depicts self-contained unit. 14.1 DECK LIFTING CYLINDER - HOSE All Capacity ITEM PART NUMBER GENERAL DESCRIPTION 788-621 6’ and 8’ Models (Nominal Deck and Lip Length) 788-331 10’... -
Page 21: Safety Side Skirts
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS SAFETY SIDE SKIRTS SIDE SAFETY SKIRTS ITEM QTY PART NO. DESCRIPTION ITEM QTY PART NO. DESCRIPTION ------- ------- 202-5024 Safety Skirt Package - 6’ & 8’ Long 012-252 Washer,Flat -3/8”ID BS Washer ------- ------- 202-5024-1... -
Page 22: Dock Power Pack Assembly
VALVE,CHECK,PILOT OP,CART,ZERO PLUG,SAE O-RING,9/16-18,HEX,SO MOTOR,AC,1HP,3450RPM,TENV,1PH VALVE,2W/2P,CART,NO,PLT OP,#8 SCREW,H.H.CAP,5/16-18 X 3/4 WASHER,FLAT,5/16",(ZINC PLATE) NUT,HEX,5/16-18 BRACKET,MOTOR MOUNTING,M-4560 FITTING,ELBOW,90 DEG,37 DEG LABEL,BLUE GIANT,MOD NO,SN CARTRIDGE,2W/2P,NO,4000PSI,#8 COIL,24VDC,#8,HIRSCHMAN,LOW WT PLUG,ORIFICE 3/32DRILL,1/16NPT 208-460V, Three Phase, 50-60HZ ITEM NO DESCRIPTION BASE ASSY,M4560,MOD,(2)9/16SAE P ASSY,QM,MDLR,DC,BRGS BLD RSV SCREW,SHC,1/4-20 X 2.75,BLK OX FILTER,SCREEN M-SERIES SUCT. -
Page 23: General Parts
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS GENERAL PARTS 18.1 MOLDED RUBBER BUMPERS MOLDED RUBBER BUMPERS PART ID DESCRIPTION DB13 4" x 10" x 13" DB18 4" x 10" x 18" DB30 4" x 10" x 30" DBL18 4" x 18" x 18" 18.2 FACE PLATES FOR MOLDED RUBBER BUMPERS PART ID... - Page 24 A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS DOCK LEVELER TROUBLESHOOTING 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. PROBLEM PROBLEM CAUSE Deck will not raise when...
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Page 25: Dock Leveler Troubleshooting
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS DOCK LEVELER TROUBLESHOOTING 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. PROBLEM PROBLEM CAUSE 1. - Page 26 A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS DOCK LEVELER TROUBLESHOOTING 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. PROBLEM PROBLEM CAUSE Lip lowers slowly in normal...
- Page 27 A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS DOCK LEVELER TROUBLESHOOTING 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. PROBLEM PROBLEM CAUSE Deck raises more slowly...
- Page 28 A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS TROUBLE SHOOTING DOCK LEVELER TROUBLESHOOTING 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. PROBLEM PROBLEM CAUSE Deck will not lower from fully...
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Page 29: Control Station Troubleshooting
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS CONTROL STATION TROUBLESHOOTING 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. PROBLEM PROBLEM CAUSE No display on the menu... - Page 30 A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS NOTES...
- Page 31 NOTES...
- Page 32 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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