Blue Giant H7012 User manual

PIT STYLE DOCK LEVELERS
WARNING
Do not install, operate or service this product unless you
have read and fully understand the entire contents of this
manual in combination with owners manual. Failure to do
so may result in property damage, bodily injury or death.
INSTALLATION & TECHNICAL MANUAL
ISSUE DATE: AUGUST 31, 2018 REV.1 (PART # 038-1073EI)STARTING FROM MAY 1, 2018 / SERIAL # 440190.1
ACTUAL PRODUCT MAY NOT APPEAR EXACTLY AS SHOWN

BLUE GIANT SERIES DOCK LEVELERS—INSTALLATION & TECHNICAL MANUAL
2AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
1.0 GENERAL SITE CHECKLIST FOR DOCK LEVELLER 4
2.0 INTRODUCTION 5
2.1 WARRANTY INFORMATION 5
2.2 EXCLUSION OF LIABILITY 5
2.3 MANUFACTURER’S NOTE 5
2.4 INSTALLER’S GUIDELINES 5
3.0 SAFETY MESSAGE COLOR IDENTIFICATION 6
3.1 OPERATIONAL SAFETY WARNINGS 6
4.0 LOCKOUT / TAGOUT PROCEDURE AND RULES 7
5.0 HOW TO READ THIS MANUAL 7
6.0 DOCK LEVELER FORKLIFT HANDLING 8
7.0 DOCK STRUT SET-UP 9
7.1 ENGAGING THE DOCK STRUT 9
7.2 DISENGAGING THE DOCK STRUT 9
8.0 INSTALLATION LAYOUT 10
9.0 TOOLS REQUIRED FOR INSTALLATION 11
9.1 RECOMMENDED EQUIPMENT FOR RIGGING OR HOISTING 12
10.0 INSTALLATION FOR PIT TYPE DOCK LEVELERS 13
10.1 GENERAL DESCRIPTION 13
10.2 GENERAL DESCRIPTION - HYDRAULIC DOCK LEVELER 14
10.3 GENERAL DESCRIPTION - MECHANICAL DOCK LEVELER 14
11.0 EQUIPMENT COMPONENT ILLUSTRATIONS 15
11.1 COMPONENTS AS SHIPPED CHECKLIST 15
12.0 GENERAL DIMENSIONS 16
12.1 OPERATING RANGES 16
13.0 PIT DIMENSIONS 17
14.0 INSTALLATION GUIDELINES 17
14.1 DOCK LEVELER INSTALLATION 19
15.0 SP1 CONTROL STATION INSTALLATION 27
16.1 SP1 WIRING DIAGRAM—110–130V SINGLE PHASE 28
16.2 SP1 WIRING DIAGRAM—208–240V SINGLE PHASE 29
17.0 LAMINATED BUMPER INSTALLATION 30
17.1 WEDGE ANCHORS 30
17.2 EMBEDDED ANCHOR BOLTS 30
17.3 WELDING/ANCHORING 30
18.0 COMMISSIONING AND START-UP PROCEDURES 30
19.0 PLANNED MAINTENANCE 31
20.0 HYDRAULIC DOCK LEVELER TROUBLESHOOTING 31
21.0 MECHANICAL DOCK LEVELER TROUBLESHOOTING 32
22.0 ALTERNATIVE: SP2 CONTROL STATION INSTALLATION 34
23.0 SP2 WIRING DIAGRAM—115V SINGLE PHASE 35
TABLE OF CONTENTS

BLUE GIANT SERIES DOCK LEVELER—INSTALLATION & TECHNICAL MANUAL
3AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
24.0 ALTERNATIVE: BLUE GENIUS™ CONTROL PANEL INSTALLATION 36
25.0 BLUE GENIUS™ ELECTRICAL WIRING INSTALLATION 37
25.1 BLUE GENIUS™ CONTROL PANEL WIRING LAYOUT 38
26.0 BLUE GENIUS™ GOLD WIRING DIAGRAM—115V SINGLE PHASE 39
26.1 BLUE GENIUS™ GOLD WIRING DIAGRAM—230V SINGLE PHASE 40
27.0 OPTIONAL EXTERIOR DRIVER TRAFFIC LIGHT INSTALLATION 41
27.1 OPTIONAL EXTERIOR DRIVER WARNING SIGN INSTALLATION 41
28.0 OPTIONAL LIP HOME SENSOR PACKAGE INSTALLATION - BLUE GENIUS™ EQUIPPED DOCKS ONLY 42
TABLE OF CONTENTS

BLUE GIANT SERIES DOCK LEVELERS—INSTALLATION & TECHNICAL MANUAL
4AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
1.0 GENERAL SITE CHECKLIST FOR DOCK LEVELER
Yes No Comments
1Review site conditions. Have you completed and
reviewed site survey report?  
2Does the pit fit the leveler that has been provided?
See Section 13.0 "Pit Dimensions"  
3Is the electrical power present to hook up to?
i.e. on inside wall near control install location  
4Was the conduit(s) installed and properly
positioned?  
5Did you check to see if the proper voltage is
supplied (Hydraulic only)  
6
When unpacking, were all the parts included?
See Section 11.1 "Components as Shipped
Checklist"
 
7
Do you have all the tools needed to complete the
job? This includes ladder(s), safety equipment
and personal safety devices. See Section 9.0
"Tools Required for Installation"
 
8
Do you have the anchors for the (optional) exterior
driver traffic light, warning sign and control box?
Supplied by: You, contractor, or installer
 
9Have you read this installation manual and fully
understood it?  
10
Do you have the Blue Giant technical support
number? 1.800.872.2583. Before calling, make
sure to have serial # of equipment.
 
11 Do you know what an ESD "Electrostatic Sensitive
Device" is and how to handle?  

DEALER INFORMATION
Name:
Contact:
Telephone:
2.3 MANUFACTURER’S NOTE
The dock equipment has been carefully inspected and tested at
the manufacturer’s plant prior to shipment, but should be checked
upon receipt for transport damage. Any observed transport
damage is to be listed on the signed copy of the freight document.
Notify the freight forwarder of any damage WITHIN 48 HOURS.
2.2 EXCLUSION OF LIABILITY
The manufacturer assumes no liability for damage or injury to
persons or property which occur as a result of defects or faults in
or incorrect use of the Loading Dock Equipment. The manufacturer
also assumes no liability for lost profits, operating downtimes, or
similar indirect losses incurred by the purchaser. Injury to third
parties, irrespective of its nature, is not subject to compensation.
The manufacturer reserves the right to make changes at any time
to the modules, components, and accessories, concurrent with
its continuing product improvements and development program.
Specifications, operating instructions, and illustrations included in
this manual are subject to change without notice. Please contact
manufacturer for the latest information.
BLUE GIANT SERIES DOCK LEVELER—INSTALLATION & TECHNICAL MANUAL
5AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
2.0 INTRODUCTION
The following is a quick reference to important procedures that
must be followed while installing the Loading Dock Equipment. It is
not intended to cover, or suggest that it does cover, all procedures
necessary to ensure safe installation and operation. All person-
nel who install and / or use this dock equipment should be aware
of and abide by all workplace safety regulations applicable to the
installation and operation of the Loading Dock. These laws and
regulations include but are not limited to:
• The Occupational Safety and Health Act
• Canada Occupational Health and Safety Regulations
• Occupational Safety and Health Acts for Individual States
(USA)
For additional information on these regulations as well as industry
standards that may apply to this product, please contact:
American National Standards Institute (ANSI)
1899 L Street, Washington, DC 20036
Telephone: [phone]
www.ansi.org
Also a member of:
Loading Dock Equipment Manufacturers
A Division of Material Handling Industry
8720 Red Oak Blvd, Suite 201, Charlotte, NC, 28217-3992
Telephone: [phone]
www.mhi.org/lodem
2.1 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.
To validate warranty on recently purchased equipment,
please complete and submit your information with our
online Warranty Registration at www.bluegiant.com.
For more information about Blue Giant Warranty Support, please
contact your local Blue Giant Equipment dealer, representative or
authorized partner near you. You may also visit www.bluegiant.com
or phone [phone].
NOTE: Failure to validate warranty at the time of receipt can
seriously affect the outcome of any claim.
NOTE: Improper installation of equipment may void any
applicable warranties.
2.4 INSTALLER’S GUIDELINES
Please read all instructions carefully before installing this
Blue Giant dock product. It is the installer’s responsibility to
comply with the following:
• The installation of Blue Giant dock products should comply with
all applicable local or national building codes and regulations,
including any that may supersede this manual.
• Site surveys and other applicable install-related documentation
must be properly and accurately completed prior to installation.
Failure to comply with this requirement may result in an
improper install and possible voiding of the warranty.
• Only Blue Giant-supplied or approved parts must be used. Any
unauthorized parts substitution may void the warranty.
Always lockout and tagout any power source before performing
any electrical work, in accordance with OSHA regulations and
approved electrical codes. The installer is responsible for reading,
understanding, and complying with all personal protective
equipment (PPE) policies in effect.

Serious injury or death will likely occur if the
instructions are not followed.
Serious injury or death may occur if the instructions
are not followed.
Procedures marked notice must be followed in
order to prevent damage to machinery.
Instructions marked caution concern safe operating
procedure. Failure to comply may result in personal injury.
BLUE GIANT SERIES DOCK LEVELERS—INSTALLATION & TECHNICAL MANUAL
6AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
3.0 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. If warning decals become damaged or missing, replace them immediately. Avoid accidents by recognizing dangerous
procedures or situations before they occur.
1. The upper hinge point is a hazardous pinch point. Do not use
fingers or hands to remove foreign materials.
2. Post safety warnings and barricade working area at dock level
and at ground level to prevent unauthorized use of the leveler
during maintenance/service.
3. Never leave the dock leveler unattended in the raised position.
4. Always make sure that the lip is seated inside the night lock after
putting the dock in the parked position.
5. Never leave loads sitting on the dock leveler.
6. Do not attempt to raise the dock leveler if someone is standing
on it.
7. Do not use the dock leveler if the lip’s full width is not fully
supported by the vehicle load bed.
8. Do not operate the dock leveler beyond its rated capacity.
9. Do not drive or walk onto the truck until it is parked against
the dock bumpers and the wheels are chocked, or the vehicle
restraint has been fully engaged.
10. Never attempt to lift or hold the lip out by hand. Serious personal
injury could occur.
11. Never remove the wheel chocks until loading/ unloading is
finished and the truck driver has been given permission to
depart.
1. Only trained personnel should operate or service this equipment.
2. Do not operate the dock equipment until the transport vehicle is
parked against the dock bumpers.
3. Always park the dock equipment after use.
4. Conduct routine inspections and maintenance. Failure to do so
could cause equipment damage and or personal injury.
5. Always call your authorized service representative or
manufacturer immediately if a malfunction occurs.
1. Do not ground welding equipment to any electrical components.
2. Do not attach welder as ground to leveler platform when welding
on base frame assembly. Attach welder ground to base frame
assembly only.
3. Do not allow the drill to go too deeply when drilling holes in the
control box. Damage to the control systems may occur.
4. Never use air to blow debris from control box. Use a vacuum to
remove debris from control box.
5. Do not connect green ground lead into control box until all
welding has been completed.
6. Always keep the work area clean and free of litter.
7. Always clean all side openings of dirt and debris.
8. Always clean all dirt and debris from the lip hinge.
9. Always clean up dry and liquid spills immediately after they
occur.
10. Always maintain proper lighting in the work area.
11. If a procedure is not clearly defined in this manual, contact your
authorized Service Representative.
1. Do not enter the pit area below the dock leveler.
2. BEFORE BEGINNING ANY SERVICE PROCEDURES:
– Disconnect the power and follow all lockout / tagout
procedures.
3. Never operate a broken or damaged dock leveler. Have repairs
done immediately by a qualified service technician.
4. Always secure and center loads on the forklifts. Loose or
unbalanced loads are dangerous.
NOTICE
CAUTION
DANGER
WARNING
3.1 OPERATIONAL SAFETY WARNINGS
DANGER NOTICE
WARNING
CAUTION

XXXXXXXXXXXX
XXXXXXXXXXX
OPERATE
DO NOT
This Installation and Technical manual covers standard
installation steps for the Blue Giant Hydraulic and Mechanical
dock levelers.
Applies only to Hydraulic Dock Leveler
Applies to Hydraulic and Mechanical Dock
Levelers
Applies only to Mechanical Dock Leveler
LEGEND
BLUE GIANT SERIES DOCK LEVELER—INSTALLATION & TECHNICAL MANUAL
7AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
Approved way to lockout / tagout.
WARNING
Always lockout and tagout any power source before performing any
work on any electrical devices or electrical controls according to
OSHA regulations and approved local electrical codes.
4.0 LOCKOUT / TAGOUT PROCEDURE AND RULES
In accordance with the rules and regulations of the Occupational
Safety and Health Administration (OSHA), all affected employees
must be notified that the machine or equipment will be shut down
and locked out to perform repair or maintenance work. The work
area must be checked to ensure that all personnel have been
removed or safely repositioned. 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. It is
mandatory that tagout notices not be susceptible to deterioration
or illegibility due to weather conditions or exposure to chemicals
and moisture.
5.0 HOW TO READ THIS MANUAL
M
H
ALL

Min.42”
90°
Fork Pockets
2x
REAR VIEW
SIDE VIEW
*Cross section for clarity.
BLUE GIANT SERIES DOCK LEVELERS—INSTALLATION & TECHNICAL MANUAL
8AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
6.0 DOCK LEVELER FORKLIFT HANDLING
All Blue Giant dock levelers come equipped with fork pockets located at the rear of the unit for safe and convenient handling. To ensure
that the dock leveler does not experience any unnecessary damage, always lift from the rear fork pockets when using a forklift.
Failure to follow proper handling procedures may result in serious equipment damage.
NOTICE
ALL

7.0 DOCK STRUT SET-UP
7.1 ENGAGING THE DOCK STRUT
7.2 DISENGAGING THE DOCK STRUT
Engaged Service Stand (part # 796-710) and Dock Strut (part # 2000659).
Dock Strut
Service Stand
DANGER WARNING
Post safety warnings and barricade work area at dock and
ground level. Notify all affected personnel that work is being
performed on the unit and follow proper lock-out procedure.
Ensure that power to the unit has been completely cut off
and cannot be turned back on accidentally.
Failure to properly secure the dock leveler deck prior to
working underneath it may result in property damage, bodily
injury, or death. Engage the Dock Strut AND Service Stand
first. If the device cannot be successfully engaged, contact
your authorized service representative.
WARNING
Head protection and other applicable PPE is recommended
when working under or around the raised deck.
WARNING
Install dock strut and secondary service stand only when the
unit is fully raised and deployed.
WARNING
Use of a service stand (Part #796-710) in conjunction with the
dock strut is required when working under the leveler.
This dock is equipped with a one piece dock strut that must be
used, in conjunction with a service stand, during under-dock
inspections or repairs / maintenance. The V-shape ensures safe
headboard and lip support.
To apply the dock strut, one person raises the deck while another
puts the strut in place.
It is recommended that a retrieval tool be used when retrieving
the dock strut from its storage position beneath the dock.
NOTE: It is recommended that this step be performed
with assistance.
CAUTION
Remove the service stand only AFTER disengaging the
dock strut (or equivalent)
CAUTION
Use of a service stand and hard hat while performing this step
is required.
After verifying that it is safe to disengage the dock strut, pull up-
wards on the dock strut and lower gently into the storage position.
Do not stand in the pathway of the dock leveler during the disen-
gagement process in case the dock falls unexpectedly.
BLUE GIANT SERIES DOCK LEVELER—INSTALLATION & TECHNICAL MANUAL
9AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
ALL

DISCONNECTPOWER
BEFOREOPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
BLUE GIANT SERIES DOCK LEVELERS—INSTALLATION & TECHNICAL MANUAL
10 AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
8.0 INSTALLATION LAYOUT
NEW CONSTRUCTION
(CONDUIT POURED IN CONCRETE)
Run one 1/2" (16mm) trade size conduit
from the control station to the motor
junction box.
Optional: Run one 1/2" (16mm) trade
size conduit from the control station
to the pit for future expansion (e.g.
interlocks, combos, etc.)
MINIMUM CONCRETE STRENGTH
3,000 P.S.I.
See Sections 21.0 and 23.0 for
alternative details.
1
2
* Drawings not to scale
ISO View
ELECTRICAL REQUIREMENTS
• Mount control station to wall.
• Fused disconnect provided by others and wiring by others.
• Install wiring from control station to hydraulic powerpack.
• Install wiring from control station to power supply.
Refer to Isometric View
Inside Building View*
Front Elevation View*
Typical layout
50" typ.
(1270 mm)
20" typ.
(508mm)
SINGLE PUSH BUTTON
CONTROL STATION
(mounted on left side)
MOTOR WIRING
MAIN POWER
(from fused
disconnect)
50" typ.
(1270mm)
1
2
14"
(356mm)
20"
(508mm)
SINGLE PUSH BUTTON
CONTROL STATION
(mounted on drivers side)
1
1
2
HYDRAULIC POWERPACK
(to control station)
4"
(102mm)
H
H
CONTROL CABLES, LOW VOLTAGE (OPT)
POWER/MOTOR WIRING, HIGH VOLTAGE
NOTE: Suggested for to
accommodate future expansion.
M

9.0 TOOLS REQUIRED FOR INSTALLATION
BLUE GIANT SERIES DOCK LEVELER—INSTALLATION & TECHNICAL MANUAL
11AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
Electrician's Tools
Hammer Drill Tape Measure
Ball Peen Hammer
2' Level
5
/
8" and ¼" Concrete Bit Carbide
Chip Hammer
Small Flat Screwdriver
(flat tip to be suitable for .150 slot)
Large 1
/
8" x 3
/
8" Screwdriver
Crowbar 3'-5'
Chisel
Sledge Hammer 10 lb
Welder
Combination wrench set 3
/
8" to 1"
Socket Set 3
/
8" to 1" Grinder with Zip Blades As Well

Sling and Hoist Ring Forklift
Funnel
Nut Driver Drill Bit 5/16"
Angle Measurement Tool
9.0 TOOLS REQUIRED FOR INSTALLATION CONT'D
9.1 RECOMMENDED EQUIPMENT FOR RIGGING OR HOISTING
Drill/Screwdriver
Boom Truck
Conduit Bender Torque Wrench
BLUE GIANT SERIES DOCK LEVELERS—INSTALLATION & TECHNICAL MANUAL
12 AUGUST 31, 2018 REV.1 (PART # 038-1073EI)

BLUE GIANT SERIES DOCK LEVELER—INSTALLATION & TECHNICAL MANUAL
13AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
WARNING
Do not install, operate, or service this product unless you have read and followed the safety practices, warnings, and installation
instructions contained in this manual and owner's manual. Failure to do so could result in death or serious injury. Always use dock
leveler support when working under a dock leveler ramp or lip.
Place barricades around the pit on the dock floor and driveway while installing, maintaining or repairing dock leveler or vehicle
restraint.
Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury.
Inadequate lifting equipment or practices can cause a load to fall unexpectedly. Make sure the lifting chain or other lifting devices
are in good condition and have a rated capacity of as much as 5000 lb (2268 kg) for the lifting angle used. Never allow anyone
to stand on or near the dock leveler when it is lifted or positioned. Stand clear of the dock leveler when it is positioned. Failure to
follow this warning can allow the dock equipment to fall, tip, or swing into people, causing death or serious injury.
Dock Lip
Temporary
Front Leveling
Plate (2x)
Adjustable
Lip Stop
Dock Deck
Fixed
Toe Guard (2x)
Temporary
Rear Leveling
Plate (2x)
Lip Tubes
Headboard
Lip Home
Sensor
Mounting
Holes
Dock
Strut
Dock Strut
Anchor Point
Tilt Bar
Lip Keeper (2x)
Mounting
Foot (2x) Base Frame
Leveling
Legs (4x)
(Optional)
Rear
Frame
Leveling
Screw (4x)
Fork
Pocket (2x)
Rear Frame
to Curb Angle
10.0 INSTALLATION FOR PIT TYPE DOCK LEVELERS
10.1 GENERAL DESCRIPTION
See below for names of general Blue Giant dock components. These names will be used throughout the manual.
ALL
ALL

BLUE GIANT SERIES DOCK LEVELERS—INSTALLATION & TECHNICAL MANUAL
14 AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
10.2 GENERAL DESCRIPTION - HYDRAULIC DOCK LEVELER
See below for names of assemblies unique to the Hydraulic Dock Leveler. These names will be used throughout the manual.
Lifting Assembly
Lip Deployment Assembly
Hydraulic Powerpack
LEGEND
H
10.3 GENERAL DESCRIPTION - MECHANICAL DOCK LEVELER
See below for names of assemblies unique to the Mechanical Dock Leveler. These names will be used throughout the manual.
Lifting Assembly
Mechanical Hold-Down
Lip Deployment Assembly
Lip Lock Assembly
Mechanical Fall Arrest System
End Loading Bracket
LEGEND
M

2
A
B
3
1
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ate, raising the deck.
After the button is released, the bags deate, allowing the deck to lower smoothly onto the trailer bed.
The Advanced Single Push Button Control Station controls an independent hydraulic or airbag dock leveler via a constant pressure UPbutton.
The Overhead Door Interlock feature (optional) prevents the dock leveler from being used whenever the overhead doors are closed.
DEPLOYING THE DOCK LEVELER
1. 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.
2. The dock leveler will then descend with the
deployed lip on the vehicle load bed. When
the dock has fully deployed on the load bed,
loading and unloading may commence.
STORING THE DOCK LEVELER
1. Tostore the dock leveler, press the ‘UP’
button. The dock will raise and the lip will
retract.
2. When the lip has fully retracted, release
the button. The dock will resume the stored
position with the lip in the night lock.
BELOW LEVEL / END LOADING
1. Hold the control station’s ‘UP’ button until the
lip clears the night lock by about 6-10 inches.
Then release. While the deck is lowering,
pull the fall-safe disengaging chain on the
deck to partially extend the lip and to lower to
the below level position, with the lip hanging
between the dock face and the truck bed.
DANGER
1. Only trained and authorized personnel may operate this dock leveler.
2. Read, understand, and follow the instructions on this document.
3. Prior to using the dock leveler:
• Ensure that the dock leveler is free and clear of all debris, snow and ice.
• Ensure that all personnel near the dock leveler are aware that it is being
operated.
• Operate the dock leveler through one complete cycle to conrm
that it is functioning properly.If the dock leveler is equipped with a
communications package, conrm that the lights are working as
required.
• Inspect unit for signs of structural damage or mechanical malfunction. If
damage is observed or the restraint fails to operate properly,remove it
from service and notify maintenance personnel immediately.
• Conrm that the transport vehicle has been properly restrained.
4. When using the dock leveler:
• Keep hands and feet clear of pinch points.
• If the dock leveler is equipped with a light communication package, load
and unload on green only.
• Do not exceed the rated capacity as indicated on the serial plate.
• Do not leave equipment or material unattended on the dock leveler.
• Keep a safe distance from both edges.
• If dock leveler fails to operate as outlined in the accompanying manual’s
operating instructions, refer to the Troubleshootingsection.
5. If service or maintenance is required:
• Only authorized service personnel shall maintain or service the unit.
APPLIES TOALL DOCK LEVELERS
OPERATING INSTRUCTIONS
Only for the Airbag Dock Leveler
038-752Ewww.BlueGiant.com
DISCONNECTPOWER
BEFOREOPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
DISCONNECTPOWER
BEFOREOPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
DISCONNECTPOWER
BEFOREOPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
DISCONNECTPOWER
BEFOREOPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
DISCONNECTPOWER
BEFOREOPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
DISCONNECTPOWER
BEFOREOPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
4
5
BLUE GIANT SERIES DOCK LEVELER—INSTALLATION & TECHNICAL MANUAL
15AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
11.1 COMPONENTS AS SHIPPED CHECKLIST
11.0 EQUIPMENT COMPONENT ILLUSTRATIONS
BUMPERS CONTROLS
ITEM QTY. PART NO. DESCRIPTION APPROX. WEIGHT
1 1 HXXXXX Hydraulic Dock Leveler Varies by Model
MXXXXX Mechanical Dock Leveler
2A2DB411 Laminated Bumpers 50 lb 23 kg
BDB411WB Laminated Bumpers Single Flange 48 lb 22 kg
3 1
027-006-L Control Assembly SP1 110–130V Single Phase 1 lb 0.45 kg
027-007-L Control Assembly SP1 208–240V Single Phase 1 lb 0.45 kg
4 1 Model Dependent Operation Placard — —
5 1 Model Dependent Owner's Manual — —
H
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BLUE GIANT SERIES DOCK LEVELERS—INSTALLATION & TECHNICAL MANUAL
16 AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
12.0 GENERAL DIMENSIONS
MODEL TOTAL DECK WIDTH (A) FRAME WIDTH (B)
LIP LENGTH (D)
16" (406mm) 18" (457mm) 20" (508mm)
DIMENSION "E"
_6006
72" (1829mm) 73.5" (1867mm)
73.125" (1857mm) 75.125" (1908mm) 77.125" (1959mm)
_6008 97.125" (2467mm) 99.125" (2518mm) 101.125" (2569mm)
_6010 121.125" (3077mm) 123.125" (3127mm) 125.125" (3178mm)
H6012 145.125" (3686mm) 147.125" (3737mm) 149.125" (3788mm)
_6606
78" (1981mm) 79.5" (2019mm)
73.125" (1857mm) 75.125" (1908mm) 77.125" (1959mm)
_6608 97.125" (2467mm) 99.125" (2518mm) 101.125" (2569mm)
_6610 121.125" (3077mm) 123.125" (3127mm) 125.125" (3178mm)
H6612 145.125" (3686mm) 147.125" (3737mm) 149.125" (3788mm)
_7006
83" (2108mm)
*77" (1956mm) 84.5" (2172mm)
73.125" (1857mm) 75.125" (1908mm) 77.125" (1959mm)
_7008 97.125" (2467mm) 99.125" (2518mm) 101.125" (2569mm)
_7010 121.125" (3077mm) 123.125" (3127mm) 125.125" (3178mm)
H7012 145.125" (3686mm) 147.125" (3737mm) 149.125" (3788mm)
*A
4.5"
B
E
D
L
* 3" taper dimension on both sides of lip (7' levelers only).
Dimensions "E" includes deck plate, lip plate, and .25" gap.
12.1 OPERATING RANGES
DEPTH RANGE
DOCK LENGTH
6' (1.8 m) 8' (2.4 m) 10' (3 m)
16" LIP 18" LIP 20" LIP 16" LIP 18" LIP 20" LIP 16" LIP 18" LIP 20" LIP
12"
(305mm)
UR 12" (305mm) 12" (305mm) 12" (305mm) 12" (305mm) 12" (305mm) 12" (305mm) 12" (305mm) 12" (305mm) 12" (305mm)
LR 9.6" (244mm) 9" (229mm) 8.9" (226mm) 10" (254mm) 9.5" (241mm) 9.2" (234mm) 10.5" (267mm) 9.8" (249mm) 9.5" (241mm)
BACK FRAME HEIGHT
REAR 19.5" (495mm)
FRONT 20" (508mm)
ALL
Lower Range
Upper Range
Finished Floor
Pit Floor
H1

BLUE GIANT SERIES DOCK LEVELER—INSTALLATION & TECHNICAL MANUAL
17AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
WARNING
13.0 PIT DIMENSIONS
14.0 INSTALLATION GUIDELINES
NOMINAL SIZE
PIT WIDTH (W) PIT LENGTH (L)
in mm in mm
6' x 6' 1829 x 1829mm
74 1880
63 1600
6' x 8' 1829 x 2438mm 87 2210
6' x 10' 1829 x 3048mm 111 2819
6' x 12'* 1829 x 3658mm 144 3658
6' 6" x 6' 1981 x 1829mm
80 2032
63 1600
6' 6" x 8' 1981 x 2438mm 87 2210
6' 6" x 10 1981 x 3048mm 111 2819
6' 6" x 12* 1981 x 3658mm 144 3658
7' x 6' 2133 x 1829mm
85 2159
63 1600
7' x 8' 2133 x 2438mm 87 2210
7' x 10' 2133 x 3048mm 111 2819
7' x 12'* 2133 x 3658mm 144 3658
Standard Lip Lengths: 16", 18", 20" (406, 457, 508mm)
Standard Frame
Depth: Front: 19.5" (495mm) Rear: 19" (483mm)
Standard Pit Depth: Front (H): 20" (508mm) Rear (H1): 19.5" (495mm)
Pit to Deck Width: W= A + 2"
WL
H
H1
S2
S1
Prior to installation, clean the pit thoroughly and verify that all dimensions are in accordance with manufacturer specifications.
1. Must be level side-to-side and front-to-back.
2. Must be square at both rear corners.
3. Side curb angles must be parallel to each other.
4. Finished floor to be flush with top surface of curb angle.
The leveler must be welded to an embedded curb angle or other firmly embedded dock steel as indicated in the installation instructions.
NOTE: Do not attach the dock leveler to the concrete with bolts or anchors alone.
Use caution when lifting or moving the leveler. Do not attempt to lift without suitable hoisting equipment capable of lifting as much
as 5000 lb (2268 kg). Do not work beneath a raised object. Follow all hoisting safety requirements.
*12' length only available for Hydraulic models.
S1 must be equal to S2 within .125" - .25" squareness tolerance.
*8 Piece curb angle set show.
ALL

DISCONNECTPOWER
BEFOREOPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
Perform a temporary electrical hook-up to allow use of power unit
to raise the dock leveler.
Hydraulic
Powerpack
Motor wiring
(to control station)
Main power
(from fused disconnect)
Temporary
motor wiring
(hydraulic powerpack)
ALL
BLUE GIANT SERIES DOCK LEVELERS—INSTALLATION & TECHNICAL MANUAL
18 AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
H
H1
Measure the height of dock leveler front corners, bottom of frame
to top of deck plate, typically 20" (508 mm). Measure depth of pit
at both front corners where front bottom corners of frame will be
positioned.
14.1 DOCK LEVELER INSTALLATION
Measure the height of the dock leveler rear corners from the bottom
of frame to top of dock deck, typically 19" (483 mm). Measure
depth of pit at both rear corners where rear bottom corners of
frame will be positioned.
19" typ.
(483 mm)
Dock rear frame
STEP 1
STEP 2
Dock front frame
(lip removed for clarity)
20" typ.
(508 mm)
All electrical work must be performed by trained and authorized
personnel.
WARNING
H
STEP 3
TEMPORARY
ALL

5000lb
5000lb
2268kg
2268kg
STEP 6
Ensure that the front and rear temporary leveling plates are resting
on the curb angles and that the deck is flush with the finished floor. If
flush, tack weld the frame to the rear curb angle at both corners and
in the middle using 1" (25.4mm) welds.
NOTE: The leveling plates and bolts can be used to assist in
adjusting out of square.
NOTE: Touch up all welds with appropriately matched paints.
ALL
ALL
BLUE GIANT SERIES DOCK LEVELER—INSTALLATION & TECHNICAL MANUAL
19AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
14.1 DOCK LEVELER INSTALLATION CONT'D.
ALL
Sling the dock leveler into place squarely above the pit and lower
gently. Locate and square the dock leveler to best suit both the pit
and dock face. Space between the sides of the deck and the sides
of the pit should be equal.
Use caution when lifting or moving the leveler. Do not attempt to lift
without suitable hoisting equipment capable of lifting as much as
5000 lb (2268 kg). Do not work beneath a raised object. Follow all
hoisting safety requirements.
WARNING
Chain Lift
Weight varies by model
STEP 4
If the rear beam does not line up squarely with the rear curb angle,
trim the filler angle to suit.
NOTE: Ensure that there is a 1" typ. (25.4mm) (.75" - 1.25" min/max)
(19mm - 32mm min/max) equally spaced gap between each side of
the leveler and the pit wall.
Top View
Top View
Trim here
(example)
Rear curb angle Filler angle
STEP 5
1" typ. 1" typ.
3x 1" weld
W
L
*1" = 25.4mm
*1" = 25.4mm

NOTCH
WELD
HERE
STEP 7
Finish welding the rear frame to the rear curb angle of the pit. Width
of weld is dependent on dock width.
• 6' wide dock: Six welds - 2" (51mm) welds for end, 8" (203mm)
welds for center welds
• 6'6" wide dock: Six welds - 4" (102mm) welds for end, 8"
(203mm) welds for center welds
• 7' wide dock: Six welds - 6" (152mm) welds for end welds, 8"
(203mm) welds for center welds
NOTE: Follow weld notches in back channel.
16
3
245
Rear curb angle Rear Frame
Finish weld here
7' wide dock shown 6" weld (152mm)8" weld (203mm)
NOTCH
WELD
HERE
6"
STEP 8
With the dock in the home position, remove the rear temporary
leveling plates.
ALL
ALL
BLUE GIANT SERIES DOCK LEVELERS—INSTALLATION & TECHNICAL MANUAL
20 AUGUST 31, 2018 REV.1 (PART # 038-1073EI)
14.1 DOCK LEVELER INSTALLATION CONT'D.
STEP 9
Loosen the shipping bolts from the front of the dock leveler lip,
allowing the mounting feet to settle on the pit floor.
If they do not reach the curb angle within a 1/2" (12mm) then remove
the shipping bolt to close the gap.
DANGER
If installing a Mechanical dock leveler, be aware that the
deployment mechanism may have triggered during shipping
and, as a result, the dock may pop up when the shipping
bolts are loosened.
ALL