Blue Giant U Series Operating instructions

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.
INSTALLATION & OWNER’S MANUAL
U-SERIES VERTICAL STORING DOCK LEVELER
with BLUE GENIUSTM CONTROLS
U-Series Vertical Storing Dock Leveler with Blue Genius™ Controls
Issue Date: October 30, 2012. REV.3 (Part# 038-722E)
BLUE GENIUSTM SERIES
WARNING

TABLE OF CONTENTS
1. ABOUT THE VERTICAL STORING DOCK LEVELER.................................................................................................. 1
1.1 Owner’s Purchase Record........................................................................................................................................ 1
2. INTRODUCTION............................................................................................................................................................. 2
2.1 Warranty Information................................................................................................................................................ 2
2.2 Exclusion of Liability................................................................................................................................................. 2
2.3 Manufacturer’s Note................................................................................................................................................. 2
3. OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION................................................................... 3
3.1 Operational Safety Warnings.................................................................................................................................... 3
4. LOCKOUT / TAGOUT PROCEDURE AND RULES....................................................................................................... 4
5. MAINTENANCE STRUT SETUP.................................................................................................................................... 5
5.1 Engaging the Maintenance Strut.............................................................................................................................. 5
5.2 Disengaging the Maintenance Strut......................................................................................................................... 5
6. STANDALONE VS DOCK ARRANGEMENT (Installation Pictorial)........................................................................... 6
7. INSTALLATION INSTRUCTIONS................................................................................................................................... 7
7.1 Rear Curb Channel and Frame Installation.............................................................................................................. 7
7.2 Hydraulic Power Pack and Hose Installation............................................................................................................ 7
7.3 Electrical and Hydraulic Dock Installation................................................................................................................ 7
7.4 Deck Installation....................................................................................................................................................... 8
7.5 Cylinder Installation.................................................................................................................................................. 8
8. TEST OPERATION......................................................................................................................................................... 9
9. CONTROL STATION OPERATION................................................................................................................................. 10
10. OPERATING INSTRUCTIONS........................................................................................................................................ 11
10.1 Functional Description............................................................................................................................................ 11
10.2 Stop Button Function.............................................................................................................................................. 11
10.3 Starting Procedure.................................................................................................................................................. 11
10.4 Deploying the Dock Leveler- Above Level.............................................................................................................. 11
10.5 Returning Dock Leveler to the Stored Position....................................................................................................... 12
10.6 Deploying the Dock Leveler- Below Level............................................................................................................... 12
10.7 Returning to Normal Lip-on-Load Bed Operation.................................................................................................... 12
11. MAINTENANCE.............................................................................................................................................................. 14
11.1 Planned Maintenance............................................................................................................................................. 14
11.2 Operator Daily Inspection...................................................................................................................................... 14
11.3 Routine Servicing and Maintenance...................................................................................................................... 14
11.4 Planned Maintenance Intervals.............................................................................................................................. 14
11.5 Maintenance Sequence.......................................................................................................................................... 14
11.6 Recommended Hydraulic Fluids............................................................................................................................ 14
11.7 PM Checklist- Dock Equipment.............................................................................................................................. 15
12. PARTS ILLUSTRATION- VERTICAL LOADING DOCK................................................................................................ 16
13. COMPONENT LIST- VERTICAL LOADING DOCK....................................................................................................... 17
14. RECOMMENDED SPARE PARTS................................................................................................................................. 18
15. VERTICAL STORING DOCK LEVELER POWER PACK............................................................................................... 19
16. SHIPMENT KIT- VERTICAL STORING DOCK............................................................................................................. 20
17. TROUBLESHOOTING.................................................................................................................................................... 21

1. 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. It is the perfect loading dock solution for facilities
that must maintain strict temperature or humidity controls.
The Blue Genius™ Touch Control Panel with advanced microprocessor technology controls the operation of the dock
leveler and alerts both the driver and dock attendants of safe/unsafe conditions. Its onboard diagnostics and
communications feature a user-friendly, multi-language LCD intelligent text display and keypad with supervisory
override.
The manufacturer offers a full line of dock levelers, dock safety equipment, accessories, ergonomic and scissor lift
equipment, and industrial trucks. Concurrent with a continuing product improvement program, specifications are subject
to change without notice. Please contact the manufacturer for latest information. Some features illustrated may be
optional in certain market areas.
Dealer:
Date in Service:
Number of Units:
Serial Number(s):
Door # :
OWNER’S PURCHASE RECORD
Please record information for future inquiries
1. 1 OWNER’S PURCHASE RECORD
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
1

Loading Dock Equipment Manufacturers
A Product Section of Material Handling Industry of America,
A Division of Material Handling Industry
8720 Red Oak Blvd., Suite 201, Charlotte, NC, 28217-3992
Telephone: [phone] Fax: [phone]
ALSO MEMBERS OF :
American National Standards Institute (ANSI)
1430 Broadway
New York, NY 10018
[phone]
LOADING DOCK EQUIPMENT MANUFACTURERS
2. INTRODUCTION
The following is a quick reference to important procedures that must be followed while using the Dock Leveler System.
It is not intended to cover, or suggest that it does cover, all procedures necessary to ensure safe operation. All operators
should be aware of and abide by all workplace safety regulations applicable to the operation of the Dock Leveler System.
These laws and regulations include but are not limited to:
• The Occupational Safety and Health Act (USA)
• Occupational Safety and Health Acts for Individual States (USA)
• Canadian Material Handling Regulations
For additional information on these regulations as well as industry standards that may apply to this product, please
contact:
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 Dock Leveler System. 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 development program. Specifications, operating instructions, and illustrations
included in this manual are subject to change without notice. Please contact manufacturer for the latest information.
MANUFACTURER’S NOTE
The Dock Leveler 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
2.3 MANUFACTURER’S NOTE
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 on-line
Warranty Registration at www.BlueGiant.com.
For more information about Blue Giant's 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 that failure to validate warranty at the time of receipt can seriously affect the outcome of any claim.
2.1 WARRANTY INFORMATION
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
2

3.1 OPERATIONAL SAFETY WARNINGS
• ONLY TRAINED PERSONNEL should operate or service this equipment.
• DO NOT operate leveler until truck/trailer is parked against the dock bumpers and the truck/trailer has been secured.
• ALWAYS return the leveler platform to the proper stored position.
• ALWAYS conduct routine inspections and maintenance. Failure to conduct could cause personal injury or damage to equipment.
• ALWAYS call your authorized service representative or manufacturer immediately if a malfunction occurs.
• DO NOT operate leveler with anyone standing in its path.
• DO NOT service leveler unless the maintenance stand is properly engaged. See SECTION:
ENGAGING MAINTENANCE STRUT
• BEFORE BEGINNING ANY SERVICE PROCEDURES:
– Position the dock leveler in the vertically stored position.
– Disconnect the power and follow all LOCKOUT / TAGOUT procedures in this manual
• DO NOT operate leveler without following the procedure below if the leveler has not been in service
for an extended period of time.
• PROCEDURE FOR FILLING CYLINDER:
– Touch and hold the ‘UP’ button (Run Pump) to operate for (35) seconds
• Keep away from hinge when operating leveler.
• POST SAFETY WARNINGS AND BARRICADE WORKING AREA
at dock level and at ground level to prevent unauthorized use of the
dock leveler during maintenance/service.
• During installation, anchors must be properly torqued to obtain the
necessary anchoring strength. DO NOT USE IMPACT DRIVERS.
• DO NOT drive or walk onto truck/trailer until the truck/trailer is parked
against the dock bumpers and the wheels are chocked or the vehicle
restraint has been fully engaged and the lights have changed to
GREEN inside and RED outside.
• NEVER attempt to lift the lip or hold the lip out by hand. Serious
personal injury could occur.
• DO NOT remove lifting equipment until:
a) the main cylinder has been filled.
b) the maintenance stand has been installed and engaged.
• ALWAYS check the rigging to make sure that it is secure before
attempting to lift the unit. Never stand under any unit being lifted.
• NEVER remove the wheel chocks until loading/ unloading is finished
and the truck driver has been given permission to drive away from the
dock.
• DO NOT ground welding equipment to any hydraulic cylinder or
electrical components.
• DO NOT attach welder as ground to leveler platform when welding
on base frame assembly. Attach welder ground to base frame
assembly only. Damage to bearings or hydraulic equipment will
occur.
• DO NOT allow the drill to go too deeply into the box when drilling
holes in the control box. Damage to the control systems may
occur.
• NEVER use air to blow debris from control box. Use a vacuum to
remove debris from control box.
• DO NOT connect green ground lead into control box or junction box
until all welding has been completed.
• CHECK HYDRAULIC FLUID LEVEL. Deck mounted power unit
has been filled with fluid but cylinders, hoses and manifold are
shipped dry.
• NOTE - check motor rotation. Jog the motor until rotation has been
determined. DO NOT allow the motor to run in reverse for more
than a couple of seconds, because this will damage the power unit.
• DO NOT force valve adjustment screws against internal stops.
Damage will occur to the valve/seat.
• If a procedure is not clearly defined in this manual, contact your
authorized service representative.
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. If warning decals are damaged, they must be replaced. Contact your distributor for replacements.
Improper operation can cause accidents. Don’t take chances with incorrect or damaged equipment. Read and understand the procedures for safe
operation and maintenance outlined in this manual.
Avoid accidents by recognizing dangerous procedures or situations before they occur.
3. OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION
This is the highest level statement. Failure to follow the listed
instructions will most likely result in severe 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.
This is a statement of serious hazard. Failure to follow the listed
instructions could place the individual at risk of serious injury or death.
IMPORTANT is used to draw attention to a procedure that needs to be
followed to prevent machine damage.
CRUSH HAZARD.
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
3

4. LOCKOUT / TAGOUT PROCEDURE and RULES
XXXXXXXXXXXX
XXXXXXXXXXX
OPERATE
DO NOT
ABOVE: APPROVED WAY TO LOCKOUT / TAGOUT
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 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.
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.
!
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
4

5. MAINTENANCE STRUT SETUP
:
Correct way to LOCK IN
Maintenance Strut.
Move Maintenance Strut From Stored
Position to Engaged Position.
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.
When maintenance has been completed, perform the
previously outlined steps in reverse and return to the stored
position.
1. Touch the ‘Deck’ button until the platform stops moving.
2. Remove the linchpin and locking pin from the bracket on the
platform.
3. Move the maintenance strut from the stored position to the
engaged position. (See diagram below.)
4. Insert the locking pin through the maintenance strut and lock
it with the linchpin.
5. Swing the maintenance strut into the maintenance bracket.
(See Diagram at top right of this page.)
6. Insert the locking pin into the maintenance strut as shown.
Failure to lock the pin in correctly could cause the dock
leveler to collapse.
5.1 Engaging the Maintenance Strut
:
5.2 Disengaging the Maintenance Strut
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.
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
5

6. STANDALONE VS DOCK ARRANGEMENT
MOTOR WIRING
(to Blue Genius
control station)
NOTE: FUSED
DISCONNECT BY
OTHERS
BLUE GENIUS
CONTROL STATION
(MOUNTED &
WIRED BY
OTHERS)
TRAFFIC LIGHTS
(MOUNTED & WIRED BY OTHERS)
OVERHEAD
DOOR SENSOR
(OPTIONAL)
DOCK HYDRAULIC
LINES , HOME
POSITON SENSOR
AND RANGE SENSOR
CLOSED PIT
LAYOUT
66”
MAIN POWER
(TO CONTROL STATION)
POWER
PACK
SOLENOID VALVE
WIRING
REMOTE I/O BOX
!
CAUTION
MOV E O N
GREEN ONLY
!
CAUTION
MOV E O N
GREEN ONLY
ELECTRICAL REQUIREMENTS-
• MOUNT CONTROL BOX STATION TO WALL, SIGNAL LIGHTS AND DRIVER WARNING SIGNS
• FUSED DISCONNECT PROVIDED BY OTHERS AND WIRING BY OTHERS
• INSTALL CABLE FROM CONTROLBOX STATION TO POWER PACK
• INSTALL CABLE FROM CONTROLBOX STATION TO POWER SUPPLY
GROUND LEVEL
TRAFFIC LIGHTS
(MOUNTED DRIVERS SIDE)
PART #032-461
DRIVER WARNING SIGN
(MOUNTED DRIVERS SIDE)
PART #038-225
84”
RUN 3 CONDUITS. ONE FOR THE
COMMUNICATION CABLE,ONE
FOR THE POWER WIRING TO THE
POWER PACK AND ONE TO THE
BACK OF THE DOCK FOR THE
HYDRAULIC LINES AND
SENSORS.
NEW CONSTRUCTION (VS DOCK):
DRILL ONE HOLE THROUGH THE WALLTO THE OUTSIDE FOR THE L.E.D OUTSIDE
TRAFFIC LIGHTS (OPTIONAL).
RUN ONE 1 1/2” I.D. CONDUIT FROM CONTROL STATION TO THE I/O BOX (ABOVE THE
POWER PACK) FOR THE COMMUNICATION CABLES, OUTSIDE TRAFFIC LIGHTS
& DOOR SENSOR CABLE (OPTIONAL).
RUN ONE 1-1/2” I.D. CONDUIT FROM THE CONTROLSTATION POWER LINE
CONNECTION TO THE DOCKS POWER PACK MOTOR JUCTION BOX.
RUN ONE 3” I.D. CONDUIT FROM THE POWER PACK TO THE BACK OF THE DOCK PIT
FOR THE HYDRAULIC LINES, HOME POSITION SENSOR & RANGE SENSOR.
MINIMUM CONCRETE STRENGTH 3,000 P.S.I.
HYDRAULIC HOSE LINES
POWER WIRING
CABLES
COMMUNICATION CABLES
CONTROL STATION
(MOUNTED ON DRIVERS SIDE)
123
456
789
#0*
EnterOn Green
DoNot Enter
STOP
Deck
LIP
SEL
ESC
>
>
1 2 3
6
5
4
789
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0
#
www.BlueGiant.com
Leveler
Disconnectpower
CAUTION
!
beforeopening pan
DoNot Enter
66”
NOTE: ALL CONDUIT
ENTRY INTO CONTROL
PANEL FROM BOTTOM.
ARRANGE WIRING TO
AVOID HIGH & LOW
VOLTAGE CROSSING
OVER INSIDE CONTROL
BOX.
DO NOT RUN MAIN POWER
WIRING THROUGH TOP OF
CONTROL STATION
COMM CABLE
TO REMOTE I/O
MAIN POWER
(from fused disconnect)
& MOTOR WIRING
(to hyd. Power Pack)
84”
1
2
3
4
1
2
3
4
TRAFFIC LIGHT
CABLE
(to the outside)
DOOR SENSOR
(optional)
C
L
1/8’’
SENSOR
18mm
FRONT ELEVATION VIEW*
INSIDE BUILDING VIEW*
NOTE: *DRAWINGS NOT TO SCALE
30mm
1/4’’
SENSOR
!
!!
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.
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
6

7. INSTALLATION INSTRUCTIONS
CONDUIT
ACCESS
HOLE
3” x 3” x 1/4”
CURB ANGLE
(supplied by others)
REAR CURB
CHANNEL AND
FRAME
ASSEMBLY
(to be poured in
place when floor
slab is poured)
7.1 Rear Curb Channel Back Frame
Installation
1. Pour pit floor concrete into place. Allow to set.
2. Locate the back frame and position it relative to the door
frame.
3. Install reinforcement bars as required to support concrete.
7.2 Hydraulic Power Pack and Hose
Installation
1. Install remote power pack in a suitable location on the wall,
at least 8’ (2438mm) above floor level.
1. Mount Blue Genius Control Station assembly on the left side
of the door’s interior frame, at least 66 inches (1676mm)
above floor level (measure from the top of the control box to
the floor).
2. Securely mount the exterior traffic lights and signs on the
exterior wall adjacent to the doorway (on the driver’s side), at
approximately 7 feet (2134mm) above ground level.
3. Drill one hole through the wall to the outside for the L.E.D
control cable. Run cable through to the control box. Install
cable gland, run cable through, and tighten it.
4. Run one 1/2” I.D. conduit from control station to the hydraulic
power pack remote I/O for the shielded communication
cable.
5. Run one 1/2” I.D. conduit from the control station to the dock’s
hydraulic power pack motor junction box.
7.3 Electrical and Hydraulic Dock Installation
6. Complete the electrical hookup between the exterior traffic
lights and control panel.
7. Run hydraulic hoses (for lip and deck) from the power pack to
the dock leveler.
8. Run control cable via conduit from the remote I/O to the dock
leveler.
For a pictorial of this procedure, see Section 6.
6 5/32"
11 29/32" 12 17/32"
1/4"
8 3/32"
1 9/32"
5"
1 1/2"
1 1/2"
CONDUIT INSTALL
AREA
NOTE:
INSTALL HIGH POWER CONDUIT
FROM BOTTOM OF PANEL.
Figure 1: Blue GeniusTM control station dimensions
and conduit install area
FIGURE 1: NEW INSTALL
3” x 3” x 1/4”
CURB ANGLE
(supplied by others)
FIGURE 2: RETROFIT
REAR CURB
CHANNEL AND
FRAME
ASSEMBLY
(to be welded and
anchored in place)
CONDUIT
ACCESS
HOLE
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. The front face of the curb channel must be retained in a true vertical position during pour, and the finished
floor must be flush with the upper surface of the curb channel, along the full width of the frame.
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
7

7. INSTALLATION INSTRUCTIONS
1. Using slings rated for a minimum capacity of 3000 lbs, (1500
kg), sling the deck assembly into place directly above the
previously poured-in rear frame.
2. Lower the deck assembly gently and guide it to line up the
bottom clevis holes to the pivot hinges on the rear frame.
3. Install the deck pivot pins and secure with split pins.
4. Put maintenance stand securely in place.
5. Install the home position and range sensors. Adjust the
proximity switch by loosening the holding nuts and setting
the gap. Once the desired adjustment has been made,
re-tighten the holding nuts. Ensure that the detected object
can never physically come in contact with the sensor end;
otherwise the switch will be damaged. Complete wiring to
the remote I/O.
7.4 Deck Installation
Failure to prime with hydraulic fluid and bleed all air out of the hydraulic system as instructed will cause the dock leveler deck
to fall abruptly and possibly result in serious injury or death.
1. After ensuring that the cylinder is at its shortest extension, fill
the hydraulic reservoir of the power unit with hydraulic fluid.
(Fluid level should reach approximately ½” below the bottom
of the filler neck. Attach two hydraulic hoses to the deck
cylinder and a third to the lip cylinder.
2. Connect all three hoses to the hydraulic power pack.
NOTE: If the hydraulic hose lines are not pre-filled with oil,
air purging is required. Activate the electrical power supply
to enable the control box, and place the end of the DECK
hose into an appropriate container. Touch and hold the
‘Deck’ button. Run the power unit air free oil flows from the
hose, and then securely attach the fully loaded hose to the
deck cylinder’s base-end fitting. Place the LIP hose end into
an appropriate container, and then touch and hold the ‘Lip’
button to run the power unit until clear oil flows from the
hose. Attach the loaded hose securely to the lip cylinder’s
base.
3. Power on the control panel and activate the deck and lip.
4. Refill the hydraulic reservoir to approximately ½” below the
base of the filler neck.
5. Hold the rod end of the deck cylinder slightly away from the
deck and frame. Touching the ‘Deck’button, extend the deck
cylinder to its maximum length.
6. Loosen the locking-set screw. Then turn the threaded
adjusting block clockwise around the cylinder rod to shorten
it or counter-clockwise to lengthen it as required in order to
allow a tap-in-fit installation of the lower cylinder pin through
the clevis holes of the rear frame brackets. The deck must
remain upright when the cylinder is fully extended.
7.5 Cylinder Installation
7. Line the rod eye up with the clevis holes in the rear frame.
8. Secure the cylinder pin with split pins.
9. Securely and permanently tighten the set-screw to lock the
adjusting block in position.
10. Turn off and lockout the electrical supply to the touch button
station to prevent accidental operation of the dock leveler.
11. Place shims between the pit floor and the underside of the
rear frame cylinder. Locate, position, and weld into place.
Adequate shims (not supplied) are required to ensure that
brackets will not deflect downward under load pressure.
12. Install the specified dock bumpers and risers as required on
the dock area’s outside wall.
13. Locate and securely mount the operations placard to the
inside wall, close to the Blue Genius control station, and in
clear view of the dock leveler operator.
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
8

8. 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.
1. Shut off the power to the dock and the Blue GeniusTM control
station. Using a crane, boom, or similar type of lowering
equipment, carefully lower the deck until it is fully horizontal.
Then turn the power back on.
2. After both the dock and control station have completed the
‘power on’ cycle, touch and hold the ’Deck’ touch button to
raise the deck and lip. When the deck reaches its fully
raised position and stops, it must be properly upright
(slightly past vertical). If not, the deck lift cylinder requires
readjusting. This is accomplished by removing the cylinder
pin, loosening the setscrew and turning the threaded
adjustable rod eye of the cylinder: counterclockwise out of
the cylinder rod to lengthen the cylinder, or clockwise into
the cylinder rod to shorten it. The set screw must then be
tightened to lock the rod eye in position. (See Figure 1)
3. Touch and hold the ‘Down’ touch button to allow the dock
leveler deck, with the lip extended, to descend.
4. Release the ‘Down’ touch button. The motion of the deck
must stop at any position when the button is released.
5. Touch and hold the ‘Lip’ touch button. The deck will remain
stationary and the lip will lower.
6. Release the ‘Lip’ touch button, then press it again. The lip
will resume the extended position.
7. Operate the ‘Down’ button. The deck and the extended lip
will descend to the bottom of the pit and stop at the fully
below dock level position.
Note: If a transport vehicle had been parked in place
against the dock bumpers, the lip would have come to rest
on the vehicle load bed, allowing loading / unloading to
begin.
8. Perform a final inspection and determine that all work is
completed satisfactorily. Clean the pit and work area
thoroughly and apply touch-up paint to weld burn areas,
scratches, etc.
9. Test operate the unit through several cycles of all functions.
10. Mount the Owner’s Manual securely in a place where it can
be easily and immediately accessed by the operator.
Control Box Illustration
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. Serious damage to the dock leveler and / or
personal injury could occur.
Never enter the pit area without locking out the electrical power
supply and engaging the maintenance strut.
DECK UP
DECK DOWN
STOP FUNCTION
LIP OUT
www.BlueGiant.com
Gold Series
TM
T o u c h C o n t r o l
DISCONNECTPOWER
BEFORE OPENING.
READANDFU LLYUNDERSTAND
THEOWNER’S MANUAL BEFORE
OPERATINGTHISPRODUCT.

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#038-244E
Do Not Enter
Proceed With Caution
STOP
0
ESC
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897
564
2 31
D
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E
V
E
L
E
R
Enter On Green


BlueGenius
Figure 1 :
Lift Cylinder Rod Adjustment
SHORTEN
LENGTHEN
SET SCREW
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
9

9. CONTROL STATION OPERATION
CONTROL STATION TYPE - Independent Vertical Dock Leveler
Caution
YELLOW LIGHT
(Proceed With Caution)
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
10

10. OPERATING INSTRUCTIONS
www.BlueGiant.com
GoldSeries
TM
Touc h C control
DISCONNECTPOWER
BEFORE OPENING.
READANDFULLY UNDERSTAND
THEOWNER’SMANUAL BEFORE
OPERATINGTHISPRODUCT.
  
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Enter On Green
STOP
STOP ALARM WILL BEEP UNTIL
THE STOP MODE IS EXITED
Optional Alarm
Blue Genius
The operating instructions in this manual include references
to the advanced communication lights package (control
station and traffic lights.) This is an optional feature and may
not be included with your dock leveler.
1. The truck reverses into position against the dock leveler
bumpers. Outside traffic light (optional) is GREEN and
control station light (optional) remains RED.
Do not install, operate and/or service this leveler unless
you have been trained and authorized to do so, and have
read and understood all of the safety information and
instructions contained herein and on the leveler.
Do not operate the dock leveler beyond its rated
capacity.
Do not operate this leveler until you have checked its
condition. Report the need for leveler repairs to your
supervisor immediately and do not operate leveler until
repairs are made.
Never try to lift or move any part of the dock leveler
manually.
Keep hands and feet clear of pinch points at all times.
Secure the transport vehicle with wheel chocks or a vehicle
restraint before commencing loading / unloading.
Do not drive on leveler unless lip is securely on the
transport vehicle load bed and has a minimum of 4”
(100mm) projection on truck bed.
Do not exceed 4 mph when driving over dock leveler.
Do not drive over edges of the leveler and / or dock bumper
blocks (bumpers blocks are not structural).
10.1 Functional Description
The dock leveler is stored in the vertical position behind the
overhead door, allowing for a complete energy efficient seal.
The vertical storing dock includes a “controlled lowering”
hydraulic system, meaning that the dock attendant must hold
the touch button to lower the unit.
Key features include: high tensile steel, U-beam deck
construction, hydraulic fall-safe, maintenance strut and a
self-locking device.
10.2 Stop Button Function
Should the dock leveler need to be stopped immediately, or
left in a certain position because of an unexpected interference
or a potentially dangerous situation, the Blue GeniusTM control
station has a temporary ‘STOP’ button.
Touching the ‘STOP’ button during dock operation will cause
the unit to stop in mid motion while the internal alarm (optional)
will beep until the stop function is exited.
To exit the ‘STOP’ mode touch ‘ESC’.
10.3 Starting Procedure
10.4 Deploying The Dock Leveler -
Above Level
WARNING
1. After the truck is parked and chocked /restrained in place,
touch and hold the ‘Down’ button. The LCD screen will read
‘Deck Lowering’. The control panel light is RED and the traffic
light changes from GREEN to RED. Keep holding the ‘Deck’
button until the lip makes full contact with the truck bed.
Release the button. The onscreen message will change to
‘Deck Deployed’. The control panel light will turn GREEN
while the outside traffic light remains RED.
Deck Lowering
MENU DISPLAY SCREEN:
Deck Deployed
www.BlueGiant.com
GoldSeries
TM
enius
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8 9
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GoldSeries
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Proceed With Caution
2. Perform and complete the loading / unloading operation.
NOTE: Ensure that the full width of the lip overlaps the truck
bed by a minimum of 4” (102mm) to provide full dock
leveler support.
NOTE: While in use, the dock leveler raises and lowers
automatically in conjunction with the movement of the
truck load bed.
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
11

10. OPERATING INSTRUCTIONS
The transport vehicle should never be allowed to depart
with the lip plate resting on the load bed.
WARNING
10.7 Returning To Normal Lip-on
Load Bed Operation
1. After below level / end loading and unloading has been
completed, touch and hold the ‘Deck’button until the deck is
high enough for the lip to deploy safely onto the truck bed.
The LCD screen will read ‘Deck Raising’. Release the ‘Deck’
button and touch and hold the ‘Lip’ button until the lip is fully
raised. The LCD message will change to ‘Lip Raising’.
Release the ‘Lip’ button and touch and hold the ‘Down’
button until the deck is fully deployed onto the truck bed.
The LCD message will change to ‘Deck Deployed’.
10.5 Returning Dock Leveler To The
Stored Position
1. Touch and hold the ‘Deck’ button. The control panel
light turns RED. The deck will rise.The LCD screen will
read ‘Deck Moving’ and the deck will rise to the stored
position. Hold the button until the lip is in the upright
(parked) position. The message will change to ‘Dock
Leveler Restored’.
10.6 Deploying the Dock Leveler:
Below Level / End Loading
This section outlines dock leveler operation in situations where
contact of the dock leveler lip plate with the transport vehicle
load bed is not possible (e.g. loading/unloading the first skid
or pallet from the load bed, where there is insufficient surface
area to extend the dock leveler lip plate).
1. After the vehicle has been restrained, hold the ‘Deck’ button
to lower the deck. When the deck is halfway down, release
the button. The LCD screen will read ‘Ready to Lower Deck’.
Touch and hold the ‘Lip’ button. The LCD message will
change to ‘Lip Lowering’. When the lip lowers, touch and
hold the ‘Down’ button. The LCD message will change to
‘Deck Lowering’. When the deck has fully deployed, the LCD
screen will read ‘Deck Deployed’.
www.BlueGiant.com
GoldSeries
TM
enius
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lue
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To u c h Co n t r o l
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BEFOREOPENING.
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www.BlueGiant.com
Gold Series
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Blue Genius
Deck Deployed
MENU DISPLAY SCREEN:
Deck Raising
MENU DISPLAY SCREEN:
Deck Moving
Dock Leveler Restored
www.BlueGiant.com
GoldSeries
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Blue Genius
4
7
Deck Lowering
MENU DISPLAY SCREEN:
Ready to Lower Deck
Lip Lowering
www.BlueGiant.com
GoldSeries
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Deck Lowering
Deck Deployed
www.BlueGiant.com
GoldSeries
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DISCONNECTPOWER
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READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
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U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
12

10. OPERATING INSTRUCTIONS
Deck Raising
MENU DISPLAY SCREEN:
Lip Raising
Deck Lowering
Deck Deployed
www.BlueGiant.com
GoldSeries
TM
Touc h C o n tro l
DISCONNECTPOWER
BEFOREOPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
 
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Blue Genius
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U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
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11. MAINTENANCE
MAINTENANCE & SERVICE TIME INTERVALS FOR SPECIFIC DOCK COMPONENTS CHART
!!
Do not operate and/or service this dock leveler until you have read
and understood all of the safety information and instructions
contained herein and on the dock leveler.
Do not work under or around dock leveler without first placing
adequate barriers to positively prevent vehicle traffic from entering
the work area.
Follow proper lock-out/tag-out procedures.
Keep hands and feet clear of dock leveler pinch points and wear
appropriate safety attire - glasses, gloves and work boots.
In addition to the daily operator inspection, the manufacturer
recommends (and local government regulations may require)
that a planned maintenance (PM) and safety inspection
program be performed by a trained and authorized service
technician on a regular basis to maintain the equipment is in
safe operating condition. The PM will provide an opportunity to
make a thorough inspection of the safety and operating
condition of the dock leveler. Necessary adjustments and
repairs can be done during the PM, which will increase the life
of components and reduce unscheduled downtime.
Recommended procedures for a periodic planned maintenance
program that covers inspections, operational checks, cleaning,
lubrication, and minor adjustments are outlined in this manual.
An authorized dealer or distributor is prepared to assist with a
planned maintenance program by offering trained service
personnel with expertise in dock leveler maintenance
requirements.
The dock leveler should always be examined by the operator
PRIOR TO ANY USE to verify that it is safe to operate.
The manufacturer recommends making multiple photocopies
of the Operator’s Daily Checklist. The operator should fill out
this form to keep a daily record of operation and maintenance
issues.
Regular maintenance and care of the dock leveler is very important
for cost and operation efficiency and more importantly; operator
safety. A faulty dock leveler is a potential source of danger to the
operator, and to other personnel working near it. As with all quality
equipment, keep the dock leveler in good operating condition by
following the recommended schedule of maintenance.
Failure to properly maintain or operate the dock leveler within its
rated capacity can void the manufacturer warranty.
Arrange for a qualified dock leveler repair technician to perform
regularly scheduled planned maintenance on your dock leveler
every 3 months for single shift operations or monthly for multi-shift
operations.
Call your authorized manufacturer/ dealer for further details.
1. Cleaning, including pit area.
2. Visual inspection of all components.
3. Lubrication, as required. (by a trained service technician only)
4. Test operate all functions.
5. Adjustments, if required. (by a trained service technician only)
6. Check for missing or damaged dock bumpers.
7. Record inspection details and findings for owners’ files.
Normal, All Season Weather Conditions:
- Valvoline All Weather 36 or equivalent.
Note: Dextron II Automatic Transmission Fluid may be used
if other suitable oils are not available.
Extreme Low Temperature Conditions:
- Esso Univis N15 or Gulf Harmony Arctic 15 or suitable
equivalent.
The Maintenance strut must be in place before commencing
maintenance procedures.
DECK
CYLINDER
INSPECT
CLEAN
LUBRICATE
ADJUST
DECK
ASSEMBLY MAINTENANCE
STAND LIP HINGE
ASSEMBLY LIP
CYLINDER HYDRAULIC
OIL RESERVOIR
As Needed Every 90 Days
Pivot Points (Light Oil) Every 90 Days
(Light Oil) Drain, Flush & Change
Once Per Year
Every 90 Days
(Grease)
As Needed Not Required Not Required
Not Required
Not Required As Needed Fill As Needed
ALL THE ABOVE EVERY 90 DAYS
(for multi-shift operations every 30 days is required)
ALL THE ABOVE EVERY 90 DAYS
Clean Lip As Required (for multi-shift operations every 30 days is required)
Note :Inmanylocalities,allliftingdevicesmustbeinspectedaminimumonceperyear.

11.2 Operator Daily Inspection
11.1 Planned Maintenance
11.3 Routine Servicing and Maintenance
11.4 Planned Maintenance Intervals
11.5 Maintenance Sequence
11.6 Recommended Hydraulic Fluids
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
14

!WARNING
P M C H E C K L I S T – DOCK EQUIPMENT
Barricade Work Area
CLEAN
Repairs?
OK CHECK / ADJUST / LUBE Repairs? OK
Check Main Lift Cylinder
Pit Area Check Lip Lift Cylinder
Deck Hinge Check Clevis Pins & Lubricate
Lip Hinge Check Push-Button Station
CHECK
Repairs?
OK
Check Wiring Harness
Check Full Operating Cycle Check Oil Level (Top off as needed)
Check Instruction, Caution, Danger
Labels Check Automatic Return To Dock
Check Welds On Dock Leveler Check Dock Bumpers
Check Maintenance Strut / Lip Latch Check Weather Seals
Check Ramp Rear Hinges Check Dock Seal/Dock Shelter
Check Dock Leveler Structure, Sub
Frame, Shim
Lubricate Rear Hinges & Pins
Lubricate Dock Leveler Lip Hinge
Structural Damage
Check Lip Crown Check For Proper Operation
Dock Bumpers / Extensions
Overhead Door
Curb Angle Place Updated Service Sticker On
Equipment
Safety Skirts Clean Up Of Dock Leveler Area
COMMENTS
REPAIRS RECOMMENDED
Customer Tel
SWO#
Location Cust. Contact
Date Inspected By
11.7 PM CHECK LIST - DOCK EQUIPMENT
Do not install this leveler, operate and/or service
unless you have been trained and authorized to do so.
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
15

12. PARTS ILLUSTRATION - VERTICAL STORING DOCK
6
5
28
16
3
2
1
15 172624
27
8
7
9
10
18
19
13
12
11
4
23
14
13
14
325
22
21
21
22
23
20
6A
6B
6C
16"
18"
20"
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
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13. COMPONENT LIST - VERTICAL STORING DOCK
ITEM QTY. PART NO. DESCRIPTION
1 1 23-003600 Back Frame Weld
2 3 23-004069 Pivot Pin
3 8 013-1273/16 Dia. Spring Pin X 1.50
4 1 23-005213 Deck Weld
5 1 111-595Lip Shaft
6 1 See BelowLip Weld
7 1 23-003585Service Stand
8 1 23-003570 Swivel Leveling Mtg
9 1 23-003586 Pin (Sevice Stand)
10 1 013-029 Hairpin Cotter
11 1 788-599Lip Cylinder
12 1 034-601Fitting
13 2 107-196 Clevis Pin
14 2 013-0101/4 Dia. Spring Pin 1.25 Lg.
ITEM QTY. PART NO. DESCRIPTION
15 1 23-003336-O Cylinder Assy.
16 1 23-003569 Pin
17 1 200-02704-1 Pin, Cylinder
18 2 23-003568 Clevis Plate
19 4 010-048HHCS
20 4 012-220 Regular Spring Lock Washers (U.S.)
21 2 010-006Cap Screw 5/16-18 X 1 Hh Gr. 5 Zc
22 2 012-200 Regular Spring Lock Washers 5/16”(U.S.)
23 2 011-502 Hex Nuts(U.S.)
24 1 034-599Fitting 90 6Mp-4Mp
25 1 033-661 Velocity Fuse
26 1 034-500Fitting
27 2 028-199Sensor Xs2 30Blpal2 - Telemec
28 1 028-206Sensor Xs2 30Blpal2 - Telemec 5 Motor
ITEM QTY. PART NO. DESCRIPTION
6A 1 200-0254516" Lip Weld
6B 1 200-02545-1 18" Lip Weld
6C 1 200-02545-2 20" Lip Weld
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
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14. RECOMMENDED SPARE PARTS
Part #
Description
Qty Req'd
23-003585 SERVICE STAND 1
1)DNATSECIVRESROF(NIPTOVIP685300-32 1)NIPTOVIPROF(NIPKCOL920-310
23-003570 SWIVEL LEVELING MTG 1
**HARDWARE REQ'D:** 3MOTTOB)KCED(,NIPTOVIP423300-32
QTY: 6 Spring Pin, Part # 013-127
* Complements for Hydraulics (Lip Cylinder) *
Part # Description Qty Req'd
788-599-1 CYLINDER-LIP ASS'Y 1
1REDNILYCPILROFTIK,LAES402-630 1RAB819-901#ROFGNIHSUB100-810 2)REDNILYCPILROF(GNITTIF106-430
**HARDWARE REQ'D:** 112-740 CLEVIS PIN (LIP) TOP 1
QTY: X 1 Part # 011-530 Nut
**HARDWARE REQ'D:** 1MOTTOB)PIL(REDNILYC,NIP691-701
QTY: 1 Part # 013-010 Spring Pin
* Complements for Hydraulics (Main Cylinder) *
Part # Description Qty Req'd
23-003336-1 CYLINDER ASS'Y WITH SENSOR BRACKET 1
1REDNILYCKCEDROFTIK,LAES 1POT)REDNILYCKCEDROF(GNITTIF995-430
034-601 FITTING (FOR DECK CYLINDER) BOTTOM 1
033-661 VELOCITY FUSE 1
1POT)KCED(REDNILYC,NIP965300-32
**HARDWARE REQ'D:** 1MOTTOB)KCED(REDNILYC,NIP1-40720-002
QTY: X 2 Sping Pin, Part # 013-127
**HARDWARE REQ'D:** 1ETALPPOTTOVIPREDNILYC865300-32
QTY: X 4 Bolt, Part # 010-042 & QTY: X 4 Reg. Spring Lock Washer (U.S.), Part # 012-220
028-199 PROXIMITY SENSOR (30MM) - For Cylinder 1
1)MM81(ROSNESYTIMIXORP002-820
U-SERIES VERTICAL STORING DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
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