Blue Giant BLUE GENIUS SERIES Operating instructions

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.
INSTALLATION &
OWNER’S MANUAL
A-SERIES HYDRAULIC DOCK LEVELER
with BLUE GENIUSTM CONTROL STATION BLUE GENIUSTM SERIES
WARNING
A-Series Hydraulic Dock Leveler with Blue GeniusTM Controls. Issue Date: September 25, 2012. Rev.5 (Part#038-726E)
Applies to Serial Numbers 369651 and up.

TABLE OF CONTENTS
1. ABOUT THE A-SERIES HYDRAULIC DOCK LEVELER with BLUE GENIUSTM CONTROLS.................................. 1
1.1 Owner’s Purchase Record...................................................................................................................................... 1
2. INTRODUCTION ......................................................................................................................................................... 2
2.1 Warranty Information............................................................................................................................................. 2
2.1 Exclusion of Liability.............................................................................................................................................. 2
2.2 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. STANDALONE DOCK ARRANGEMENT .................................................................................................................... 5
6. WELD INSTALLATION PICTORIAL............................................................................................................................. 6
7. DOCK LEVELER INSTALLATION INSTRUCTIONS................................................................................................... 7
7.1 Installation Inspection............................................................................................................................................. 8
8. ELECTRICAL AND HYDRAULIC INSTALLATION...................................................................................................... 9
8.7 Electrical and Hydraulic Dock Installation.............................................................................................................. 9
8.2 Final Inspection..................................................................................................................................................... 9
9. CONTROL STATION OPERATION.............................................................................................................................. 10
10. OPERATING INSTRUCTIONS..................................................................................................................................... 11
10.1 Functional Description.......................................................................................................................................... 11
10.2 Stop Button Function............................................................................................................................................ 11
10.3 Deploying the Dock (Deck Button Only- Method 1) ........................................................................................... 12
10.4 Deploying the Dock (Deck Button and Lip Button- Method 2)............................................................................. 12
10.5 Storing the Dock Leveler..................................................................................................................................... 13
10.6 Below Level / End Loading.................................................................................................................................. 13
10.7 Returning to Normal Lip on Load Bed Operation................................................................................................ 13
10.8 Auto-Return Functional Description...................................................................................................................... 13
10.9 Auto-Return Activate / Deactivate......................................................................................................................... 14
11. MAINTENANCE............................................................................................................................................................ 15
11.1 Planned Maintenance.......................................................................................................................................... 15
11.2 Operator Daily Inspection.................................................................................................................................... 15
11.3 Routine Servicing and Maintenace...................................................................................................................... 15
11.4 Planned Maintenance Intervals ........................................................................................................................... 15
11.5 Maintenance Sequence....................................................................................................................................... 15
11.6 Recommended Hydraulic Fluids.......................................................................................................................... 15
11.7 PM Checklist........................................................................................................................................................ 16
12. HYDRAULIC CYLINDERS........................................................................................................................................... 17
12.1 Hydraulic Deck Lifting Cylinder............................................................................................................................ 18
12.2 Hydraulic Lip Extension Cylinder......................................................................................................................... 18
13. VELOCITY FUSE- FALL SAFE.................................................................................................................................... 18
14. LEVELER HYDRAULIC HOSES.................................................................................................................................. 19
14.1 Deck Lifting Cylinder Hose- All Capacity............................................................................................................. 19
14.2 Lip Extension Cylinder- Hose All Capacity........................................................................................................... 19
15. SAFETY SIDE SKIRTS................................................................................................................................................. 20
16. SAFETY STRUT ASSEMBLY...................................................................................................................................... 20
17. DOCK POWER PACK ASSEMBLY.............................................................................................................................. 21
18. GENERAL PARTS....................................................................................................................................................... 22
18.1 Molded Rubber Bumpers.................................................................................................................................... 22
18.2 Face Plates for Molded Rubber Bumpers........................................................................................................... 22
18.3 Laminated Bumpers............................................................................................................................................ 22
18.4 Face Plates for Laminated Bumpers .................................................................................................................. 22
18.5 Flood Light.......................................................................................................................................................... 22
19. DOCK LEVELER TROUBLESHOOTING.................................................................................................................... 23
20. CONTROL STATION TROUBLESHOOTING............................................................................................................... 28

1. ABOUT the A-SERIES HYDRAULIC DOCK LEVELER with BLUE GENIUSTM 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. Hydraulic lip cylinders
increase operating efficiency and reduce maintenance requirements.
The Blue Genius™ Touch Control Panel with advanced microprocessor technology controls the operation of the
restraint and alerts both the driver and dock attendants of safe/unsafe conditions. Its onboard diagnostics and
communcations 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
A-SERIES HYDRAULIC 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: (704) 676-1190 Fax: (704) 676-1199
ALSO MEMBERS OF :
American National Standards Institute (ANSI)
1430 Broadway
New York, NY 10018
(212) 642-4900
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 1-905-457-3900.
* Note that failure to validate warranty at the time of receipt can seriously affect the outcome of any claim.
2.1 WARRANTY INFORMATION
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
2

3.1 OPERATIONAL SAFETY WARNINGS
3. 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. If warning decals become damaged or missing, replace them immediately. Avoid accidents by
recognizing dangerous procedures or situations before they occur.
Serious injury or death will likely occur if the instructions are not
followed. Procedures marked IMPORTANT must be followed in order to prevent
damage to machinery.
Serious injury or death may occur if the instructions are not followed. Instructions marked CAUTION concern safe operating procedure.
Failure to comply may result in personal injury.
• DO NOT operate leveler with anyone standing in the path of operation.
• BEFORE BEGINNING ANY SERVICE PROCEDURES:
– Disconnect the power and follow all LOCKOUT / TAGOUT procedures.
• DO NOT operate leveler without filling the cylinder if the unit has not been in service for an extended period of time.
• Procedure for filling cylinder:
– Press and hold the ‘Deck’ button (Run Pump). Operate for (25) 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 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 the transport vehicle until it 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 or hold the lip out by hand. Serious
personal injury could occur.
• ALWAYScheck the rigging to make sure that it is secure before
proceeding 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 depart, or
the Vehicle Restraint has been released and the lights have
changed to RED inside and GREEN outside.
• 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. Otherwise damage to bearings or hydraulic
equipment will occur.
• DO NOT allow the drill to go too deeply 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, otherwise the power unit may become
damaged.
• 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.
• ONLY TRAINED PERSONNEL should operate or service this equipment.
• DO NOT operate leveler until freight carrier is parked against the dock bumpers and has been secured by a vehicle restraint and/or chocks.
• 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.
A-SERIES HYDRAULIC 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.
!
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
4

4”
20”
14”
DOCK JUNCTION
BOX
MOTOR JUNCTION
BOX
5. STANDALONE DOCK ARRANGEMENT
X
UNDER DOCK
AUTO-RETURN
SENSOR
(optional)
MOTOR WIRING
(to Blue Genius
control station)
DOCK
HYDRAULICS
CONTROL CABLE
(to Blue Genius control
station)
NOTE: FUSED DISCONNECT
BY OTHERS
BLUE GENIUS
CONTROL STATION
(MOUNTED & WIRED
BY OTHERS)
TRAFFIC LIGHTS (OPTIONAL)
(MOUNTED & WIRED BY OTHERS)
84”
MAIN POWER
(TO CONTROL STATION)
!
CAUTION
MOV E O N
GREEN ONLY
!
CAUTION
MOV E O N
GREEN ONLY
ELECTRICAL REQUIREMENTS-
• MOUNT CONTROL BOX STATION TO WALL, SIGNAL LIGHTSAND DRIVER WARNING SIGNS
• FUSED DISCONNECT PROVIDED BY OTHERS AND WIRING BY OTHERS
• INSTALL CABLE FROM CONTROL BOX STATION TO POWER PACK
• INSTALL CABLE FROM CONTROL BOX STATION TO POWER SUPPLY
GROUND LEVEL
TRAFFIC LIGHTS
(MOUNTED DRIVERS SIDE)
PART #032-461
(OPTIONAL)
DRIVER WARNING SIGN
(MOUNTED DRIVERS SIDE)
PART #038-225
(OPTIONAL)
84”
RUN TWO CONDUITS. ONE FOR
THE COMMUNICATION CABLE
AND ONE FOR THE POWER
WIRING TO THE POWER PACK.
NEW CONSTRUCTION (FH DOCK):
1. DRILL ONE HOLE THROUGH THE WALL TO THE OUTSIDEA FOR THE L.E.D
COMMUNICATION LIGHTS (OPTIONAL).
2. RUN ONE 1/2” I.D. CONDUIT FROM CONTROL STATION TO THE DOCK JUNCTION BOX
FOR CONTROL CABLES.
3. RUN ONE 1/2” I.D. CONDUIT FROM THE CONTROL STATION POWER LINE CONNECTION
TO THE DOCKS POWER PACK MOTOR JUCTION BOX.
MINIMUM CONCRETE STRENGTH 3,000 P.S.I.
HYDRAULIC HOSE LINES
POWER WIRING
CABLES
COMMUNICATION CABLES
CONTROL STATION
(MOUNTED ON DRIVERS SIDE, LIGHTS OPTIONAL)
MAIN POWER
(from fused disconnect)
MOTOR WIRING
(to hyd. Power Pack) CONTROL
CABLE
(to Dock Junction Box)
TRAFFIC
LIGHT CABLE
(optional,
to the outside)
123
456
789
#0*
EnterOn Green
DoNot Enter
STOP
Deck
LIP
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
#
www.BlueGiant.com
Leveler
Disconnectpower
CAUTION
!
beforeopening pan
66” NOTE: ALL CONDUIT
ENTRY INTO CONTROL PANEL
FROM BOTTOM.ARRANGE
WIRING TOAVOID HIGH & LOW
VOLTAGE CROSSING OVER
INSIDE CONTROL BOX.
DO NOT RUN MAIN POWER
WIRING THROUGH TOP OF
CONTROL STATION
!
!!
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.
FRONT ELEVATION VIEW*
INSIDE BUILDING VIEW*
NOTE: *DRAWINGS NOT TO SCALE
66”
OVERHEAD DOOR
INTERLOCK
(OPTIONAL)
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
5

DOCK LEVELER
BASE FRAME
SHIM LIFT ARM
BASE BRACKET
5" X 5" - 127mm x 127 mm
STITCH WELD
1/4" 6”
SHIM BOTH SIDES
5" X 5" - 127mm x 127 mm
SHIM BOTH SIDES
5" X 5" - 127mm x 127 mm
SHIM 4" x 4"
(102mm x 102mm)
FORK LIFT TRUCK HANDLING SLING HANDLING
HYDRAULIC
6. WELD INSTALLATION PICTORIAL
WELD INSTALLATION PICTORIAL
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
6

7. DOCK LEVELER INSTALLATION INSTRUCTIONS
LENGTH
PIT MUST BE
KEPT SQUARE
WIDTH
DOCK BUMPERS
Typically 19-1/2” or
23-1/2” (495 or 595mm).
Typically 19” or
23”(485 or 585mm)
Figure 1 : Pit Layout - Typical (Four piece curb angle shown)
!
IMPORTANT
!
IMPORTANT
!
Do not install, operate and/or service this leveler until you
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.
Keep hands and feet clear of dock leveler pinch points.
WARNING
!
!
The information below is crucial to proper installation:
Pit Curb Angles
A. Must be level side-to-side and front-to-back.
B. Must be square at both rear corners.
C. Side curb angles must be parallel to each other.
D. Finished floor to be flush with top surface of curb angle.
The leveler must be welded to a firmly embedded steel or other
dock steel as described in the installation instructions.
Do not attempt to use only bolts or anchors, to attach the dock
leveler to the concrete.
1. Prior to installation, clean pit thoroughly and verify that all
dimensions are in accordance with manufacturer
specifications.
2. Measure height of rear corners of dock leveler, bottom of
frame to top of deck plate, typically 19” or 23”(485 or
585mm). Measure depth of pit at both rear corners where
rear bottom corners of frame will be positioned. Locate and
place suitable shims (not supplied) in pit corners to produce a
depth to match frame height.
3. Measure height of dock leveler front corners, bottom of frame
to top of deck plate, typically 19-1/2” or 23-1/2” (495 or
595mm). Measure depth of pit at both front corners where
front bottom corners of frame will be positioned. Locate and
place suitable shims (not supplied) at both front corners to
produce a depth to match frame height. See Figure 1.
!WARNING
!WARNING
All electrical work must be performed by trained and authorized
personnel.
4. Prepare to hook up electrical wires and hydraulic hoses if
required. Identify hose ends as “Lip” and “Deck”. For units
with self-contained (mounted under deck) power pack,
establish a temporary electrical hook-up to enable deck to be
raised and lowered during installation. For units with a wall
mounted (remote) power pack, prepare hydraulic hoses for
“pulling” through conduit and electrical wires for temporary
hook up.
Use caution when lifting or moving the leveler. Do not attempt
to lift without suitable hoisting equipment capable of lifting as
much as 3500 lbs. Do not work beneath a raised object. Follow
all hoisting safety requirements.
5. Using extreme caution, sling dock leveler into place squarely
above pit and lower gently onto pre-located shims. Locate
and square dock leveler to best suit pit and dock face. Space
between sides of deck and sides of pit should be equal. Line
up the bottom clevis holes to the pivot edges of the rear
frame.
It is important that the shims fill the space between the
bottom edge of the back beam and face of the curb angle, as
well as behind each hinge lug on the top edge. Confirm that
the top of the back beam is flush with the top surface of the
rear curb angle, and then finish weld back beam to curb
angle.
6. If the rear beam does not line up squarely with the rear curb
angle, use 3” x 6” (75mm x 150mm) shims of suitable
thickness to fully support top rear and bottom rear of rear
beam at weld areas. Weld rear beam to curb steel with 1/4”
x 6” (6mm x 150mm) welds, on 9-5/8” (250mm) centers.
7. Remove sling brackets, chains, etc. from the deck. Remove
and discard the shipping bolt from the front of the dock
leveler lip plate. Remove the bolts from the upper shipping
hole in the rear tilt bars and place them in the lower operating
holes.
8. Check the deck height to confirm that it is flush with the top
of the side curb angles and tack-weld all front shims to the
front curb angle and front frame.
9. Adjust the lip proximity sensor by loosening the holding nuts
and setting the gap. Once the desired adjustment has been
achieved, re-tighten the holding nuts.
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
7

10. Mount Blue Genius Control Station assembly in a suitable
location. Mount power unit in a suitable location if
applicable (remote power pack).
11. If power unit is mounted remote from pit (wall mounted)
permanently attach hydraulic hoses. “Lip” hose is
attached to the top fitting on the power unit manifold block
and the “Deck” hose is attached to the side fitting.
12. Perform a temporary electrical hook-up to allow use of
power unit to raise dock leveler. Confirm correct motor
rotation on start-up of 3 phase units – if motor runs but
deck will not raise, qualified personnel to interchange any
two motor leads.
13. Touch and hold “Deck” button to raise deck and extend lip.
Raise and position maintenance strut. Release the button
and allow dock leveler to lower onto maintenance strut.
Install additional blocking to assure deck can not lower
unexpectedly and place traffic barriers as required.
14. Remove the pin from telescopic maintenance strut, and
extend the maintenance strut to the desired height. Then
reinsert pin to engage the strut to the head board.
!
Do not work beneath the dock leveler without engaging the
maintenance strut.
Do not work beneath the dock leveler without following
proper lockout procedures. Disconnect and lockout the
electrical power supply, and confirm that there is no power
to the dock leveler control panel. Also confirm that it cannot
be turned on again accidentally.
15. Rear frame on most models has one or more vertical frame
members in addition to rear corner vertical members.
Place adequate shims directly under each vertical member
to fill space between bottom frame and floor of pit. Finish
weld all rear shims. Reminder: the rear frame MUST be
flush with the floor.
16. Measure thickness of shims that were installed under
middle of front frame and place same thickness of 6” x 6”
(150mm x 150mm) shims under base of deck cylinder.
Finish weld to cylinder mounting plate.
17. Finish weld all shims securely to the front curb angle and
front frame, under the lip keeper supports.
18. Weld the rear frame to the pit’s rear curb angle. (See Figure
2).
19. Install specified dock bumpers as required. Do not use the
dock leveler to be used without bumpers, as damage to
both building and leveler may result.
20. Release bottom safety skirts by removing and discarding
shipping bolts, one bolt from each side.
21. Make permanent electrical and hydraulic connections as
required.
21. Mount the operations placard on the wall in plain view of
dock leveler operations.
1. Clean up the entire work area and apply touch-up paint to all
welds, scratches and burns.
2. Test operate the unit through several full cycles of operation.
Refer to the Operating Procedures section. If problems are
noted, consult the TROUBLESHOOTING section of this
manual.
3. Leave these Instructions with the dock leveler for use by
owner.
7.1 Installation Inspection
UPPER REAR
PIT ANGLE
REAR FRAME
BAR
7. DOCK LEVELER INSTALLATION INSTRUCTIONS
1/2” X 8” (13mm x 203mm) WELD
BACK OF DECK
FRAME
CONCRETE PIT
1/2” X 6” (13mm x 152mm) WELD
CENTER
LINE
REAR PIT ANGLE
CAST-IN
REAR FILLER
(OPTIONAL- AS
REQUIRED BY
PIT LENGTH)
1/2” X 6” (13mm x 152mm) WELD
1/2” X 6” (13mm x 152mm) WELD
1/2” X 8”
(13mm x 203mm) WELD
ENSURE THAT EQUAL SPACING EXISTS
BETWEEN WELDS
ENSURE THAT EQUAL SPACING EXISTS
BETWEEN WELDS
FIGURE 2
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
8

8. ELECTRICAL AND HYDRAULIC INSTALLATION
1. Securely mount the exterior traffic lights (optional) and signs
on the exterior wall adjacent to the doorway (on the driver’s
side), at approximately 8 feet (2438mm) above floor level.
2. Drill one hole through the wall to the outside for the L.E.D
communication lights cable. Run cable through to the control
box. Install cable gland, run cable through, and tighten it.
3. Run one 1/2” I.D. conduit from control station to the dock
junction box for the control cable.
4. Run one 1/2” I.D. conduit from the control station to the dock’s
power pack motor junction box.
5. Complete the electrical hookup between the exterior traffic
lights (optional) and control panel.
For a pictorial of this installation procedure, see Section
5.
1. Check all hydraulic connections for leaks and tighten as
required.
2. Check that all electrical and hydraulic conduits, hoses, and
wires are mechanically protected against damage and are
adequately secured.
3. Return all wiring diagrams to the Blue Genius™ Control
Panel.
4. Mount warning placard next to the Blue Genius™ Control
Panel.
5. Leave these instructions near the dock leveler for easy
future access.
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.
8.1 Electrical and Hydraulic Dock Installation
8.2 Final Inspection
6 5/32"
11 29/32" 12 17/32"
1/4"
8 3/32"
1 13/16"
5 1/2"
5 27/32"
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.
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
9

www.BlueGiant.com
Gold Series
T o u c h C o n t r o l
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLYUNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
R
#038-244E
Do Not Enter
Caution
Enter On Green
STOP
0
ESC
SEL
8 97
5 64
2 31
9. CONTROL STATION OPERATION
SCROLL ‘UP’
SELECT
ESCAPE
SCROLL ‘DOWN’
RED LIGHT
(Do Not Enter)
MENU SCREEN
YELLOW LIGHT
(Proceed With Caution)
GREEN LIGHT
(Enter On Green)
CONTROL STATION KEY PAD
(Activation, Security,
Features, Etc.)
‘STOP’
(Stop / Deck, Lip)
D
O
C
K
L
E
V
E
L
E
R
CONTROL STATION TYPE - Independent Hydraulic Dock Leveler
LEVELER ‘DECK’ / ‘LIP’
(Raise Deck / Lip)
LEVELER ‘LIP’
(Extend Lip)
Blue Genius
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
10

9. OPERATING INSTRUCTIONS
The A-Series Hydraulic Dock Leveler serves as a bridge
between a loading dock floor and the load bed of a transport
vehicle. The leveler’s upper deck plate, complete with a
hinged, vertically hanging lip, is in a shallow pit at the edge
of the dock, flush with the dock’s edge and the floor surface.
It is hydraulically operated via the Blue Genius™ Control
Station.
After the door has been opened, the rear of a transport
vehicle is parked and restrained in place against the outer
wall of the loading dock, in working alignment with the dock
leveler. The leveler is then operated by maintaining pressure
on a touch button to raise the front of the deck. The hinged
lip plate raises with the deck, its leading edge swinging out
horizontally over the rear of the transporter vehicle once the
deck reaches its fully raised position. The dock attendant
releases the push button, causing the deck and extended lip
to lower together until the lip’s underside comes to rest on
the load bed of the transporter vehicle. A solid bridge is now
formed between the dock and the truck.
During loading/unloading operations, both deck and lip
automatically follow the raising and lowering movement of
the transporter vehicle.
Once all work is completed, the dock attendant returns the
leveler to its original stored position.
Secure the transport vehicle with a vehicle restraint, wheel chocks or other
method before commencing traffic across the dock leveler.
10.1 Functional Description
10.2 Stop Button Function
Do not operate 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.
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 repairs to your supervisor
immediately and do not operate the unit until repairs
are made. Neglect may cause a minor repair to become
a major service problem and cause the leveler to become
unsafe.
Never try to lift or move any part of the dock leveler
manually.
Do not drive on the leveler unless the lip is securely on
the truck bed and has a minimum of 4” (100mm) overlap
on its surface.
Do not exceed 4 mph when driving over the dock leveler.
Do not drive over edges of the leveler and / or dock
bumper blocks (bumpers blocks are not structural). The Blue GeniusTM Control Station has a temporary ‘STOP’ button
for situations where the dock leveler might need to be stopped
immediately or left in a certain position because of an unexpected
interference or a potentially dangerous situation.
Touching the ‘STOP’ button during operation will cut the power to
the unit and cause the leveler to lower to a hard stop via gravity.
To exit the ‘STOP’ mode touch ‘ESC’.
10. OPERATING INSTRUCTIONS
D
O
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K
L
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V
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Truck / Vehicle Dock Leveler
ICC Bar
Dock Bumper
Loading Dock
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STOP
Lip
Deck
Release
Engage
SEL
ESC
>
>
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Restraint
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Leveler
ESC
SEL
www.BlueGiant.com
GoldSeries
TM
enius
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B
T o u c h C o n t r o l
DISCONNECTPOWER
BEFORE OPENING.
READANDFULLY UNDERSTAND
THEOWNER’SMANUAL BEFORE
OPERATINGTHISPRODUCT.
R
#038-244E
Do Not Enter
Caution
Enter On Green
STOP
0
ESC
SEL
8 97
5 64
2 31
STOP
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
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Deck
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Engage
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ESC
>
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Restraint
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Leveler
10. OPERATING INSTRUCTIONS
10.3 Deploying the Dock (Deck Button
Only- Method 1)
1. Raise the dock leveler by touching and holding the ‘Deck’
button. The control station light instantly changes to RED
and the outside traffic light remains RED (optional). If the
deck button continues to be pressed while the dock is in the
fully raised position, the lip will then deploy.
3. Release the ‘Deck’ button. The dock leveler will then descend
with the deployed lip on the vehicle load bed and the LCD
message will change to ‘Deck Moving’. The outside traffic
light remains RED (optional) and the control station light will
turn GREEN (optional). Wait for the dock to fully deploy on
the vehicle load bed before commencing loading / unloading
operations. NOTE: Ensure that the full width of the lip
overlaps the vehicle load bed by a minimum of 4” (102mm).
Deck Deployed
MENU DISPLAY SCREEN:
Min. 4”
www.BlueGiant.com
GoldSeries
TM
enius
G
lue
B
Touch Control
DISCONNECTPOWER
BEFORE OPENING.
READANDFULLY UNDERSTAND
THEOWNER’SMANUAL BEFORE
OPERATINGTHISPRODUCT.
WARNING
R
#038-244E
Do Not Enter
Caution
Enter On Green
STOP
0
ESC
SEL
8 97
5 64
2 31
D
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K
L
E
V
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L
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www.BlueGiant.com
TM
enius
G
lue
B
T o u c h Con t r o l
DISCONNECTPOWER
BEFORE OPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
R
#038-244E
Do Not Enter
Proceed With Caution
Enter On Green
STOP
0
ESC
SEL
8 97
56
4
2 31
D
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Deck Raising...
MENU DISPLAY SCREEN:
10.4 Deploying the Dock (Deck Button
and Lip Buttons- Method 2)
2. Deploy the lip by touching and holding the ‘Lip’ button. Both
the outside traffic light and control station lights (optional)
remain RED. The LCD message will change to ‘Lip Moving’.
NOTE: The ‘Lip’ button should only be touched after the lip
has cleared the keepers.
1. After the truck has been secured, raise the dock leveler by
touching and holding the ‘Deck’ button. The control station
light (optional) instantly changes to RED and the outside
traffic light remains RED (optional). The LCD message will
read ‘Deck Raising’. Release the ‘Deck’ button once the
leveler has reached a height where the lip can be deployed.
123
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EnterOnGreen
ProceedWithCaution
DoNotEnter
STOP
Lip
Deck
Release
Engage
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
#
Restraint
www.BlueGiant.com
Leveler
www.BlueGiant.com
TM
enius
G
lue
B
T o u c h Con t r o l
DISCONNECTPOWER
BEFORE OPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
R
#038-244E
Do Not Enter
Proceed With Caution
Enter On Green
STOP
0
ESC
SEL
8 97
56
4
2 31
D
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Lip Moving
MENU DISPLAY SCREEN:
3. Once the lip has deployed, release the ‘Lip’ button. Both
dock leveler and extended lip will descend onto the vehicle
load bed. The LCD message will change to ‘Deck Moving’.
The outside traffic light (optional) remains RED and the
control station light (optional) turns GREEN, advising dock
staff that loading / unloading operations may begin. NOTE:
Ensure that the full width of the lip overlaps the vehicle load
bed by a minimum of 4” (102mm).
Deck Deployed
MENU DISPLAY SCREEN:
Min. 4”
www.BlueGiant.com
GoldSeries
TM
enius
G
lue
B
Touch Control
DISCONNECTPOWER
BEFORE OPENING.
READANDFULLY UNDERSTAND
THEOWNER’SMANUAL BEFORE
OPERATINGTHISPRODUCT.
WARNING
R
#038-244E
Do Not Enter
Caution
Enter On Green
STOP
0
ESC
SEL
8 97
5 64
2 31
D
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K
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A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
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10. OPERATING INSTRUCTIONS
10.5 Storing the Dock Leveler
1. To return the dock leveler to the stored position, touch and
hold the ‘Deck’ button. The outside traffic light (optional)
remains RED and the control station light (optional) immedi-
ately turns from GREEN to RED. The dock will raise and the
lip will retract. The LCD screen will read ‘Deck Raising’.
www.BlueGiant.com
GoldSeries
TM
enius
G
lue
B
Touc h Con t rol
DISCONNECTPOWER
BEFORE OPENING.
READANDFULLY UNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
R
#038-244E
Do Not Enter
Proceed With Caution
Enter On Green
STOP
0
ESC
SEL
8 97
5 64
2 31
D
O
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Deck Raising
MENU DISPLAY SCREEN:
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EnterOnGreen
ProceedWithCaution
DoNotEnter
STOP
Lip
Deck
Release
Engage
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
#
Restraint
www.BlueGiant.com
Leveler
2. When the lip has fully retracted, release the ‘Deck’ button.
The LCD message will change to ‘Deck Moving’.The dock
will fall back to the stored position with the lip resting in the
lip keepers. The control station light (optional) will change
from GREEN to RED and the outside traffic light (optional)
turns GREEN. The LCD message will change to ‘Dock
Leveler Restored’.
1. Chock the vehicle wheels. Below level / end loading can take
place ONLY after the truck has been properly restrained.
2. Hold the ‘Deck’ button to raise the deck. Both the control
station light and the outside traffic light (optional) are RED.
10.6 Below Level / End Loading
This section outlines dock leveler operation in situations where
the lip plate cannot make contact with the transport vehicle load
bed (e.g. loading / unloading the first skid or pallet from the load
bed when there is insufficient surface area to extend the dock
leveler lip plate).
3. When the dock is fully raised, the lip extends. When the lip
is partially extended (approximately 2” [50mm]), release the
button to return the dock to the stored position. Since the lip
is out and clear of the lip keepers, the dock will descend
past the floor level so that below level / end loading can be
accomplished. The outside traffic light (optional) is RED and
the control station light is GREEN (optional).
NOTE: Dock personnel must exercise caution when walking
on or around the leveler while it is in the below level position,
as a gap exists between the leveler edge and the vehicle
load bed.
123
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#0*
EnterOnGreen
ProceedWithCaution
DoNotEnter
STOP
Lip
Deck
Release
Engage
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
#
Restraint
www.BlueGiant.com
Leveler
www.BlueGiant.com
TM
enius
G
lue
B
Touch Control
DISCONNECTPOWER
BEFOREOPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
WARNING
R
#038-244E
Do Not Enter
Caution
Enter On Green
STOP
0
ESC
SEL
8 97
5 64
2 31
D
O
C
K
L
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L
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R
1. After below level / end loading or unloading has been
completed, touch and hold the ‘Deck’ button until the dock is
high enough to safely deploy onto the vehicle load bed. The
control station light and outside traffic light will both be RED
until the deck and lip descend onto the load bed. Then the
control station light will turn GREEN.
123
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789
#0*
EnterOnGreen
ProceedWithCaution
DoNotEnter
STOP
Lip
Deck
Release
Engage
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
#
Restraint
www.BlueGiant.com
Leveler
MENU DISPLAY SCREEN:
Deck Raising
TM
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Do Not Enter
Proceed With Caution
Enter On Green
STOP
ESC
SEL
D
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0
8 97
5 64
2 31
10.7 Returning to Normal Lip on Load Bed
Operation
Should the transport vehicle ever depart the loading dock while
the dock leveler is still deployed, the optional auto-return
function returns the leveler to the stored position automatically.
This added safety feature prevents a dangerous situation for
cross-traffic from arising.
TM
123
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EnterOnGreen
ProceedWithCaution
DoNotEnter
STOP
Lip
Deck
Release
Engage
SEL
ESC
>
>
1 2 3
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789
*
0
#
Restraint
www.BlueGiant.com
Leveler
10.8 Auto-Return Functional Description
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
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10. OPERATING INSTRUCTIONS
DOCK RETURNS TO STORED
POSITION AUTOMATICALLY
R
123
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#0*
EnterOnGreen
ProceedWithCaution
DoNotEnter
STOP
Lip
Deck
Release
Engage
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
#
Restraint
www.BlueGiant.com
Leveler
WARNING
Auto Park in xx ALARM WILL SOUND AS LEVELER
RETURNS TO THE STORED
POSITION IN AUTO RETURN MODE.
Optional Alarm
1. If the truck departs while the deck is still deployed, the LCD
screen will read ‘WARNING- Auto Park in XX” (depending on
preprogrammed countdown time). The RED control panel
light will flash and the dock will automatically resume the
stored position.
NOTE: To stop the dock from parking after the Auto Park
mode has been activated, press any key. The feature will be
disabled until the dock is properly parked.
10.9 Auto-Return Activate / Deactivate
TM
enius
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T o u c h Con t rol
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Do Not Enter
Proceed With Caution
Enter On Green
STOP
ESC
SEL
D
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0
8 97
5 64
2 31
A-SERIES HYDRAULIC 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
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
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!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.
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
16

12. HYDRAULIC CYLINDERS
12.1 HYDRAULIC DECK LIFTING CYLINDER
ITEM QTY 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 Seal Kit for all Deck Lifting Cylinders
12.2 HYDRAULIC LIP EXTENSION CYLINDER
ITEM QTY PART NUMBER GENERAL DESCRIPTION
--------------- 1 211-7002 Lip Extension Cylinder - (Double Acting)
--------------- 1 211-7002-1 Seal Kit for Lip Cylinder
13. VELOCITY FUSE – FALL SAFE
ITEM QTY PART NUMBER GENERAL DESCRIPTION
11033-661 Velocity Fuse – All Models
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
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14. LEVELER HYDRAULIC HOSES
14.1 DECK LIFTING CYLINDER - HOSE All Capacity
ITEM QTY PART NUMBER GENERAL DESCRIPTION
1 1 788-621 6’ and 8’ Models (Nominal Deck and Lip Length)
1 1 788-331 10’ & 12’ Models (Nominal Deck and Lip Length)
14.2 LIP EXTENSION CYLINDER - HOSE ALL CAPACITY
ITEM QTY PART NUMBER GENERAL DESCRIPTION
2 1 788-329 6’ and 8’ Models (Nominal Deck & Lip Length)
2 1 788-334 10’ & 12’ Models (Nominal Deck & Lip Length)
1
NOTE: Illustration depicts self-contained unit.
A-SERIES HYDRAULIC DOCK LEVELER WITH BLUE GENIUS™ CONTROLS
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