Airbag Dock Leveler Owner`s Manual

OWNER’S MANUAL
AIRBAG DOCK LEVELER
WITH CONTROLS
ACTUAL PRODUCT MAY NOT APPEAR EXACTLY AS SHOWN
WARNING
Do not 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.
STARTING FROM MARCH, 2016 / SERIAL # 411892
ISSUE DATE: MARCH 1, 2016, REV.3 (PART # 038-880E)
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
TABLE OF CONTENTS
1.0
ABOUT THE AIRBAG DOCK LEVELER WITH CONTROLS4
2.0
1.1
OWNER’S PURCHASE RECORD
4
INTRODUCTION5
2.1
WARRANTY INFORMATION
5
2.2
EXCLUSION OF LIABILITY
5
2.3
MANUFACTURER’S NOTE
5
2.4
OWNER’S RESPONSIBILITY
6
3.0
OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION7
3.1
OPERATIONAL SAFETY WARNINGS
7
4.0
LOCKOUT / TAGOUT PROCEDURE AND RULES8
5.0
CONTROL STATION OPERATION9
6.0
5.1
BUTTON FUNCTION
9
MAINTENANCE STAND SET-UP10
6.1ENGAGING THE MAINTENANCE STAND
10
10
7.0
6.2
DISENGAGING THE MAINTENANCE STAND
MAINTENANCE11
7.1
PLANNED MAINTENANCE
11
7.2
OPERATOR DAILY INSPECTION
11
7.3
ROUTINE SERVICING AND MAINTENANCE
11
7.4
PLANNED MAINTENANCE INTERVALS
11
7.6
MAINTENANCE SEQUENCE
11
8.0
OPERATING INSTRUCTIONS12
8.1
FUNCTIONAL DESCRIPTION
12
8.2
DEPLOYING THE DOCK LEVELER
13
8.3
STORING THE DOCK LEVELER
13
8.4
BELOW LEVEL / END LOADING
14
9.0
CHECKLIST - AIRBAG DOCK LEVELER - OPERATOR AND PLANNED MAINTENANCE PROGRAM15
10.0 RECOMMENDED SPARE PARTS16
10.1 OPTIONAL SUPPORT COMPONENTS
17
11.0 DECAL IDENTIFICATION AND LOCATION18
12.0 EQUIPMENT COMPONENT ILLUSTRATIONS19
12.1 COMPONENTS AS SHIPPED CHECK LIST
19
12.2 MECHANICAL ASSEMBLY 20
12.3 AIRBAG AND PLATFORM ASSEMBLY
22
12.4 DECK SIZE AND CAPACITIES
23
12.5 LIP SIZE AND CAPACITIES 23
12.6 FRAME SIZE
24
12.7 PIT DIMENSIONS
24
2
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
TABLE OF CONTENTS CONT'D.
12.8 CONTROLS 25
13.0 DOCK LEVELER TROUBLESHOOTING26
14.0 WIRING DIAGRAMS27
14.1 SP1 WIRING DIAGRAM—110–130V SINGLE PHASE
27
14.2 SP1 WIRING DIAGRAM—208–240V SINGLE PHASE
28
15.0 ALTERNATIVE CONTROL STATION OPTIONS29
15.1 SP2 CONTROLS
29
15.2 BLUE GENIUS™ CONTROLS
30
15.3 BLUE GENIUS™ CONTROLS WIRING DIAGRAMS
30
15.4 SP2 WIRING DIAGRAM—115V SINGLE PHASE
31
15.5 SP2 WIRING DIAGRAM—230V SINGLE PHASE
32
15.6 BLUE GENIUS™ GOLD WIRING DIAGRAM—115V SINGLE PHASE
33
15.7 BLUE GENIUS™ GOLD WIRING DIAGRAM—230V SINGLE PHASE
34
15.8 OPTIONAL EXTERIOR TRAFFIC LIGHT / MIRROR IMAGE SIGN
35
15.9 OPTIONAL DOCK INTERLOCK SENSOR
35
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
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AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
1.0 ABOUT THE AIRBAG DOCK LEVELER WITH CONTROLS
The Airbag Dock Leveler combines Blue Giant’s advanced, environmentally friendly air lifting system with the same durable structural
design that has made Blue Giant a global leader in the design, manufacture, and distribution of loading dock systems.
Supported by a minimum of six heavy-duty U-beams, the airbag dock leveler has a high-volume, low-pressure (HVLP) air lifting system
that is both easy and ergonomic to operate. When activated via the single push-button control station, the air bag inflates, raising the
deck and deploying the lip. After the button is released, the bag deflates, allowing the deck to lower smoothly onto the trailer bed.
The airbag dock leveler operates safely and efficiently under the toughest conditions: temperature extremes, heavy usage, and exposure
to caustic substances. The deck compensates laterally when under load to allow a smooth cross-docking transition, minimizing the
risk of worker injury and cargo or equipment damage. Mechanical fall-safe legs limit platform free-fall, providing an added degree of
protection at the loading dock.
1.1 OWNER’S PURCHASE RECORD
OWNER’S PURCHASE RECORD
Please record information for future inquiries and to validate warranty. (See Section 2.1 "Warranty Information" for warranty validation)
Dealer:
Date in Service:
Number of Units:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
The manufacturer offers a full line of dock levelers, dock safety equipment, accessories, ergonomic and scissor lift equipment, seals and
shelters, and industrial trucks. Concurrent with a continuing product improvement program, specifications are subject to change without
notice (See Section 2.2 "Exclusion of Liability" of this manual). Please contact the manufacturer for latest information. Some features
illustrated may be optional in certain market areas.
NOTICE
See Section 11.0 "Decal Identification and Location" item #5 for serial number location.
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ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
2.0INTRODUCTION
2.1 WARRANTY INFORMATION
The following is a quick reference to important procedures that
must be followed while using the Loading Dock Equipment. 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 Loading Dock. These laws and regulations include
but are not limited to:
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.
• The Occupational Safety and Health Act
• Canada Occupational Health and Safety Regulations
• Occupational Safety and Health Acts for Individual States
(USA)
For additional information on these regulations as well as industry
standards that may apply to this product, please contact:
American National Standards Institute (ANSI)
1430 Broadway
New York, NY 10018
Telephone: 212.642.4900
www.ansi.org
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 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.
DEALER INFORMATION
Name:
Contact:
Telephone:
* NOTE that failure to validate warranty at the time of receipt can
seriously affect the outcome of any claim.
Also a member of:
2.2 EXCLUSION OF LIABILITY
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
www.mhi.org/lodem
The manufacturer assumes no liability for damage or injury to
persons or property which occur as a result of defects or faults in
or incorrect use of the Loading Dock Equipment. The manufacturer
also assumes no liability for lost profits, operating downtimes, or
similar indirect losses incurred by the purchaser. Injury to third
parties, irrespective of its nature, is not subject to compensation.
The manufacturer reserves the right to make changes at any time
to the modules, components, and accessories, concurrent with
its continuing product improvements and development program.
Specifications, operating instructions, and illustrations included in
this manual are subject to change without notice. Please contact
manufacturer for the latest information.
2.3 MANUFACTURER’S NOTE
The dock equipment has been carefully inspected and tested at
the manufacturer’s plant prior to shipment, but should be checked
upon receipt for transport damage. Any observed transport
damage is to be listed on the signed copy of the freight document.
Notify the freight forwarder of any damage WITHIN 48 HOURS.
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
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AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
2.4 OWNER’S RESPONSIBILITY
1. The owner should recognize the inherent danger of the
interface between the dock and the freight carrier. The owner
should, therefore, train and instruct operators in the safe use
of the dock equipment and accessories in accordance with the
manufacturer’s recommendations.
8. Modifications or alterations of dock equipment shall be made
only with written permission of the original manufacturer. These
changes shall also satisfy all safety recommendations of the
original equipment manufacturer for the particular application
of the dock equipment.
2. The owner should thoroughly familiarize themselves with
the following procedures and specifications, and request
immediate replacement of all manufacturer-supplied
documents that are missing, damaged, or otherwise illegible.
9. The owner or a trained and authorized representative shall
verify that all freight carrier brakes have been applied and a
vehicle restraint and/or wheel chocks properly engaged before
cross-docking procedures such as loading and unloading
begin.
• Installation instructions
• Operating instructions
• Planned maintenance procedures
• Inspections procedures
• Replacement parts lists
Upon receipt of any newly purchased dock equipment, the
owner shall verify the presence of owner’s manuals, operating
placards, and any other documentation necessary for
training dock personnel how to use the equipment safely and
effectively.
3. Nameplates, cautions, instructions, and posted warnings shall
not be obscured from the view of operating or maintenance
personnel for whom such warnings are intended.
4. Manufacturer’s recommended periodic maintenance and
inspection procedures shall be followed, and written records
of the performance of these procedures should be kept as per
warranty guidelines.
5. Dock equipment that is structurally damaged, experiencing
performance irregularities, or has been potentially
compromised (i.e. sudden loss of support due to premature
truck departure) shall be removed from service until a trained
and authorized manufacturer’s representative can conduct an
inspection and perform any necessary repairs.
6. As with any piece of machinery, dock equipment requires
routine maintenance, lubrication, and adjustments. Your
local Blue Giant® representative offers owners the option
of a Planned Maintenance Program (P.M.P.). As part of this
service, your local Blue Giant® representative will do all routine
maintenance, lubrication, and adjustments.
7. The owner shall ensure that all nameplates, caution/instruction
markings or labels are in place and legible, and that the
appropriate operating/maintenance manuals are provided
to authorized users. Replacement name plates, caution/
instruction labels, and manuals containing operating and
maintenance instructions are available through the Blue Giant
Aftermarket Department. See section 11.0 "Decal Identification
and Location" for more information.
6
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
10. Unless specifically agreed to in writing by Blue Giant Equipment
Corporation at the time of order (and prior to manufacture), all
Blue Giant Dock equipment is sold as a complete offering, and
must not be altered or added to in any manner (which includes
configuration and function) without written permission from an
authorized manufacturer’s representative.
11.If, at the request of the owner, Blue Giant does not supply
all or some of the dock equipment power unit and/or control
station components, the owner shall assume responsibility for
any and all operational and safety issues associated with the
resulting configuration.
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
3.0 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.
DANGER
Serious injury or death will likely occur if the
instructions are not followed.
WARNING
Serious injury or death may occur if the instructions
are not followed.
NOTICE
Procedures marked important must be followed in
order to prevent damage to machinery.
CAUTION
Instructions marked caution concern safe operating
procedure. Failure to comply may result in personal injury.
3.1 OPERATIONAL SAFETY WARNINGS
DANGER
1. Do not enter the pit area below the dock leveler.
2. BEFORE BEGINNING ANY SERVICE PROCEDURES:
– Disconnect the power and follow all lockout / tagout
procedures.
3. Never operate a broken or damaged dock leveler. Have repairs
done immediately by a qualified service technician.
4. Always secure and center loads on the forklifts. Loose or
unbalanced loads are dangerous.
WARNING
1. The upper hinge point is a hazardous pinch point. Do not use
fingers or hands to remove foreign materials.
2. Post safety warnings and barricade working area at dock level
and at ground level to prevent unauthorized use of the leveler
during maintenance/service.
3. Never leave the dock leveler unattended in the raised position.
4. Always make sure that the lip is seated inside the night lock after
putting the dock in the parked position.
5. Never leave loads sitting on the dock leveler.
6. Do not attempt to raise the dock leveler if someone is standing
on it.
7. Do not use the dock leveler if the lip’s full width is not fully
supported by the vehicle load bed.
8. Do not operate the dock leveler beyond its rated capacity.
9. Do not drive or walk onto the truck until it is parked against
the dock bumpers and the wheels are chocked, or the vehicle
restraint has been fully engaged.
10. Never attempt to lift or hold the lip out by hand. Serious personal
injury could occur.
11. Never remove the wheel chocks until loading/ unloading is
finished and the truck driver has been given permission to
depart.
NOTICE
1. Do not ground welding equipment to any electrical components.
2. Do not attach welder as ground to leveler platform when welding
on base frame assembly. Attach welder ground to base frame
assembly only.
3. Do not allow the drill to go too deeply when drilling holes in the
control box. Damage to the control systems may occur.
4. Never use air to blow debris from control box. Use a vacuum to
remove debris from control box.
5. Do not connect green ground lead into control box until all
welding has been completed.
6. Always keep the work area clean and free of litter.
7. Always clean all side openings of dirt and debris.
8. Always clean all dirt and debris from the lip hinge.
9. Always clean up dry and liquid spills immediately after they
occur.
10. Always maintain proper lighting in the work area.
11. If a procedure is not clearly defined in this manual, contact your
authorized Service Representative.
CAUTION
1. Only trained personnel should operate or service this equipment.
2. Do not operate the dock equipment until the transport vehicle is
parked against the dock bumpers.
3. Always park the dock equipment after use.
4. Conduct routine inspections and maintenance. Failure to do so
could cause equipment damage and or personal injury.
5. Always call your authorized service representative or
manufacturer immediately if a malfunction occurs.
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
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AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
4.0 LOCKOUT / TAGOUT PROCEDURE AND RULES
In accordance with the rules and regulations of the Occupational
Safety and Health Administration (OSHA), all affected employees
must be notified that the machine or equipment will be shut down
and locked out to perform repair or maintenance work. The work
area must be checked to ensure that all personnel have been
removed or safely repositioned. The machine or equipment power
supply shall be locked in the OFF position or disconnected from
the energy source. Blue Giant strongly recommends that only
OSHA-approved lockout devices and procedures be utilized.
WARNING
Always lockout and tagout any power source before performing any
work on any electrical devices or electrical controls according to
OSHA regulations and approved local electrical codes.
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.
D
OP O N
ER OT
AT
E
XX
XX XXX
XX XX
XX XX
XX XX
XX X
X
Approved way to lockout / tagout.
8
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
5.0 CONTROL STATION OPERATION
5.1 BUTTON FUNCTION
INDEPENDENT TYPE CONTROL STATION
Controls one individual dock leveler only, equipped with a constantpressure ‘UP’ button.
‘UP’ button activates the dock leveler when pressed and held.
DISCONNECT POWER
BEFORE OPENING.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
Note: Contactors come standard with control box.
CAUTION
For safety reasons, the operator’s view of the moving dock leveler must not be obstructed at any time.
Potential obstructions include but are not limited to the dock wall, curtains, and stacked cargo. Ensure that the operator’s field
of vision is clear throughout the dock leveler operating cycle.
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
9
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
6.0 MAINTENANCE STAND SET-UP
DANGER
Never work in the path of the dock leveler platform
without engaging the maintenance stand. If the device
cannot be engaged successfully, contact your authorized
service representative or the manufacturer.
WARNING
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.
6.1 ENGAGING THE MAINTENANCE STAND
WARNING
WARNING
DO NOT work under
dock leveler without:
1. Correctly engaging
maintenance strut
and pin.
2. Installing safety barriers
at rear of dock to
prevent dock usage.
3. On hydraulic docks,
disconnect and lock
out electrical power supply
as required by
law and ensure power
cannot be turned
on accidentally.
Do not attempt to apply the maintenance stand until the
deck and lip are both fully deployed.
Failure to follow these
warnings could
result in serious injury
or death.
832-317
CAUTION
Use of a secondary safety stand (Blue Giant Part # 796-710)
in conjunction with the maintenance stand is strongly
recommended.
This dock comes with a one-piece maintenance stand that must
be used during under-dock inspections or repairs / maintenance.
The V-shaped groove ensures safe headboard and lip support.
To apply the maintenance stand, one person raises the deck while
another puts the stand in place and inserts the locking pin at its
base to secure it.
Maintenance Stand
Safety Stand
Engaged Maintenance Stand (part # 26-011895) and Safety Stand
(part # 796-710).
6.2 DISENGAGING THE MAINTENANCE STAND
After verifying that it is safe to disengage the maintenance stand,
remove the locking pin from the mounting bracket and have
someone press and hold the control station “UP” button.
Once the deck and lip are clear of the maintenance stand, carefully
push the device back into the pit.
Do not stand in the pathway of the dock leveler during the
disengagement process in case the dock falls unexpectedly.
Locking pin in secure position, if desired a padlock may also be used
instead of the locking pin.
10 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
7.0MAINTENANCE
7.3 ROUTINE SERVICING AND MAINTENANCE
WARNING
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.
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.
Do not work under or around dock leveler without first placing
adequate barriers to positively prevent vehicle traffic from
entering the work area.
Failure to properly maintain or operate the dock leveler within its
rated capacity can void the manufacturer warranty.
Follow proper lock-out/tag-out procedures.
7.4 PLANNED MAINTENANCE PROGRAM INTERVALS
Keep hands and feet clear of dock leveler pinch points and
wear appropriate safety attire - glasses, gloves and work
boots.
Arrange for a qualified dock leveler repair technician to perform
regularly scheduled planned maintenance on your dock leveler
every three months for single shift operations or monthly for multishift operations. Call your authorized manufacturer/ dealer for
further details.
The maintenance strut must be in place before commencing
maintenance procedures.
7.6 MAINTENANCE SEQUENCE
7.1 PLANNED MAINTENANCE PROGRAM (PMP)
In addition to the daily operator inspection, the manufacturer
recommends (and local government regulations may require)
that a planned maintenance program (PMP) 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 PMP 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 PMP, which will increase the life of components and
reduce unscheduled downtime.
1.
2.
3.
4.
5.
6.
7.
Cleaning, including pit area.
Visual inspection of all components.
Lubrication, as required (by a trained service technician only).
Test operate all functions.
Adjustments, if required (by a trained service technician only).
Check for missing or damaged dock bumpers.
Record inspection details and findings for owner's files.
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.
7.2 OPERATOR DAILY INSPECTION
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 PMP Checklist (See Section 9.0 "Checklist - Airbag Dock
Leveler - Operator and Planned Maintenance Program." The
operator should fill out this form to keep a daily record of operation
and maintenance issues.
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AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
8.0 OPERATING INSTRUCTIONS
WARNING
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.
OPERATING INSTRUCTIONS
Only for the Airbag Dock Leveler
Supported by a minimum of six heavy-duty U-beams, the Airbag Dock Leveler has a high-volume, low-pressure air lifting system that presents an
eco-friendly alternative to oil-powered hydraulics. When activated via the Single Push Button control station, the air bags in
k to lower smoothly onto the trailer bed.
The Advanced Single Push Button Control Station controls an independent hydraulic or airbag dock leveler via a constant pressure UP button.
The Overhead Door Interlock feature (optional) prevents the dock leveler from being used whenever the overhead doors are closed.
DEPLOYING THE DOCK 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 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.
1. Raise the dock leveler by pushing the ‘UP’
button. If the button is still being pressed while
the dock is in its fully raised position, the lip
will then deploy.
2. The dock leveler will then descend with the
deployed lip on the vehicle load bed. When
the dock has fully deployed on the load bed,
loading and unloading may commence.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
STORING THE DOCK LEVELER
1. To store the dock leveler, press the ‘UP’
button. The dock will raise and the lip will
retract.
2. When the lip has fully retracted, release
the button. The dock will resume the stored
position with the lip in the night lock.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
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" (102mm) 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).
Confirm brakes have been set and air has been removed
from the air-ride suspension (if applicable).
BELOW LEVEL / END LOADING
1. Hold the control station’s ‘UP’ button until the
lip clears the night lock by about 6-10 inches.
Then release. While the deck is lowering,
pull the fall-safe disengaging chain on the
deck to partially extend the lip and to lower to
the below level position, with the lip hanging
between the dock face and the truck bed.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
DANGER
1. Only trained and authorized personnel may operate this dock leveler.
2. Read, understand, and follow the instructions on this document.
3. Prior to using the dock leveler:
• Ensure that the dock leveler is free and clear of all debris, snow and ice.
• Ensure that all personnel near the dock leveler are aware that it is being
operated.
•
that it is functioning properly. If the dock leveler is equipped with a
required.
• Inspect unit for signs of structural damage or mechanical malfunction. If
damage is observed or the restraint fails to operate properly, remove it
from service and notify maintenance personnel immediately.
•
4. When using the dock leveler:
• Keep hands and feet clear of pinch points.
• If the dock leveler is equipped with a light communication package, load
and unload on green only.
• Do not exceed the rated capacity as indicated on the serial plate.
• Do not leave equipment or material unattended on the dock leveler.
• Keep a safe distance from both edges.
• If dock leveler fails to operate as outlined in the accompanying manual’s
operating instructions, refer to the Troubleshooting section.
5. If service or maintenance is required:
• Only authorized service personnel shall maintain or service the unit.
APPLIES TO ALL DOCK LEVELERS
www.BlueGiant.com
038-752E
Airbag Dock Leveler operation placard—part # 038-752E.
8.1 FUNCTIONAL DESCRIPTION
The Airbag Dock Leveler serves as a bridge between a loading
dock floor and a truck bed. 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.
Common Terms:
Dock Leveler (Typical)
Truck / Vehicle / Trailer
Dock Bumper
Home / Lip Sensor
(Restraint Interlock)
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. To activate the
dock leveler, press the ‘UP’ button on the control station. The air
bag will inflate, raising the deck.
Once the lip extends, release the button. The bag will deflate,
allowing the deck to lower onto the truck bed.
Vehicle
ICC Bar
Dock Face
Driveway
Vehicle Restraint*
Wheel Chock
* For Reference
12 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
STANDARD OPERATION PROCEDURES
8.2 DEPLOYING THE DOCK LEVELER
1. Raise the dock leveler by pushing the ‘UP’ button. If the button
is still being pressed while the dock is in its fully raised position,
the lip will then deploy.
2. The dock leveler will then descend with the deployed lip on the
vehicle load bed. When the dock has fully deployed on the load
bed, loading and unloading may commence.
3. After ensuring that there is a minimum overlap of 4" (102mm)
between the dock leveler lip and the truck bed, begin loading
or unloading.
CONTROL STATION
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
8.3 STORING THE DOCK LEVELER
1. To store the dock leveler, press the ‘UP’ button. The dock will
raise and the lip will retract.
2. When the lip has fully retracted, release the button. The dock
will resume the stored position with the lip in the night lock.
3. Disengage the vehicle restraint (if applicable) and / or remove
the wheel chocks, allowing the truck to depart.
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 13
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
8.4 BELOW LEVEL / END LOADING
1. After the truck has been chocked and / or restrained in place,
hold the control station’s ‘UP’ button until the lip clears the
night lock by approximately 6-10".
2. Then release. While the deck is lowering, pull the fall-safe
disengaging chain on the deck to partially extend the lip and to
lower to the below level position, with the lip hanging between
the dock face and the truck bed.
3. When below level / end loading is complete, resume normal
leveler operation by pressing and holding the ‘UP’ button until
the deck is raised and the lip is fully extended.
Release the button and allow the deck to lower onto the truck
bed. If end loading was the last operation, press and hold the
'UP' button until the lip clears the night lock and then release.
The deck will fall back into the stored position.
14 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
9.0 CHECKLIST - AIRBAG DOCK LEVELER - OPERATOR AND PLANNED MAINTENANCE PROGRAM
INSPECTED BY:DATE:
SERIAL #:DOOR #:
Forward this checklist to the person responsible for dock equipment maintenance. See Section 1.1 "Owner's Purchase Record" for
Date in Service.
NOTICE
To make a valid warranty claim you must keep a record of your operator and maintenance checklist.
Ministry of Labor guidelines also require you to follow these procedures and keep a copy for your records.
INSTRUCTIONS FOR USE: Indicate “OK for USE” with a check mark in the appropriate box of each inspection point.
OPERATOR c
MAINTENANCE PERSON c
EVERY DAY:
EVERY 90 DAYS (30 DAYS FOR MULTI-SHIFT OPERATIONS)
c Remove any debris that may have accumulated around the
dock equipment
c Inspect and clean the deck assembly
c Check structural and welds
c Verify complication-free operation of the dock equipment
and the interior and exterior lights system if so equipped
c Inspect the maintenance stand
c Verify complication-free operation of the control panel
c Inspect, clean, and apply lube to the lip hinge assembly
c Problem reported*
c Lubricate the deck assembly pivot points
PHOTOCOPY THIS CHECKLIST AND FILL OUT REGULARLY FOR YOUR RECORDS.
*Explain faults briefly in the space provided below:
DANGER
When repairing or conducting maintenance procedures on electrical components, perform lockout / tagout steps
according to OSHA regulations and approved electrical codes.
DANGER
Prior to maintenance, place adequate barriers to prevent
unauthorized personnel and vehicle traffic from entering
the work area.
WARNING
All repairs and maintenance work are to be conducted by
trained and authorized personnel ONLY.
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 15
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
10.0 RECOMMENDED SPARE PARTS
1
2
3
4
5
6
7
8
9
10.0 RECOMMENDED SPARE PARTS
REPLACEMENT PARTS AIRBAG DOCK LEVELER
REPLACEMENT PARTS AIRBAG DOCK LEVELER
QTY
REQ’D
ITEM
PART NO.
DESCRIPTION
1
26-011298
Push Rod, Lip Deploy
1
2
26-011300
Link Plate, Lip Deploy
1
3
26-011555
Lip Deploy
1
4
26-011301-1
Lower Link Assembly
1
5
013-524
Pin 3/8" Dia. x 1-3/8", Lip Deploy
2
16 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
ITEM
QTY
REQ’D
PART NO.
DESCRIPTION
26-011305
Chain Assembly (6' L)
1
26-011304
Chain Assembly (8 & 10') L
1
7
788-197-1
Pull Chain, Fall-Safe
1
8
071-012
Tension Spring, Fall-Safe
1
9
080-900-1
Patch Kit (includes 1 pc of 60" x
36" vinyl and glue)
1
6
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
10.0 RECOMMENDED SPARE PARTS CONT'D.
10.1 OPTIONAL SUPPORT COMPONENTS
12
10*
13
13
10.0 RECOMMENDED SPARE PARTS
10.1 OPTIONAL SUPPORT COMPONENTS
OPTIONAL SUPPORT COMPONENTS FOR AIRBAG DOCK LEVELER
REPLACEMENT PARTS FOR AIRBAG DOCK LEVELER
ITEM
PART NO.
10
025-176
DESCRIPTION
Power Cable - 10' L (* Optional)
QTY
REQ'D
1
Blower Motor (1PH / 60Hz) Only
12
26-012925
115V
26-012925-1
230V
26-013428
13
26-012959
26-013576
13
020-015
14
See Section 12.3 for
breakdown of parts
included
ITEM
14
PART NO.
26-011563
DESCRIPTION
Maintenance Holder
for Tray and Bag
QTY
REQ'D
1
1
6' L
Airbag
8' L
1
10' L
Polypropylene Wheel
4
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 17
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
11.0 DECAL IDENTIFICATION AND LOCATION
1
SAFETY INSTRUCTIONS
DANGER
Unsupported dock leveler ramps can
lower unexpectedly.
Before allowing vehicle to leave the
dock, always:
• Ensure no equipment, material or
people are on dock leveler.
• Return dock leveler to its stored
position at dock level.
OPERATION
1. Read and follow all instructions and warnings in user’s
manual.
2. Use of dock leveler restricted to trained operators.
3. Always chock trailer wheels or engage trailer restraint before
operating dock leveler or beginning to load or unload.
4. Never use hands or equipment to move ramp or lip.
5. Before activating dock leveler:
• Ensure trailer is backed in against bumpers.
• Remove any end loads if required.
• Check trailer alignment to avoid lip interference. If lip does
not lower to trailer bed, reposition vehicle.
6. Ensure truck bed supports extended lip or leveler frame
supports ramp before driving on ramp.
Call 1-(800)668-7078 for replacement placards, warning labels, or user’s manual.
Failure to follow posted instructions will result in death or serious injury.
2
DANGER
DANGER
Do not walk on
lip to lower
dock leveler
Ne pas marcher
sur la lèvre pour
l’abaisser
4
DANGER
7. Stay clear of hinges, front, and sides of moving dock leveler.
8. Never use damaged or malfunctioning dock leveler. Report
problems immediately to supervisor.
MAINTENANCE/SERVICE
1. Read and follow all instructions, warnings and maintenance
schedules in user’s manual.
2. Maintenance/Service of dock leveler restricted to trained
personnel.
3. Place barriers on driveway and dock floor to show service
work is being performed.
4. DO NOT ENTER PIT unless dock leveler is securely
supported by maintenance strut.
5. If electrically powered turn off and use OSHA lockout/tagout
procedures.
Un niveleur non soutenu peut
s'abaisser soudainement.
Avant de permettre le véhicule de partir
du quai, toujours:
• S'assurer qu'il n'y ait aucun équipement,
matériau ou personnel sur le niveleur.
• Retourner le niveleur en position
de repos au niveau du quai.
Un défaut de suivre ces instructions peut causer des blessures graves ou la mort.
WARNING
3
WARNING
CONSIGNES DE SÉCURITÉ
FONCTIONNEMENT
1. Lire et suivre toutes instructions et avertissements dans le guide d'utilisation.
2. L'utilisation du niveleur réservée à des préposés formés.
3. Toujours caler les roues de la remorque ou engager le système de retenue
avant d'utiliser le niveleur ou de commencer le (dé)chargement.
4. Ne jamais utiliser les mains ou de l'équipement pour déplacer la rampe ou la
lèvre.
5. Avant d'actionner le niveleur de quai:
• S'assurer que la remorque soit stationnée contre les butoirs.
• Ôter les charges en bout s'il y a lieu.
• Vérifier l'alignement du véhicule pour empêcher de l'interférence avec la
lèvre. Si la lèvre ne descend pas sur le plateau du camion, repositionner le
véhicule.
6. S'assurer que le plateau du camion supporte la lèvre étendue ou le cadre du
niveleur supporte la rampe avant de conduire sur la rampe.
7. Rester loin des pentures et du devant et côtés du niveleur en mouvement.
8. Ne jamais utiliser un niveleur endommagé ou défectueux. Aviser le
superviseur immédiatement d'un problème quelconque.
ENTRETIEN/SERVICE
1. Lire et suivre toutes instructions, avertissements et programmes d'entretien
dans le guide.
2. L'entretien/service du niveleur réservé au personnel formé.
3. Placer des barrières sur l'approche et le plancher du quai pour signaler des
travaux d'entretien.
4. NE PAS ENTRER DANS LA FOSSE sauf si le niveleur est bien soutenu par
la béquille d'entretien.
5. S'il s'agit d'une unité électrique, couper le courant et suivre les procédures
de verrouillage/étiquetage de l'OSHA.
Do NOT lift on this side.
Product will be damaged.
CAUTION
MISE EN GARDE
6
To lift product: Insert forks in fork pocket located below.
Alternatively, position forks underneath strap located on top of
product.
DO NOT work under dock leveler without:
1. Correctly engaging maintenance strut
and pin.
2. Installing safety barriers at rear of dock to
prevent dock usage.
3. On hydraulic docks, disconnect and lock
out electrical power supply as required by
law and ensure power cannot be turned
on accidentally.
038-220
038-098
Appelez 1- (800) 668-7078 pour remplacer des panneaux, étiquettes ou guides d'utilisation.
Pour soulever ce produit: Insérez les fourches dans la poche
fourchette située ci-dessous. Alternativement, positionner les
fourches en dessous de la sangle situé sur le dessus du produit.
038-098EF
Failure to follow these warnings could
result in serious injury or death.
832-317
7
1
4
038-017E
DANGER
WARNING
Unsupported dock leveler ramps can
lower unexpectedly.
Before allowing vehicle to leave the
dock, always:
• Ensure no equipment, material or
people are on dock leveler.
• Return dock leveler to its stored
position at dock level.
Do NOT lift on this side.
Prodect will be damaged.
038-098
Failure to follow posted instructions will result in death or serious injury.
SAFETY INSTRUCTIONS
OPERATION
1. Read and follow all instructions and warnings in user’s
manual.
2. Use of dock leveler restricted to trained operators.
3. Always chock trailer wheels or engage trailer restraint before
operating dock leveler or beginning to load or unload.
4. Never use hands or equipment to move ramp or lip.
5. Before activating dock leveler:
• Ensure trailer is backed in against bumpers.
• Remove any end loads if required.
• Check trailer alignment to avoid lip interference. If lip does
not lower to trailer bed, reposition vehicle.
6. Ensure truck bed supports extended lip or leveler frame
supports ramp before driving on ramp.
DANGER
7. Stay clear of hinges, front, and sides of moving dock leveler.
8. Never use damaged or malfunctioning dock leveler. Report
problems immediately to supervisor.
MAINTENANCE/SERVICE
1. Read and follow all instructions, warnings and maintenance
schedules in user’s manual.
2. Maintenance/Service of dock leveler restricted to trained
personnel.
3. Place barriers on driveway and dock floor to show service
work is being performed.
4. DO NOT ENTER PIT unless dock leveler is securely
supported by maintenance strut.
5. If electrically powered turn off and use OSHA lockout/tagout
procedures.
Call 1-(800)668-7078 for replacement placards, warning labels, or user’s manual.
CONSIGNES DE SÉCURITÉ
Un niveleur non soutenu peut
s'abaisser soudainement.
Avant de permettre le véhicule de partir
du quai, toujours:
• S'assurer qu'il n'y ait aucun équipement,
matériau ou personnel sur le niveleur.
• Retourner le niveleur en position
de repos au niveau du quai.
Un défaut de suivre ces instructions peut causer des blessures graves ou la mort.
FONCTIONNEMENT
1. Lire et suivre toutes instructions et avertissements dans le guide d'utilisation.
2. L'utilisation du niveleur réservée à des préposés formés.
3. Toujours caler les roues de la remorque ou engager le système de retenue
avant d'utiliser le niveleur ou de commencer le (dé)chargement.
4. Ne jamais utiliser les mains ou de l'équipement pour déplacer la rampe ou la
lèvre.
5. Avant d'actionner le niveleur de quai:
• S'assurer que la remorque soit stationnée contre les butoirs.
• Ôter les charges en bout s'il y a lieu.
• Vérifier l'alignement du véhicule pour empêcher de l'interférence avec la
lèvre. Si la lèvre ne descend pas sur le plateau du camion, repositionner le
véhicule.
6. S'assurer que le plateau du camion supporte la lèvre étendue ou le cadre du
niveleur supporte la rampe avant de conduire sur la rampe.
7. Rester loin des pentures et du devant et côtés du niveleur en mouvement.
8. Ne jamais utiliser un niveleur endommagé ou défectueux. Aviser le
superviseur immédiatement d'un problème quelconque.
ENTRETIEN/SERVICE
1. Lire et suivre toutes instructions, avertissements et programmes d'entretien
dans le guide.
2. L'entretien/service du niveleur réservé au personnel formé.
3. Placer des barrières sur l'approche et le plancher du quai pour signaler des
travaux d'entretien.
4. NE PAS ENTRER DANS LA FOSSE sauf si le niveleur est bien soutenu par
la béquille d'entretien.
5. S'il s'agit d'une unité électrique, couper le courant et suivre les procédures
de verrouillage/étiquetage de l'OSHA.
Appelez 1- (800) 668-7078 pour remplacer des panneaux, étiquettes ou guides d'utilisation.
038-226EF
6
1
WARNING
DO NOT work under dock leveler without:
1. Correctly engaging maintenance strut
and pin.
2. Installing safety barriers at rear of dock to
prevent dock usage.
3. On hydraulic docks, disconnect and lock
out electrical power supply as required by
law and ensure power cannot be turned
on accidentally.
Failure to follow these warnings could
result in serious injury or death.
832-317
3
7
ITEM
1
2
QTY
2
2
PART NO.
038-226
038-220
EF
ES
EF
ES
DESCRIPTION
5
2
5
BLUE GIANT EQUIPMENT CORPORATION
www.BlueGiant.com
Danger Decal - Safety Instructions
MADE IN CANADA
Danger Decal - Do Not Walk on Lip
MODEL
AB6006-30
SERIAL NO.
398790-01
CAPACITY
30,000 LBS / 13,636 KGS
ELECTRICS
115V / 1PH / 60HZ
FALL SAFE CAP
MFG
3
1
832-317
Warning Decal - Maintenance Strut
4
1
038-096
Warning Decal - Do Not Lift on This Side
4
03/2015
(MM/YYYY)
MODIFICATIONS AND ADDITIONS WHICH AFFECT
CAPACITY AND SAFE OPERATION SHALL NOT BE
PERFORMED BY THE CUSTOMER OR USER WITHOUT
THE MANUFACTURER'S PRIOR WRITTEN APPROVAL.
CAPACITY, OPERATION AND MAINTENANCE
INSTRUCTION, PLATES, TAGS OR DECAL BE
CHANGED ACCORDINGLY.
5
2
6
1
7
1
108-120
038-098
EF
ES
EF
ES
038-017E
Serial Plate Decal
COMPLIES WITH ANSI MH30.1
"REFER TO SAFETY AND OPERATING INSTRUCTIONS
IN YOUR OWNERS MANUAL"
109-120E
Lift Caution Decal
Blue Giant Logo Decal
EF = English / French | ES = English / Spanish
18 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
5
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
12.0 EQUIPMENT COMPONENT ILLUSTRATIONS
12.1 COMPONENTS AS SHIPPED CHECK LIST
OPERATING INSTRUCTIONS
Only for the Airbag Dock Leveler
Supported by a minimum of six heavy-duty U-beams, the Airbag Dock Leveler has a high-volume, low-pressure air lifting system that presents an
eco-friendly alternative to oil-powered hydraulics. When activated via the Single Push Button control station, the air bags in
k to lower smoothly onto the trailer bed.
The Advanced Single Push Button Control Station controls an independent hydraulic or airbag dock leveler via a constant pressure UP button.
The Overhead Door Interlock feature (optional) prevents the dock leveler from being used whenever the overhead doors are closed.
DEPLOYING THE DOCK LEVELER
1. Raise the dock leveler by pushing the ‘UP’
button. If the button is still being pressed while
the dock is in its fully raised position, the lip
will then deploy.
2. The dock leveler will then descend with the
deployed lip on the vehicle load bed. When
the dock has fully deployed on the load bed,
loading and unloading may commence.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
STORING THE DOCK LEVELER
1. To store the dock leveler, press the ‘UP’
button. The dock will raise and the lip will
retract.
2. When the lip has fully retracted, release
the button. The dock will resume the stored
position with the lip in the night lock.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
BELOW LEVEL / END LOADING
1. Hold the control station’s ‘UP’ button until the
lip clears the night lock by about 6-10 inches.
Then release. While the deck is lowering,
pull the fall-safe disengaging chain on the
deck to partially extend the lip and to lower to
the below level position, with the lip hanging
between the dock face and the truck bed.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
DANGER
1. Only trained and authorized personnel may operate this dock leveler.
2. Read, understand, and follow the instructions on this document.
3. Prior to using the dock leveler:
• Ensure that the dock leveler is free and clear of all debris, snow and ice.
• Ensure that all personnel near the dock leveler are aware that it is being
operated.
•
that it is functioning properly. If the dock leveler is equipped with a
required.
• Inspect unit for signs of structural damage or mechanical malfunction. If
damage is observed or the restraint fails to operate properly, remove it
from service and notify maintenance personnel immediately.
•
4. When using the dock leveler:
• Keep hands and feet clear of pinch points.
• If the dock leveler is equipped with a light communication package, load
and unload on green only.
• Do not exceed the rated capacity as indicated on the serial plate.
• Do not leave equipment or material unattended on the dock leveler.
• Keep a safe distance from both edges.
• If dock leveler fails to operate as outlined in the accompanying manual’s
operating instructions, refer to the Troubleshooting section.
5. If service or maintenance is required:
• Only authorized service personnel shall maintain or service the unit.
APPLIES TO ALL DOCK LEVELERS
www.BlueGiant.com
B
038-752E
4
A
BUMPERS
2
CONTROLS
3
5
1
Airbag Tray Tie Down
Shipping Bracket
6
For Shipping Only
(remove after installation)

ITEM
QTY
PART NO.
1
1
ABXXXX-XX*
A
2
B
2
3
DESCRIPTION
Air Bag Dock Leveler
Air Bag Dock Leveler with DLB
DB411
DB411WB
027-006-L
1
027-007-L
(remove prior to operation)
F
S
F
S
APPROX. WEIGHT
See Section 12.4
*
Varies by Model
Laminated Bumper, Dual Flange
50 lb
23 kg
Laminated Bumper, Single Flange
48 lb
22 kg
Control Assembly SP1 110–130V Single Phase
See Section 12.8
1 lb
0.45 kg
Control Assembly SP1 208–240V Single Phase
See Section 12.8
1 lb
0.45 kg
4
1
038-752E
Operation Placard
—
—
5
1
038-880E
Owner's Manual (this one)
—
—
6
1
26-013417
Shipping Bracket, Lip Tie Down
10 lb
4.5 kg
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 19
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
12.2 MECHANICAL ASSEMBLY
31
3
34
33
32
2
19
12 13
21
40
20
18
11
4
10
9
17 16
15
36
7
12
37
5
8
8
35
27
6
14
30 29 28
25
1
25
23
26
38
39
24
22
41
20 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
12.2 MECHANICAL ASSEMBLY
NOTE
DESCRIPTION
NOTE

Lip Deployment Assembly
Includes parts highlighted

Fall Safe Legs Assembly
Includes parts highlighted
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
See Section
12.6
Frame
2
1
See Section
12.4
Deck
3
1
See Section
12.5
Lip
4
1
26-011298
Push Rod

5
1
26-011300
Link Plate

6
1
26-011301-1
Lower Link Assembly
26-011305
Chain Assembly (6' L)
7
1
26-011304

ITEM
27


NOTE
Chain Assembly (8' L)
Chain Assembly (10' L)
DESCRIPTION
NOTE
Maintenance Stand
Assembly
Includes parts highlighted
QTY.
1
PART NO.
DESCRIPTION
26-011308-1
Top Plate (6' L)
26-011308-1
Top Plate (8' L)
26-011308-1
Top Plate (10' L)
28
2
26-005610
Pin (Rear Fixed Hinge)
29
4
012-214
Washer Flat USS 3/4"
30
4
013-029
Hairpin Cotter
109-699
Shaft (6' W)
31
1
109-687-1
Shaft (6' 6" W)
109-690
Shaft (7' W)
32
2
010-006
Cap Screw 5/16-18 x 1 HH GR.5 ZN
33
2
012-200
Regular Spring Lock Washers
5/16" (U.S.)

8
2
013-524
Clevis Pin

9
1
011-032
HHCS 5/8 - 11 UNC x 2 GR.5
34
2
011-502
Hex Nuts (U.S.)

10
1
010-044
HHCS 1/2 - 13 UNC x 2
35
4
011-020
Philip Head Cap Screw

11
1
012-275
Flat Spacer Washer (U.S.)
36
4
011-545
Nylon Insert Locknuts 1/4"-20NC

12
5
013-020
Cotter Pin 1/8 x 1"
37
4
012-209
Washer Fender 1/4
 13
1
013-543
Clevis Pin
38
1
014-016
Setscrew Socket HD 5/16"-24 x 1/2"

14
1
26-011551
Pin
39
1
011-518
Nuts HEX 5/16-24 Plated

15
1
26-011389
Fall Safe Legs (6' L & 8' L - 19" Frame)

16
2
013-012
Spring pin

17
1
012-250
Washer Flat USS 1"

18
1
017-012
Tension Spring

19
1
788-197-1

20
1
010-077
Cap Screw 3/8 - 16 x 1-1/4 HH GR.2

21
1
011-552
Nylon Insert Locknuts 3/8" - 16 (U.S.)

22
1
011-554
Nylon Insert Locknuts 1/2"-13(U.S.)

23
1
010-027
HHCS 1/2 - 13 UNC x 2½

24
1
013-510
Pin and Key Ring

25
1
26-011895-1

26
1
012-679
26-011389-1
Fall Safe Legs (10' L - 19" Frame)
40
41
2
1
26-013420
Safety Skirt Package (6' L)
26-013332
Safety Skirt Package (8' L)
26-013430
Safety Skirt Package (10' L)
See Section
12.3
Air Bag and Platform Assembly
Pull Chain
Safety Strut
Washer Flat SAE 1/2 ZP
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 21
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
12.3 AIRBAG AND PLATFORM ASSEMBLY
9
8
11
7
10
18
20
1
19
5
2
6
AIR BAG & PLATFORM ASSY - BLOWER MOTOR INCL.
17
4
3
u
u
29 25
u
28
u
27
16
21
22
23
u
26
13
30
u
PART NO.
A
B
A
B
A
B
6'
31
u
24
115V
SIZE
(LONG)
8
12
14
10
15
230V
SIZE
(LONG)
26-013427
26-013429
26-012963
26-014280
26-013579
26-013579
6'
8
10
PART NO.
A
B
A
B
A
B
26-013427-1
26-013429-1
26-012963-1
26-014280-1
26-013579-1
26-013579-1
A: 18" - 21" Frame B: 22" - 23" Frame
ITEM
QTY.
PART NO.
26-013425-1
1
1
26-013001-1
26-013577
26-013426-1
2
1
26-013002-1
26-013578
DESCRIPTION
LH
Platform
RH
Platform
6' L
10' L
035-096
26-004820
15
1
16
2
011-545
6' L
17
1
090-385-0040
8' L
18
1
26-013333
6
013-028
Hairpin Cotter
6
2
012-266
Washer Flat SAE 3/4" ZP
7
1
10
9
011-042
26-012978-3
Wheels Axis
26-013428
Air Bag
26-012978-1
1
5
011-543
1
1
Wheel
9
12
14
020-018
9
26-012978-2
13
26-011266-1
26-012961
Airbag Clamp Bar
10' L
4
26-013576
DESCRIPTION
26-011267
8' L
1
1
PART NO.
1
6' L
4
8
QTY.
11
8' L
3
26-012959
ITEM
Connector
Reinforce
Bracket
10' L
19
1
013-009
20
1
26-013415
21
22
22 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
2
2
010-001
012-210
PART NO.
23
2
011-545
1
26-012925
Blower Motor Assy
26-012925-1
Blower Motor Assy
6' L
8' L
10' L
Flex Pipe Coupling
6' L
Pipe
091-958-0440
Hook Plate
Nylon Insert Locknuts
5/16-18
Capscrew Hex Socket
5/16-18x1"
QTY.
24
1
Elbow Fitting w/Barb
091-958-0254
091-958-0370
ITEM
8' L
10' L
1/4 - 20 Nylon Nut
Tube
Collar
Cap Screw 1/4-20 x
1 HH
Washer Flat USS
1/4 ZP
Nylon Insert Locknuts
1/4" - 20NC
115V / 1PH / 60Hz
230V / 1PH / 60Hz
ITEM # 24 INCLUDES PARTS LISTED BELOW: u
u
25
1
26-013411
L Cover
u
26
1
26-013412-1
R Cover
u
27
1
035-210
u
28
1
Rear Hinge Pin
Spring Pin 1/4" D x 1" L
DESCRIPTION
ITEM # 28
INCLUDES:
031-033
031-034
Filter
Motor
115V
230V
090-T12-2
Ground Wire Assy ¹
010-219
Head Cap Screw ¹
u
29
1
025-015
Cable Gland
u
30
1
091-409-1200
u
31
3
011-545
3/C-14 AWG Cable
Nylon Insert Locknuts ¹
¹ = Not visible on drawing
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
12.5 LIP SIZE AND CAPACITIES
12.4 DECK SIZE AND CAPACITIES
DECK SIZE
(NOMINAL)
6' x 6'
6' x 8'
6' x 10'
6' 6" x 6'
6' 6" x 8'
6' 6" x 10'
CAPACITY
7' x 8'
7' x 10'
PART NO.
AB
AB with DLB
DECK
WIDTH
CAPACITY
LB
KG
LENGTH
PART NO.
AB
AB with DLB
16"
406mm
26-011387
26-013861-2
18"
457mm
26-011387-1
26-013861-5
26-013862-2
20"
508mm
26-011387-2
26-013861-8
26-013424
26-013862-2
16"
406mm
26-011535-3
26-013861-1
AB6008-30
26-013419
26-013862-5
18"
457mm
26-011535-4
26-013861-4
15,909 kg
AB6008-35
26-013418
26-013862-3
20"
508mm
26-011535-5
26-013861-7
40,000 lb
18,144 kg
AB6008-40
26-013301
26-013862-4
16"
406mm
26-011535
26-013861
45,000 lb
20,454 kg
AB6008-45
26-013301
26-013862-4
18"
457mm
26-011535-1
26-013861-3
20"
508mm
26-011535-2
26-013861-6
16"
406mm
26-011533
26-013869-2
18"
457mm
26-011533-1
26-013869-5
20"
508mm
26-011533-2
26-013869-8
16"
406mm
26-011536-3
26-013869-1
18"
457mm
26-011536-4
26-013869-4
20"
508mm
26-011536-5
26-013869-7
16"
406mm
26-011536
26-013869
18"
457mm
26-011536-1
26-013869-3
20"
508mm
26-011536-2
26-013869-6
16"
406mm
26-011296
26-013870-2
18"
457mm
26-011296-1
26-013870-5
20"
508mm
26-011296-2
26-013870-8
16"
406mm
26-011537-3
26-013870-1
18"
457mm
26-011537-4
26-013870-4
20"
508mm
26-011537-5
26-013870-7
16"
406mm
26-011537
26-013870
18"
457mm
26-011537-1
26-013870-3
20"
508mm
26-011537-2
26-013870-6
30,000 lb
13,636 kg
AB6006-30
26-013302
26-013862
35,000 lb
15,909 kg
AB6006-35
26-013423
26-013862-1
40,000 lb
18,144 kg
AB6006-40
26-013424
45,000 lb
20,454 kg
AB6006-45
30,000 lb
13,636 kg
35,000 lb
30,000
6'
35,000
40,000
13,636
15,909
18,144
to
to
45,000
20,454
30,000 lb
13,636 kg
AB6010-30
26-013574
26013862-6
35,000 lb
15,909 kg
AB6010-35
26-013581
26-013862-7
40,000 lb
18,144 kg
AB6010-40
26-013584
26-013862-8
45,000 lb
20,454 kg
AB6010-45
26-013584
26-013862-8
30,000 lb
13,636 kg
AB6606-30
26-013302-1
26-014001
35,000 lb
15,909 kg
AB6606-35
26-013423-1 26-014001-1
40,000 lb
18,144 kg
AB6606-40
26-013424-1 26-014001-2
45,000 lb
20,454 kg
AB6606-45
26-013424-1 26-014001-2
40,000
to
to
30,000 lb
13,636 kg
AB6608-30
26-013419-1 26-014001-5
45,000
20,454
35,000 lb
15,909 kg
AB6608-35
26-013418-1 26-014001-3
40,000 lb
18,144 kg
AB6608-40
26-013301-1 26-014001-4
45,000 lb
20,454 kg
AB6608-45
26-013301-1 26-014001-4
30,000 lb
13,636 kg
AB6610-30
26-013580
26-014001-6
35,000 lb
15,909 kg
AB6610-35
26-013582
26-014001-7
40,000 lb
18,144 kg
AB6610-40
26-013585
26-014001-8
45,000 lb
20,454 kg
AB6610-45
26-013585
26-014001-8
30,000 lb
7' x 6'
MODEL
13,636 kg
AB7006-30 26-013302-2
26-013868
35,000 lb
15,909 kg
AB7006-35
26-013423-2 26-013868-1
40,000 lb
18,144 kg
AB7006-40
26-013424-2 26-013868-2
45,000 lb
20,454 kg
AB7006-45
26-013424-2 26-013868-2
30,000 lb
13,636 kg
AB7008-30
26-013419-2 26-013868-5
35,000 lb
15,909 kg
AB7008-35
26-013418-2 26-013868-3
40,000 lb
18,144 kg
AB7008-40
26-013301-2 26-013868-4
45,000 lb
20,454 kg
AB7008-45
26-013301-2 26-013868-4
30,000 lb
13,636 kg
AB7010-30
26-013575
26-013868-6
35,000 lb
15,909 kg
AB7010-35
26-013583
26-013868-7
40,000 lb
18,144 kg
AB7010-40
26-013586
26-013868-8
45,000 lb
20,454 kg
AB7010-45
26-013586
26-013868-8
30,000
6' 6"
35,000
30,000
7'
35,000
40,000
13,636
15,909
18,144
13,636
15,909
18,144
to
to
45,000
20,454
Airbag dock leveler with Dock Lip
Barrier (DLB)
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 23
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
12.6 FRAME SIZE
DECK SIZE
(NOMINAL)
PART NO.
LENGTH
AB
AB with DLB
DECK SIZE
(NOMINAL)
LENGTH
PART NO.
AB
AB with DLB
AB6006
6' x 6'
AB6610
16"
406mm
26-011887-1
26-013863-1
18"
457mm
26-011887-5
26-013863-5
20"
508mm
26-011887-3
26-013863-3
6' 6" x 10'
16"
406mm
26-011559
26-013998
18"
457mm
26-011559-1
26-013998-1
20"
508mm
26-011559-2
26-013998-2
AB6008
6' x 8'
AB7006
16"
406mm
26-011887
26-013863
18"
457mm
26-011887-4
26-013863-4
20"
508mm
26-011887-2
26-013863-2
16"
406mm
26-011539
26-013867
18"
457mm
26-011539-1
26-013867-1
20"
508mm
26-011539-2
26-013867-2
16"
406mm
26-011888-1
26-013994-1
18"
457mm
26-011888-5
26-013994-5
20"
508mm
26-011888-3
26-013994-3
16"
406mm
26-011888
26-013994
18"
457mm
26-011888-4
26-013994-4
20"
508mm
26-011888-2
26-013994-2
7' x 6'
16"
406mm
26-011889-1
26-013995-1
18"
457mm
26-011889-5
26-013995-5
20"
508mm
26-011889-3
26-013995-3
16"
406mm
26-011889
26-013995
18"
457mm
26-011889-4
26-013995-4
20"
508mm
26-011889-2
26-013995-2
16"
406mm
26-011560
26-013999
18"
457mm
26-011560-1
26-013999-1
20"
508mm
26-011560-2
26-013999-2
AB6010
6' x 10'
AB7008
7' x 8'
AB6606
6' 6" x 6'
AB7010
7" x 10'
AB6608
6' 6" x 8'
12.7 STANDARD PIT DIMENSIONS
NOMINAL SIZE
PIT WIDTH (W)
in
PIT LENGTH (L)
mm
in
mm
61.25
1556
85.25
2165
6' x 6'
1829 x 1829mm
6' x 8'
1829 x 2438mm
6' x 10'
1829 x 3048mm
109.25
2775
6' 6" x 6'
1981 x 1829mm
61.25
1556
6' 6" x 8'
1981 x 2438mm
85.25
2165
6' 6" x 10
1981 x 3048mm
109.25
2775
7' x 6'
2133 x 1829mm
61.25
1556
7' x 8'
2133 x 2438mm
85.25
2165
7' x 10'
2133 x 3048mm
109.25
2775
74
80
85
1880
2032
2159
Lip Length:
16", 18", 20" (406, 457, 508mm)
Standard Frame
Depth:
Front: 19.5" (495mm)
Rear: 19" (483mm)
Standard Pit Depth:
Front (H): 20" (508mm)
Rear (H1): 19.5" (495mm)
24 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
W
L
H1
H
Alternatives available:
• Longer filler
• Deeper pits
• Other options – consult factory
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
12.8CONTROLS
5.28"
(135mm)
7.94"
(202mm)
DISCONNECT POWER
BEFORE OPENING.
.75"
(19mm)
READ AND FULLY UNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.
3.47"
(88mm)
5.81"
(148mm)
Front View
1.94"
(49mm)
Side View
Bottom View
COMPLETE CONTROL STATION SINGLE PUSH BUTTON SP1
COMPLETE CONTROL STATION SINGLE PUSH BUTTON SP1
WITH OVERLOAD
ITEM
ITEM
1
SINGLE PHASE
QTY
PART NO.
DESCRIPTION
VOLTAGE RANGE
1
027-006-L
115V / 1PH / 50-60 Hz
110 - 130V
1
027-007-L
230V / 1PH / 50-60Hz
208 - 240V
Decal included (part # 038-251E)
1
SINGLE PHASE
QTY
PART NO.
DESCRIPTION
VOLTAGE RANGE
1
027-006-LO
115V / 1PH / 50-60 Hz
110 - 130V
1
027-007-LO
230V / 1PH / 50-60Hz
208 - 240V
Decal included (part # 038-251E)
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 25
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
13.0 DOCK LEVELER TROUBLESHOOTING
WARNING
Do not attempt to install, make repairs or adjustments. Only a trained and authorized service technician should perform the installation
process. Contact your local dealer or distributor for assistance.
PROBLEM
PROBLEM CAUSE
Deck will not raise.
1. The blower motor may have failed or been mis-wired. Repair or replace as necessary.
In the case of potential mis-wiring, please consult wiring diagram shipped with unit.
2. The control station is not functioning properly. Replace if necessary.
3. Overload relay (optional) may have been tripped. If applicable, investigate and reset.
4. Air bag may have been damaged. Inspect and repair if required.
5. Main power feed may be disconnected or a fuse may have blown.
Reconnect power and inspect fuses.
6. Blower intake may be blocked. Check and clean if necessary.
Deck will not lower.
1. Debris may have accumulated under the platform. Remove and clean around the pit area.
2. Maintenance stand may still be engaged. Investigate and disengage.
3. Blower intake may be blocked. Check and clean if necessary.
Deck raises slowly.
1. Air bag may be damaged. Inspect and repair as required.
2. Cargo and other weight sources may be sitting on the deck. Check and remove if
necessary.
3. Blower intake may be blocked. Check and clean if necessary.
4. Blower uncoupled from bag. Check and call for service.
5. Inadequate voltage. Check line voltage.
The lip will not extend.
1.
2.
3.
4.
5.
The lip remains in the
extended position.
1. Lip may be bent or damaged. Apply lubrication, and if necessary replace the lip.
2. The lip deployment mechanism may be damaged. Conduct any necessary repairs and
replace parts as needed.
3. Debris may have collected in the lip hinge. Clean and lubricate.
The lip strikes the rear of
the truck as the deck raises,
stops, or slows down, and lip
does not extend in the locked
position.
1. Damaged or missing dock bumpers allow the truck to park too close to the leveler.
2. Height difference between the dock and truck bed may be greater than recommended
3. The lip actuator assembly may be damaged, causing lip to begin extending too early in
the cycle. Adjust as necessary.
4. The lip actuator requires adjustment.
Debris may be in the lip hinge. Check the hinge and clean away any dirt or corrosion.
Lip deployment mechanism may be damaged. Check and replace if necessary.
Damaged air bag.
Blower uncoupled from bag. Check and call for service.
Incorrect voltage. Check line voltage relative to blower motor voltage.
26 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
WD027 - 006L
14.1 SP1 WIRING DIAGRAM—110–130V SINGLE PHASE
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 27
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
WD027 - 007L
14.2 SP1 WIRING DIAGRAM—208–240V SINGLE PHASE
28 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
15.0 ALTERNATIVE CONTROL STATION OPTIONS
Control station upgrades are available for enhanced equipment
operation.
The SP2 controls an independent dock leveler via a constant
pressure “I” (UP) button and has a running timer that shuts down
the motor after a specific interval to prevent excessive motor
activity. Overhead door interlock provision terminals protect door
from incorrect leveler sequence.
The Blue Genius™ Gold Series I is a microprocessor-based control
station with a touch-sensitive ‘Deck’ button and numeric keypad.
The LED menu screen relays real-time prompts and commands
for operating and troubleshooting. For added safety, the
Blue Genius™ is available with an optional interior and exterior light
communication package, overhead door interlock and expansion
capability for future vehicle restraint and overhead door buttons.
SP2 Control
Blue Genius™ Gold Series I
15.1 SP2 CONTROLS
2
12 13
11
5
12 13
2
8
4
1
ITEM
QTY.
1
10
PART NO.
SP2S1115
1
3
DESCRIPTION
F
S
F
SP2 Control Assembly
115V Single Phase
ITEM
QTY.
7
1
8
1
9
1
S
SP2 Control Assembly
230V Single Phase
2
1
025-G023-4M
Control Box Enclosure
3
1
026-G054-M
Power Circuit Board - SP2, 1PH STD
10
4
4
025-G010-1
Mounting Tabs w/Screws
11
5
1
026-G121
Fuse F.A. 100mA, 250V 5 x 20mm
6
1
026-G202
Button Contact Block N/O
SP2S1230
9
PART NO.
028-573
6
7
DESCRIPTION
Green Push Button w/Mounting Collar
038-266EF
Decal, English / French
038-266ES
Decal, English / Spanish
038-284EF
Decal, Serial Plate / French
038-284ES
Decal, Serial Plate / Spanish
1
026-G035
3 Wire Cable
4
010-216
Screw, M4 x 8 Pan Phil
12
2
025-062
Cable Tie Mount
13
2
522-008
Ties, Wire YS-98C
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 29
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
15.2 BLUE GENIUS™ CONTROLS
11
Wiring Diagram Enclosed
2
6
7
Fuse Holder 3
9
4A
4B
4C
5
10
3
1
8
12
F2
Fuse Holder 1
Fuse Holder 2
COMPLETE CONTROL STATION ASSEMBLY - ITEM 1
ITEM
2
FUSE
QTY
F1
B
1
F2
A
1
F1
F2
C
1
1
PART NO.
(Example BGGE01115F)
DESCRIPTION
ASSY PART #
Power Board
Sub-Assembly †
(1PH 115V 50-60HZ)
BGGE01115
026-PB1230
Power Board
Sub-Assembly †
(1PH 230V 50-60HZ)
BGGE01230
Control Box Enclosure (Includes 4C)
026-PB1115
3
1
025-G010-M
4
1
025-G014-V3-M
4A
1
026-G021-M
4B
5
025-062
4C
1
025-G014
5
1
6
1
038-259E
*
F
S
F
Transparent Cover Door (4C) and Touch
Control Board (4A) (Serial # Required)
Touch Control Board (Serial # Required)
Transparent Cover Door
F
025-G010-1
ITEM
QTY
PART NO.
7
1
026-G030
8
1
9
1
Button Decal
038-284E
Ribbon Cable
S
038-283EFS
F
038-853E
Decal, Serial Plate
Decal, Do Not Drill
10
1
11
1
12
1
026-G402
Audible Speaker
F3
1
026-037-1
Fuse, 2.5A, 700V, Fast-Blow 1/4" Glass
S
026-615-1
Warning Decal
Anti-Static Poly Bag (Wiring Diagram Enclosed)
(Serial # required for diagram)
AS PER VOLTAGE - SEE ITEM 1
ITEM
QTY
PART NO.
DESCRIPTION
B
1
026-G101
Fuse, 8A, 250V, Time Delay for 1PH,
208-240V
C
1
026-G102
Fuse, 0.5A, 250V, Time Delay for 1 and 3PH,
208-240V
E
1
026-G104
Fuse, 0.75A, 250V, Time Delay for 1PH,
110-130V
Mounting Tabs with Hardware (1 pkg of 4)
* Language on decal: F = English / French S = English / Spanish
DESCRIPTION
F
S
Cable Tie Mount
S
4
F3
SINGLE PHASE
◊
F1
◊ Location on Power Board † Includes Fuses ‡ 115 Volt Control Box Shown
15.3 BLUE GENIUS™ CONTROLS WIRING DIAGRAMS
QTY
WD #
DESCRIPTION
MODEL
NOTE
1
WD-110
115V / 1PH / 50-60Hz
Blue Genius™ Single Push Button
Wiring diagram enclosed with control only
1
WD-106
230V / 1PH / 50-60Hz
Blue Genius™ Single Push Button
(See Section 15.2 Item # 11)
1
WD-161
115V / 1PH / 50-60Hz
Blue Genius™ Single Push Button w/ Advanced Light Communication
Wiring diagram
See Section 15.6
enclosed with control
1
WD-216
230V / 1PH / 50-60Hz
Blue Genius™ Single Push Button w/ Advanced Light Communication
30 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
& included in manual
See Section 15.7
REV
L N
SEE NOTES
DOCK
UP
ECN
DOCK LEVELER
MOTOR
1H.P. MAX.
M2
M1
+
M1
SEE
NOTES
M2
GND
R
B.GAGNON
CHECKED
K.MANRO
DRAWN
2013-07-18
2013-07-18
COM
SW
+24
COM
SW
+24
Fax: 905-457-2313
NA
info@bluegiant.com
SHEET 1 OF 1
WD-166
www.bluegiant.com
SP2 FIELD WIRING DIAGRAM
115-230 VOLT/1PHASE/50-60HZ
SINGLE PUSH BUTTON CON TROL
10-32VDC
N/O PNP
OVERHEAD
DOOR
PHOTO SENSOR
(800) 668-7078 or (800) USA-BLUE
WEIGHT
DRAWING NO
NONE
A
SCALE
SIZE
6350 Burnt Poplar Road, Greensboro, NC 27409
DATE
DATE
NOTES:
DISCONNECT & MOTOR PROTECTION MUST BE PROVIDED BY OTHERS
TO CONFORM WITH LOCAL & NATIONAL CODES & REGULATIONS.
DESCRI PTION
BLUE
BLACK
BROWN
THE INFORMATION CONTAINED HEREIN IS THE SOLE PROPERTY OF
BLUE GIANT EQUIPMENT CORPORATION. ANY REPRODUCTION IN PART
OR AS A WHOLE WHITOUTH THE WRITTEN PERMISSION OF BLUE GIANT
EQUIPMENT CORPORATION IS PROHIBITED.
CABLE BY OTH ERS
L1 L2/N
FUSE
100 mA, 250V,
5x20mm
NOT
USED
A
U
85 Heart Lake Road South, Brampton, Ontario, L6W 3K2
DATE
GND
WHITE
RED
DOCK LEVELER
MOTOR
JUNCTION BOX
CABLE BY OTHERS
WHITE
RED
RELAY
AUTO
RETURN
DOOR
INTERLOCK
CONTROL PANEL
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
15.4 SP2 WIRING DIAGRAM—115V SINGLE PHASE
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 31
32 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
REV
L N
SEE NOTES
DOCK
UP
ECN
DOCK LEVELER
MOTOR
1H.P. MAX.
M2
M1
+
M1
SEE
NOTES
M2
GND
R
B.GAGNON
CHECKED
K.MANRO
DRAWN
2013-07-18
2013-07-18
COM
SW
+24
COM
SW
+24
Fax: 905-457-2313
NA
info@bluegiant.com
SHEET 1 OF 1
WD-166
www.bluegiant.com
SP2 FIELD WIRING DIAGRAM
115-230 VOLT/1PHASE/50-60HZ
SINGLE PUSH BUTTON CON TROL
10-32VDC
N/O PNP
OVERHEAD
DOOR
PHOTO SENSOR
(800) 668-7078 or (800) USA-BLUE
WEIGHT
DRAWING NO
NONE
A
SCALE
SIZE
6350 Burnt Poplar Road, Greensboro, NC 27409
DATE
DATE
NOTES:
DISCONNECT & MOTOR PROTECTION MUST BE PROVIDED BY OTHERS
TO CONFORM WITH LOCAL & NATIONAL CODES & REGULATIONS.
DESCRI PTION
BLUE
BLACK
BROWN
THE INFORMATION CONTAINED HEREIN IS THE SOLE PROPERTY OF
BLUE GIANT EQUIPMENT CORPORATION. ANY REPRODUCTION IN PART
OR AS A WHOLE WHITOUTH THE WRITTEN PERMISSION OF BLUE GIANT
EQUIPMENT CORPORATION IS PROHIBITED.
CABLE BY OTH ERS
L1 L2/N
FUSE
100 mA, 250V,
5x20mm
NOT
USED
A
U
85 Heart Lake Road South, Brampton, Ontario, L6W 3K2
DATE
GND
WHITE
RED
DOCK LEVELER
MOTOR
JUNCTION BOX
CABLE BY OTHERS
WHITE
RED
RELAY
AUTO
RETURN
DOOR
INTERLOCK
CONTROL PANEL
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
15.5 SP2 WIRING DIAGRAM—230V SINGLE PHASE
C
REV
D
REV
SEE ECN 70008
DOCK LEVELER
MOTOR
JUNCTION BOX
GND
MC
M1
BROWN
BLUE
BLACK
MODIFIED DRAWING
DOCK LEVELER
MOTOR
1 H.P. MAX.
HOME/LIP
SENSOR
COM
INPUT 5
+24
COM
INPUT 6
29
30
31
32
33
34
M1
MC
*
MOTOR 1
2012-10-17
2013-06-12
M2
MC
*
B.GAGNON
CHECKED
K.MANRO
DRAWN
2013-06-12
2013-06-12
COMMUNICATION CABLE TO
BG CONTROL PANEL
(800)668-7078 or (800)USA-BLUE
WEIGHT
DRAWING NO
NONE
A
SCALE
EXTERIOR TRAFFIC
LIGHTS
AUDIBLE
WHITE
GREEN
BLACK
RED
WHITE
RED
BLACK
RED
BLACK,DRAIN
09
10
11
12
13
14
05
06
07
08
02
03
04
01
COM
GREEN
N/O
RC
+
RED
N/C
I1
I2
COM
+24
A
B
TERMINAL BLOCK IN
BG CONTROL PANEL
NA
Fax: 905-457-2313
www.bluegiant.com
info@bluegiant.com
SHEET 1 OF 1
WD-161
BLUE GENIUSFIELD WIRING DIAGRAM
115 VOLT/1PHASE/50-60HZ
SINGLE BUTTON DOCK LEVELER WITH ADVANCED LIGHT COMMUNICATION
DESCRIPTION
L N
SEE NOTES
SIZE
N
CABLE BY
OTHERS
L
POWER
6350 Burnt Poplar Road, Greensboro, NC, 27409
DATE
DATE
NOTES:
DISCONNECT & MOTOR PROTECTION MUST BE PROVIDED
BY OTHERS TO CONFORM WITH LOCAL & NAIONAL CODES
& REGULATIONS.
THE INFORMATION CONTAINED HEREIN IS THE SOLE
PROPERTY OF BLUE GIANT EQUIPMENT CORPORATION.
ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT
THE WRITTEN PERMISSION OF BLUE GIANT EQUIPMENT
CORPORATION IS PROHIBITED.
SEE
NOTES
BG CONTROL PANEL CONNECTIONS
13
14
15
16
WHITE
GREEN
BLACK
RED
* MC’S ARE INTERNALLY CONNECTED
GROUND
MOTOR 2
+24
+24
OUTPUT 5
+24
OUTPUT 6
+24
OUTPUT 4
+24
OUTPUT 3
+24
OUTPUT 2
05
06
07
08
09
10
11
12
02
03
04
OUTPUT 1
01
A
B
COM
+24
85 Heart Lake Road South, Brampton, Ontario, L6W3K2
DATE
DATE
CABLE BY OTHERS
+24
INPUT 2
+24
COM
INPUT 3
+24
COM
COM
INPUT 4
+24
COM
INPUT 1
+24
19
20
21
22
23
24
25
26
27
28
17
18
REMOTE I/O-A
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
15.6 BLUE GENIUS™ GOLD WIRING DIAGRAM—115V SINGLE PHASE
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 33
34 ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E)
REV
A
DOCK LEVELER
MOTOR
1 H.P. MAX.
HOME/LIP
SENSOR
SEE ECN 70008
DOCK LEVELER
MOTOR
JUNCTION BOX
GND
M12
M11
BROWN
BLUE
BLACK
+24
M11
INPUT 4
+24
COM
INPUT 5
+24
COM
INPUT 6
INPUT 3
+24
COM
INPUT 2
+24
COM
COM
COM
INPUT 1
+24
M12
M22
M23
GROUND
L1 L2
SEE NOTES
B.GAGNON
CHECKED
K.MANRO
2013-08-02
2013-08-02
SCALE
(800)668-7078 or (800)USA-BLUE
WEIGHT
DRAWING NO
NONE
A
SIZE
EXTERIOR TRAFFIC
LIGHTS
AUDIBLE
BLACK
RED
WHITE
RED
BLACK
RED
WHITE
GREEN
BLACK,DRAIN
09
10
11
12
13
14
05
06
07
08
02
03
04
01
COM
GREEN
N/C
N/O
RC
+
RED
I1
I2
COM
+24
A
B
TERMINAL BLOCK IN
BG CONTROL PANEL
NA
Fax: 905-457-2313
www.bluegiant.com
info@bluegiant.com
SHEET 1 OF 1
WD-216
BLUE GENIUS FIELD WIRING DIAGRAM
230 VOLT/1PHASE/50-60HZ
SINGLE BUTTON DOCK LEVELER WITH ADVANCED LIGHT COMMUNICATION
COMMUNICATION CABLE TO
BG CONTROL PANEL
DESCRIPTION
L3
6350 Burnt Poplar Road, Greensboro, NC, 27409
DATE
DATE
NOTES:
DISCONNECT & MOTOR PROTECTION MUST BE PROVIDED
BY OTHERS TO CONFORM WITH LOCAL & NAIONAL CODES
& REGULATIONS.
DRAWN
L2
POWER
CABLE BY
OTHERS
L1
THE INFORMATION CONTAINED HEREIN IS THE SOLE
PROPERTY OF BLUE GIANT EQUIPMENT CORPORATION.
ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT
THE WRITTEN PERMISSION OF BLUE GIANT EQUIPMENT
CORPORATION IS PROHIBITED.
M21
13
14
15
16
WHITE
GREEN
BLACK
RED
BG CONTROL PANEL CONNECTIONS
MOTOR2
+24
+24
OUTPUT 5
+24
OUTPUT 6
+24
OUTPUT 4
+24
OUTPUT 3
+24
OUTPUT 2
05
06
07
08
09
10
11
12
02
03
04
OUTPUT 1
01
A
B
COM
+24
85 Heart Lake Road South, Brampton, Ontario, L6W3K2
2013-06-12
M13
SEE
NOTES
MOTOR1
CABLE BY OTHERS
DATE
29
30
31
32
33
34
25
26
27
28
19
20
21
22
23
24
17
18
REMOTE I/O-A
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
15.7 BLUE GENIUS™ GOLD WIRING DIAGRAM—230V SINGLE PHASE
AIRBAG DOCK LEVELER WITH CONTROLS—OWNER’S MANUAL
15.8 OPTIONAL EXTERIOR TRAFFIC LIGHT / MIRROR IMAGE SIGN
Slim-build LED traffic lights and mirror image drive warning sign improve loading dock safety.
5" (127 mm)
1/2" (12.7 mm)
¼"
(6.35 mm)
½"
(12.7 mm)
11.875"
(307 mm)
4" (102 mm)
20"
(508 mm)
10½"
(267 mm)
11½"
(292 mm)
Ø 1/4" x 4
Supplied with
15 ft (4572mm)
of cable, 3 wire.
Ø
¼"
Exterior driver traffic light, part # 032-461.
Exterior driver warning sign, part # 038-225 (French 038-225F /
Spanish 038-225S).
NOTE: Mount to a flat surface. DO NOT deform light housing with
irregular wall surface.
15.9 OPTIONAL HOME INTERLOCK SENSOR
• Ties sequence of restraint to dock leveler operation
• Loading dock safety is improved with accurate operation
sequence
• Interior traffic light and restraint release operation relies on
interlock capability
• Mounted at parked position of any leveler
Sensor
Part # 028-199
Bracket
Part # 21-002154
Home interlock sensor (home/lip sensor), part # 26-011290.
ISSUE DATE: MARCH 1, 2016 REV.3 (PART # 038-880E) 35
Corporate 85 Heart Lake Road South
Brampton, ON, Canada L6W 3K2
t 905.457.3900 f 905.457.2313
USA 6350 Burnt Poplar Road
Greensboro, NC 27409
www.BlueGiant.com
If calling within North America: t 1.800.668.7078 f 1.888.378.5781 © Copyright Blue Giant Equipment Corporation 2016
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