Hydraulic Dock Leveler: Extra Dock Safety Series XDS Model

Hydraulic Dock Leveler
Extra Dock Safety Series XDS Model
OWNERS MANUAL
&
INSTALLATION INSTRUCTIONS
XDS Extra Dock Safety Series Dock Leveler
BLUE GIANT
IMPORTANT: Read and understand the contents of this manual before operating the equipment.
Receipt Inspection This equipment was thoroughly inspected and tested prior to leaving the factory. Before placing the equipment in service it should be thoroughly checked for damage or loss occurring in transit. If any such damage or loss is evident, a claim must be made against the carrier. Refer to: Damage in Transit information enclosed with the packing slip.
Subject Receipt Inspection Handling and Installation Installation Instructions Responsibilities and Hazards Safety Placard Operating Sequence Control Box Illustration Control Box Parts List General Assembly Illustration General Assembly Parts List Flap Actuator Flap Deployment Electrical / Hydraulic Diagrams: Index Power Pack Adjustment Auto-Return Adjustment Planned Maintenance Service / maintenance History To Order Parts Warranty
Page 1 2 3 5 6 7 9 10 11 12 14 15 16 59 59 60 61 61 62
Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP
Page 1
BLUE GIANT
Handling & Installation
DO NOT WORK BENEATH LEVELER WITHOUT: Engaging maintenance strut. Erecting a safety barrier across rear of dock leveler (to prevent access to dock leveler by fork trucks). Installing additional blocking (if required a safety stand Part #796-710 is available from Blue Giant). Failure to follow these warnings could result in serious injury or death.
Page 2
BLUE GIANT
Installation Instructions
Read and Understand all information before commencing any work 1. 2.

Prior to installation, clean pit thoroughly and verify that all dimensions are in accordance with Blue Giant specifications. Measure height of rear corners of dock leveler, bottom of frame to top of deck plate, typically 19 (485mm). 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. See Figure 2, Page 2. Measure height of front corners of dock leveler, bottom of frame to top of deck plate, typically 19-1/2 (495mm). 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 2, Page 2. Prepare for temporary hook-up of electrical wires and hydraulic hoses if required. Identify hose ends as Lip and Deck. - For units with self-contained (mounted under deck) power pack, make a temporary electrical hook-up to allow 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 or pulling through conduit. Using extreme caution, sling dock leveler into place squarely above pit and lower gently onto prelocated shims, manipulating hoses and wires as unit lowers. Locate and square dock leveler to best suit pit and dock face. Space between sides of deck and sides of pit should be equal. See Figure 1., Page 2. If rear beam does not line up squarely with 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. See Figure 2, Page 2. Note: It is important that these shims fill space between bottom edge of back beam and face of curb angle as well as top edge, behind each hinge lug. Assure the top of the back beam is flush with the top surface of rear curb angle and finish weld back beam to curb angle as detailed in Figure 2., Page 2.
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7. 8.
Check deck height to assure it is flush with top of side curb angles and tack-weld all front shims to front curb angle and front frame. Mount push button / control box assembly in a suitable location. Mount power unit in a suitable location if applicable (remote power pack).
All electrical work to be performed by a Qualified Electrician

Page 3
BLUE GIANT
Installation Instructions cont.

9.
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 Lift hose is attached to the side fitting.
10. Perform a temporary electrical hook-up to allow use of power unit to raise dock leveler. See
appropriate electrical wiring diagram, Page 14. Assure correct motor rotation on start-up of 3 phase to prevent pump damage Interchange any two power supply or motor leads toreverse motoro rotation.
11. Push and hold Up button to raise deck and extend lip. Raise and position maintenance strut.
Release Up button and allow dock leveler to lower onto maintenance strut.
Do not work under lip or deck with power supply turned ON. Disconnect and lock-out electrical power supply as required, to assure there is no electrical power to dock leveler control panel, and that electrical power can not be turned on accidently. 12. Enter pit area and remove rear corner tilt bar bolts. Reinstall in bottom holes of tilt bars. See Figure
2, Page 2.
13. 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.
14. 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.
15. Finish weld all shims securely to front curb angle and front frame. See Figure 2, Page 2.
Install specified dock bumpers as required. Note: Do not allow Dock Leveler to be used without bumpers, as damage to building and dock leveler may result.
16. Release bottom safety skirts by removing and discarding shipping bolts, one bolt each side. 17. Make permanent electrical and hydraulic connections as required. 18. Mount Warning Placard (see Page 6 for sample) to wall in plain view of dock leveler operators. 19. Lubricate thoroughly as described on Page 16. Perform a final inspection and determine that all
work is completed satisfactorily. Clean pit and work area thoroughly and apply touch-up paint to weld burn areas, scratches, etc.
20. See operating sequence, page 7 thru 8, and test operate unit through several full cycles of all
functions. Each unit is factory adjusted and should not required re-adjustment. If adjustment is required, see page or consult Blue Giant.
Page 4
BLUE GIANT
Responsibilities and Hazards

A OWNERS RESPONSIBILITIES: B OPERATORS RESPONSIBILITIES The owner's responsibility includes the following: 1. The owner should recognize the inherent danger of the interface between dock and freight carrier. The owner should, therefore, properly train and instruct operators in the safe use of Dock Levelers in accordance with the manufacturer's recommendations. Unless otherwise specified by the manufacturer there shall be at least 4" (100 mm) overlap between any supported end of a Dock Leveler and the edge of the supporting surface. Name plates, cautions, instructions and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended. Manufacturer's recommended periodic maintenance and inspection procedures shall be followed and written records of the performance of these procedures should be kept. Dock Levelers which are structurally damaged or which have experienced a sudden loss of support while being under load, such as might occur when a trailer is pulled out from under the dock leveling device, shall be removed from service, inspected by the manufacturer's authorized representative and repaired as needed before being placed back in service. The owner shall see that all nameplates, and caution and instruction markings or labels are in place and legible and that the appropriate operating and maintenance manuals are provided to users. Replacement nameplates, caution or instruction labels, and operating and maintenance manuals are available. Contact BLUE GIANT Parts & Service for more information. Modifications or alterations of Dock Levelers shall be made only with written permission of the original manufacturer. Page 5 The operators responsibility includes the following: 1. Read and understand the safety/operating information contained herein. It is the operator's responsibility to be certain that no unsafe conditions exist before using this equipment. Before operating this equipment, inspect it for proper operation and condition. If any unsafe condition exists, remove unit from service until repairs are made. Prior to using Rail Dock, inspect all safety devices to be certain they are in place and functioning properly. Before using this equipment, ensure that the loading dock area is dry as well as free of obstructions. When industrial trucks are driven on and off carriers during the loading and unloading operation, the brakes on the carrier shall be applied and wheel chocks or positive restraints that provide the equivalent protection of wheel chocks shall be engaged. A Blue Giant Vehicle Restraint that is used properly will provide this protection. Do not exceed the rated capacity as indicated on name plate. This model is designed to service vehicles up to 12" (305 mm) above and 6" (152 mm) below dock level. Do not exceed this range.
After use, always restore dock leveler to stored.
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BLUE GIANT
Safety Placard Wall Mounted
Page 6
BLUE GIANT
Operating Sequence
For models equipped with hydraulic lip and automatic return to cross traffic from below dock level features.
XDS Key Switch
Up Lip Stop Selector Switch
CONTROL BOX
1.
Dock leveler in stored position. Selector switch in AUTO position.
2.
To cycle leveler to truck bed: a) Push and hold UP button until deck is fully raised and lip extended. or b) To reduce cycle time push and hold UP button until lip has cleared truck bed. Release UP button and immediately push and hold LIP button until lip has fully extended. Note: XDS guard flap will automatically lower into deck before dock lifts. Release button and deck will lower to truck bed.
3.
4.
When truck pulls away deck will descend to lower limit. Lip will then automatically rise to a few inches above dock level then lower to stored position. Note: XDS guard flap will automatically deploy up to safety position when dock returns to stored position. Note: Pushing the stop button at anytime will stop all movement.
Page 7
BLUE GIANT
Operating Sequence contd
To service a vechile with a tail load

1. 2. Turn selector switch to MANUAL position. Push and hold UP button until deck is a few inches above level. Release UP button and immediately push LIP button to extend to just enough to clear lip keepers. Release button and deck will descend to lower limit. Note: XDS guard flap will automatically lower into deck before dock lifts. Return dock to stored position by pressing UP button until deck is a few inches above dock level and then release. Note: XDS guard flap will automatically deploy up to safety position when dock returns to stored position. For tail loading with deck in stored position insert key into guard over-ride key switch and turn to Guard Down momentarily. When loading completed, insert key into guard over-ridge key switch and turn to Guard Up until guard flap deploys up to safety position.
3.
4.
5.
To return dock leveler to stored position while vehicle is still in position

1. 2. Selector switch in AUTO position. With leveler lip vehicle bed, push and hold UP button. Deck will rise and lip begins to retract. When lip is fully retracted release button and leveler will return to stored position. Note: XDS guard flap will automatically deploy up to safety position when dock returns to stored position. Note: Pushing the stop button at anytime will stop all movement.
Page 8
BLUE GIANT
Control Box Illustration
Page 9
BLUE GIANT
Control Box Parts List

PART NO. 037H402123 047H421000 047H309000 175B808501 047B569100 047X549800 047X566407 047X541001 R4004A1200 ES154N0000 ENGRAVI135 SP10500000 ZB4BV05000 ZB4BV60000 ZB4BA20000 ZB4BA30000 ZB4BT40000 XB4BA96100 ZB4BJ20000 ZB4BG70000 ZBE1020000 ZB4BZ10100 ZB4BZ10300 ZB4BZ10500 047X573204 047X573207 047X573203 047X573210 047X573208 047B571103 047X573403 047B579578 047B579800 984X943802 047B576500 047X572900 047X572904 047B575600 047L531700 047X570802 993U503500 993U503803 993U506005 993U506040 993U506041 993U506105 QTY 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 3 1 2 2 12 1 2 2 1 18 3 26 25 60 135 375 1 30 2 1 1 1 1 1 DESCRIPTION CI9-30 CONTACTOR 110/50/60 TI 16C OVER LOAD 6.0-9.2A (BU ATI ELECTRONIC TIMER 0.1-1 TRANS 208-120 100VA 50/60 FUSE HOLDER BUSSMANN S8202 FUSE BLOCK "MIDGET" 2P 30A FUSE MDL 1.0A 250V SLOW BL FUSE FNM 1.25A 250V SLOW B BASIC 4P RELAY, COIL 120VA SOCKET 14 PIN 4FORMC LAMICOID "GUARD UP-AUTO-GU BULB SP105 130V 3W MIN BAY TELE AMBER PILOT LAMP HEAD TELE PILOT LAMP MODULE NO BLACK PUSHBUTTON GREEN PUSHBUTTON RED PUSH-PULL MUSHROOM BLUE RESET 30-130MM 2 POSITION EXTENDED SELECT 3P KEY SW, RET L & R, K/O CE 1 NC CONTACT BLOCK 1 N.O. C/W COLLAR 2 N.O. C/W COLLAR 1 N.O/ 1 N.C C/W COLLAR TERMINAL BLOCK WK4/U BLACK TERMINAL BLOCK WK4/U BLUE TERMINAL BLOCK WK4/U GREY( TERMINAL BLOCK WK4/U WHITE TERMINAL BLOCK WK4/U GREEN END BRACKET Z5.522.7453.0 END SECTION PLATE, GREY WK BLANK MARKING TAG FOR WK 4 JUMPERING COMBS TERMINAL B DIN RAIL TS35 X 7.5 UNSLOT WIRE 14AWG TEW GREEN STRAN WIRE 16AWG TEW WHITE STRAN WIRE 16AWG TEW BLACK STRAN WIRE 16AWG TEW RED STRANDE 18GA.WIRE L.2-1/4" 3/8" ST BRAIDED SLEEVING .375" (CM LABEL FUSE RATING LABEL CSA/NRTL RATINGS DIS LABEL WARNING FOR CSA/NRTL *B-G LABEL #038-084 LOCK-O *B-G LABEL #038-038 *B-G OVERLAY # 038-175-ES
Page 10
BLUE GIANT
General Assembly Illustration
Page 11
BLUE GIANT
General Assembly Parts List

ITEM 1 2 3 4 5 6 6 7 7 7 8 8 8 9 10 11 12 13 14 15 15 17 18 19 20 21 25 26 28 29 30 31 32 33 34 35 36 37 39 40 41 42 43 44 46 QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 4 1 1 1 6 4 2 2 1 2 2 2 4 1 6 4 1 4 1 1 DESCRIPTION Deck Assembly Frame Assembly Consult Factory Safety Skirt Assy (Right) Consult Factory Safety Skirt Assy (Left) Consult Factory Lip Assembly 788-635 Cylinder Assembly - 6 & 8 (1830 & 244mm) models 786-636 Cylinder Assembly - 8 (244mm) models 794-507 Hose Assembly - 7 (1830mm) models 790-939 Hose Assembly - 8 (2440mm) models 788-330 Hose Assembly - 10 (3050mm) models 792-688 Hose Assembly - 6 (1830mm) models 788-329 Hose Assembly - 8 (2440mm) models 788-333 Hose Assembly - 10 (3050mm) models Consult Factory Hinge Pin See Chart, Page 14 Control Box Assembly 788-345 Rod Assembly 788-436 Safety Strut Assy 788-344 Power Pack Mounting Bracket 788-346 Cylinder Bracket 788-599 Lip Cylinder (single acting) 788-245 Lip Cylinder (double acting) 107-196 Clevis Pin 119-600 Clevis Bolt 113-202 Cylinder Pin 113-300 Switch Activator 113-096 Pivot Block Top Plate See Chart, Page 14 Power Pack 025-601 Micro Switch 014-001 Set Screw 035-262 Hose Clip 018-017 Bushing 011-007 Machine Screw 018-001 Bushing 013-025 Cotter Pin 091-041 Lip Bumper 010-006 Cap Screw 011-552 Hex Nut 010-037 Cap Screw 011-530 Hex Jam Nut 012-211 Washer 012-200 Lock Washer 011-544 Nylock Nut 011-502 Hex Nut 010-040 Cap Screw 011-552 Nylock Nut contd PART NO 200-01093-19 200-01080-68
Page 12
BLUE GIANT
General Assembly Parts List contd

ITEM 47 48 48 49 49 50 51 52 53 54 55 60 61 62 63 64 QTY 1 2 2 1 1 1 4 4 4 8 8 1 1 1 1 2 PART NO 011-007 034-511 034-601 034-617 034-585 034-515 033-662 012-200 010-021 012-201 010-039 010-027 036-205 036-204 832-787 028-126 DESCRIPTION Machine Screw 90o Elbow 90o Elbow - 60,000 (27,250 kg) 90o Elbow 90o Elbow - 60,000 (27,250 kg) 90o Elbow Velocity Fuse Lock Washer Cap Screw Lock Washer Cap Screw Cap Screw Deck Cylinder Seal Kit Lip Cylinder (single acting) Flap Weldment Flap and Lip Switch
Charts
FH / XDS
DESCRIPTION 1 HP - 115/1/60 1 HP - 208/1/60 1 HP - 230/1/60 1 HP - 208/3/60 1 HP - 230/3/60 1 HP- 460/3/60 1 HP - 575/3/60 CONTROL BOX 027-201 027-202 027-203 027-204 027-205 027-206 027-207 POWER PACK 033-912 033-913 033-912 033-914 033-915 033-915 033-916
FHE / XDS
DESCRIPTION 1 HP - 115/1/60 1 HP - 208/1/60 1 HP - 230/1/60 1 HP - 208/3/60 1 HP - 230/3/60 1 HP - 460/3/60 1 HP - 575/3/60 CONTROL BOX 027-261 027-262 027-263 027-264 027-265 027-266 027-267 POWER PACK 033-912 033-913 033-912 033-914 033-915 033-915 033-916
FH / TL85A / XDS
DESCRIPTION 1 HP -115/1/60 1 HP - 208/1/60 1 HP - 230/1/60 1 HP - 208/3/60 1 HP - 230/3/60 1 HP - 460/3/60 1 HP - 575/3/60 CONTROL BOX 027-211 027-212 027-213 027-214 027-215 027-216 027-217 POWER PACK 033-912 033-913 033-912 033-914 033-915 033-915 033-916
FHE / TL85A / XDS

DESCRIPTION 1 HP - 115/1/60 1 HP - 208/1/60 1 HP - 230/1/60 1 HP - 208/3/60 1 HP - 230/3/60 1 HP - 460/3/60 1 HP - 575/3/60 CONTROL BOX 027-221 027-222 027-223 027-224 027-225 027-226 027-227 POWER PACK 033-917 033-918 033-917 033-919 033-920 033-920 033-921
Page 13
BLUE GIANT
Flap Actuator
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
QTY 1 2 2 2 1 2 1 6 2 2 1 4 2 2 6 1 1
PART NO. 200-01021 119-748 017-062 018-001 200-01003 200-01038 200-01039 105-878 107-196 200-01042 034-511 011-508 012-220 010-048 013-011 028-126 100-5003-3
DESCRIPTION Safety Lip Actuator Bar Weldment Push Roller Spring Bushing Guide Block top Strap Clevis Weldment Cylinder 2.25 Stoke Spacer Washer Clevis Pin Support Roller Pin Adapter 90o Hex Nuts Regular Spring Lock Washers Hex Head Cap Screw Spring Pin 1/4 dia. Limit Switch Hose #4 High Pressure Straight
Page 14
BLUE GIANT
Flap Deployment
Page 15
BLUE GIANT
XDS Electrical / Hydraulic Diagrams

Index
Basic Model FH Voltage 115/1/60 Dwing No. 2001 2001-1 2001-2 2002 2002-1 2002-2 2003 2003-1 2003-2 2004 2004-1 2004-2 2005 2005-1 2005-2 2006 2006-1 2006-2 2007 2007-1 2007-2 2007-3 2008 2008-1 2008-2 2008-3 2009 2009-1 2009-2 2009-3 2010 2010-1 2010-2 2010-3 2011 2011-1 2011-2 2011-3 2012 2012-1 2012-2 2012-3 Description Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram FH /TL-85A Combo Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram FH /TL-85A Combo Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram FH /TL-85A Combo Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram FHE /TL-85A Combo Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram FHE /TL-85A Combo Electrical Schematic Control Box Wiring Diagram Dock Leveler Wiring Diagram FHE /TL-85A Combo Page No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
208-230/1/60
3 Phase
FHE
115/1/60
208-230/1/60
3 Phase
FH / TL-85A
115/1/60
208-230/1/60
3 Phase
FHE / TL-85A
115/1/60
208-230/1/60
3 Phase
Page 16
BLUE GIANT
FH Electrical Schematic 115/1/60
Page 17
BLUE GIANT
FH Control Box 115/1/60
Page 18
BLUE GIANT
FH Dock Leveler 115/1/60
Page 19
BLUE GIANT
FH Electrical Schematic 208-230-1-60
Page 20
BLUE GIANT
FH Control Box 208-230/1/630
Page 21
BLUE GIANT
FH Dock Leveler 208-230/1/60
Page 22
BLUE GIANT
FH Electrical Schematic 3 Phase
Page 23
BLUE GIANT
FH Control Box 3 Phase
Page 24
BLUE GIANT
FH Dock Leveler 3 Phase
Page 25
BLUE GIANT
FHE Electrical Schematic 115/1/60
Page 26
BLUE GIANT
FHE Control Box 115/1/60
Page 27
BLUE GIANT
FHE Dock Leveler 115/1/60
Page 28
BLUE GIANT
FHE Electrical Schematic 208-230-1-60
Page 29
BLUE GIANT
FHE Control Box 208-230/1/630
Page 30
BLUE GIANT
FHE Dock Leveler 208-230/1/60
Page 31
BLUE GIANT
FHE Electrical Schematic 3 Phase
Page 32
BLUE GIANT
FHE Control Box 3 Phase
Page 33
BLUE GIANT
FHE Dock Leveler 3 Phase
Page 34
BLUE GIANT
FH / TL-85A Electrical Schematic 115/1/60
Page 35
BLUE GIANT
FH / TL-85A Control Box 115/1/60
Page 36
BLUE GIANT
FH / TL-85A Dock Leveler 115/1/60
Page 37
BLUE GIANT
FH / TL-85A Combo 115/1/60
Page 38
BLUE GIANT
FH / TL-85A Electrical Schematic 208-230/1/60
Page 39
BLUE GIANT
FH / TL-85A Control Box 208-230/1/60
Page 40
BLUE GIANT
FH / TL-85A Dock Leveler 208-230/1/60
Page 41
BLUE GIANT
FH / TL-85A Combo 208-230/1/60
Page 42
BLUE GIANT
FH / TL-85A Electrical Schematic 3 Phase
Page 43
BLUE GIANT
FH / TL-85A Control Box 3 Phase
Page 44
BLUE GIANT
FH / TL-85A Dock Leveler 3 Phase
Page 45
BLUE GIANT
FH / TL-85A Combo 3 Phase
Page 46
BLUE GIANT
FHE / TL-85A Electrical Schematic 115/1/60
Page 47
BLUE GIANT
FHE / TL-85A Control Box 115/1/60
Page 48
BLUE GIANT
FHE / TL-85A Dock Leveler 115/1/60
Page 49
BLUE GIANT
FHE / TL-85A Combo 115/1/60
Page 50
BLUE GIANT
FHE / TL-85A Electrical Schematic 208-230/1/60
Page 51
BLUE GIANT
FHE / TL-85A Control Box 208-230/1/60
Page 52
BLUE GIANT
FHE / TL-85A Dock Leveler 208-230/1/60
Page 53
BLUE GIANT
FHE / TL-85A Combo 208-230/1/60
Page 54
BLUE GIANT
FHE / TL-85A Electrical Schematic 3 Phase
Page 55
BLUE GIANT
FHE / TL-85A Control Box 3 Phase
Page 56
BLUE GIANT
FHE / TL-85A Dock Leveler 3 Phase
Page 57
BLUE GIANT
FHE / TL-85A Combo 3 Phase
Page 58
BLUE GIANT
Power Pack Adjustment

3. Locate the main relief valve marked (RV). Use the flat screwdriver, turn the screw fully clockwise and then back it off turn. To adjust the sequence valve (the larger screw located directly below the main relief) turn it fully clockwise and then back it out 1-complete turn. Finally, to set the return-flow-control marked (FC) turn it fully clockwise and then back it out of a turn. The three locking caps can now be re-installed with care being taken to ensure that the sealing rings are properly located. Caps must be snug to eliminate the possibility of leaks.
4.
5. 6.
Note:
Power packs are all factory tested and preset to 2000 psi (138 bar) main relief pressure and 1750 psi (120 bar) sequence pressure. The flow control is also set so that deck return-speed is approximately the same as deck lifting-speed. These settings can be achieved in the field, to approximate values, through the use of: ! 1 (25mm) wrench. ! Large flat screwdriver ! And the following procedure: 1. Raise dock leveler and position it on the maintenance strut. Place a safety stand between the deck assembly and the lower frame to assure the deck can not lower. Do not work beneath the deck without adequate blocking to assure the deck will not lower unexpectedly. A safety stand is available from Blue Giant (Part #796-710). 2. Using the 1 (25mm) wrench and turning counter-clockwise remove the 3 hexagonal, locking caps being careful not to lose the sealing rings for each cap.
The unit is now roughly set and should perform properly: In the event that it does not, follow the trouble shooting procedures below. Troubleshooting: ! Deck will not lift: Increase main relief (RV) by turning it slightly clockwise. ! Motor stalls upon full extension: Lower main relief (RV) by turning it slightly counter-clockwise. ! Lip extends before deck or wont fully retract: Increase sequence setting (large screw) by turning it slightly clockwise. ! Lip wont extend or is slow to extend: Lower sequence setting (large screw) by turning is slightly counter-clockwise. ! Return speed is to fast: Increase flow control (FC) by turning it slightly clockwise. ! Return speed is too slow: Lower flow control (FC) by turning it slightly counter-clockwise.
Auto-Return Adjustment
When the deck bottoms out the lip retracts completing circuit to motor starter. Deck rises slightly above floor level. As the lip fully retracts the circuit to the motor starter is broken and deck returns to floor level with lip inside lip keepers. When servicing a truck below floor level with lip extended the auto return circuit is automatically broken by the limit switch. When servicing a truck below floor level with the lip retracted the auto return switch must be broken by placing the selector switch in the MANUAL position. If lip fails to return inside of lip keepers adjustment switch activator by moving it towards position A, at 1/16 (1.5mm) increments. When the deck fails to stop cycling adjust switch activator by moving it towards position B at 1/16 (1.5mm) increments.
Selector Switch for the auto-return to operate place the selector switch in AUTO position. Normal Operation when truck pulls away deck descends to below floor level.
Page 59
BLUE GIANT
Planned Maintenance
Under normal conditions no daily care is required except for removal of dirt, ice, or snow from deck and lip hinge. Following is a list of maintenance checks to be performed on the electrical, hydraulic and mechanical components. ELECTRICAL SYSTEM: Periodically check for wire and cable damage. Keep water and ice away from power pack. HYDRAULIC SYSTEM: These checks are to be performed every three months. 1. Hydraulic oil level should be kept to within 1 of top of reservoir with deck in fully lowered position. In fully raised position oil depth in reservoir should be 1-1/2 (38mm) above suction fitting. 2. Use only good quality hydraulic oil. For all season us, where operating temperature will not be below o o 40 F (-40 C) the following oils are recommended: Esso Univis N Artic; Gulf Harmony Arctic 15; or equal For all season use, where the temperature will not o o be below 20 F (-7 C) the following oil is recommended: Dextron II or equal. Breather cap and filters must be kept clean, wash in a suitable cleaning solvent.
4. 5. 6.
Hydraulic system and surrounding area must be kept clean and free of debris. Leaking or damaged hoses and fittings should be repaired or replaced immediately. HYDRAULIC OIL CHANGE: Three months after equipment is placed in service and every twelve months thereafter. To change oil raise deck fully and brace it. Place selector switch in control box (if so equipped) in manual position. Disconnect deck cylinder hose from deck cylinder and place loose end into a suitable used oil container. Pump oil from reservoir by pressing up button until oil has been expelled. DO NOT RUN THE PUMP DRY Stop motor immediately when a full stream of oil stops flowing out of hose. Examine oil, if oil is extremely dirty, consult Blue Giant for additional oil changing procedures. Fill reservoir with new hydraulic fluid to a level that is 1 (25mm) below top of tank. Reconnect hose to cylinder and tighten fitting securely. Cycle dock leveler repeatedly until up and down motion is smooth (air is system causes jerky operation_. Dispose of used oil properly).
3.
MECHANICAL SYSTEM: Following procedures should be performed at least once a month. 1. Lubricate all pivot points (see diagram below). 2. Check for excessive wear, visual damage, etc.
Page 60
BLUE GIANT
Service / Maintenance History

Date Work Performed Comments / Notes
To Order Parts
For prompt service when ordering parts, please provide the following information to your local distributor. 1. Model and Serial number of the equipment. 2 Part number, description and quantity 3 Shipping instructions When in doubt as to part required, please provide a sketch or the used part as a sample.
Record Here For Future Reference

Model Number: Serial Number: Distributor:
BLUE GIANT EQUIPMENT CORPORATION 85 Heart Lake Road South, Brampton, ON L6W 3K2 Phone: 800 668 7078 / 905 457 3900 Fax: 888 378 5781 / 905 450 6555 www.BlueGiant.com
Page 61
BLUE GIANT
Warranty Policy
XDS Extra Dock Safety Series
BLUE GIANT warrants to the original purchaser its loading dock equipment to be free from defective factory material and workmanship. All warranties begin on the date of delivery to the first user or the sixtieth (60) day after date of shipment, whichever comes first. Parts or components which fall under normal usage within the following specified time periods and are proven to be defective will be repaired or replaced by BLUE GIANT without charge for parts or labor unless stated otherwise herein. Replacement parts will be supplied F.O.B. factory.
WARRANTY TIME PERIODS: A-Series Dock Leveler and Door & Dock Guard 1.) TEN (10) YEARS STRUCTURAL
Deck, frame, support beams, lip and hinge. 2.) FIVE (5) YEARS PARTS ONLY / ONE (1) YEAR - LABOR Powerpack, hose and fittings. 3.) ONE (1) YEAR PARTS and LABOR All parts and components not listed above. Includes Door and Dock Guard.
TL-85 Vehicle Restraint (XDS-3000 Model Only)

1.) FIVE (5) YEARS PARTS ONLY Structural components, Vehicle Restraint body and Locking Arm, except pins, bushings, and cylinder. 2.) ONE (1) YEAR PARTS and LABOR Powerpack, and all parts and components, except fuses and light bulbs.
WARRANTY IS VOID IF:

1.) 2.) 3.) 4.) Warranty validation form is not completed and returned to BLUE GIANT. Equipment is modified or repaired in any manner not approved by BLUE GIANT. Equipment is overloaded beyond rated capacity. Equipment is used in abrasive or corrosive conditions, freezers or excessive moisture.
THE FOLLOWING ARE NOT COVERED UNDER WARRANTY:

1.) Adjustments, including initial field set-up. Adjustments are considered part of normal maintenance procedures. 2.) Repairs required as a result of: Failure to follow maintenance and/or lubrication procedures specified in the owners manual. Abuse, willful damage, accident, or neglect. Shipping damage. (Claim must be made with freight carrier.) 3.) Repair/replacement to Door and Dock Guard and Components as a result of impact damage. BLUE GIANT DOES NOT ASSUME RESPONSIBILITY OR LIABILITY FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES, OR FOR LOSS OF PROFIT OR DAMAGE TO TRADE OR BUSINESS WHICH RESULTS FROM THE EQUIPMENT. THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES, EITHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION CONTAINED HEREIN.
BLUE GIANT EQUIPMENT CORPORATION www.BLUEGIANT.com

Warranty: Part #038-666E
Page 62
BLUE GIANT EQUIPMENT CORPORATION

85 Heart Lake Road South, Brampton, Ontario Canada L6W 3K2 Tel 800 668 7078 Fax 888 378 5781
wwwBlueGiant.com
If calling from outside North America: Tel 905 457 3900 Fax 905 450 6555
BLUE GIANT offers a full line of Dock Levelers, Dock Safety Equipment, Accessories, Ergonomic and Scissor Lift Equipment, and Industrial Trucks. Concurrent with our continuing product improvement program, specifications are subject to change without notice. Please contact BLUE GIANT for latest information. Some features illustrated may be optional in certain market areas.
Warning: This manual may not be copied, quoted or transferred in any form or medium to any individual or company, in whole or in part without written consent from Blue Giant.

Hydraulic Dock Leveler: Extra Dock Safety Series XDS Model

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Hydraulic Dock Leveler: Extra Dock Safety Series XDS Model

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Hydraulic Dock Leveler

Extra Dock Safety Series XDS Model

XDS Extra Dock Safety Series Dock Leveler

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

Handling & Installation

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

Read and Understand all information before commencing any work 1. 2.

All electrical work to be performed by a Qualified Electrician

XDS Extra Dock Safety Series Dock Leveler

Installation Instructions cont.

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

Responsibilities and Hazards

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

Safety Placard Wall Mounted

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

XDS Key Switch

Up Lip Stop Selector Switch

Dock leveler in stored position. Selector switch in AUTO position.

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

Operating Sequence contd

To service a vechile with a tail load

To return dock leveler to stored position while vehicle is still in position

XDS Extra Dock Safety Series Dock Leveler

Control Box Illustration

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

Control Box Parts List

XDS Extra Dock Safety Series Dock Leveler

General Assembly Illustration

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

General Assembly Parts List

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

General Assembly Parts List contd

FHE / TL85A / XDS

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

XDS Electrical / Hydraulic Diagrams

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

FH Electrical Schematic 115/1/60

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

FH Control Box 115/1/60

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

FH Dock Leveler 115/1/60

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP

XDS Extra Dock Safety Series Dock Leveler

FH Electrical Schematic 208-230-1-60

Issue Date: 12/12/03 (Part #038-643E) Rev.1-PP