Blue Giant DL Series Owner's Manual
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Blue Giant DL Series Owner's Manual

Stationary dock lift
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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 bodily injury or
death.
STARTING FROM SEPTEMBER 24, 2019 / SERIAL # 0.
OWNER'S MANUAL
STATIONARY DOCK LIFT
ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)

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  • Page 1 OWNER’S MANUAL STATIONARY DOCK LIFT 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 bodily injury or death.

  • Page 3: Table Of Contents

    STATIONARY DOCK LIFT — OWNER’S MANUAL Table of Contents ABOUT THE DL-SERIES DOCK LIFT WITH CONTROLS OWNER’S PURCHASE RECORD INTRODUCTION WARRANTY INFORMATION EXCLUSION OF LIABILITY MANUFACTURER’S NOTE OWNER’S RESPONSIBILITY SAFETY MESSAGE COLOR IDENTIFICATION OPERATIONAL SAFETY WARNINGS LOCKOUT / TAGOUT PROCEDURE AND RULES ELECTROSTATIC SENSITIVE DEVICE PROTECTION POLICY HOW TO READ THIS MANUAL CONTROL STATION OPERATION...
  • Page 4 STATIONARY DOCK LIFT — OWNER’S MANUAL ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)

  • Page 5: About The Dl-Series Dock Lift With Controls

    Concurrent with a continuing product improvement program, specifications are subject to change without notice (See “2.2 EXCLUSION OF LIABILITY” on page 7). Please contact the your Blue Giant Dealer for latest information. Some features illustrated may be optional in certain market areas.
  • Page 6 STATIONARY DOCK LIFT — OWNER’S MANUAL ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)

  • Page 7: Introduction

    2.1 WARRANTY INFORMATION Thank you for purchasing Blue Giant products. We appreciate your business, and are confident that our product will serve you for many years to come. In the event that you experience a problem with our product, our Customer Support Team is here to support the Blue Giant Product(s) that you have purchased.

  • Page 8: Manufacturer's Note

    If, at the request of the owner, Blue Giant does not supply all or some of the dock lift equipment power unit and/or control panel components, the owner shall assume responsibility for any and all operational and safety issues associated with the resulting configuration.
  • Page 9 STATIONARY DOCK LIFT — OWNER’S MANUAL warranty and can result in serious injury, including death. 11. Operational placard must be visible from equipment location and permanently attached to a wall or structure. 12. The owner shall ensure that inspections are performed to the lifting device as prescribed by law or regulation. ISSUE DATE: March 10, 2020 REV.
  • Page 10 STATIONARY DOCK LIFT — OWNER’S MANUAL 10 ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)

  • Page 11: Safety Message Color Identification

    • Conduct routine inspections and maintenance. Failure to do so could cause equipment damage and or personal injury. • Always contact your Blue Giant Dealer immediately if a malfunction occurs. ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)
  • Page 12 Always clean up dry and liquid spills immediately after they occur. • Always maintain proper lighting in the work area. • If a procedure is not clearly defined in this manual, contact your Blue Giant Dealer. 12 ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)

  • Page 13: Lockout / Tagout Procedure And Rules

    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 and/or local jurisdiction lockout devices and procedures be utilized. The energy isolating device must bear a prominent warning tag indicating that work is being done on the equipment and the name of the authorized employee responsible for the lockout.

  • Page 14: Electrostatic Sensitive Device Protection Policy

    FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES DO NOT DISCARD. Any components shipped back to Blue Giant must be in their original packaging (along with completed RGA form taped to the OUTSIDE of the static bag) or warranty may be voided. 038-850E Prior to handling PCBs, wear a static grounding wrist strap and clip it to an electrical ground.

  • Page 15: How To Read This Manual

    This Owner’s Manual covers standard operating steps for the Blue Giant Dock Lifts. There are many configurations or custom designs whose specifications may not be fully reflected in this manual. Contact your Blue Giant Dealer to obtain the General Arrangement drawing for application specific designs.
  • Page 16 STATIONARY DOCK LIFT — OWNER’S MANUAL 16 ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)

  • Page 17: Control Station Operation

    STATIONARY DOCK LIFT — OWNER’S MANUAL 6.0 CONTROL STATION OPERATION Depending on the specific installation, the control station may be mounted on a guard rail attached to the dock lift, on a separate guard post, or on an adjacent wall. See ”9.0 OPERATING INSTRUCTIONS” on page 33 for more information. 6.1 PUSH BUTTON CONTROLS This section describes the push button controls to operate the dock lift.
  • Page 18 STATIONARY DOCK LIFT — OWNER’S MANUAL • DOWN push button The DOWN push button control opens the hydraulic pressure release valve to drain oil back into the oil reserve of the Powerpack. This causes the lift to lower at a controlled and safe speed. Callout Description Press the DOWN push button...
  • Page 19 STATIONARY DOCK LIFT — OWNER’S MANUAL Unhook lip chain from deck side guard post before attempting. The HYDRAULIC LIP DOWN push button control opens the hydraulic pressure release valve to drain oil back into the oil reserve of the Powerpack. Release push button when the lip is fully lowered to the ground or the trailer bed.
  • Page 20 STATIONARY DOCK LIFT — OWNER’S MANUAL 20 ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)

  • Page 21: Dock Lift Strut And Stand Set-Up

    Drop-in Style Maintenance Strut Part# 1005834-01 and 1005834-02 Applicable to a lift table with a self-weight maximum of 3000 lbs or less. For all other requirements, contact your Blue Giant Dealer. This Maintenance Strut is found on: • 8 in. lowered height DL table with 4 in. wide legs •...
  • Page 22 STATIONARY DOCK LIFT — OWNER’S MANUAL Callouts Description Rolling end hook side Wheel track side Hook A on this edge Hook B on this edge Storage area of drop-in Maintenance Strut. Not on concrete. Part# 828-418-1, 828-418-3, and 838-702 This Maintenance Strut is stored within the lower frame of the lift. There is one strut per table and is applicable to tables with a total self- weight maximum between 3000 lbs or less.
  • Page 23 1 strut 2 struts 10,000 lbs to 20,000 lbs 2 struts 2 struts Non-standard smaller raised height tables may require a shorter Maintenance Strut, contact your Blue Giant Dealer. One flip-style Maintenance Strut Callout Description Store flip-style strut here Engage flip-style strut here...

  • Page 24: Disengaging The Dock Lift Maintenance Strut

    Flip Style Maintenance Strut and Drop-in Style Maintenance Strut Examine the Maintenance Strut for damage or if it is missing. Contact your Blue Giant Dealer for service or repair, as required. When all work is completed and the area around the lift is cleared, an authorized person shall inform all affected personnel before removing the lock out and tag out from the electrical connections to the lift hydraulic Powerpack.

  • Page 25: Engaging The Dock Lift Service Stand

    Failure to properly secure the dock lift deck prior to working underneath it may result in bodily injury or death. • Engage the Maintenance Strut AND Service Stand before working. If both cannot be successfully engaged, contact your Blue Giant Dealer.

  • Page 26: Disengaging The Dock Lift Service Stand

    Maintenance Strut. As much as possible, never reach in with a body part to move the Maintenance Strut. Examine the Maintenance Strut for damage or if it is missing. Contact your Blue Giant Dealer for service or repair, as required.

  • Page 27: Maintenance

    Recommended procedures for a periodic planned maintenance program that covers inspections, operational checks, cleaning, lubrication, and minor adjustments are outlined in the Owner’s Manual for this product. Contact your Blue Giant Dealer regarding for assistance with a planned maintenance program by offering trained service personnel with expertise in dock lift maintenance requirements.

  • Page 28: Checking Rollers / Bearings

    Failure to properly secure the dock lift deck prior to working underneath it may result in bodily injury, or death. • Engage the Maintenance Strut AND Service Stand before working. If both cannot be successfully engaged, contact your Blue Giant Dealer.

  • Page 29: Daily Maintenance Procedures (Dmp) Checklist

    STATIONARY DOCK LIFT — OWNER’S MANUAL 8.7 DAILY MAINTENANCE PROCEDURES (DMP) CHECKLIST Use checklist to aid the daily maintenance inspection. DANGER • When repairing or conducting maintenance procedures on electrical components, perform lockout / tagout steps according to OSHA regulations and approved electrical codes. •...
  • Page 30 STATIONARY DOCK LIFT — OWNER’S MANUAL DEALER: PLANNED MAINTENANCE PROGRAM - PMP CHECKLIST DOCK LIFTS Customer: SWO# Location: Date: Contact: Telephone: Inspected By: Signature: Model / Serial #: Voltage: Phase: NOTE TO TECHNICIAN: Dock / Door # Dock / Door # Dock / Door # Dock / Door # Dock / Door #...

  • Page 31: Lubrication Points And Powerpack Reservoir Level

    STATIONARY DOCK LIFT — OWNER’S MANUAL 8.8 LUBRICATION POINTS AND POWERPACK RESERVOIR LEVEL Only trained technicians should lubricate the lift and fill the Powerpack reservoir. Contact your Blue Giant Dealer regarding oil options. WARNING • Do not attempt to install, make repairs, or adjustments. Only a trained and authorized service technician should perform the installation process.
  • Page 32 STATIONARY DOCK LIFT — OWNER’S MANUAL 32 ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)

  • Page 33: Operating Instructions

    STATIONARY DOCK LIFT — OWNER’S MANUAL 9.0 OPERATING INSTRUCTIONS Follow the safe operating instructions to ensure personnel, load, and equipment safety. 9.1 LOAD TRANSFER When transferring loads onto and off of a dock lift, the transfer vehicle and cargo weight distribution should NEVER exceed the maximum single axle load value on the weight rating decal.
  • Page 34 STATIONARY DOCK LIFT — OWNER’S MANUAL WARNING • Lift operator must be present during all steps of this procedure. Only one (1) rider/operator is permitted on the deck when lift is in motion. • Do not exceed (rated/lifting) capacity or load classification of lift as listed on the manufacturer/product nameplate. Capacity includes: forklift/manual equipment, pallet(s), material(s)/goods, operator, and any other objects on the deck/platform.
  • Page 35 STATIONARY DOCK LIFT — OWNER’S MANUAL Callout Description Unhook personnel restraint chains on the entry or building side. If job required, drive forklift or transfer device onto the deck of the lift. Verify that the load is positioned on the deck between where the scissor legs will be in the raised position AND in the lateral (left/right) center of the deck.
  • Page 36 STATIONARY DOCK LIFT — OWNER’S MANUAL 10. If present, verify that any entry (or building) side lip is manually raised and chained, or the hydraulic lip is fully raised and chained. Callout Description Hook lip chain on the entry or building side.

  • Page 37: Lowering Lift

    STATIONARY DOCK LIFT — OWNER’S MANUAL NOTE: Verify that the deck lip has a minimum of four (4) in. (102 mm) of overlap with the trailer bed. Callout Description Minimum 4 inch (100 mm) overlap. 14. Remove exit (or trailer) side personnel restraint chains. If present, do the same for any interlock door or gate on the exit side.
  • Page 38 STATIONARY DOCK LIFT — OWNER’S MANUAL WARNING • Lift operator must be present during all steps of this procedure. Only one (1) rider/operator is permitted on the deck when lift is in motion. • Do not exceed (rated/lifting) capacity or load classification of lift as listed on the manufacturer/product nameplate. Capacity includes: forklift/manual equipment, pallet(s), material(s)/goods, operator, and any other objects on the deck/platform.
  • Page 39 STATIONARY DOCK LIFT — OWNER’S MANUAL during the lowering of the lift. NOTE: Illustration simplified for clarity; never operate unit without guard rails, lip(s) and all chains setup in full restraint positions. Callout Description Center of gravity of load shall be on this deck section, between the scissor legs, during the lift lowering.
  • Page 40 STATIONARY DOCK LIFT — OWNER’S MANUAL If present, any Powerpack mounted bell, acoustic warning, or visual warning beacon will operate while the lift is in motion. Callout Description DOWN push button 10. When deck is level with the building side floor or stops lowering, release the button.
  • Page 41 STATIONARY DOCK LIFT — OWNER’S MANUAL 13. If job required, drive forklift or transfer device off of lift deck. 14. If transfer complete, reattach entry (or building) side personnel restraint chains. If present, do the same for any interlock door or gate on the exit side. Callout Description Hook personnel restraint chains...
  • Page 42 STATIONARY DOCK LIFT — OWNER’S MANUAL 42 ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)

  • Page 43: Decal Identification And Location

    Ne PAS mettre Ne PAS rester d’équipement de protección personal. protection debout, BLUE GIANT EQUIPMENT CORPORATION individuelle. les mains ou www.BlueGiant.com Voltage s’assoir ou MADE IN CANADA Hazardous Tension FABRIQUE AU CANADA Peligroso.

  • Page 44: Operation Placard

    STATIONARY DOCK LIFT — OWNER’S MANUAL Callout Part No. Description 038-1105EFS Reminds personnel to lock out the electrical feeds before attempting work on the lift (on exterior of electrical box) 038-1097 Proposition 65 Cancer and Reproductive Harm Warning - California only 038-1107EFS Rated dock capacity and electrics (Located on Powerpack) 10.1 OPERATION PLACARD...
  • Page 45 • Do NOT work on or under the lift without present and legible. properly engaging the lift's maintenance device. Blue Giant recommends the use of a secondary Do NOT leave the control station where it can be means of securing the scissor lift while accidently operated or damaged.

  • Page 46: Equipment Component Illustrations

    • Do NOT work on or under the lift without present and legible. properly engaging the lift's maintenance device. Blue Giant recommends the use of a secondary Do NOT leave the control station where it can be means of securing the scissor lift while accidently operated or damaged.

  • Page 47: Mechanical Assembly

    STATIONARY DOCK LIFT — OWNER’S MANUAL 11.2 MECHANICAL ASSEMBLY This exploded view displays common components of the dock lift. ITEM QTY. DESCRIPTION Guard Rail Assembly Spring Pin Slotted Lip Shaft/Rod Lip Assembly (Varies by Model) 37° JLC female Swivel Fitting Main Hose Main Hose T-Fitting Cylinder Hose to T-Fitting...

  • Page 48: Dock Lift Parameters

    STATIONARY DOCK LIFT — OWNER’S MANUAL 11.3 DOCK LIFT PARAMETERS This is a partial list of available Dock Lifts by size, capacity, lowered/raised heights, and Powerpack options. Contact your Blue Giant Dealer regarding a full list of options. Powerpack Options Deck...
  • Page 49 The 5.0GPM Powerpacks times are approximately 0.76 times multiple of the standard capacity unit. The 7.3GPM Powerpacks times are approximately 0.52 times multiple of the standard capacity unit. Faster lift times are available, contact your Blue Giant Dealer. Dimension Powerpack...

  • Page 50: Powerpack Part Identification

    STATIONARY DOCK LIFT — OWNER’S MANUAL 12.0 POWERPACK PART IDENTIFICATION The assembly and parts of the Powerpack (Pit or Remote) are listed below for easy reference. Refer to the electrical drawings for specific wiring requirements ITEM DESCRIPTION Powerpack 3 HP Powerpack 5 HP Powerpack 7.5 HP Powerpack 10 HP...
  • Page 51 STATIONARY DOCK LIFT — OWNER’S MANUAL 51 ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)

  • Page 52: Troubleshooting

    Failure to properly secure the dock lift deck prior to working underneath it may result in bodily injury, or death. • Engage the Maintenance Strut and Service Stand before working. If both cannot be successfully engaged, contact your Blue Giant Dealer.
  • Page 53 (if equipped). Scissor leg bushings seized. Lowering valve defective. Replace. Deck raises slowly. Pressure relief bypassing. Foreign material lodged between ball and seat. Contact your Blue Giant Dealer. Faulty Power Pack. Replace Power Pack. Weight overload. Remove weight to until load matches nameplate weight capacity rating.

  • Page 54: Optional Equipment

    STATIONARY DOCK LIFT — OWNER’S MANUAL 14.0 OPTIONAL EQUIPMENT These components are available as additional options for the DL dock lifts. 14.1 CUSTOM LIP CONFIGURATIONS Dock Lift lips are available in several material types and actuation. • Lip size and configuration - extended length and multiple lips •...
  • Page 55 STATIONARY DOCK LIFT — OWNER’S MANUAL ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)
  • Page 56 Mississauga, ON, Canada L5T 2N6 Greensboro, NC 27409 t 905.457.3900 f 905.457.2313 www.bluegiant.com If calling within North America: t 1.800.872.2583 f 1.888.378.5781 © Copyright Blue Giant Equipment Corporation 2020 56 ISSUE DATE: March 10, 2020 REV. 1.1 (PART # 038-1099)

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