AUTOMATIC LIGHTS COMMUNICATION PACKAGE
(Dock Lip Sensor Version)
INSTALLATION & OWNER’S MANUAL

DO NOT INSTALL, OPERATE OR SERVICE THIS PRODUCT UNLESS YOU HAVE READ AND
FULLY UNDERSTOOD THE ENTIRE CONTENTS OF THIS MANUAL. FAILURE TO DO SO MAY
RESULT IN PROPERTY DAMAGE, BODILY INJURY OR DEATH.
Automatic Lights Communication Package (Dock Lip Sensor Version)
Issue Date: April 5, 2011, Rev.0 (Part#038-790E)
TABLE OF CONTENTS
1.
2
3.
4.
5.
INTRODUCTION ......................................................................................................................................................
1.1 Warranty Policy....................................................................................................................................................
1.2 Exclusion of Liability.............................................................................................................................................
1.3 Manufacturer's Note.............................................................................................................................................
AUTOMATIC LIGHT COMMUNICATION PACKAGE INSTALLATION.....................................................................
ABOUT THE AUTOMATIC LIGHT COMMUNICATION PACKAGE.........................................................................
OPERATING INSTRUCTIONS..................................................................................................................................
TROUBLESHOOTING...............................................................................................................................................
1
1
1
1
2
3
3
3
OWNER’S PURCHASE RECORD
OWNER’S PURCHASE RECORD
Dealer:
Serial Number(s):
Please record information for future inquiries
Date in Service:
Number of Units:
Door # :
The manufacturer offers a full line of dock levelers, dock safety equipment, accessories, ergonomic and scissor lift
equipment, and industrial trucks. Concurrent with a continuing product improvement program, specifications are subject
to change without notice. Please contact the manufacturer for latest information. Some features illustrated may be
optional in certain market areas.
AUTOMATIC LIGHTS COMMUNICATION PACKAGE WITH DOCK LIP SENSOR
1.
INTRODUCTION
The following is a quick reference to important procedures that must be followed while using the Automatic Lights Communication System. It is not intended to cover, or suggest that it does cover, all procedures necessary to ensure safe
operation. All operators should be aware of and abide by all workplace safety regulations applicable to the operation of
the Automatic Lights Communication System. These laws and regulations include but are not limited to:
• The Occupational Safety and Health Act (USA)
• Occupational Safety and Health Acts for Individual States (USA)
• Canadian Material Handling Regulations
For additional information on these regulations as well as industry standards that may apply to this product, please
contact:
American National Standards Institute (ANSI)
1430 Broadway
New York, NY 10018
(212) 642-4900
ALSO MEMBERS OF :
LOADING DOCK EQUIPMENT MANUFACTURERS
Loading Dock Equipment Manufacturers
A Product Section of Material Handling Industry of America,
A Division of Material Handling Industry
8720 Red Oak Blvd., Suite 201, Charlotte, NC, 28217-3992
Telephone: (704) 676-1190 Fax: (704) 676-1199
1.1
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 Warranty Center
is here to support the Blue Giant Product(s) that you have purchased.
To validate warranty on recently purchased equipment, please complete and submit your information with our on-line
Warranty Registration at www.BlueGiant.com.
For more information about Blue Giant's Warranty Support, please contact your local Blue Giant Equipment dealer,
representative or authorized partner near you. You may also visit www.BlueGiant.com or phone 1-905-457-3900.
* Note that failure to validate warranty at the time of receipt can seriously affect the outcome of any claim.
1.2
EXCLUSION OF LIABILITY
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 Automatic Lights Communication System. The manufacturer also assumes no liability for
lost profits, operating downtimes, or similar indirect losses incurred by the purchaser. Injury to third parties, irrespective
of its nature, is not subject to compensation.
The manufacturer reserves the right to make changes at any time to the modules, components, and accessories,
concurrent with its continuing product development program. Specifications, operating instructions, and illustrations
included in this manual are subject to change without notice. Please contact manufacturer for the latest information.
MANUFACTURER’S
NOTE
1.3
MANUFACTURER’S NOTE
The Automatic Lights Communication System 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.
1
AUTOMATIC LIGHTS COMMUNICATION PACKAGE WITH DOCK LIP SENSOR
2.
AUTOMATIC LIGHT COMMUNICATION PACKAGE INSTALLATION
NEW CONSTRUCTION:
AUTO LIGHT PACKAGE
CONTROL BOX
(MOUNTED & WIRED BY
OTHERS)
1 RUN ONE 1/2” I.D. CONDUIT FROM THE CONTROL STATION TO THE LED TRAFFIC LIGHTS.
2 RUN ONE 1/2” I.D. CONDUIT FROM THE LIGHT BOX TO THE DOCK’S LIP HOME SENSOR.
NOTE: FUSED DISCONNECT
BY OTHERS
MINIMUM CONCRETE STRENGTH 3,000 P.S.I.
MAIN POWER
POWER WIRING
HYDRAULIC HOSE LINES
(TO CONTROL STATION)
CABLES
66”
(typ.)
2
50”
(typ.)
1
TRAFFIC LIGHTS
(MOUNTED & WIRED BY OTHERS)
14
”
20
”
4”
X
84” (typ.)
LIP / HOME SENSOR
!!!

DO NOT WIRE HIGH AND LOW VOLTAGES IN THE SAME CONDUIT. High
voltage range is 115V and up. Lower voltages include the communication and
solenoid wiring as well as the I/O.
ELECTRICAL REQUIREMENTS• MOUNT CONTROL BOX STATION TO WALL
• FUSED DISCONNECT PROVIDED BY OTHERS AND WIRING BY OTHERS
• INSTALL WIRING FROM CONTROL BOX STATION TO POWER PACK
• INSTALL WIRING FROM CONTROL BOX STATION TO POWER SUPPLY
AUTO LIGHT PACKAGE CONTROL BOX
(MOUNTED & WIRED BY OTHERS)
DRIVER WARNING SIGN
(MOUNTED DRIVERS SIDE)
PART #038-225
!
CAUTION
MOV E O N
GREEN ONLY
MAIN POWER
(from fused disconnect)
NOITUAC
!
N O E VOM
YLNO NEERG
66”
50”
(typ.)
TRAFFIC LIGHTS
(MOUNTED & WIRED
BY OTHERS)
PART #032-461
(typ.)
TRAFFIC LIGHT
CABLE
(to the outside)
84” (typ.)
CONTROL CABLE
(to Lip/Home Sensor)
GROUND LEVEL
FRONT ELEVATION VIEW*
INSIDE BUILDING VIEW*
NOTE: *DRAWINGS NOT TO SCALE
2
AUTOMATIC LIGHTS COMMUNICATION PACKAGE WITH DOCK LIP SENSOR
3.
ABOUT THE AUTOMATIC LIGHTS COMMUNICATION PACKAGE
The Blue Giant Manual Light Communication Package advises both dock staff and truck drivers of safety conditions at the loading
dock via an interconnected combination of onboard lights system and LED exterior traffic lights. Insert the key and turn the selector
switch to the ‘Auto’ setting (in the center). When the dock is parked, the light box’s RED bulb should be lit, and the exterior traffic
light should be GREEN. NOTE: Should it ever be necessary to operate the lights package manually, an experienced dock attendant
will change the interior and exterior lights by turning the selector switch to the appropriate setting. Please exercise appropriate
caution when in manual mode.
4.
OPERATING INSTRUCTIONS
1. When the truck parks against the dock bumpers, secure the ICC bar with a
vehicle restraint or chock the wheels. Do a visual inspection to confirm that the
vehicle is securely restrained before activating the dock leveler.
2. Use the control station to raise the dock leveler. The traffic light is RED and the
light box’s GREEN bulb will come on once the lip leaves the parked position. (See
Figure 1)
3. After the dock leveler descends with the deployed lip on the truck bed, loading
and unloading may begin. (See Figure 2)
4. After loading and unloading is finished and the dock is stored with lip in the lip
keepers, the RED bulb will light up on the light box and the exterior traffic light
will turn GREEN. (See Figure 3)
5. The vehicle departs after being released and normal cycle is completed.
Figure 1
STOP
www.BlueGiant.com
Min. 4”
Figure 2
5.
Figure 3
TROUBLESHOOTING

PROBLEM
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 CAUSE
Communication Lights do
not turn on.
1. Power supply to the control station enclosure is turned off.
2. Faulty wiring or connections.
3. Fuse blown in control station.
One light (either inside or
outside) does not operate.
1. Faulty wiring or connections.
2. Faulty LED lights.
3. Faulty key / selector switch.
Communication Lights do
not change color when the
selector switch is moved.
1. Faulty wiring or connections.
2. Damaged relay selectors.
3. Faulty key / selector switch.
3
AUTOMATIC LIGHTS COMMUNICATION PACKAGE WITH DOCK LIP SENSOR
NOTES
4
NOTES
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 2013