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INSTALLATION &
OWNERS MANUAL
WARNING
DO NOT INSTALL, OPERATE OR SERVICE THIS PRODUCT UNLESS YOU HAVE READ AND
FULLY UNDERSTAND THE ENTIRE CONTENTS OF THIS MANUAL. FAILURE TO DO SO MAY
RESULT IN PROPERTY DAMAGE, BODILY INJURY OR DEATH.
TL85A Vehicle Restraint With Blue Genius Controls. Issue Date: October 2, 2012 Rev. 4. (Part#038-706E)
Applies to serial numbers 370132 and up.
TABLE OF CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
1
1
2
2
2
2
3
3
4
5
6
6
6
6
6
7
7
7
8
9
9
9
9
10
10
11
12
13
14
15
16
16
16
16
16
17
1. 1
Dealer:
Serial Number(s):
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.
2.
INTRODUCTION
The following is a quick reference to important procedures that must be followed while using the Vehicle Restraint
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 Vehicle
Restraint 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 :
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 Warranty Center
is here to support the Blue Giant Product(s) that you have purchased.
To validate warranty on recently purchased equipment, please complete and submit your information with our on-line
Warranty Registration at www.BlueGiant.com.
For more information about Blue Giant's Warranty Support, please contact your local Blue Giant Equipment dealer,
representative or authorized partner near you. You may also visit www.BlueGiant.com or phone 1-905-457-3900.
* Note that failure to validate warranty at the time of receipt can seriously affect the outcome of any claim.
2.2
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 Vehicle Restraint 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.
MANUFACTURERS
NOTE
2.3
MANUFACTURERS NOTE
The Vehicle Restraint has been carefully inspected and tested at the manufacturers plant prior to shipment, but should
be checked upon receipt for transport damage. Any observed transport damage is to be listed on the signed copy of the
freight document. Notify the freight forwarder of any damage WITHIN 48 HOURS.
2
3.
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.
3.1
4.
D
OP O N
ER OT
AT
E
XX
XX XXX
XX XX
XX XX
XX XX
XX X
X
5.
DRILL ONE HOLE THROUGH THE WALL TO THE OUTSIDE AND WIRE THE L.E.D.
TRAFFIC LIGHTS.
INSTALL " I.D. CONDUIT FROM THE CONTROL PANEL TO THE REMOTE POWER
PACK FOR THE MOTOR WIRING.
INSTALL ONE 3" I.D. CONDUIT FROM THE REMOTE POWER PACK TO THE DOCK
FACE FOR THE RESTRAINTS HYDRAULIC LINES AND COMMUNICATION CABLE.
RUN " I.D. CONDUIT FROM THE R I/O TO THE PIT FOR THE LIP
SENSOR CONTROL CABLE.
REMOTE
POWER
PACK
MAIN POWER
(TO CONTROL STATION)
(SEE BELOW NOTE)
66"
COMMUNICATION CABLES
20
"
4"
TO
RESTRAINT
WALL
MOUNT
ARM VALVE
ARM
HYD
84"
BREATHER
LINE
(CYL. RETURN)
TO LIP
SENSOR
TRAFFIC LIGHTS
(MOUNTED & WIRED BY OTHERS)
BLUE GENIUS
CONTROL BOX
(MOUNTED & WIRED
BY OTHERS)
LIP SENSOR
REMOTE
I/O
COMM.
CABLE
(TO CONTROL)
8"
PRESSURE
SWITCH
TO
RESTRAINT
MOTOR
J-BOX
CAST-IN-PLACE MOUNTING
PLATE (OPTIONAL)
2
MOTOR
WIRING
!!!
CONCRETE PAD
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, SIGNAL LIGHTS AND DRIVER WARNING SIGNS
FUSED DISCONNECT PROVIDED BY OTHERS AND WIRING BY OTHERS
INSTALL CABLE FROM CONTROL BOX STATION TO POWER PACK
INSTALL CABLE FROM CONTROL BOX STATION TO POWER SUPPLY
INSTALLATION DETAILS:
FOR RESTRAINT, KEEP BASE PLATE 90 DEGREES TO THE DOCK FACE AND PROVIDE POSITIVE SUPPORT
BETWEEN THE DRIVEWAY AND THE UNDERSIDE OF THE RESTRAINT. SUFFICIENT SHIMS MUST BE
POSITION AND WELDED SECURELY IN PLACE. WITH THE RESTRAINT POSITIONED, USE THE BACK PLATE
AS A TEMPLATE AND DRILL SIX (6) HOLES 3/4" DIA. X 6.5" DEEP FOR ANCHORS.
FLOOR ANCHORING IS OPTIONAL TO DOCK FACE MOUNTING.
RESTRAINT EXTENSION PLATE REQUIRED FOR PROJECTED PIT APPLICATION (OPTIONAL ACCESSORIES).
COMMUNICATION
CABLE
POWER PACK
DO NOT
CAUTION
MOVE ON
GREEN ONLY
NOITUAC
>
MOTOR
WIRING
>
SEL
Restraint
Do Not Enter
Engage
Proceed With Caution
NO EVOM
YLNO NEERG
ESC
Release
Enter On Green
NOTE:
ALL CONDUIT
ENTRY INTO CONTROL PANEL
FROM BOTTOM. ARRANGE
WIRING TO AVOID HIGH & LOW
VOLTAGE CROSSING OVER
INSIDE CONTROL BOX.
11
22
RESTRAINTS HYDRAULIC
HOSES
(to the outside)
55
77
#
#
00
66
STOP
! CAUTION
Disconnect power
before opening panel.
TRAFFIC LIGHTS
(MOUNTED DRIVERS SIDE)
CONTROL STATION
(MOUNTED ON
DRIVERS SIDE)
66"
CL
84"
MAIN POWER
FEED CABLE
(FROM FUSED
DISCONNECT)
TRAFFIC LIGHT
RESTRAINT
CABLE
(TO THE OUTSIDE)
(DOCK FACE)
LIP SENSOR
(IN PIT)
3
CAST-IN-PLACE MOUNTING
PLATE (OPTIONAL)
HYDRAULIC VEHICLE RESTRAINT
VIEW A
(INSIDE BUILDING)
8"
12"
NOTE:
FRONT VIEW SHOWS THE VEHICLE RESTRAINT IN ITS
ENGAGED/ RAISED POSITION.
* DRAWINGS NOT TO SCALE
GROUND LEVEL
6.
Do not install, operate, or service the TL85A Vehicle Restraint unless trained and authorized to do so. Read all safety information and
instructions in this manual.
When restraint is being installed, place adequate barriers to prevent vehicle traffic from entering the work area.
Follow proper lockout / tagout procedures.
6.1
Install Preparations
6.3
1. Clean all dirt and debris from the driveway and dock face where
the vehicle restraint is to be installed.
2. To ensure maximum strength, the vehicle restraint should be
installed on a poured concrete dock face or concrete pad. For
cement block construction or a dock face with poor quality
concrete, obtain custom lag plates and/or lag anchors from the
manufacturer. If an asphalt driveway is broken, cracked, or
otherwise damaged (i.e. missing pieces), a 6 deep concrete
pad should be poured as a replacement.
6.4
Install Mounting
TOP EDGE OF
PIT OPENING / FLOOR
WAND
CONCRETE
DOCK FACE
SHIMS (13 X 6)
THICKNESS AS REQUIRED
5/8 x 6 Concrete
Anchor Bolts
Recommended Torque:
110 ft-lb (149 Nm)
Optional
Floor Mount Anchor Bolts
in Concrete Pad (See Step
8.2)
ABOVE: WHEN INSTALLING THE RESTRAINT MOUNT TO A CONCRETE DOCK FACE AS SHOWN.
6
7.
DO NOT WIRE HIGH AND LOW VOLTAGES IN THE SAME CONDUIT. High voltage range is 115V and up. Lower
voltages include the communication and solenoid wiring as well as the I/O.
During installation, place adequate barriers to prevent vehicle traffic from entering the work area, and follow proper
lockout / tagout procedures.
7.1
7.2
TL85A Installation
1. Drill one hole through the wall to the outside and wire the
L.E.D. traffic lights.
Final Inspection
4. Run i.d. conduit from the restraint to the pit for the lip sensor
control cable.
.
Figure 2: Blue GeniusTM control station dimensions
and conduit install area.
1/4"
6 5/32"
11 29/32"
WARNING
12 17/32"
8 3/32"
8.
Blue Genius
T
MENU SCREEN
SCROLL UP
R
TM
ESC
ESCAPE
SELECT
SEL
SCROLL DOWN
RED LIGHT
(Do Not Enter)
R
E
S
T
R
A
I
N
T
Do Not Enter
YELLOW LIGHT
(Proceed With Caution)
RESTRAINT ENGAGE
(Raise Restraint Arm)
RESTRAINT RELEASE
(Lower Restraint Arm)
Caution
GREEN LIGHT
(Enter On Green)
Enter On Green
0
Gold Series
STOP
(Stop Restraint)
STOP
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLY UNDERSTAND
THE OWNERS MANUAL BEFORE
OPERATING THIS PRODUCT.
www.BlueGiant.com
#038-244E
CARRIER VEHICLE
RELEASE
9.
OPERATING INSTRUCTIONS
WARNING
ESC
ius
B lueGen
C
Do Not
ESC
TM
SEL
R
E
S
T
R
A
I
N
T
Enter
SEL
Caution
n
r On Gree
Ente
9
BEFORE
FULLY
AND
MANUAL
READ
PRODUCT.
THIS
THE OWNERS
OPERATING
t.com
lueGian
www.B
#038-244
>
STOP
STOP
ECT POWER
.
DISCONN OPENING D
BEFORE UNDERSTAN
ESC
>
Do Not Enter
SEL
Restraint
Engage
Gold Series
Enter On Green
Release
Leveler
Deck
Lip
11
22
55
7
7
##
00
66
STOP
www.BlueGiant.com
Functional Description
Proceed
Truck / Vehicle
Loading Dock
ESC
TM
SEL
Do Not
Dock Leveler
ius
B lueGen
Blue Genius
Ready
R
E
S
T
R
A
I
N
T
Enter
tion
With Cau
Enter On
Green
STOP
DISCONN
ECT POWER
.
OPENING D
BEFORE UNDERSTAN
BEFORE
FULLY
AND
MANUAL
READ
PRODUCT.
THIS
THE OWNERS
OPERATING
t.com
lueGian
www.B
E
#038-244
ESC
>
>
9.1
9.3
Do Not Enter
SEL
Restraint
Engage
Release
Enter On Green
Gold Series
11
22
55
7
7
##
00
66
STOP
www.BlueGiant.com
Dock Bumper
ICC Bar
Vehicle Restraint
9.2
3. Touch the Engage button. The hook will rotate from the
home position to secure the ICC bar and the LCD screen will
read Engaging. The traffic light will turn RED and the control
panel light will remain RED. When the ICC bar is secured, the
LCD screen will read Restraint is Engaged, followed by
Dock Leveler Restored and Ready to Raise Deck. After the
deck is deployed onto the truck bed, the control panel light
will turn GREEN.NOTE: If the vehicle has no ICC bar and the
restraint is interlocked with the dock leveler, please refer to
the Vehicle Restraint Override Procedure (Section 9.5).
9.
OPERATING INSTRUCTIONS
9.5
Restraint Engaging
Restraint is Engaged
ius
B lueGen
C
ESC
Do Not
SEL
R
E
S
T
R
A
I
N
T
Enter
tion
With Cau
Proceed
Enter On
Green
TM
STOP
ECT POWER
.
DISCONN OPENING
BEFORE UNDERSTAND
BEFORE
FULLY
AND
MANUAL
READ
PRODUCT.
THIS
THE OWNERS
OPERATING
#038-244E
t.com
ueGian
www.Bl
>
ESC
>
Do Not Enter
ius
B lueGen
Gold Series
SEL
Restraint
ESC
TM
SEL
Engage
Proceed With Caution
Release
Enter On Green
11
22
55
7
7
##
00
66
R
E
S
T
R
A
I
N
T
STOP
www.BlueGiant.com
Do Not
Proceed
Enter
247
tion
With Cau
Enter On
Green
Optional Alarm
STOP
ECT POWER
.
DISCONN OPENING
BEFORE
UNDERSTAND
BEFORE
FULLY
AND
MANUAL
READ
PRODUCT.
THIS
THE OWNERS
OPERATING
www.Bl
ueGiant
.com
#038-244E
>
Gold Series
ESC
>
SEL
Do Not Enter
Restraint
Engage
Enter On Green
Release
Leveler
Deck
Lip
11
22
55
77
#
#
0
0
STOP
www.BlueGiant.com
VISUALLY CHECK TO
ENSURE NO ICC BAR
IS PRESENT
9.4
MANUALLY CHOCK
WHEELS
Restraint Releasing
ius
B lueGen
C
ESC
TM
SEL
Do Not
Proceed
tion
With Cau
Enter On
R
E
S
T
R
A
I
N
T
Enter
Green
STOP
ESC
>
4
7
>
ECT POWER
.
DISCONN OPENING D
BEFORE
UNDERSTAN
BEFORE
FULLY
AND
MANUAL
READ
PRODUCT.
THIS
THE OWNERS
OPERATING
Do Not Enter
SEL
Restraint
Engage
t.com
ueGian
#038-244E
www.Bl
Release
Enter On Green
11
22
55
7
7
#
#
00
STOP
www.BlueGiant.com
Gold Series
10
10.
INSTRUCTIONS FOR USE: Indicate OK for Use with a check mark () in the appropriate box of each inspection point.
Visually inspect the Vehicle Restraint and take note of obvious damage
the last shift.
Check that the Operating Hazards Placard is present in correct location and is legible.
Check that all communication lights are operating correctly.
Upper Red and Lower Green, Outside and Inside.
Inspect for damaged or missing parts, rust, corrosion, bent parts, cracks, etc.
Inspect operating controls to ensure they are not missing, damaged or broken.
Clean away all foreign material such as parts of broken skids, etc. from area in which the Vehicle Restraint is located.
Check for missing or damaged dock bumpers mounted on dock face.
Visually inspect the Vehicle Restraint for signs of structural damage or mechanical malfunction as you operate the Vehicle Restraint throughout the day. Be alert to abnormal sounds or operation.
INSPECTED BY:
DATE:
! WARNING
Do not operate and/or service unless you have been
trained and authorized to do so.
11
11.
NORMAL
OPERATION
BYPASS
OPERATION
COVER
12
12.
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
1.
2.
3.
4.
13
13.
16
23
13"
32
17
31
17
26
14
33
DETAIL A
SCALE 1 : 4
20
34
26
27
36
25
11
29
18
20
23
36
30
47
32
24
31
20
19
3
7
33
16
15
14
28
13
21
22
12
35
28 1/8"
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Qty.
1
1
1
2
4
1
1
1
2
1
2
1
1
1
1
1
1
1
1
3
1
Description
Body Weldment
Hinge Pin
Hold Plate Assembly
Spring Pin
Bushing
Cylinder Pin
Spring Holder Pin
Cylinder Assembly, 2 dia.
Fitting
Bar, Wear
Pivot Block Top Plate
Hose Assembly #4- 24 long
Front Cover
Wand Mounting Block
Mounting Flat
Sensor Wand
Top Cover
Plug Button 2: dia. x 1/8
Angular Position Cam
Proximity Sensor JB-18-ML-TPNBA
Tube Polyethylene 24 long
Part No.
51-001977
115-099
51-003011
013-011
018-017
115-307
115-094
035-662
034-633
252-0019
113-096
780-613 A
115-100
51-002317
116-863
116-868
115-103
R3-93002
51-001945
028-200
090-909-2880
14
Item No.
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
47
48
49
50
Qty.
1
1
1
3
3
2
2
1
1
1
1
1
1
1
1
1
1
58.5
1
Description
Male Elbow 90Degree- D1/4 Tube
Wand Axle Weldment
Extension Spring 0.5 d x 0.034 thick x 1.25 long
PG16 Cable Gland
PG16 Metal Locknut
PG16 Multi-Hole Seal
Spring Wire 1 5/8 OD. X thick
Junction Box Bracket
Grommet- 1.5 x 2 1/8
Bearing Square Block
Ball Bearing- R10-2RS-ID 5/8 OD 1 3/8 11/32
Metallic Spacer
Junction Box 4x4
Hydraulic Command Assembly
Hole Plug 1.75 dia.
Manual Release Valve Warning
Zinc Plating Body Weldment (Not Shown)
Zinc Plating Misc. Parts (Not Shown)
Zinc Plating Wand (Not Shown)
Part No.
040-007
51-002052
017-085
025-174
025-177
025-175
017-034
51-002204
037-079
51-002213
018-640
51-002306
025-G020-C
51-003116
515-0001
038-057
050-027
050-505
050-027-2
14.
Part #
Description
033-508-24A
035- 293- A
028-200
116-868
51- 002317
116-863
017- 085
51- 002052
017-034
115-094
115- 307
113- 096- 1
035-662
HARDWARE REQ'D
Qty: X 2, Part # 018-017 BUSHING & Qty: X 1, Part # 034-511 ADAPTER 90 DEG
1
1
3
1
1
1
1
1
2
1
1
2
1
035- 662- 1
SEAL, KIT FOR CYLINDER
780- 613
HOSE ASS'Y # 4 HOSE (288")
090-909-2880 TUBING (POLYETHYLENE)
1
1
1
51- 003011
HARDWARE REQ'D
Qty: X 1, Part # 040-007 MALE ELBOW (BRASS) 90 DEG. FOR TUBING # 090-909-2880
HARDWARE REQ'D: Qty: X 2, EACH
Qty Req'd
HARDWARE REQ'D
115-099
HINGE PIN
Qty: X 2, Part # 013-011 SPRING PIN FOR HINGE PIN # 115-099
HARDWARE REQ'D
115-103
TOP COVER
Qty: X 2, Part # 010-012 CAPSCREW & Qty: X 2, Part # 0012-201 LOCK WASHER
HARDWARE REQ'D
115-100
FRONT COVER
Qty: X 4, Part # 010-012 CAPSCREW & Qty: X 4, Part # 0012-201 LOCK WASHER
51- 001945
15
15.
GENERAL PARTS
15.1
DESCRIPTION
DB13
DB18
DB30
DBL18
DESCRIPTION
DB13FP
DB18FP
15.3
MOLDED RUBBER
BUMPER
LAMINATED BUMPERS
LAMINATED BUMPERS
PART ID
DESCRIPTION
DB411
DB511
DB412
DB512
DB421
DB521
DB431
DB531
DESCRIPTION
DB411FP
DB511FP
DB412FP
DB512FP
15.5
ITEM
1
2
LAMINATED BUMPER
WITH FACE PLATE
FLOOD LIGHT
QTY
1
1
PART ID
LDL-150
026-725
DESCRIPTION
LOADING DOCK LIGHT - 150W MAX
90W HALOFLOOD BULB - 130V
2
16
16.
Single Phase:
Part #
Description
026-PB1115
026-PB1230
Three Phase:
Part #
Description
026-PB3230
026-PB3400
026-PB3460
026-PB3575
Qty Req'd
1
1
Qty Req'd
1
1
1
1
Description
026-G020
025-G014
Part #
Description
026-G025M
026-G025-99
026-G030
Qty Req'd
1
1
1
Qty Req'd
1
1
1
Fuses:
Part #
Description
026-G100
026-G101
026-G102
026-G103
026-G104
026-G105
026-G106
026-G107
026-G107
Qty Req'd
FUSE,315mA, 700V,
17
5
5
5
5
5
5
5
5
5
If calling within North America: t 1.800.668.7078 f 1.888.378.5781 Copyright Blue Giant Equipment Corporation 2013