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TL85A VEHICLE RESTRAINT WITH

BLUE GENIUS™ CONTROLS

BLUE GENIUS TM SERIES

INSTALLATION &
OWNER’S 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.

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ABOUT THE TL85A WITH BLUE GENIUSTM CONTROLS...........................................................................................
1.1 Owner’s Purchase Record......................................................................................................................................
INTRODUCTION .........................................................................................................................................................
2.1 Warranty Information.............................................................................................................................................
2.2 Exclusion of Liability..............................................................................................................................................
2.3 Manufacturer's Note..............................................................................................................................................
OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION................................................................
3.1 Operational Safety Warnings................................................................................................................................
LOCKOUT / TAGOUT PROCEDURE AND RULES.....................................................................................................
TL85A INSTALLATION ARRANGEMENT...................................................................................................................
VEHICLE RESTRAINT INSTALLATION INSTRUCTIONS..........................................................................................
6.1 Install Preparations...............................................................................................................................................
6.2 Install Mounting.....................................................................................................................................................
6.3 Electrical and Hydraulic Installation.......................................................................................................................
6.4 Final Inspection and Setup...................................................................................................................................
ELECTRICAL AND HYDRAULIC INSTALLATION......................................................................................................
7.1 TL85A Installation..................................................................................................................................................
7.2 Final Inspection.....................................................................................................................................................
CONTROL STATION OPERATION..............................................................................................................................
OPERATING INSTRUCTIONS.....................................................................................................................................
9.1 Functional Description.........................................................................................................................................
9.2 Stop Button Function...........................................................................................................................................
9.3 Operating Procedure- Deploying the Restraint Arm............................................................................................
9.4 Undeploying the Restraint Arm............................................................................................................................
9.5 Vehicle Restraint Override Feature: Operate Dock Without Vehicle Restraint....................................................
PM CHECKLIST- VEHICLE RESTRAINT....................................................................................................................
EMERGENCY VEHICLE RESTRAINT LOWERING PROCEDURE.............................................................................
VEHICLE RESTRAINT TROUBLESHOOTING............................................................................................................
TL85A PARTS ILLUSTRATION......................................................................................................................................
TL85A RECOMMENDED SPARE PARTS LIST.............................................................................................................
GENERAL PARTS........................................................................................................................................................
15.1 Molded Rubber Bumpers......................................................................................................................................
15.2 Laminated Bumpers.............................................................................................................................................
15.3 Face Plates For Laminated Bumpers...................................................................................................................
15.4 Flood Light...........................................................................................................................................................
RECOMMENDED SPARE PARTS LIST FOR BLUE GENIUS GOLD SERIES II........................................................

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specifications are subject to change without notice. The TL85A may be wall or ground mounted. Maintenance-free NEMA 4 rated sensors ensure accurate ICC bar detection and indicate when the restraint arm is locked or in the parked position. multi-language LCD intelligent text display and keypad with supervisory override support. Some features illustrated may be optional in certain market areas.545 kgs) and vertical ICC bar capture range of 12-26” (305mm to 660mm) above grade. and industrial trucks. 1. 1 . Please contact the manufacturer for latest information. Its onboard diagnostics and communications feature a user-friendly.000 lbs (14. 1 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. ergonomic and scissor lift equipment. ABOUT THE TL85A VEHICLE RESTRAINT with BLUE GENIUSTM CONTROLS The Blue Giant TL85A Vehicle Restraint System is a non-impact design with a restraining power of 32. Using a combination of red /yellow / green LED control station lights and red / green exterior traffic lights.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 1. The Blue Genius™ Gold Series II Touch Control Panel with advanced microprocessor technology controls the operation of the restraint. It has a horizontal restraining range of up to 12” (305mm) from the dock face (extension plates are available) and forty-five degree actuated arm lock. the Blue Genius™ keeps both the truck driver and dock attendants advised on the safety status of cross-docking travel. accessories. dock safety equipment. Concurrent with a continuing product improvement program.

please contact your local Blue Giant Equipment dealer. MANUFACTURER’S NOTE 2.BlueGiant. or similar indirect losses incurred by the purchaser. It is not intended to cover. components. Specifications. operating downtimes. The manufacturer reserves the right to make changes at any time to the modules. and are confident that our product will serve you for many years to come.BlueGiant.com. Please contact manufacturer for the latest information. We appreciate your business.com or phone 1-905-457-3900. Suite 201. * Note that failure to validate warranty at the time of receipt can seriously affect the outcome of any claim. and illustrations included in this manual are subject to change without notice. 28217-3992 Telephone: (704) 676-1190 Fax: (704) 676-1199 2. concurrent with its continuing product development program. 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. or suggest that it does cover. irrespective of its nature. NC. 2.3 MANUFACTURER’S NOTE The Vehicle Restraint has been carefully inspected and tested at the manufacturer’s plant prior to shipment. Charlotte. For more information about Blue Giant's Warranty Support. and accessories. please contact: American National Standards Institute (ANSI) 1430 Broadway New York.. 2 . To validate warranty on recently purchased equipment. representative or authorized partner near you. A Division of Material Handling Industry 8720 Red Oak Blvd. please complete and submit your information with our on-line Warranty Registration at www. our Warranty Center is here to support the Blue Giant Product(s) that you have purchased. 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. All operators should be aware of and abide by all workplace safety regulations applicable to the operation of the Vehicle Restraint System. Any observed transport damage is to be listed on the signed copy of the freight document.1 WARRANTY INFORMATION Thank you for purchasing Blue Giant products. INTRODUCTION The following is a quick reference to important procedures that must be followed while using the Vehicle Restraint System. The manufacturer also assumes no liability for lost profits. but should be checked upon receipt for transport damage. In the event that you experience a problem with our product. operating instructions. Notify the freight forwarder of any damage WITHIN 48 HOURS. You may also visit www.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 2. is not subject to compensation. Injury to third parties.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. all procedures necessary to ensure safe operation.

• DO NOT allow the drill to go too deeply when drilling holes in the control box. Damage to the control systems may occur. • Post safety warnings and barricade working area at dock level and at ground level to prevent unauthorized use of the restraint during maintenance/service. Jog the motor until rotation has been determined. Deck mounted power unit has been filled with fluid but cylinders. anchors must be properly torqued to obtain the necessary anchoring strength. If warning decals become damaged or missing. Damage will occur to the valve/seat. Use a vacuum to remove debris from control box. Serious injury or death will likely occur if the instructions are not followed. • ALWAYS return the restraint arm to the proper undeployed position. • DO NOT operate restraint until freight carrier is parked against the dock bumpers. To prevent the possibility of equipment damage and serious injury or death. Instructions marked CAUTION concern safe operating procedure. • • DO NOT ground welding equipment to any hydraulic cylinder or electrical components. hoses and manifold are shipped dry. • NOTE .check motor rotation. Failure to conduct could cause personal injury or damage to equipment. OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION This manual includes color-coded safety messages that clarify instructions and specify areas where potential hazard exists. DO NOT allow the motor to run in reverse for more than a couple of seconds. • DO NOT drive or walk onto the transport vehicle until it is parked against the dock bumpers and the wheels are chocked. 3. contact your authorized Service Representative. Avoid accidents by recognizing dangerous procedures or situations before they occur. • BEFORE BEGINNING ANY SERVICE PROCEDURES: – Disconnect the power and follow all LOCKOUT / TAGOUT procedures. • DO NOT connect green ground lead into control box or junction box until all welding has been completed.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 3. • ALWAYS conduct routine inspections and maintenance. • If a procedure is not clearly defined in this manual. or the vehicle restraint has been fully engaged and the lights have changed to GREEN inside and RED outside. • During installation. • NEVER use air to blow debris from control box. • NEVER remove the wheel chocks until loading/ unloading is finished and the truck driver has been given permission to depart. • DO NOT force valve adjustment screws against internal stops. • ONLY TRAINED PERSONNEL should operate or service this equipment. Serious injury or death may occur if the instructions are not followed. please observe strictly the instructions and warnings contained in the messages. or the Vehicle Restraint has been released and the lights have changed to RED inside and GREEN outside. replace them immediately. • Keep away from restraint arm when the vehicle restraint is in operation.1 OPERATIONAL SAFETY WARNINGS • DO NOT operate restraint with anyone standing in the path of operation. Failure to comply may result in personal injury. 3 . Never stand under any unit being lifted. • CHECK HYDRAULIC FLUID LEVEL. Procedures marked IMPORTANT must be followed in order to prevent damage to machinery. otherwise the power unit may become damaged. DO NOT USE IMPACT DRIVERS. • ALWAYS check the rigging to make sure that it is secure before proceeding to lift the unit.

Blue Giant® strongly recommends that only OSHA-approved lockout devices be utilized.  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. D OP O N ER OT AT E XX XX XXX XX XX XX XX XX XX XX X X ABOVE: APPROVED WAY TO LOCKOUT / TAGOUT 4 . all affected employees must be notified that the machine or equipment will be shut down and locked out to perform repair or maintenance work.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 4. It is mandatory that tagout notices not be susceptible to deterioration or illegibility due to weather conditions or exposure to chemicals and moisture. LOCKOUT / TAGOUT PROCEDURE and RULES ! In accordance with the rules and regulations of the Occupational Safety and Health Administration (OSHA). The machine or equipment power supply shall be locked in the OFF position or disconnected from the energy source. 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. The work area must be checked to ensure that all personnel have been removed or safely repositioned.

TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 5. WITH THE RESTRAINT POSITIONED. USE THE BACK PLATE AS A TEMPLATE AND DRILL SIX (6) HOLES 3/4" DIA. 2 INSTALL ½" I.S.D.000 P. CABLE 3 (TO CONTROL) 3 8" PRESSURE SWITCH TO RESTRAINT RUN ONE CONDUIT FOR THE HOSE AND CONTROL CABLE FROM THE REMOTE POWER PACK TO THE RESTRAINT AS SHOWN. CONDUIT FROM THE REMOTE POWER PACK TO THE DOCK FACE FOR THE RESTRAINT’S HYDRAULIC LINES AND COMMUNICATION CABLE. FLOOR ANCHORING IS OPTIONAL TO DOCK FACE MOUNTING. SUFFICIENT SHIMS MUST BE POSITION AND WELDED SECURELY IN PLACE. TL85A INSTALLATION ARRANGEMENT REMOTE I/O BOX NEW CONSTRUCTION (REMOTE POWER PACK & RESTRAINT): (REQUIREMENTS BELOW BY OTHERS) 4 1 DRILL ONE HOLE THROUGH THE WALL TO THE OUTSIDE AND WIRE THE L.D. 4 RUN ½" I. CONDUIT FROM THE CONTROL PANEL TO THE REMOTE POWER PACK FOR THE MOTOR WIRING. HYDRAULIC VEHICLE 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. 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. CONSULT MANUFACTURE IF OTHER CONDITIONS EXIST. X 6. COMMUNICATION CABLE POWER PACK DO NOT RUN MAIN POWER WIRING THROUGH TOP OF CONTROL STATION 2 ! CAUTION MOVE ON GREEN ONLY NOITUAC > MOTOR WIRING > SEL Restraint Do Not Enter Engage Proceed With Caution ! DRIVER WARNING SIGN (MOUNTED DRIVERS SIDE) NO EVOM YLNO NEERG ESC Release Enter On Green NOTE: ALL CONDUIT ENTRY INTO CONTROL PANEL FROM BOTTOM.E. * DRAWINGS NOT TO SCALE FRONT ELEVATION VIEW Vehicle Restraint Installation Pictorial 5 RUN ONE CONDUIT FOR THE HOSE AND CONTROL CABLE FROM THE REMOTE POWER PACK TO THE RESTRAINT AS SHOWN. RESTRAINT EXTENSION PLATE REQUIRED FOR PROJECTED PIT APPLICATION (OPTIONAL ACCESSORIES). 3 INSTALL ONE 3" I. TRAFFIC LIGHTS. 2 NOTE: FUSED DISCONNECT BY OTHERS 3 REMOTE POWER PACK MOTOR POWER FEED MAIN POWER (TO CONTROL STATION) (SEE BELOW NOTE) MINIMUM CONCRETE STRENGTH 3.D. CONDUIT FROM THE R I/O TO THE PIT FOR THE LIP SENSOR CONTROL CABLE. 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 NOTE: DOCK FACE & DRIVEWAY TO BE CONSTRUCTED OF CONCRETE AND IN GOOD CONDITION.I. TRAFFIC LIGHTS (MOUNTED DRIVERS SIDE) CONTROL STATION (MOUNTED ON DRIVERS SIDE) 66" CL 84" 1 MAIN POWER FEED CABLE (FROM FUSED DISCONNECT) 3 TRAFFIC LIGHT RESTRAINT CABLE (TO THE OUTSIDE) (DOCK FACE) 4 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. CABLE POWER WIRING 66" HYDRAULIC HOSE LINES 1 COMMUNICATION CABLES 20 " 4" TO RESTRAINT WALL MOUNT ARM VALVE 3 ARM HYD 84" BREATHER LINE 4 (CYL. Lower voltages include the communication and solenoid wiring as well as the I/O.5" DEEP FOR ANCHORS. 11 22 RESTRAINTS HYDRAULIC HOSES (to the outside) 3 4 55 77 8 9 # # 00 * 66 STOP ! CAUTION Disconnect power before opening panel. GROUND LEVEL .D. ARRANGE WIRING TO AVOID HIGH & LOW VOLTAGE CROSSING OVER INSIDE CONTROL BOX. ELECTRICAL REQUIREMENTS• MOUNT CONTROL BOX STATION TO WALL. RETURN) TO LIP SENSOR 4 TRAFFIC LIGHTS (MOUNTED & WIRED BY OTHERS) BLUE GENIUS CONTROL BOX (MOUNTED & WIRED BY OTHERS) LIP SENSOR REMOTE I/O COMM. High voltage range is 115V and up.

2) ABOVE: WHEN INSTALLING THE RESTRAINT MOUNT TO A CONCRETE DOCK FACE AS SHOWN. Shims must be a minimum 13” x 6” in size and be permanently welded together and to the base-plate. a 6” deep concrete pad should be poured as a replacement. Read all safety information and instructions in this manual. 2. If an asphalt driveway is broken. the wand must be in the forward position.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 6. modify the wand.2 Electrical and Hydraulic Installation Final Inspection and Setup 1. and centered with the door frame. 6. Install Mounting 1. cracked.e. missing pieces). When restraint is being installed. Tighten fasteners securely. securely mount the hydraulic power pack horizontally on an interior wall adjacent to the doorway opening. position the vehicle restraint square against the dock face. Permanently mount the sensor wand onto the sensor switch with the set screws provided.3 Also refer to Section 7: Electrical and Hydraulic Installation. Securely mount the exterior traffic lights and signs on the exterior wall adjacent to the doorway at approximately 84” above the driveway. 1. 6. at approximately 8 feet (2438 mm) above floor level. 2. or securely under the dock. For cement block construction or a dock face with poor quality concrete. 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. or otherwise damaged (i. 3. 6. Keep the vehicle restraint base plate at a 90 degree angle to the dock face and place a sufficient thickness of shims (not supplied) between the driveway surface and the base plate’s outer edge. Follow proper lockout / tagout procedures. With the vehicle restraint properly positioned and using back plates as a template. 2. To ensure maximum strength. operate. drill six holes 5/8” in diameter and 6” deep in the dock face concrete. place adequate barriers to prevent vehicle traffic from entering the work area. obtain custom lag plates and/or lag anchors from the manufacturer. Clean all dirt and debris from the driveway and dock face where the vehicle restraint is to be installed.4 4. Contact point must not be above the top edge of the pit opening and floor If the contact point is higher.1 Install Preparations 6. or service the TL85A Vehicle Restraint unless trained and authorized to do so. 1. When at rest. Optional anchoring to concrete pad rather than wall plate. VEHICLE RESTRAINT INSTALLATION INSTRUCTIONS  Do not install. the vehicle restraint should be installed on a poured concrete dock face or concrete pad. Using suitable hoisting equipment. Clean out holes and install anchors and lag bolts (supplied with the restraint) with a torque of 110ft/lbs (149Nm). For the remote power pack. 6 . Rotate the wand (move backward) to make contact with the dock face.

Drill one hole through the wall to the outside and wire the L. Ensure that all fasteners have been tightened and locked.d. 7.D. place adequate barriers to prevent vehicle traffic from entering the work area. Return all wiring diagrams to the Blue Genius™ Control Panel.d. Lower voltages include the communication and solenoid wiring as well as the I/O. If required.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 7. conduit from the remote power pack to the dock face for the restraint’s hydraulic lines and communication cable. During installation. (This procedure requires the installer to follow the control box menu screen during start-up. conduit from the restraint to the pit for the lip sensor control cable.E. High voltage range is 115V and up. 7. Final Inspection 1. Trim cable to appropriate length during install. hoses.d. or interference may result and create intermittent communication problems. and wires are mechanically protected against damage and are adequately secured. Figure 2: Blue GeniusTM control station dimensions and conduit install area. Leave these instructions near the vehicle restraint for easy future access. 4. Install ½” i. Check that all electrical and hydraulic conduits.2 TL85A Installation 1. and follow proper lockout / tagout procedures. . 4. 3. conduit from the control panel to the remote power pack for the motor wiring. Check all hydraulic connections for leaks and tighten as required. With the restraining arm fully lowered. Install one 3” i. traffic lights. 11 29/32" WARNING 12 17/32" Do not loop the communication cable excessively. 6 5/32" 6. level should be approximately ½” below the top of the reservoir. Mount warning placard next to the control panel. top up with Valvoline ISO32 or Mobil DTE13 hydraulic fluid. 2. ELECTRICAL AND HYDRAULIC INSTALLATION  DO NOT WIRE HIGH AND LOW VOLTAGES IN THE SAME CONDUIT. 8. Cycle test the vehicle restraint a minimum of 10 times to bleed trapped air back to the reservoir. 1/4" 5. Check hydraulic fluid level in the reservoir.) 2.1 7. Run ½’ i. 8 3/32" 7 . 3.

BlueGiant. CONTROL STATION OPERATION INDEPENDENT TYPE CONTROL STATION . READ AND FULLY UNDERSTAND THE OWNER’S MANUAL BEFORE OPERATING THIS PRODUCT. Security. Features) 1 2 3 4 5 6 7 8 9 0 Gold Series ‘STOP’ (Stop Restraint) STOP  DISCONNECT POWER BEFORE OPENING.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 8.com 8 #038-244E CARRIER VEHICLE RELEASE . www.Controls Vehicle Restraints Only Blue Genius T MENU SCREEN o u c h C o n t r o SCROLL ‘UP’ R TM l 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 CONTROL STATION KEY PAD (Override.

construction. DISCONN OPENING D BEFORE UNDERSTAN ESC > Do Not Enter SEL Restraint Engage Gold Series Proceed With Caution Enter On Green Release Leveler Deck Lip 11 22 3 4 55 7 7 8 9 ## 00 * 66 STOP www. The traffic light will turn RED and the control panel light will remain RED.NOTE: If the vehicle has no ICC bar and the restraint is interlocked with the dock leveler. Operating Procedure. Report the need for repairs to your supervisor immediately and do not operate the unit until repairs are made. ESC R ius B lueGen C T o u c Do Not Do not operate the restraint until you have checked its condition.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 9.BlueGiant. When the ICC bar is secured.Deploying the Restraint Arm 1. THIS THE OWNER’S OPERATING t.3 Do Not Enter SEL Restraint Engage Proceed With Caution Release Enter On Green Gold Series 11 22 3 4 55 7 7 8 9 ## 00 * 66 STOP www. OPERATING INSTRUCTIONS WARNING Do not operate this vehicle restraint unless you have been trained and authorized to do so. The Blue GeniusTM Control Panel has a temporary ‘STOP’ button for situations where the dock leveler might need to be stopped immediately or left in a certain position because of an unexpected interference or a potentially dangerous situation. After the deck is deployed onto the truck bed.B E #038-244 ESC > 0 > 9. The vehicle’s ICC bar operates the sensor wand on the vehicle restraint. Keep hands and feet clear of the vehicle restraint pinch points at all times. Neglect may cause a minor repair to become a major service problem and cause the leveler to become unsafe. 9 . Functional Description 2. it restrains a vehicle by acting as a barrier to the under ride guard (ICC bar). THIS THE OWNER’S OPERATING t. R C T o u c Proceed Truck / Vehicle Loading Dock o n t r ESC TM o l MENU DISPLAY SCREEN: SEL h 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 1 2 3 4 5 6 7 8 9 STOP DISCONN ECT POWER . restricting any forward movement caused by vehicle creep or unscheduled departure. When engaged. The lights remain GREEN outside and RED inside. OPENING D BEFORE UNDERSTAN BEFORE FULLY AND MANUAL READ PRODUCT. Touch the ‘Engage’ button. Freight carrier under ride guards differ in strength.com lueGian www.1 9. and attachment. The freight carrier reverses firmly into position against the dock bumpers. and the need to use wheel chocks in conjunction with the restraining device. To exit the ‘STOP’ mode touch ‘ESC’. The hook will rotate from the home position to secure the ICC bar and the LCD screen will read ‘Engaging’. followed by ‘Dock Leveler Restored’ and ‘Ready to Raise Deck’. TRUCTIONS o n t r ESC TM o l SEL h R E S T R A I N T Enter SEL Caution n r On Gree Ente 1 2 3 4 5 6 7 8 9 BEFORE FULLY AND MANUAL READ PRODUCT. the overall connection strength.B #038-244 E > 0 STOP STOP ECT POWER .2 Stop Button Function 3. Touching the ‘STOP’ button during operation will cause the unit to stop in mid motion. It is hydraulically operated via the Blue Genius™ Control Panel. It is a nonimpact design that is both engaged and released by the dock attendant.5). The outside traffic light is GREEN and control station light is RED. please refer to the Vehicle Restraint Override Procedure (Section 9. The restraint arm is fully lowered. and have read and understood all of the safety information and instructions contained herein. the control panel light will turn GREEN.com Dock Bumper ICC Bar Vehicle Restraint 9.com lueGian www.com Never try to lift or move any part of the vehicle restraint manually. It is therefore recommended that users of vehicle restraint devices review the means of attachment to the freight carrier. The TL85 Vehicle Restraint is used to restrain a freight carrier at the loading dock.BlueGiant. The Blue GeniusTM Control Panel is powered on and ready for use. the LCD screen will read ‘Restraint is Engaged’.

DISCONN OPENING BEFORE UNDERSTAND BEFORE FULLY AND MANUAL READ PRODUCT. it will ‘pound’ down two (2) times to dissolve the blockage. If the restraint cannot be engaged.Bl Release Enter On Green 11 22 3 4 55 7 7 8 9 # # 00 * 6 STOP www. After the final unsuccessful attempt. the screen will read ‘Restraint Arm Blocked’. remove the wheel chocks. The control station light will change to RED and the LCD screen will read ‘Truck Restraint Releasing’.BlueGiant. THIS THE OWNER’S OPERATING 0 #038-244E t. 10 .com VISUALLY CHECK TO ENSURE NO ICC BAR IS PRESENT 9. The control panel light will be RED. return the dock to the stored position. the LCD screen will read ‘Blue Genius Ready’ and the traffic light will turn GREEN. The LCD screen will read ‘Arm Blocked.BlueGiant. THIS THE OWNER’S OPERATING Do Not Enter SEL Restraint Engage t.com Gold Series NOTE: If the restraint arm encounters any obstructions that prevent it from lowering.com #038-244E ALARM WILL BEEP INDICATING THAT NO ICC BAR IS PRESENT > Gold Series * ESC > SEL Do Not Enter Restraint Engage Proceed With Caution Enter On Green Release Leveler Deck Lip 11 22 3 4 55 77 8 9 # # 0 0 * 6 STOP www. When the arm reaches the home position. accompanied by an intermittent alarm. and reset the control station by touching the restraint’s ‘Release’ button. (i.Retrying’ followed by ‘Restraint Releasing’. 2.com ueGian #038-244E Proceed With Caution www.5 MENU DISPLAY SCREEN: Restraint Engaging Restraint is Engaged 1. After the dock leveler is safely parked. OPERATING INSTRUCTIONS 9.Bl R > C ESC > Do Not Enter ius B lueGen Gold Series SEL T Restraint o u c o n t r ESC TM o l SEL h Engage Proceed With Caution Release ENTER ACTIVATION CODE : Enter On Green 11 22 3 4 55 7 7 8 9 ## 00 * 66 R E S T R A I N T STOP www.Undeploying the Restraint Arm MANUALLY CHOCK WHEELS 1. DISCONN OPENING BEFORE UNDERSTAND BEFORE FULLY AND MANUAL READ PRODUCT.BlueGiant. The outside traffic light will turn RED.Bl ueGiant .e. Dock Leveler Restored R ius B lueGen C T o u c o n t r ESC Do Not l SEL R E S T R A I N T Enter tion With Cau Proceed Enter On Green 2 3 4 5 6 7 8 9 1 Ready to Raise Deck TM o h Vehicle Restraint Override Feature: Operate Dock Without Vehicle Restraint STOP ECT POWER . touch the ‘Release’ button to disengage the vehicle restraint. because of a broken or damaged ICC bar) chock the vehicle wheels and enter the Activation Code *247 on the control station keypad. DISCONN OPENING D BEFORE UNDERSTAN BEFORE FULLY AND MANUAL READ PRODUCT. After loading / unloading is completed.4 Operating Procedure. MENU DISPLAY SCREEN: Restraint Releasing Blue Genius Ready R ius B lueGen C o u c o n t r ESC TM o l SEL h Do Not Proceed tion With Cau Enter On 1 R E S T R A I N T Enter 2 Green 3 5 6 8 9 0 STOP ESC > 4 7 > T ECT POWER .com ueGian www. The control station light will change from RED to GREEN and the dock leveler will be ready for use.com Do Not Proceed Enter 247 tion With Cau Enter On Green 1 2 3 4 5 6 7 8 9 0 Optional Alarm STOP ECT POWER .TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 9. THIS THE OWNER’S OPERATING www.

□ Upper Red and Lower Green. that may have been caused by operation during □ Check that the Operating Hazards Placard is present in correct location and is legible. □ Check for missing or damaged dock bumpers mounted on dock face. INSPECTED BY: DATE: Forward checklist to the person responsible for Vehicle Restraint maintenance. 11 . damaged or broken.VEHICLE RESTRAINT INSTRUCTIONS FOR USE: Indicate “OK for Use” with a check mark (√) in the appropriate box of each inspection point. Outside and Inside. □ Check that all communication lights are operating correctly. etc. □ Visually inspect the Vehicle Restraint for signs of structural damage or mechanical malfunction as you operate the Vehicle Restraint throughout the day. PM CHECK LIST . ! WARNING Do not operate and/or service unless you have been trained and authorized to do so. etc. □ Inspect operating controls to ensure they are not missing. □ Clean away all foreign material such as parts of broken skids. Explain faults briefly in the space provided below. rust. cracks.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 10. bent parts. □ Inspect for damaged or missing parts. corrosion. Be alert to abnormal sounds or operation. from area in which the Vehicle Restraint is located. □ Visually inspect the Vehicle Restraint and take note of obvious damage the last shift.

After the arm is stored. Replace the cover on the manual release valve. Turn red knob fully Clockwise firmly until snug to CLOSE Valve for NORMAL OPERATION Turn red knob Counter Clockwise to OPEN Valve for BYPASS OPERATION MANUAL RELEASE VALVE PROCEDURE DECAL LOCATED ON THE INSIDE OF THE PROTECTIVE CAP COVER ABOVE: Emergency Lowering Procedure 12 . 3. NOTE: if red stem is visible. Keep hands and feet away from operating space of the restraint arm. Turn valve stem counter-clockwise to open the manual release valve and release the restraint arm. cover does not need to be removed. EMERGENCY VEHICLE RESTRAINT LOWERING PROCEDURE Should a power failure occur. normal operation can resume. 4. Once valve is closed.  Releasing pressure will cause the restraint arm to spring forward abruptly.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 11. 1. or the vehicle restraint or control panel malfunction while the restraint arm is in the vertical locked position (preventing a vehicle from departing). turn the valve stem clockwise until snug. Remove Tamper Proof Cap to access Manual Release Valve. allowing the arm to return to the stored position. Manual Release Valve must be COMPLETELY CLOSED for safe operation. Remove cover from the manual release valve. 2. the manual release valve can be opened.

Faulty wiring or connection. 2. Outside traffic light is RED and control panel light does not come on. PROBLEM CAUSE The restraint arm will not raise when the ENGAGE button is touched. VEHICLE RESTRAINT TROUBLESHOOTING  PROBLEM Do not attempt to install. Faulty power pack pump. The motor runs. Faulty wiring or connection. The restraint arm raises. Faulty wiring or loose connection. 3. but does not lock in the 90 degree position. 2. 1. Faulty wiring or connection. The restraint arm does not lower when the operator touches the RELEASE button. 1.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 12. Hydraulic oil fluid levels low or depleted. The valve may be set too high: adjust pressure with 5/16” allen key. Replace restraint arm solenoid. 13 . 4. and both control panel and outside traffic lights are RED. Faulty motor contactor coil. The restraint arm will not raise when the ENGAGE button is touched. Both control panel and outside traffic lights are RED. Only a trained and authorized service technician should perform the installation process. 2. 3. Replace if necessary. The motor does not run. 1. Faulty locking solenoid. Pressure relief valve is out of adjustment in the power pack. 2. Replace if necessary. Replace if necessary. 1. Contact your local dealer or distributor for assistance. 2. Faulty wiring or connection. Check levels. Refer to the Emergency Lower Procedure for the manual release of the locking mechanism. Faulty power pack pump. 1. Leaking or disconnected hydraulic hose. make repairs or adjustments. The restraint arm raises to a fully vertical position and motor runs. Energize solenoid valve open. Power loss.

2” dia.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 13.R10-2RS-ID 5/8” –OD 1 3/8” 11/32” Metallic Spacer Junction Box 4x4 Hydraulic Command Assembly Hole Plug 1. 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 47 48 49 50 Qty.1. 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. 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. Manual Release Valve Warning Zinc Plating Body Weldment (Not Shown) Zinc Plating Misc.75” dia.24’ long Front Cover Wand Mounting Block Mounting Flat Sensor Wand Top Cover Plug Button 2: dia.5” x 2 1/8” Bearing Square Block Ball Bearing.5 1 Description Male Elbow 90Degree. Fitting Bar. x 1/8” Angular Position Cam Proximity Sensor JB-18-ML-TPNBA Tube Polyethylene 24’ long Part No. TL85A PARTS ILLUSTRATION 24 20 16 23 13" 32 17 31 17 4 26 14 33 DETAIL A SCALE 1 : 4 20 34 26 27 3 36 25 11 29 18 20 23 8 6 5 2 4 36 30 47 32 24 31 20 2 4 19 3 7 33 16 8 15 14 28 13 21 22 12 35 28 1/8" 9 Item No.034” thick x 1.D1/4 Tube Wand Axle Weldment Extension Spring 0. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Qty.5” d x 0. Wear Pivot Block Top Plate Hose Assembly #4. 1 1 1 3 3 2 2 1 1 1 1 1 1 1 1 1 1 58. X ¼” thick Junction Box Bracket Grommet.25” long PG16 Cable Gland PG16 Metal Locknut PG16 Multi-Hole Seal Spring Wire 1 5/8” OD. 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 .

1 SEAL. Part # 040-007 MALE ELBOW (BRASS) 90 DEG. Part # 018-017 BUSHING & Qty: X 1. KIT FOR CYLINDER 780.1 035-662 VALVE SOLENOID. Part # 0012-201 LOCK WASHER 1 51. Part # 010-012 CAPSCREW & Qty: X 2.662.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 14.096.002052 017-034 115-094 115. Part # 010-012 CAPSCREW & Qty: X 4. EACH Qty Req'd PLATE. PRESSURE PROXIMITY SENSOR 18MM SHIELDED FLAT WAND WAND MOUNTING BLOCK MOUNTING BLOCK TOP PLATE EXTENSION SPRING (WAND) WAND AXLE WELDMENT SPRING SPRING HOLDER PIN (TOP) CYLINDER CYLINDER PIN (BOTTOM) PIVOT BLOCK TOP PLATE CYLINDER HARDWARE REQ'D Qty: X 2.A 028-200 116-868 51.085 51. Part # 034-511 ADAPTER 90 DEG 1 1 3 1 1 1 1 1 2 1 1 2 1 035. HOLD WELDM'T HARDWARE REQ'D 115-099 HINGE PIN Qty: X 2. 24VDC COIL SWITCH. TL85A RECOMMENDED SPARE PARTS LIST Part # Description 033-508-24A 035.002317 116-863 017.293.613 HOSE ASS'Y # 4 HOSE (288") 090-909-2880 TUBING (POLYETHYLENE) 1 1 1 51. Part # 0012-201 LOCK WASHER 1 HARDWARE REQ'D 115-100 FRONT COVER Qty: X 4.003011 1 HARDWARE REQ'D Qty: X 1.307 113.001945 ANGULAR POSITION CAM 15 1 . FOR TUBING # 090-909-2880 HARDWARE REQ'D: Qty: X 2. Part # 013-011 SPRING PIN FOR HINGE PIN # 115-099 1 HARDWARE REQ'D 115-103 TOP COVER Qty: X 2.

5" x 36" x 10" DB531 5.5 ITEM 1 2 LAMINATED BUMPER WITH FACE PLATE FLOOD LIGHT QTY 1 1 PART ID LDL-150 026-725 DESCRIPTION LOADING DOCK LIGHT .5" x 14" x 10" DB412 4.5" x 14" x 10" DB511 5.5" x 24" x 10" DB521 5.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 15.5" x 36" x 10" 15.5" x 14" x 10" DB511FP 5.5" x 14" x 20" 15.5" x 14" x 20" DB512 5.5" x 24" x 10" DB431 4.5" x 14" x 20" DB421 4.5" x 14" x 10" DB412FP 4.130V 1 2 16 .5" x 14" x 20" DB512FP 5.4 FACE PLATES FOR LAMINATED BUMPERS PART ID DESCRIPTION DB411FP 4.3 FACE PLATE FOR MOLDED BUMPER MOLDED RUBBER BUMPER LAMINATED BUMPERS LAMINATED BUMPERS PART ID DESCRIPTION DB411 4.1 MOLDED RUBBER BUMPERS MOLDED RUBBER BUMPERS PART ID DESCRIPTION DB13 4" x 10" x 13" DB18 4" x 10" x 18" DB30 4" x 10" x 30" DBL18 4" x 18" x 18" 15. GENERAL PARTS 15.2 FACE PLATES FOR MOLDED RUBBER BUMPERS PART ID DESCRIPTION DB13FP 4" x 10" x 13" DB18FP 4" x 10" x 18" 15.150W MAX 90W HALOFLOOD BULB .

17 5 5 5 5 5 5 5 5 5 . FAST ACTING FOR 3PH. 700V.75A. TIME DELAY FOR 1PH. RECOMMENDED SPARE PARTS.BLUE GENIUS GOLD SERIES II Single Phase: Part # Description 026-PB1115 026-PB1230 POWER BOARD SUBASSY (1PH 115V 50-60HZ) POWER BOARD SUBASSY (1PH 230V 50-60HZ) Three Phase: Part # Description 026-PB3230 026-PB3400 026-PB3460 026-PB3575 POWER BOARD SUBASSY (3PH 230V 50-60HZ) POWER BOARD SUBASSY (3PH 400V 50-60HZ) POWER BOARD SUBASSY (3PH 460V 50-60HZ) POWER BOARD SUBASSY (3PH 575V 50-60HZ) Qty Req'd 1 1 Qty Req'd 1 1 1 1 Touch Boards: Screen (S/N Required) Requires Software version (Must also purchase the cover & decal) Part # Description 026-G020 025-G014 CONTROL/TOUCH BOARD/W LED&LCD MODULES Part # Description 026-G025M 026-G025-99 026-G030 REMOTE I/O-A BOARD REMOTE I/O-B BOARD WITH DOOR CONTROL RIBBON CABLE. FAST ACTING FOR 3 PH. 250V. 250V.5A. 0. .208-240V FUSE. 700V. FAST ACTING FOR 3PH. 400mA. 15A.208-240V FUSE. 700V.315mA. TIME DELAY FOR 1 PH.TIME DELAY FOR 1PH FUSE.25A. 110-130V Qty Req'd FUSE. TIME DELAY FOR 1PH.315mA. 250V. 16 WIRE /PIN /W CONNECTORS Qty Req'd 1 1 1 TRANSPARENT COVER DOOR DECAL. 8A.575-600V FUSE. PART NO.380-415V FUSE. 208-240V. TIME DELAY FOR 1&3PH FUSE.0. 500mA. 700V. IS BASED ON S/N 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 FUSE. 10-130V. 250V.TL85A VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS 16.440-480V FUSE.

888.com If calling within North America: t 1. Canada L6W 3K2 t 905.457.BlueGiant.5781 © Copyright Blue Giant Equipment Corporation 2013 .668.Corporate 85 Heart Lake Road South Brampton.378.7078 f 1.3900 f 905.800.457.2313 USA 6350 Burnt Poplar Road Greensboro. NC 27409 www. ON.