Blue Giant BLUE GENIUS TL85 Series Operating instructions

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.
INSTALLATION &
OWNER’S MANUAL
WARNING
TL85 VEHICLE RESTRAINT WITH
BLUE GENIUS™ CONTROLS
TL85 Vehicle Restraint With Blue Genius™ Controls. Issue Date: October 2, 2012 Rev. 3 (Part#038-707E)
Applies to Serial Numbers 370169 and up.
BLUE GENIUSTM SERIES

TABLE OF CONTENTS
1. ABOUT THE TL85 WITH BLUE GENIUSTM CONTROLS........................................................................................... 1
1.1 Owner’s Purchase Record...................................................................................................................................... 1
2. INTRODUCTION ......................................................................................................................................................... 2
2.1 Warranty Information............................................................................................................................................. 2
2.2 Exclusion of Liability.............................................................................................................................................. 2
2.3 Manufacturer's Note.............................................................................................................................................. 2
3. OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION................................................................ 3
3.1 Operational Safety Warnings................................................................................................................................ 3
4. LOCKOUT / TAGOUT PROCEDURE AND RULES..................................................................................................... 4
5. TL85 SELF CONTAINED POWER PACK ARRANGEMENT....................................................................................... 5
6. VEHICLE RESTRAINT INSTALLATION INSTRUCTIONS.......................................................................................... 6
6.1 Install Preparations............................................................................................................................................... 6
6.2 Install Mounting..................................................................................................................................................... 6
6.3 Electrical and Hydraulic Installation....................................................................................................................... 6
6.4 Final Inspection and Setup................................................................................................................................... 6
7. ELECTRICAL AND HYDRAULIC INSTALLATION...................................................................................................... 7
7.1 TL85 and Dock (Pit Mounted)............................................................................................................................... 7
7.2 Final Inspection..................................................................................................................................................... 7
8. CONTROL STATION OPERATION.............................................................................................................................. 8
9. OPERATING INSTRUCTIONS..................................................................................................................................... 9
9.1 Functional Description......................................................................................................................................... 9
9.2 Stop Button Function........................................................................................................................................... 9
9.3 Operating Procedure- Deploying the Restraint Arm............................................................................................ 9
9.4 Undeploying the Restraint Arm............................................................................................................................ 10
9.5 Vehicle Restraint Override Feature: Operate Dock Without Vehicle Restraint.................................................... 10
10. PM CHECKLIST- VEHICLE RESTRAINT.................................................................................................................... 11
11. EMERGENCY VEHICLE RESTRAINT LOWERING PROCEDURE............................................................................. 12
12. VEHICLE RESTRAINT TROUBLESHOOTING............................................................................................................ 13
13. TL85 PARTS ILLUSTRATION...................................................................................................................................... 14
14. TL85 RECOMMENDED SPARE PARTS LIST............................................................................................................. 15
15. GENERAL PARTS........................................................................................................................................................ 16
15.1 Molded Rubber Bumpers...................................................................................................................................... 16
15.2 Laminated Bumpers............................................................................................................................................. 16
15.3 Face Plates For Laminated Bumpers................................................................................................................... 16
15.4 Flood Light........................................................................................................................................................... 16
16. RECOMMENDED SPARE PARTS LIST FOR BLUE GENIUS GOLD SERIES II........................................................ 17

1. ABOUT THE TL85 VEHICLE RESTRAINT with BLUE GENIUSTM CONTROLS
The Blue Giant TL85 Vehicle Restraint System is a non-impact design with a restraining power of 32,000 lbs (14,545
kgs) and vertical ICC bar capture range of 12-26” (305mm to 660mm) above grade. 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.
Maintenance-free NEMA4 rated sensors ensure accurate ICC bar detection and indicate when the restraint arm is locked
or in the parked position. The TL85 may be wall or ground mounted.
The Blue Genius™ Gold Series II Touch Control Panel with advanced microprocessor technology controls the
operation of the restraint. Using a combination of red /yellow / green LED control station lights and red / green exterior
traffic lights, the Blue Genius™ keeps both the truck driver and dock attendants advised on the safety status of
cross-docking travel. Its onboard diagnostics and communications feature a user-friendly, multi-language LCD intelligent
text display and keypad with supervisory override support.
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.
Dealer: Date in Service:
Number of Units:
Serial Number(s):
Door # :
OWNER’S PURCHASE RECORD
Please record information for future inquiries
1. 1 OWNER’S PURCHASE RECORD
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
1

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: [phone] Fax: [phone]
ALSO MEMBERS OF :
American National Standards Institute (ANSI)
1430 Broadway
New York, NY 10018
[phone]
LOADING DOCK EQUIPMENT MANUFACTURERS
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:
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.
MANUFACTURER’S NOTE
The Vehicle Restraint 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.
2.2 EXCLUSION OF LIABILITY
2.3 MANUFACTURER’S NOTE
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 [phone].
* Note that failure to validate warranty at the time of receipt can seriously affect the outcome of any claim.
2.1 WARRANTY INFORMATION
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
2

3.1 OPERATIONAL SAFETY WARNINGS
3. OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION
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.
Serious injury or death will likely occur if the instructions are
not followed. Procedures marked IMPORTANT must be followed in order to prevent damage to machinery.
Serious injury or death may occur if the instructions are not
followed. Instructions marked CAUTION concern safe operating
procedure. Failure to comply may result in personal injury.
• DO NOT operate restraint with anyone standing in the path of operation.
• BEFORE BEGINNING ANY SERVICE PROCEDURES:
– Disconnect the power and follow all LOCKOUT / TAGOUT procedures.
• Keep away from restraint arm when the vehicle restraint is in
operation.
• Post safety warnings and barricade working area at dock level and
at ground level to prevent unauthorized use of the restraint during
maintenance/service.
• During installation, anchors must be properly torqued to obtain the
necessary anchoring strength. DO NOT USE IMPACT DRIVERS.
• DO NOT drive or walk onto the transport vehicle until it is parked
against the dock bumpers and the wheels are chocked, or the
vehicle restraint has been fully engaged and the lights have
changed to GREEN inside and RED outside.
• ALWAYS check the rigging to make sure that it is secure before
proceeding to lift the unit. Never stand under any unit being lifted.
• NEVER remove the wheel chocks until loading/ unloading is finished
and the truck driver has been given permission to depart, or the
Vehicle Restraint has been released and the lights have changed to
RED inside and GREEN outside.
• DO NOT ground welding equipment to any hydraulic cylinder or
electrical components.
• DO NOT allow the drill to go too deeply when drilling holes in the
control box. Damage to the control systems may occur.
• NEVER use air to blow debris from control box. Use a vacuum to
remove debris from control box.
• DO NOT connect green ground lead into control box or junction box
until all welding has been completed.
• CHECK HYDRAULIC FLUID LEVEL. Deck mounted power unit has
been filled with fluid but cylinders, hoses and manifold are shipped
dry.
• NOTE - check motor rotation. Jog the motor until rotation has been
determined. DO NOT allow the motor to run in reverse for more than
a couple of seconds, otherwise the power unit may become
damaged.
• DO NOT force valve adjustment screws against internal stops.
Damage will occur to the valve/seat.
• If a procedure is not clearly defined in this manual, contact your
authorized Service Representative.
• ONLY TRAINED PERSONNEL should operate or service this equipment.
• DO NOT operate restraint until freight carrier is parked against the dock bumpers.
• ALWAYS return the restraint arm to the proper undeployed position.
• ALWAYS conduct routine inspections and maintenance. Failure to conduct could cause personal injury or damage to equipment.
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
3

4. LOCKOUT / TAGOUT PROCEDURE and RULES
XXXXXXXXXXXX
XXXXXXXXXXX
OPERATE
DO NOT
ABOVE: APPROVED WAY TO LOCKOUT / TAGOUT
In accordance with the rules and regulations of the Occupational
Safety and Health Administration (OSHA), all affected
employees must be notified that the machine or equipment will
be shut down and locked out to perform repair or maintenance
work. The work area must be checked to ensure that all
personnel have been removed or safely repositioned. 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 lockout
devices 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. It
is mandatory that tagout notices not be susceptible to
deterioration or illegibility due to weather conditions or exposure
to chemicals and moisture.
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.
!
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
4

MOTOR WIRING
5. TL85 SELF CONTAINED POWER PACK ARRANGEMENT
HYDRAULIC VEHICLE RESTRAINT
LIP SENSOR
CONCRETE PAD
NOTE: DOCK FACE & DRIVEWAY TO BE CONSTRUCTED
OF CONCRETE AND IN GOOD CONDITION.
CONSULT MANUFACTURER IF OTHER
CONDITIONS EXIST.
CAST-IN-PLACE MOUNTING
PLATE (OPTIONAL)
NOTE: FUSED DISCONNECT
BY OTHERS
BLUE GENIUS
CONTROL BOX
(MOUNTED & WIRED
BY OTHERS)
TRAFFIC LIGHTS
(MOUNTED & WIRED BY OTHERS)
66”
84”
MAIN POWER
(TO CONTROL STATION)
MOTOR POWER FEED
8”
C
L
!
CAUTION
MOVE ON
GREEN ONLY
!
CAUTION
MOVE ON
GREEN ONLY
123
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#0*
EnterOn Green
ProceedWithCaution
DoNot Enter
Release
Engage
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
#
Restraint
Disconnectpower
CAUTION
!
beforeopeningpanel
.
66”
ELECTRICAL REQUIREMENTS-
• MOUNT CONTROL BOX STATION TO WALL, SIGNALLIGHTS AND DRIVER WARNING SIGNS
• FUSED DISCONNECT PROVIDED BY OTHERS AND WIRING BY OTHERS
• INSTALL CABLE FROM CONTROLBOX STATION TO POWER PACK
• INSTALL CABLE FROM CONTROLBOX STATION TO POWER SUPPLY
NOTE:
FRONT VIEW SHOWS THE TL85 VEHICLE RESTRAINT IN ITS
ENGAGED/ RAISED POSITION.
* DRAWINGS NOT TO SCALE
VIEW A
(INSIDE BUILDING) FRONT ELEVATION VIEW
GROUND LEVEL
1/2” DIA. CONDUIT FOR
COMMUNICATION CABLE
1/2” DIA. CONDUIT FOR
MOTOR WIRING CABLE
HYDRAULIC VEHICLE RESTRAINT
CAST-IN-PLACE MOUNTING
PLATE (OPTIONAL)
CONTROL STATION
(MOUNTED ON
DRIVERS SIDE)
Vehicle Restraint Installation Pictorial
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).
MAIN POWER
FEED CABLE
(from fused
disconnect)
TRAFFIC LIGHT
CABLE
(to the outside)
RESTRAINTS
MOTOR WIRING
(to the outside)
COMMUNICATION
CABLE
(to the outside)
8”
12”
84”
(REQUIREMENTS BELOW BY OTHERS)
NEW CONSTRUCTION (REMOTE POWER PACK & RESTRAINT):
1. DRILL ONE HOLE THROUGH THE WALLTO THE OUTSIDE AND WIRE
THE L.E.D TRAFFIC LIGHT.
2. INSTALL ONE 1/2” I.D. CONDUIT FROM THE CONTROL STATIONS MOTOR POWER FEED
TO THE DOCK FACE FOR THE RESTRAINTS POWER WIRING
3. INSTALL ONE 1/2” I.D. CONDUIT FROM THE CONTROL STATION
TO THE DOCK FACE FOR THE RESTRAINTS I/O BOX COMMUNICATION CABLE.
MINIMUM CONCRETE STRENGTH 3,000 P.S.I.
POWER WIRING
COMMUNICATION CABLES
HYDRAULIC HOSE LINES
CABLE
TO LIP SENSOR
COMMUNICATION
CABLE
(TO CONTROL STATION)
MOTOR WIRING MUST HAVE ITS
OWN CONDUIT SEPARATE FROM
THE COMMUNICATION CABLE
MOTOR WIRING MUST HAVE ITS
OWN CONDUIT SEPARATE FROM
THE COMMUNICATION CABLE
COMMUNICATION CABLE MUST
HAVE ITS OWN CONDUIT SEPARATE
FROM THE MOTOR WIRING
COMMUNICATION CABLE MUST
HAVE ITS OWN CONDUIT SEPARATE
FROM THE MOTOR WIRING
MOTOR
WIRING
NOTE: ALL CONDUIT
ENTRY INTO CONTROL PANEL
FROM BOTTOM.ARRANGE
WIRING TOAVOID HIGH & LOW
VOLTAGE CROSSING OVER
INSIDE CONTROL BOX.
DO NOT RUN MAIN POWER
WIRING THROUGH TOP OF
CONTROL STATION
!
!!
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.
TRAFFIC LIGHTS
(MOUNTED DRIVERS SIDE)
PART #032-461
DRIVER WARNING SIGN
(MOUNTED DRIVERS SIDE)
PART #038-225
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
5

6. VEHICLE RESTRAINT INSTALLATION INSTRUCTIONS
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.
3. Using suitable hoisting equipment, position the vehicle restraint
square against the dock face, and centered with the door
frame.
4. 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. Shims must be a minimum 13” x 6” in size and be
permanently welded together and to the base-plate.
1. With the vehicle restraint properly positioned and using back
plates as a template, drill six holes 5/8” in diameter and 6” deep
in the dock face concrete. Clean out holes and install anchors
and lag bolts (supplied with the restraint) with a torque of
110ft/lbs (149Nm). Optional anchoring to concrete pad rather
than wall plate.
Refer to Section 7: Electrical and Hydraulic Installation
1. Securely mount the exterior traffic lights and signs on the
exterior wall adjacent to the doorway at approximately 84”
above the driveway.
1. Permanently mount the sensor wand onto the sensor switch
with the set screws provided. When at rest, the wand must
be in the forward position. Tighten fasteners securely.
2. Rotate the wand (move backward) to make contact with the
dock face. Contact point must not be above the top edge of
the pit opening and floor If the contact point is higher, modify
the wand.

Do not install, operate, or service the TL85 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.
SHIMS (13” X 6”)
THICKNESS AS REQUIRED 5/8” x 6” Concrete
Anchor Bolts
Recommended Torque:
110 ft-lb (149 Nm)
CONCRETE
DOCK FACE
TOP EDGE OF
PIT OPENING / FLOOR
WAND
ABOVE: WHEN INSTALLING THE RESTRAINT MOUNT TO A CONCRETE DOCK FACE AS SHOWN.
6.1 Install Preparations
6.2 Install Mounting
6.3 Electrical and Hydraulic Installation
6.4 Final Inspection and Setup
Optional
Floor Mount Anchor Bolts
in Concrete Pad (See Step
6.2)
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
6

7. ELECTRICAL AND HYDRAULIC INSTALLATION
1. If conduits for the restraint were not poured in with the
concrete, install 1/2” dia. conduit for the communication wires
from the vehicle restraint, along the dock face, up and through
the wall, and up to the control station.
2. Install one ½” dia. conduit for the power / motor wiring from the
restraint, along the dock face, up and through the wall, and up
to the control station.
3. Install one conduit from the control station, through the wall, to
the exterior LED traffic lights.
4. Complete the electrical hookup between the vehicle restraint
and the control station, and between the exterior traffic lights
and control station.
1. Ensure that all fasteners have been tightened and locked.
2. Cycle test the vehicle restraint a minimum of 10 times to
bleed trapped air back to the reservoir. (This procedure
requires the installer to follow the control box menu screen
during start-up.)
3. Check hydraulic fluid level in the reservoir. With the
restraining arm fully lowered, level should be approxi-
mately ½” below the top of the reservoir. If required, top up
with Valvoline ISO32 or Mobil DTE13 hydraulic fluid.
4. Check all hydraulic connections for leaks and tighten as
required.
5. Check that all electrical and hydraulic conduits, hoses, and
wires are mechanically protected against damage and are
adequately secured.
6. Return all wiring diagrams to the Blue Genius™ control
station.
7. Mount warning placard next to the Blue Genius™ control
station.
8. Leave these instructions near the vehicle restraint for easy
future access.
7.1 TL85 and DOCK (both pit mounted)
7.2 Final Inspection
6 5/32"
11 29/32" 12 17/32"
1/4"
8 3/32"
Figure 1: Blue GeniusTM control station dimensions
and conduit install area.

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.
Do not loop the communication cable excessively, or
interference may result and create intermittent communi-
cation problems. Trim cable to appropriate length during
install.
WARNING
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
7

www.BlueGiant.com
Gold Series
TM
enius
G
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T o u c h C o n t r o l
DISCONNECT POWER
BEFORE OPENING.
READ AND FULLYUNDERSTAND
THE OWNER’S MANUAL BEFORE
OPERATING THIS PRODUCT.

R
#038-244E
Do Not Enter
Caution
Enter On Green
STOP
R
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I
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ESC
SEL
7 98
4 65
1 32
8. CONTROL STATION OPERATION
INDEPENDENT TYPE CONTROL STATION
- Controls Vehicle Restraints Only
SCROLL ‘UP’
SELECT
ESCAPE
SCROLL ‘DOWN’
RESTRAINT ‘ENGAGE’
(Raise Restraint Arm)
RESTRAINT ‘RELEASE’
(Lower Restraint Arm) CARRIER VEHICLE RELEASE
RED LIGHT
(Do Not Enter)
MENU SCREEN
YELLOW LIGHT
(Proceed With Caution)
GREEN LIGHT
(Enter On Green)
CONTROL STATION KEY PAD
(Override, Security, Features) ‘STOP’
(Stop Restraint)
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
8

9. OPERATING INSTRUCTIONS
The TL85 Vehicle Restraint is used to restrain a freight carrier
at the loading dock. It is a nonimpact design that is both
engaged and released by the dock attendant. When engaged,
it restrains a vehicle by acting as a barrier to the under ride
guard (ICC bar), restricting any forward movement caused by
vehicle creep or unscheduled departure. It is hydraulically
operated via the Blue Genius™ Control Panel.
9.1 Functional Description
9.2 Stop Button Function
Do not operate this vehicle restraint unless you have been
trained and authorized to do so, and have read and under-
stood all of the safety information and instructions
contained herein.
Do not operate the restraint until you have checked its
condition. Report the need for repairs to your supervisor
immediately and do not operate the unit until repairs are
made. Neglect may cause a minor repair to become a
major service problem and cause the leveler to become
unsafe.
Never try to lift or move any part of the vehicle restraint
manually.
Keep hands and feet clear of the vehicle restraint pinch
points at all times.
Freight carrier under ride guards differ in strength,
construction, and attachment. It is therefore recommended
that users of vehicle restraint devices review the means of
attachment to the freight carrier, the overall connection
strength, and the need to use wheel chocks in conjunction
with the restraining device.
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.
Touching the ‘STOP’ button during operation will cause the unit
to stop in mid motion.
To exit the ‘STOP’ mode touch ‘ESC’.
9. OPERATING INSTRUCTIONS
Truck / Vehicle Dock Leveler
Vehicle Restraint
ICC Bar
Dock Bumper
Loading Dock
123
456
789
#0*
EnterOnGreen
ProceedWithCaution
DoNotEnter
STOP
Lip
Deck
Release
Engage
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
#
Restraint
www.BlueGiant.com
Leveler
ESC
SEL
www.BlueGiant.com
GoldSeries
TM
enius
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DISCONNECTPOWER
BEFORE OPENING.
READANDFULLY UNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
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Do Not Enter
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STOP
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SEL
8 97
5 64
2 31
STOP
123
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ProceedWithCaution
DoNotEnter
STOP
Release
Engage
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
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Restraint
www.BlueGiant.com
www.BlueGiant.com
GoldSeries
TM
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T o u c h Con t rol
DISCONNECTPOWER
BEFORE OPENING.
READANDFULLY UNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
 
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Do Not Enter
Proceed With Caution
Enter On Green
STOP
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Bl ue G e niu s
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MENU DISPLAY SCREEN:
9.3 Operating Procedure- Deploying the
Restraint Arm
1. The Blue GeniusTM Control Panel is powered on and ready for
use. The restraint arm is fully lowered. The outside traffic
light is GREEN and control station light is RED.
2. The freight carrier reverses firmly into position against the
dock bumpers. The vehicle’s ICC bar operates the sensor
wand on the vehicle restraint. The lights remain GREEN
outside and RED inside.
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).
WARNING
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
9

9. OPERATING INSTRUCTIONS
9.4 Operating Procedure- Undeploying the
Restraint Arm
1. After the dock leveler is safely parked, touch the ‘Release’
button to disengage the vehicle restraint. The control station
light will change to RED and the LCD screen will read ‘Truck
Restraint Releasing’. When the arm reaches the home
position, the LCD screen will read ‘Blue Genius Ready’ and
the traffic light will turn GREEN.
9.5 Vehicle Restraint Override Feature:
Operate Dock Without Vehicle Restraint
1. If the restraint cannot be engaged, (i.e. because of a broken
or damaged ICC bar) chock the vehicle wheels and enter the
Activation Code *247 on the control station keypad. The
control station light will change from RED to GREEN and the
dock leveler will be ready for use. The outside traffic light will
turn RED.
2. After loading / unloading is completed, return the dock to the
stored position, remove the wheel chocks, and reset the
control station by touching the restraint’s ‘Release’ button.
Restraint Releasing
MENU DISPLAY SCREEN:
Blue Genius Ready
www.BlueGiant.com
GoldSeries
TM
enius
G
lue
B
Touc h C o n tro l
DISCONNECTPOWER
BEFORE OPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
 
R
#038-244E
Do Not Enter
Proceed With Caution
Enter On Green
STOP
R
E
S
T
R
A
I
N
T
0
ESC
SEL
8
97
564
23
1
123
456
789
#0*
EnterOnGreen
ProceedWithCaution
DoNotEnter
STOP
Release
Engage
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
#
Restraint
www.BlueGiant.com
www.BlueGiant.com
GoldSeries
TM
enius
G
lue
B
T o u c h C o n t rol
DISCONNECTPOWER
BEFORE OPENING.
READANDFULLYUNDERSTAND
THEOWNER’SMANUAL BEFORE
OPERATINGTHISPRODUCT.
 
R
#038-244E
Do Not Enter
Proceed With Caution
Enter On Green
STOP
R
E
S
T
R
A
I
N
T
0
ESC
SEL
8
97
5 64
2 31
123
456
789
#0*
EnterOnGreen
ProceedWithCaution
DoNotEnter
STOP
Release
Engage
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
#
Restraint
www.BlueGiant.com
Restraint Engaging
MENU DISPLAY SCREEN:
Restraint is Engaged
Dock Leveler Restored
Ready to Raise Deck
ENTER ACTIVATION CODE : 247
*
www.BlueGiant.com
GoldSeries
TM
enius
G
lu
e
B
T o u c h C o n t r o l
DISCONNECTPOWER
BEFORE OPENING.
READANDFULLY UNDERSTAND
THEOWNER’SMANUALBEFORE
OPERATINGTHISPRODUCT.
 
R
#038-244E
STOP
R
E
S
T
R
A
I
N
T
0
ESC
SEL
897
5 6
4
2 3
1
123
456
789
#0*
EnterOnGreen
ProceedWithCaution
DoNotEnter
STOP
Lip
Deck
Release
Engage
SEL
ESC
>
>
1 2 3
6
5
4
789
*
0
#
Restraint
www.BlueGiant.com
Leveler
VISUALLY CHECK TO
ENSURE NO ICC BAR
IS PRESENT
ALARM WILL BEEP
INDICATING THAT NO
ICC BAR IS PRESENT
Optional Alarm
MANUALLY CHOCK
WHEELS
Do Not Enter
Proceed With Caution
Enter On Green
NOTE: If the restraint arm encounters any obstructions that
prevent it from lowering, it will ‘pound’ down two (2) times to
dissolve the blockage. The control panel light will be RED,
accompanied by an intermittent alarm. The LCD screen will
read ‘Arm Blocked- Retrying’followed by ‘Restraint Releasing’.
After the final unsuccessful attempt, the screen will read
‘Restraint Arm Blocked’.
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
10

!WARNING
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 that may have been caused by operation during
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 Re-
straint throughout the day. Be alert to abnormal sounds or operation.
Explain faults briefly in the space provided below.
INSPECTED BY: DATE:
Forward checklist to the person responsible for Vehicle Restraint maintenance.
Do not operate and/or service unless you have been
trained and authorized to do so.
10. PM CHECK LIST - VEHICLE RESTRAINT
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
11

Should a power failure occur, or the vehicle restraint or control
panel malfunction while the restraint arm is in the vertical locked
position (preventing a vehicle from departing), the manual
release valve can be opened, allowing the arm to return to the
stored position.

1. Remove cover from the manual release valve. NOTE: if red
stem is visible, cover does not need to be removed.
2. Turn valve stem counter-clockwise to open the manual release
valve and release the restraint arm.
3. After the arm is stored, turn the valve stem clockwise until
snug. Once valve is closed, normal operation can resume.
4. Replace the cover on the manual release valve.
ABOVE: Emergency Lowering Procedure
MANUAL RELEASE VALVE PROCEDURE
DECAL LOCATED ON THE INSIDE OF THE
PROTECTIVE CAP
Releasing pressure will cause the restraint arm to spring
forward abruptly. Keep hands and feet away from
operating space of the restraint arm.
Turn red knob fully
Clockwise firmly until
snug to CLOSE Valve for
NORMAL
OPERATION BYPASS
OPERATION
Turnredknob
CounterClockwise
to
OPEN
Valvefor
Manual Release Valve must be COMPLETELY
CLOSED for safe operation. Remove Tamper
Proof Cap to access Manual Release Valve.
COVER
11. EMERGENCY VEHICLE RESTRAINT LOWERING PROCEDURE
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
12

12. VEHICLE RESTRAINT TROUBLESHOOTING
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
PROBLEM

The restraint arm will not
raise when the ENGAGE
button is touched. The
motor runs, and both
control panel and outside
traffic lights are RED.
1. Faulty wiring or connection. Energize solenoid valve open.
2. Hydraulic oil fluid levels low or depleted. Check levels.
3. Leaking or disconnected hydraulic hose.
4. Faulty power pack pump. Replace if necessary.
1. Faulty wiring or connection.
2. Faulty motor contactor coil. Replace restraint arm solenoid.
The restraint arm raises to
a fully vertical position and
motor runs. Both control
panel and outside traffic
lights are RED.
1. Faulty wiring or connection.
2. Pressure relief valve is out of adjustment in the power pack. The valve may be set too
high: adjust pressure with 5/16” allen key.
3. Faulty power pack pump. Replace if necessary.
The restraint arm raises,
but does not lock in the 90
degree position.
1. Faulty wiring or loose connection.
2. Faulty locking solenoid. Replace if necessary.
The restraint arm does not
lower when the operator
touches the RELEASE
button.
1. Faulty wiring or connection.
2. Power loss. Refer to the Emergency Lower Procedure for the manual release of the
locking mechanism.
The restraint arm will not
raise when the ENGAGE
button is touched. The
motor does not run.
Outside traffic light is RED
and control panel light
does not come on.
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
13

31
22 24
12 13 19
14
25
8
7
222
15
16
9
17
4
23
3536
28 1/8"
29
31
DETAIL A
SCALE 1 : 4
22
15
24 23
30
38
2221
26 2833 27 32 3720
2 32
5
8 6
11
3
18
20
33
4
34
R1
R1
13. TL85 PARTS ILLUSTRATION
Item No. Qty. Descripon Part No.
1 1 Body Weldment 51-001977
2 1 Hinge Pin 115-099
3 1 Hold Plate Assembly 51-003011
4 2 Spring Pin 013-011
5 4 Bushing 018-017
6 1 Cylinder Pin 115-307
7 1 Spring Holder Pin 115-094
8 1 Cylinder Assembly, 2” dia. 035-662
9 2 Fing 034-633
10 1 Bar, Wear 252-0019
11 2 Pivot Block Top Plate 113-096
12 1 Hose Assembly 100-5000-5
13 1 Cable, 4Wire, 18GA 515-0001
14 1 Front Cover 115-100
15
1
Wand Mounng Block
51-002317
16
1
Mounng Flat
116-863
17
1
Sensor Wand
116-868
18 1 Top Cover 115-103
19 1 Plug Buon 2: dia. x 1/8” R3-93002
20 1 Hole Plug 1 ¾” dia. 037-081
21 1 Angular Posion Cam 51-001945
22 3 Proximity Sensor JB-18-ML-TPNBA 028-200
23 1 Wand Axle Weldment 51-002052
Item No.
Qty.
Descripon
Part No.
24 1 Extension Spring 0.5” d x 0.034” thick x 1.25” long 017-085
25 2 Spring Wire 1 5/8” OD. X ¼” thick 017-034
26 3 PG16 Cable Gland 025-174
27 3 PG16 Metal Locknut 025-177
28 2 PG16 Mul-Hole Seal 025-175
29 1 Bearing Square Block 51-002213
30 1 Ball Bearing- R10-2RS-ID 5/8” –OD 1 3/8” 11/32” 018-640
31 1 Metallic Spacer 51-002306
32 1 Juncon Box 4x4 025-G020-C
33 1 Juncon Box 4x4 025-G020-N
34 1 Juncon Box Bracket 51-002204
35 1 Hydraulic Command Assembly 51-003116
36 1 Cable, 4Wire 18GA 515-0001
37 1 PG9 Metal Locknut 025-176
38 1 PG9 Cable Gland 025-173
43 1 Zinc Plang Body Weldment (Not Shown) 050-027
44 62.6 Zinc Plang Misc. Parts (Not Shown) 050-505
45
1
Zinc Plang Wand (Not Shown)
050-027-2
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
14

14. TL85 RECOMMENDED SPARE PARTS LIST
Part #
Description
Qty Req'd
033-508-24A VALVE SOLENOID, 24VDC COIL 1
1ERUSSERP,HCTIWSA-392-530
028-200 PROXIMITY SENSOR 18MM SHIELDED 3
116-868FLAT WAND 1
1KCOLBGNITNUOMDNAW713200-15
116-863 MOUNTING BLOCK TOP PLATE 1
1)DNAW(GNIRPSNOISNETXE580-710 1TNEMDLEWELXADNAW250200-15
017-034SPRING 2
115-094SPRING HOLDER PIN (TOP) CYLINDER 1
1)MOTTOB(NIPREDNILYC703-511 2ETALPPOTKCOLBTOVIP1-690-311
HARDWARE REQ'D 035-662 CYLINDER 1
Qty: X 2, Part # 018-017 BUSHING & Qty: X 1, Part # 034-511 ADAPTER 90 DEG
1REDNILYCROFTIK,LAES1-266-530 1)"882(ESOH4#Y'SSAESOH316-087
HARDWARE REQ'D 1)ENELYHTEYLOP(GNIBUT0882-909-090
Qty: X 1, Part # 040-007 MALE ELBOW (BRASS) 90 DEG. FOR TUBING # 090-909-2880
HARDWARE REQ'D: Qty: X 2, EACH
1T'MDLEWDLOH,ETALP110300-15
HARDWARE REQ'D 115-099 HINGE PIN 1
Qty: X 2, Part # 013-011 SPRING PIN FOR HINGE PIN # 115-099
HARDWARE REQ'D
115-103
TOP COVER
1
HARDWARE REQ'D
115-103
TOP COVER
1
Qty: X 2, Part # 010-012 CAPSCREW & Qty: X 2, Part # 0012-201 LOCK WASHER
HARDWARE REQ'D
115-100 FRONT COVER 1
Qty: X 4, Part # 010-012 CAPSCREW & Qty: X 4, Part # 0012-201 LOCK WASHER
1MACNOITISOPRALUGNA549100-15
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
15

15. GENERAL PARTS
15.1 MOLDED RUBBER BUMPERS
15.3 LAMINATED 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"
PART ID DESCRIPTION
DB13FP 4" x 10" x 13"
DB18FP 4" x 10" x 18"
PART ID DESCRIPTION
DB411 4.5" x 14" x 10"
DB511 5.5" x 14" x 10"
DB412 4.5" x 14" x 20"
DB512 5.5" x 14" x 20"
DB421 4.5" x 24" x 10"
DB521 5.5" x 24" x 10"
DB431 4.5" x 36" x 10"
DB531 5.5" x 36" x 10"
PART ID DESCRIPTION
DB411FP 4.5" x 14" x 10"
DB511FP 5.5" x 14" x 10"
DB412FP 4.5" x 14" x 20"
DB512FP 5.5" x 14" x 20"
MOLDED RUBBER BUMPERS
LAMINATED BUMPERS
15.2 FACE PLATES FOR
MOLDED RUBBER BUMPERS
15.4 FACE PLATES FOR
LAMINATED BUMPERS
LAMINATED BUMPER
WITH FACE PLATE
FACE PLATE FOR
MOLDED BUMPER
MOLDED RUBBER
BUMPER
15.5 FLOOD LIGHT
ITEM QTY PART ID DESCRIPTION
1 1 LDL-150 LOADING DOCK LIGHT - 150W MAX
2 1 026-725 90W HALOFLOOD BULB - 130V
1
2
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
16

16. RECOMMENDED SPARE PARTS- BLUE GENIUS GOLD SERIES II
Single Phase:
Part #
Description
Qty Req'd
026-PB1115 POWER BOARD SUBASSY (1PH 115V 50-60HZ) 1
026-PB1230 POWER BOARD SUBASSY (1PH 230V 50-60HZ) 1
Three Phase:
Part #
Description
Qty Req'd
026-PB3230 POWER BOARD SUBASSY (3PH 230V 50-60HZ) 1
026-PB3400 POWER BOARD SUBASSY (3PH 400V 50-60HZ) 1
026-PB3460 POWER BOARD SUBASSY (3PH 460V 50-60HZ) 1
026-PB3575 POWER BOARD SUBASSY (3PH 575V 50-60HZ) 1
Touch Boards: Screen (S/N Required)
Requires Software version (Must also purchase the cover & decal)
Part #
Description
Qty Req'd
026-G020 CONTROL/TOUCH BOARD/W LED&LCD MODULES 1
1ROODREVOCTNERAPSNART410G-520
DECAL, PART NO. IS BASED ON S/N
1
DECAL, PART NO. IS BASED ON S/N
1
Part #
Description
Qty Req'd
1DRAOBA-O/IETOMERM520G-620
026-G025-99 REMOTE I/O-B BOARD WITH DOOR CONTROL 1
026-G030 RIBBON CABLE, 16 WIRE /PIN /W CONNECTORS 1
Fuses:
Part #
Description
Qty Req'd
026-G100 FUSE, 15A, 250V, TIME DELAY FOR 1PH, 110-130V 5
026-G101
FUSE, 8A, 250V, TIME DELAY FOR 1 PH,208-240V 5
026-G102
FUSE, 0.5A, 208-240V, TIME DELAY FOR 1&3PH 5
026-G103
FUSE, .25A, 250V, TIME DELAY FOR 1PH,208-240V 5
026-G104
FUSE,0.75A, 250V, 10-130V,TIME DELAY FOR 1PH 5
026-G105
FUSE, 500mA, 700V, FAST ACTING FOR 3 PH,380-415V 5
026-G106
FUSE, 400mA, 700V, FAST ACTING FOR 3PH,440-480V 5
026-G107
FUSE,315mA, 700V, FAST ACTING FOR 3PH,575-600V 5
026-G107 FUSE,315mA, 700V, 5
TL85 VEHICLE RESTRAINT WITH BLUE GENIUS™ CONTROLS
17

Corporate 85 Heart Lake Road South
Brampton, ON, Canada L6W 3K2
t905.457.3900 f905.457.2313
USA 6350 Burnt Poplar Road
Greensboro, NC 27409
www.BlueGiant.com
If calling within North America: t1.800.668.7078 f1.888.378.5781 ©Copyright Blue Giant Equipment Corporation 2013