Blue Giant Blue Genius Series Installation & Owner's Manual
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Blue Giant Blue Genius Series Installation & Owner's Manual

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XDS3000 DOOR and DOCK GUARD with
TL85 VEHICLE RESTRAINT
and BLUE GENIUS
TM
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.
CONTROLS
INSTALLATION &
OWNER'S MANUAL
XDS3000 and Blue Genius
TM
. Issue Date: January 11, 2013. Rev.4 (Part#038-730E)
BLUE GENIUS
WARNING
SERIES
TM

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  • Page 1 XDS3000 DOOR and DOCK GUARD with TL85 VEHICLE RESTRAINT BLUE GENIUS SERIES and BLUE GENIUS CONTROLS 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.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS ABOUT THE XDS3000 EXTRA DOCK SAFETY SYSTEM..................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..................... XDS DOCK AND TL85A INSTALLATION........................
  • Page 3 TABLE OF CONTENTS XDS COMPLETE POWER PACK ASSEMBLY......................26 PICTORIAL COMPONENT PARTS DRAWING......................HYDRAULIC PARTS- DRAWING..........................TL85 PARTS ILLUSTRATION............................TL85A PARTS ILLUSTRATION............................ GENERAL PARTS ............................... 24.1 Molded Rubber Bumpers............................ 24.2 Face Plates for Molded Rubber Bumpers......................24.3 Laminated Bumpers............................24.4 Face Plates for Laminated Bumpers........................24.5 Flood Light................................

  • Page 4: About The Xds3000 Extra Dock Safety System

    Toe guards, a maintenance strut, and laminated bumpers provide extra safety to personnel and building during use. It includes the Blue Giant TL85 vehicle restraint, which applies 32,000lbs (14,545kgs) of restraining force behind its powerful mechanical locking device.

  • Page 5: Introduction

    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.

  • Page 6: Operator's Manual Safety Message Color Identification

    XDS3000 with Blue Genius™ Controls 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.

  • Page 7: Lockout / Tagout Procedure And Rules

    The machine or equipment power supply shall be locked in the OFF position or disconnected from the energy source. Blue Giant® strongly recommends that only OSHA-approved lockout devices be utilized. The energy isolating device must bear a prominent...

  • Page 8: Xds Dock And Tl85A Installation

    XDS3000 with Blue Genius™ Controls 5. XDS DOCK (pit mounted) and TL85A (wall mounted) COMBO INSTALLATION NEW CONSTRUCTION (COMBO DOCK C/W POWER PACK & RESTRAINT): RESTRAINTS 1. DRILL ONE HOLE THROUGH THE WALL TO THE OUTSIDE AND WIRE THE L.E.D REMOTE POWER MOTOR POWER FEED PACK...

  • Page 9: Xds Dock And Tl85 Installation

    XDS3000 with Blue Genius™ Controls XDS3000 with TL85 (self-contained) NEW CONSTRUCTION (COMBO DOCK & RESTRAINT): MINIMUM CONCRETE STRENGTH 3,000 P.S.I. 1. Run motor wiring from the control panel to the pit motor box for the dock and restraint. 2. Run the communication cable from the control panel through the pit DOCK to the restraint.

  • Page 10: Weld Installation Pictorial

    XDS3000 with Blue Genius™ Controls WELD INSTALLATION PICTORIAL WELD INSTALLATION PICTORIAL (Shim placement guidance only- dock depicted may not be same model covered in this manual) FORK LIFT TRUCK HANDLING SLING HANDLING STITCH WELD 1/4" 6” SHIM BOTH SIDES 5" X 5" - 127mm x 127 mm DOCK LEVELER BASE FRAME SHIM BOTH SIDES...

  • Page 11: Installation Instructions

    XDS3000 with Blue Genius™ Controls DOCK LEVELER INSTALLATION INSTRUCTIONS  Do not install, operate and/or service this leveler until you have read and understood all of the safety information and instructions contained herein and on the leveler. Do not work under or around leveler being installed without first placing adequate barriers to positively prevent vehicle traffic from entering the work area.

  • Page 12: Installation Inspection

    XDS3000 with Blue Genius™ Controls DOCK LEVELER INSTALLATION INSTRUCTIONS 10. Mount Blue Genius Control Station assembly in a suitable REAR FRAME location. Mount power unit in a suitable location if applicable (remote power pack). UPPER REAR PIT ANGLE 11. If power unit is mounted remote from pit (wall mounted) permanently attach hydraulic hoses.

  • Page 13: Vehicle Restraint Installation Instructions

    XDS3000 with Blue Genius™ Controls VEHICLE RESTRAINT INSTALLATION INSTRUCTIONS  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.

  • Page 14: Electrical And Hydraulic Installation

    XDS3000 with Blue Genius™ Controls ELECTRICAL AND HYDRAULIC INSTALLATION  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.

  • Page 15: Control Station Operation

    XDS3000 with Blue Genius™ Controls CONTROL STATION OPERATION COMBINATION TYPE CONTROL STATION - Controls XDS3000 RESTRAINT ‘ENGAGE’ YELLOW LIGHT (Raise Restraint Arm) (Proceed With Caution) RESTRAINT ‘RELEASE’ CARRIER VEHICLE Caution (Lower Restraint Arm) RELEASE DDG Manual Control (Manually raise or lower)

  • Page 16: Operating Instructions

    XDS3000 with Blue Genius™ Controls OPERATING INSTRUCTIONS  Do not operate this leveler unless you have been trained Dock Leveler and authorized to do so, and have read and understood Door and Dock Guard Truck / Vehicle all of the safety information and instructions contained herein and on the leveler.

  • Page 17: Operating Procedure (Method 1) Deploying The Xds Dock (Deck Button Only)

    XDS3000 with Blue Genius™ Controls OPERATING INSTRUCTIONS 2. The dock leveler, its lip deployed, will descend onto the MENU DISPLAY SCREEN: vehicle load bed. The outside traffic light remains RED and R e s t r a i n t E n g a g i n g R e s t r a i n t i s E n g a g e d the control station light stays GREEN.

  • Page 18: Operating Procedure: Returning Dock To Stored Position

    XDS3000 with Blue Genius™ Controls OPERATING INSTRUCTIONS NOTE: Ensure that the full width of the lip overlaps the truck Optional Alarm load bed by a minimum of 4” (102mm) to provide full dock ALARM WILL BEEP WHEN THE leveler support. DDG IS DEPLOYED Ent er Do No t...

  • Page 19: Deploying The Dock Leveler: Returning To Normal Lip-On-Load Bed Operation

    XDS3000 with Blue Genius™ Controls OPERATING INSTRUCTIONS This section outlines dock leveler operation in situations where 4. Perform below level / end loading or unloading operation. the lip plate cannot make contact with the transport vehicle load bed. (e.g. Loading / unloading the first skid or pallet from the load bed when there is insufficient surface area to extend the Ente r Do Not...

  • Page 20: Ddg And Overheard Door Sensor

    XDS3000 with Blue Genius™ Controls OPERATING INSTRUCTIONS 11.9 DDG & Overhead Door Sensor (optional) 11.10 Vehicle Restraint Override Feature The DDG in conjunction with the overhead door sensor offers 1. If the truck has no ICC bar, enter the override code *247 on an extra degree of safety during loading and unloading the control station keypad.

  • Page 21: Emergency Vehicle Restraint Lowering Procedure

    XDS3000 with Blue Genius™ Controls EMERGENCY VEHICLE RESTRAINT LOWERING PROCEDURE 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 Releasing pressure will cause the restraint arm to spring stored position.

  • Page 22: Maintenance

    XDS3000 with Blue Genius™ Controls MAINTENANCE   The Maintenance strut must be in place before commencing Do not operate and/or service this dock leveler until you have read maintenance procedures. and understood all of the safety information and instructions contained herein and on the dock leveler.

  • Page 23: Pm Checklist- Dock Equipment

    XDS3000 with Blue Genius™ Controls 13.7 PM CHECK LIST - DOCK EQUIPMENT P M C H E C K L I S T – DOCK EQUIPMENT Customer S W O # Location Cust. Contact Date Inspected By Barricade Work Area C L E A N C H E C K / A D J U S T / L U B E Repairs?

  • Page 24: Pm Checklist- Vehicle Restraint

    XDS3000 with Blue Genius™ Controls 13.8 PM CHECK LIST - VEHICLE RESTRAINT 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.

  • Page 25: Hydraulic Cylinders

    XDS3000 with Blue Genius™ Controls HYDRAULIC CYLINDERS 14.1 Hydraulic Deck Lifting Cylinder ITEM PART NUMBER GENERAL DESCRIPTION --------------- ------------- 788-635-1 Deck Lifting Cylinder – (6’ & 8’ Long Docks) --------------- ------------- 788-636-1 Deck Lifting Cylinder – (10’ & 12’ Long Docks) --------------- ------------- 036-205...

  • Page 26: Leveler Hydraulic Hoses

    XDS3000 with Blue Genius™ Controls LEVELER HYDRAULIC HOSES 16.1 Deck Lifting Cylinder - Hose All Capacity ITEM PART NUMBER GENERAL DESCRIPTION 788-621 6’ and 8’ Models (Nominal Deck & Lip Length) 788-331 10’ & 12’ Models (Nominal Deck & Lip Length) 16.2 Lip Extension Cylinder - Hose All Capacity ITEM...

  • Page 27: Side Safety Skirts

    XDS3000 with Blue Genius™ Controls SIDE SAFETY SKIRTS Side Safety Skirts ITEM QTY PART NO. DESCRIPTION ITEM QTY PART NO. DESCRIPTION ------- ------- 202-5024 Safety Skirt Package - 6’ & 8’ Long 012-252 Washer,Flat -3/8”ID BS Washer ------- ------- 202-5024-1 Safety Skirt Package - 10’...

  • Page 28: Xds Flap Actuator- Parts

    XDS3000 with Blue Genius™ Controls XDS FLAP ACTUATOR - PARTS ITEM QTY PART NO. DESCRIPTION ITEM QTY PART NO. DESCRIPTION 200-01021 Safety Lip Actuator Bar Weldment 200-01042 Support Roller Pin 119-748 Push Roller 034-511 Adapter 90o 017-062 Spring 011-508 Hex Nuts 018-001 Bushing 012-220...

  • Page 29: Xds Complete Power Pack Assembly

    XDS3000 with Blue Genius™ Controls XDS STANDALONE POWER PACK ASSEMBLY PORT "LIP" PORT "DECK" MONARCH BLUE GIANT MODEL NO. PART NO. SERIAL NO. BLUEGIANT.COM 19 1/16" 3/4 NPT CONDUIT CONNECTION PORT "DDG" 9 3/4" RELIEF VALVES VIEW SHOWN WITHOUT RESERVOIR & BRACKET 3 11/32"...

  • Page 30: Pictorial Component Parts Drawing

    XDS3000 with Blue Genius™ Controls PICTORIAL COMPONENT PARTS DRAWING WAND PROXIMITY SENSOR LOWER PROXIMITY SENSOR 45 DEGREE PROXIMITY SENSOR HYDRAULIC PARTS- DRAWING ITEM PART NO. DESCRIPTION ------------- 035-662 Cylinder Assembly – Complete ------------- 090-909-2400 Polyethylene Tub ------------- 780-613 Hose Assembly...

  • Page 31: Tl85 Parts Illustration

    XDS3000 with Blue Genius™ Controls TL85 PARTS ILLUSTRATION DETAIL A SCALE 1 : 4 28 1/8" Item No. Qty. Description Part No. Item No. Qty. Description Part No. Body Weldment 51-001977 Extension Spring 0.5” d x 0.034” thick x 1.25” long 017-085 Spring Wire 1 5/8”...

  • Page 32: Tl85A Parts Illustration

    XDS3000 with Blue Genius™ Controls 5.3 ELECTRICAL AND HYDRAULIC INSTALLTION TL85A PARTS ILLUSTRATION 4. If the Vehicle Restraint is being installed in combination with WARNING a hydraulic dock leveler, perform the necessary dock leveler electrical and hydraulic hook-ups as required. See wiring dia- All Electrical work to be performed by a Qualified gram located inside the control station and layout information Electrician.

  • Page 33: General Parts

    XDS3000 with Blue Genius™ Controls GENERAL PARTS MOLDED RUBBER BUMPERS 24.1 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" 24.2 FACE PLATES FOR MOLDED RUBBER BUMPERS PART ID...

  • Page 34: Vehicle Restraint Troubleshooting

    XDS3000 with Blue Genius™ Controls 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 PROBLEM CAUSE The restraint arm will not 1.

  • Page 35: Dock Leveler Troubleshooting

    XDS3000 with Blue Genius™ Controls DOCK LEVELER 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 PROBLEM CAUSE DDG does not lower when 1.
  • Page 36 XDS3000 with Blue Genius™ Controls DOCK LEVELER 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 PROBLEM CAUSE 1.
  • Page 37 XDS3000 with Blue Genius™ Controls DOCK LEVELER 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 PROBLEM CAUSE 1.
  • Page 38 XDS3000 with Blue Genius™ Controls NOTES...
  • Page 39 XDS3000 with Blue Genius™ Controls NOTES...
  • Page 40 Corporate 85 Heart Lake Road South USA 6350 Burnt Poplar Road Brampton, ON, Canada L6W 3K2 Greensboro, NC 27409 t 905.457.3900 f 905.457.2313 www.BlueGiant.com If calling within North America: t 1.800.668.7078 f 1.888.378.5781 © Copyright Blue Giant Equipment Corporation 2013...

This manual is also suitable for:

Xds3000 doorDock guardTl85 vehicle restraintBlue genius control

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