Blue Giant BLUE GENIUS SERIES Istruzioni operative

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.

INSTALLATION &

OWNER’S MANUAL

XDS3000 DOOR and DOCK GUARD with

TL85 VEHICLE RESTRAINT

and BLUE GENIUSTM CONTROLS BLUE GENIUSTM SERIES

XDS3000 and Blue GeniusTM. Issue Date: January 11, 2013. Rev.4 (Part#038-730E)

TABLE OF CONTENTS

1. ABOUT THE XDS3000 EXTRA DOCK SAFETY SYSTEM......................................................................................... 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. XDS DOCK AND TL85A INSTALLATION.................................................................................................................... 5

5. XDS DOCK AND TL85 INSTALLATION....................................................................................................................... 6

6. WELD INSTALLATION PICTORIAL............................................................................................................................. 7

7. INSTALLATION INSTRUCTIONS................................................................................................................................ 8

7.1 Installation Inspection............................................................................................................................................. 9

8. VEHICLE RESTRAINT INSTALLATION INSTRUCTIONS.......................................................................................... 10

9. ELECTRICAL AND HYDRAULIC INSTALLATION...................................................................................................... 11

9.1 TL85A and XDS .................................................................................................................................................... 11

9.2 TL85 and XDS ..................................................................................................................................................... 11

9.3 Final Inspection..................................................................................................................................................... 11

10. CONTROL STATION OPERATION.............................................................................................................................. 12

11. OPERATING INSTRUCTIONS..................................................................................................................................... 13

11.1 Functional Description......................................................................................................................................... 13

11.2 Stop Button Function........................................................................................................................................... 13

11.3 Deploying the Vehicle Restraint........................................................................................................................... 13

11.4 Operating Procedure (Method 1): Deploying the XDS Dock (Deck Button Only)................................................. 14

11.5 Operating Procedure (Method 2): Deploying the XDS Dock (Deck and Lip Buttons)......................................... 14

11.6 Operating Procedure: Returning Dock to Stored Position................................................................................... 15

11.7 Undeploying the Restraint Arm........................................................................................................................... 15

11.8 DDG- For End Loading / Unloading..................................................................................................................... 15

11.8.1 Lowered / Deactivated Position (Manually)...................................................................................................... 15

11.8.2 Deploying the Dock Leveler: Returning to Normal Lip-on-Load Bed Operation................................................ 16

11.8.3 DDG Bypass Mode.......................................................................................................................................... 16

11.9 DDG and Overheard Door Sensor...................................................................................................................... 17

11.10 Vehicle Restraint Override Feature.................................................................................................................... 17

12. EMERGENCY VEHICLE RESTRAINT LOWERING PROCEDURE............................................................................. 18

13. MAINTENANCE............................................................................................................................................................ 19

13.1 Planned Maintenance.......................................................................................................................................... 19

13.2 Operator Daily Inspection..................................................................................................................................... 19

13.3 Routine Servicing and Maintenance.................................................................................................................... 19

13.4 Planned Maintenance Intervals............................................................................................................................ 19

13.5 Maintenance Sequence........................................................................................................................................ 19

13.6 Recommended Hydraulic Fluids........................................................................................................................... 19

13.7 PM Checklist- Dock Equipment............................................................................................................................ 20

13.8 PM Checklist- Vehicle Restraint............................................................................................................................ 21

14. HYDRAULIC CYLINDERS............................................................................................................................................ 22

14.1 Hydraulic Deck Lifting Cylinder............................................................................................................................ 22

14.2 Hydraulic Lip Extension Cylinder......................................................................................................................... 22

15. VELOCITY FUSE- FALL SAFE.................................................................................................................................... 22

16. LEVELER HYDRAULIC HOSES.................................................................................................................................. 23

16.1 Deck Lifting Cylinder- Hose All Capacity............................................................................................................. 23

16.2 Lip Extension Cylinder-Hose All Capacity............................................................................................................ 23

17. SIDE SAFETY SKIRTS................................................................................................................................................. 24

18. XDS FLAP ACTUATOR- PARTS.................................................................................................................................. 25

24.2 Face Plates for Molded Rubber Bumpers........................................................................................................... 30

24.3 Laminated Bumpers............................................................................................................................................ 30

TABLE OF CONTENTS

19. XDS COMPLETE POWER PACK ASSEMBLY............................................................................................................. 26

20. PICTORIAL COMPONENT PARTS DRAWING............................................................................................................ 27

21. HYDRAULIC PARTS- DRAWING................................................................................................................................. 27

22. TL85 PARTS ILLUSTRATION...................................................................................................................................... 28

23. TL85A PARTS ILLUSTRATION.................................................................................................................................... 29

24. GENERAL PARTS ....................................................................................................................................................... 30

24.1 Molded Rubber Bumpers.................................................................................................................................... 30

24.2 Face Plates for Molded Rubber Bumpers........................................................................................................... 30

24.3 Laminated Bumpers............................................................................................................................................ 30

24.4 Face Plates for Laminated Bumpers................................................................................................................... 30

24.5 Flood Light.......................................................................................................................................................... 30

25. VEHICLE RESTRAINT TROUBLESHOOTING............................................................................................................ 31

26. DOCK LEVELER TROUBLESHOOTING..................................................................................................................... 32

1. ABOUT THE XDS3000 EXTRA DOCK SAFETY SYSTEM

Dealer:

Date in Service:

Number of Units:

Serial Number(s):

Door # :

OWNER’S PURCHASE RECORD

Please record information for future inquiries

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.

The Blue Giant XDS3000 Extra Dock Safety System features our heavy-duty I-beam dock leveler with built-in door

and dock guard (DDG). A 4” (102 mm) maintained deck tilt prolongs deck life and prevents forklift damage. The raised

guard is designed to prevent forklift roll-off and protect overhead doors from impact damage.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. It safeguards against unscheduled departures, trailer creep and trailer walk, therefore increasing safety level at

the docks.

The Blue Genius™ Touch Control Panel with advanced smart performance technology controls the operation of both the

dock leveler and vehicle restraint, and alerts both the driver and dock attendants of safe/unsafe conditions. Its onboard

diagnostics and communications feature a user-friendly, LCD intelligent text display and keypad with supervisory

override.

1. 1 OWNER’S PURCHASE RECORD

XDS3000 with Blue Genius™ Controls

Loading Dock Equipment Manufacturers

A Product Section of Material Handling Industry of America,

A Division of Material Handling Industry

8720 Red Oak Blvd., Suite 201, Charlotte, NC, 28217-3992

Telephone: (704) 676-1190 Fax: (704) 676-1199

ALSO MEMBERS OF :

American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

(212) 642-4900

LOADING DOCK EQUIPMENT MANUFACTURERS

2. INTRODUCTION

The following is a quick reference to important procedures that must be followed while using the XDS3000 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 XDS3000 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 XDS3000 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 XDS3000 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 1-905-457-3900.

* Note that failure to validate warranty at the time of receipt can seriously affect the outcome of any claim.

2.1 WARRANTY INFORMATION

XDS3000 with Blue Genius™ Controls

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 leveler with anyone standing in its path of operation.

• DO NOT service leveler unless Maintenance Stand is properly engaged.

• BEFORE BEGINNING ANY SERVICE PROCEDURES:

– Position the dock leveler in the vertically stored position.

– Disconnect the power and follow all LOCKOUT / TAGOUT procedures.

• DO NOT operate leveler without filling the cylinder if the leveler has not been in service for an extended period of time.

• Procedure for filling cylinder:

– Press and hold the ‘Deck’ button (Run Pump). Operate for (35) seconds.

• Keep away from hinge when operating leveler.

• Post safety warnings and barricade working area at dock level and

at ground level to prevent unauthorized use of the leveler 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.

• NEVER attempt to lift or hold the lip out by hand. Serious personal

injury could occur.

• DO NOT remove lifting equipment until:

a) The main cylinder has been filled.

b) The Maintenance Stand has been installed and engaged.

• 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 attach welder as ground to leveler platform when welding on

base frame assembly. Attach welder ground to base frame

assembly only. Otherwise damage to bearings or hydraulic

equipment will occur.

• 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 leveler until freight carrier is parked against the dock bumpers and has been secured.

• ALWAYS return the leveler platform to the proper stored position.

• ALWAYS conduct routine inspections and maintenance. Failure to conduct could cause personal injury or damage to equipment.

XDS3000 with Blue Genius™ Controls

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

devices 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.

!

XDS3000 with Blue Genius™ Controls

4”

20”

14”

UNDER DOCK

HYDRAULIC VEHICLE RESTRAINT

CONCRETE PAD

RESTRAINTS

REMOTE POWER

PACK

NOTE: DOCK FACE & DRIVEWAY TO BE CONSTRUCTED OF

CONCRETE AND IN GOOD CONDITION, CONSULT

MANUFACTURE 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

RUN ONE 1-1/2” I.D. CONDUIT

FOR THE 1 HOSE

COMMUNICATION CABLE FROM

THE REMOTE POWER PACK &

NETWORK JUNCTION BOX TO

THE RESTRAINT AS SHOWN.

8”

TL85 POWER PACK

CAUTION

MOV E O N

GREEN ONLY

CAUTION

MOV E O N

GREEN ONLY

123

456

789

#0*

EnterOn Green

ProceedWithCaution

DoNot Enter

Release

Engage

SEL

ESC

1 2 3

789

Restraint

Disconnectpower

CAUTION

beforeopeningpan el

66”

ELECTRICAL REQUIREMENTS:

• MOUNT CONTROL BOX STATION TO WALL, SIGNAL LIGHTS AND DRIVER WARNING SIGNS

• FUSED DISCONNECT PROVIDED BY OTHERS AND WIRING BY OTHERS

• INSTALL CABLE FROM CONTROL BOX STATION TO POWER PACK (BY OTHERS)

• INSTALL CABLE FROM CONTROL BOX STATION TO POWER SUPPLY (BY OTHERS)

GROUND LEVEL

1-1/2” DIA. CONDUIT FOR 1

HOSE COMMUNICATION

CABLE

HYDRAULIC VEHICLE RESTRAINT

CAST-IN-PLACE MOUNTING

PLATE (OPTIONAL)

CONTROL STATION

(MOUNTED ON

DRIVERS SIDE)

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)

POWER CABLE

(Dock Leveler)

TL85 HYDRAULIC HOSES &

COMMUNICATION CABLE

(to the outside)

8”

12”

84”

IF INSTALLING A COMBO DOCK /

RESTRAINT. RUN TWO 1/2”

CONDUITS. ONE FOR THE

COMMUNICATION CABLE AND

ONE FOR THE POWER WIRING TO

THE POWER PACK.

NEW CONSTRUCTION (COMBO DOCK C/W POWER PACK & RESTRAINT):

CONDUIT MADE OF RIGID PLASTIC 80 P.S.I. 8” MIN.BEND RADIUS.

MINIMUM CONCRETE STRENGTH 3,000 P.S.I.

HYDRAULIC HOSE LINES

POWER WIRING

CABLES

COMMUNICATION CABLES

DO NOT RUN MAIN POWER

WIRING THROUGH TOP OF

CONTROL STATION

NOTE: ALL CONDUIT

ENTRY INTO CONTROL

PANELFROM BOTTOM.

ARRANGE WIRING TOAVOID

HIGH & LOW VOLTAGE

CROSSING OVER INSIDE

CONTROL BOX.

TRAFFIC LIGHTS

(MOUNTED DRIVERS SIDE)

PART #032-461

DRIVER WARNING SIGN

(MOUNTED DRIVERS SIDE)

PART #038-225

5. XDS DOCK (pit mounted) and TL85A (wall mounted) COMBO INSTALLATION

STOP

Deck

Leveler

LIP PROXIMITY SENSOR

!!

DO NOT WIRE HIGH AND LOW VOLTAGES IN THE SAME CONDUIT. High

voltage range is 115V and up. Lower voltages include the communication and

solenoid wiring as well as the I/O.

REMOTE

I/O BOX

DOCK

HYDRAULICS

LIP PROXIMITY SENSOR

COMMUNICATION

CABLE

(to control box)

TO DDG SENSOR

DOCK MOTOR

JUNCTION BOX

TO CONTROL BOX

NOTE: *FRONT VI EW SHOWS THE TL85A VEHICLE RESTRAINT IN ITS ENGAGED/RAISED POSITION. *DRAWINGS NOT TO SCALE

FRONT ELEVATION VIEW*INSIDE BUILDING VIEW*

RESTRAINT MOTOR JUNCTION BOX

RESTRAINT

J-BOX

DOCK CABLE

(To Remote

I/O BOX )

COMMUNICATION

CABLE

(to the pit)

1. DRILL ONE HOLE THROUGH THE WALLTO THE OUTSIDE AND WIRE THE L.E.D

TRAFFIC LIGHTS.

2. INSTALL ONE 1/2” I.D. CONDUIT FROM THE CONTROL BOX TO THE REMOTE I/O

FOR THE DOCK’S COMMUNICATION CABLE.

3. INSTALL ONE 1/2” I.D. CONDUIT FROM THE CONTROLBOX TO THE DOCK’S POWER

PACK FOR MOTOR WIRING.

4. INSTALL 1-1/2“ I.D. CONDUIT FROM THE RESTRAINT POWER PACK TO THE DOCK FACE

FOR THE RESTRAINT’S HYDRAULIC HOSE.

5. INSTALL 1/2” CONDUIT FROM THE PIT TO DOCK FACE FOR THE CONTROL CABLE.

XDS3000 with Blue Genius™ Controls

6. XDS3000 with TL85 (self-contained)

HYDRAULIC

VEHICLE

RESTRAINT

LIP

PROXIMITY

SENSOR

NOTE: FUSED DISCONNECT

BY OTHERS

BLUE GENIUS

CONTROL BOX

(MOUNTED & WIRED

BY OTHERS)

TRAFFIC LIGHTS

(MOUNTED & WIRED

BY OTHERS)

66"

MAIN POWER

(to control station)

MOTOR WIRING FOR

DOCK

CAUTION

MOVE ON

GREEN ONLY

CAUTION

MOVE ON

GREEN ONLY

ELECTRICAL REQUIREMENTS-

• MOUNT CONTROL BOX STATION TO WALL, SIGNAL LIGHTS AND DRIVER WARNING SIGNS

• FUSED DISCONNECT PROVIDED BY OTHERS AND WIRING BY OTHERS

• INSTALL CABLE FROM CONTROL BOX STATION TO POWER PACK (BY OTHERS)

• INSTALL CABLE FROM CONTROL BOX STATION TO POWER SUPPLY (BY OTHERS)

GROUND LEVEL

1/2" DIA. CONDUIT FOR

COMMUNICATION CABLE

HYDRAULIC VEHICLE RESTRAINT

CAST-IN-PLACE

MOUNTING

PLATE (OPTIONAL)

TRAFFIC LIGHTS

(MOUNTED DRIVERS SIDE)

PART #032-461

DRIVER WARNING SIGN

(MOUNTED DRIVERS

SIDE ABOVE LIGHT)

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).

12"

15"

84"

MINIMUM CONCRETE STRENGTH 3,000 P.S.I.

POWER WIRING

COMMUNICATION CABLES

HYDRAULIC HOSE LINES

CABLE

20"

12"

14"

NOTE: WHEN INSTALLING

THE CONDUIT FOR THE HOSE

LINES AND WIRES TO CONSIDER THE

BENDING RADIUS OF THE CONDUITS. TOO

MUCH OF A BEND WILL MAKE IT DIFFICULT OR

IMPOSSIBLE TO RUN THE HOSES THROUGH AND

POSSIBLY DAMAGE THE CONDUIT ITSELF.

UNDER DOCK

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

to the restraint. DO NOT run it through the same conduit as the motor

wiring.

3. Run motor wiring from the pit motor box to the restraint.

4. Run control cable from the restraint to the pit junction box.

5. After hole has been drilled in appropriate location on the wall, wire the

LED traffic lights.

NEW CONSTRUCTION (COMBO DOCK & RESTRAINT):

CONTROL STATION

(MOUNTED ON

DRIVERS SIDE)

DO NOT RUN MAIN POWER WIRING THROUGH TOP OR OR SIDE

OF CONTROL STATION

NOTE: ALL CONDUIT

ENTRY INTO CONTROL

PANELFROM BOTTOM.

ARRANGE WIRING TO

AVOID HIGH & LOW

VOLTAGE CROSSING

OVER INSIDE CONTROL

BOX.

MAIN POWER

FEED CABLE

(from fused

disconnect)

TRAFFIC LIGHT

CABLE

(to the outside)

RESTRAINTS

MOTOR WIRING

(to the outside)

COMMUNICATION

CABLE

(to the outside)



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.

SEL

ESC

estraint

123

456

789

#0*

EnterOn Green

ProceedWithCaution

DoNot Enter

Release

Engage

1 2 3

789

Disconnectpower

CAUTION

beforeopeningpan el

STOP

FRONT ELEVATION VIEW*INSIDE BUILDING VIEW*

NOTE: *FRONT VIEW SHOWS THE VEHICLE RESTRAINT IN ITS ENGAGED/RAISED POSITION. *DRAWINGS NOT TO SCALE

MOTOR WIRING FOR

RESTRAINT

OVERHEAD DOOR

INTERLOCK

(OPTIONAL)

MOTOR WIRING

TO I/O BOX

MOTOR WIRING MUST HAVE ITS

OWN CONDUIT SEPARATE FROM

THE COMMUNICATION CABLE

MOTOR

WIRING

REMOTE

I/O BOX

REMOTE

I/O BOX

DOCK

HYDRAULICS

LIP PROXIMITY

SENSOR

TO DDG

SENSOR

DOCK

MOTOR

J-BOX

TO CONTROL

BOX

COMMUNICATION

CABLE

(to control box)

TO VEHICLE RESTRAINT

JUNCTION BOX

(atypical)

66"

(atypical)

84"

XDS3000 with Blue Genius™ Controls

DOCK LEVELER

BASE FRAME

SHIM LIFT ARM

BASE BRACKET

5" X 5" - 127mm x 127 mm

STITCH WELD

1/4"6”

SHIM BOTH SIDES

5" X5" - 127mm x 127 mm

SHIM BOTH SIDES

5" X5" - 127mm x 127 mm

SHIM 4" x 4"

(102mm x 102mm)

FORK LIFT TRUCK HANDLING SLING HANDLING

HYDRAULIC

6. WELD INSTALLATION PICTORIAL

WELD INSTALLATION PICTORIAL

(Shim placement guidance only- dock depicted may not be same model covered in this manual)

XDS3000 with Blue Genius™ Controls

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