411-254-0EI Hydraulic EdgeofDock InstallationOwnersManual

INSTALLATION & OWNERS MANUAL
HYDRAULIC EDGE-OF-DOCK LEVELER

WITH CONTROLS
ACTUAL PRODUCT MAY NOT APPEAR EXACTLY AS SHOWN
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.
ISSUE DATE: APRIL 10, 2015 REV.0 (PART # 411-254-0EI)
HYDRAULIC EDGE-OF-DOCK LEVELERINSTALLATION & OWNER'S MANUAL

TABLE OF CONTENTS
1.0
ABOUT THE MD-CH SERIES HYDRAULIC EDGE-OF-DOCK LEVELER 3
1.1
2.0
OWNERS PURCHASE RECORD
INTRODUCTION 4
2.1
WARRANTY INFORMATION
2.2
EXCLUSION OF LIABILITY
2.3
MANUFACTURERS NOTE
2.4
OWNERS RESPONSIBILITY
2.5
INSTALLERS GUIDELINES
3.0
SAFETY MESSAGE COLOR IDENTIFICATION 6
3.1
OPERATIONAL SAFETY WARNINGS
4.0
LOCKOUT / TAGOUT PROCEDURE AND RULES 7
5.0
INSTALLATION WITH PIT TYPE DOCK LEVELERS 8
5.1
INSTALLATION INSTRUCTIONS
5.2
SELF-CONTAINED POWERPACK (PER MOUNTED)
11
5.3
REMOTE POWERPACK INSTALLATION
11
5.4
INSTALLATION INSPECTION
11
5.5
INSTALLATION MOUNTING INSTRUCTIONS
11
5.5.1
8" POUR IN CHANNEL
11
5.5.2
ONE PIECE ANGLE PLATE
12
5.5.3
TWO PIECE ANGLE PLATE
12
5.5.4
OPTIONAL APPROACH RAMP
12
6.0
OPERATING INSTRUCTIONS - MD-CH SERIES EDGE-OF-DOCK LEVELER 13
6.1
FUNCTIONAL DESCRIPTION
13
6.2
PRIOR TO USE: EQUIPMENT IN HOME POSITION
14
6.3
TRAILER AT BAY
14
6.4
ENGAGING DOCK LEVELER
14
6.5
RAISING DOCK LEVELER
15
6.6
EXTENDING DOCK LEVELER
15
6.7
LIP ON LOAD BED
15
6.8
STORING DOCK LEVELER
16
6.9
DISENGAGING VEHICLE RESTRAINT / REMOVING WHEEL CHOCKS
16
7.0
PLANNED MAINTENANCE
17
7.1
ROUTINE SERVICING AND MAINTENANCE
17
7.2
AUTHORIZE USAGE
17
7.3
MAINTENANCE SEQUENCE
17
8.0
COMPONENT IDENTIFICATION
18
9.0
RECOMMENDED SPARE PARTS 19
10.0 CONTROLS 20
11.0 MD-CH SERIES HYDRAULIC EDGE-OF-DOCK LEVELER TROUBLESHOOTING 21
12.0 WIRING DIAGRAM 22

ISSUE DATE: APRIL 10, 2015 REV.0 (PART # 411-254-0)

1.0 ABOUT THE MD-CH SERIES HYDRAULIC EDGE-OF-DOCK LEVELER
The MD-CH Series Hydraulic Edge-of-Dock (EOD) Leveler from Blue Giant is ideally suited for applications where installation of pit
levelers is not feasible or where standard fleet bed heights are serviced at the loading dock. The MD-CH Series is easily installed to the
dock face providing an efficient self storing docking unit, with ease of use at the touch of a button.
1.1 OWNERS PURCHASE RECORD

OWNERS PURCHASE RECORD
Please record information for future inquiries and to validate warranty. (See Section 2.1 for warranty validation)
Dealer:
Date in Service:
Number of Units:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
Serial Number:
Door #:
The manufacturer offers a full line of dock levelers, dock safety equipment, accessories, ergonomic and scissor lift equipment, seals and
shelters, and industrial trucks. Concurrent with a continuing product improvement program, specifications are subject to change without
notice (see Section 2.2 Exclusion of Liability of this manual). Please contact the manufacturer for latest information. Some features
illustrated may be optional in certain market areas.

2.0 INTRODUCTION
2.1 WARRANTY INFORMATION
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:
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.
The Occupational Safety and Health Act

Canada Occupational Health and Safety Regulations
Occupational Safety and Health Acts for Individual States
(USA)
For additional information on these regulations as well as industry
standards that may apply to this product, please contact:
To validate warranty on recently purchased equipment,

please complete and submit your information with our
online Warranty Registration at www.BlueGiant.com.
For more information about Blue Giant 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.
DEALER INFORMATION
Name:
Contact:
American National Standards Institute (ANSI)

1430 Broadway
New York, NY 10018
Telephone: 212.642.4900
www.ansi.org
Telephone:
* NOTE that failure to validate warranty at the time of receipt can
seriously affect the outcome of any claim.
Also a member of:
2.2 EXCLUSION OF LIABILITY
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
www.mhi.org/lodem
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 the 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 improvements and development program.
Specifications, operating instructions, and illustrations included in
this manual are subject to change without notice. Please contact
manufacturer for the latest information.
2.3 MANUFACTURERS NOTE

The Vehicle Restraint has been carefully inspected and tested at
the manufacturers plant prior to shipment, but should be checked
upon receipt for transport damage. Any observed transport
damage is to be listed on the signed copy of the freight document.
Notify the freight forwarder of any damage WITHIN 48 HOURS.
4

2.4 OWNERS RESPONSIBILITY
1. The owner should recognize the inherent danger of the
interface between the dock and the freight carrier. The owner
should, therefore, train and instruct operators in the safe use
of the dock equipment and accessories in accordance with the
manufacturers recommendations.
8. Modifications or alterations of dock equipment shall be made

only with written permission of the original manufacturer. These
changes shall also satisfy all safety recommendations of the
original equipment manufacturer for the particular application
of the dock equipment.
2. The owner should thoroughly familiarize themselves with

the following procedures and specifications, and request
immediate replacement of all manufacturer-supplied
documents that are missing, damaged, or otherwise illegible.
9. The owner or a trained and authorized representative shall

verify that all freight carrier brakes have been applied and a
vehicle restraint and/or wheel chocks properly engaged before
cross-docking procedures such as loading and unloading
begin.
Installation instructions
Operating instructions
Planned maintenance procedures
Inspections procedures
Replacement parts lists

Upon receipt of any newly purchased dock equipment, the

owner shall verify the presence of owners manuals, operating
placards, and any other documentation necessary for
training dock personnel how to use the equipment safely and
effectively.
3. Nameplates, cautions, instructions, and posted warnings shall

not be obscured from the view of operating or maintenance
personnel for whom such warnings are intended.
4. Manufacturers recommended periodic maintenance and
inspection procedures shall be followed, and written records
of the performance of these procedures should be kept as per
warranty guidelines.
5. Dock equipment that is structurally damaged, experiencing
performance irregularities, or has been potentially
compromised (i.e. sudden loss of support due to premature
truck departure) shall be removed from service until a trained
and authorized manufacturers representative can conduct an
inspection and perform any necessary repairs.
6. As with any piece of machinery, dock equipment requires
routine maintenance, lubrication, and adjustments. Your
local Blue Giant representative offers owners the option
of a Planned Maintenance Program (P.M.P.). As part of this
service, your local Blue Giant representative will do all routine
maintenance, lubrication, and adjustments.
7. The owner shall ensure that all nameplates, caution/instruction
markings or labels are in place and legible, and that the
appropriate operating/maintenance manuals are provided
to authorized users. Replacement name plates, caution/
instruction labels, and manuals containing operating and
maintenance instructions are available through the Blue Giant
Aftermarket Department.
10. Unless specifically agreed to in writing by Blue Giant Equipment

Corporation at the time of order (and prior to manufacture), all
Blue Giant Dock equipment is sold as a complete offering, and
must not be altered or added to in any manner (which includes
configuration and function) without written permission from an
authorized manufacturers representative.
11. If, at the request of the owner, Blue Giant does not supply
all or some of the dock equipment power unit and/or control
station components, the owner shall assume responsibility for
any and all operational and safety issues associated with the
resulting configuration.
2.5 INSTALLERS GUIDELINES

Please read all instructions carefully before installing this
Blue Giant dock product. It is the installers responsibility to
comply with the following:
The installation of Blue Giant dock products should comply
with all applicable local or national building codes and regulations, including any that may supersede this manual.
Site surveys and other applicable install-related documentation must be properly and accurately completed prior to installation. Failure to comply with this requirement may result
in an improper install and possible voiding of the warranty.
Only Blue Giant-supplied or approved parts must be used.
Any unauthorized parts substitution may void the warranty.
Always lockout and tagout any power source before performing
any electrical work, in accordance with OSHA regulations and
approved electrical codes. The installer is responsible for reading,
understanding, and complying with all personal protective
equipment (PPE) policies in effect.

3.0 OPERATORS 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.
DANGER
Serious injury or death will likely occur if the
instructions are not followed.
WARNING
Serious injury or death may occur if the instructions
are not followed.
NOTICE
Procedures marked important must be followed in
order to prevent damage to machinery.
CAUTION
Instructions marked caution concern safe operating
procedure. Failure to comply may result in personal injury.
3.1 OPERATIONAL SAFETY WARNINGS

DANGER
1. Do not enter the pit area below the dock leveler.
2. BEFORE BEGINNING ANY SERVICE PROCEDURES:
Disconnect the power and follow all lockout / tagout
procedures.
3. Never operate a broken or damaged dock leveler. Have repairs
done immediately by a qualified service technician.
4. Always secure and center loads on the forklifts. Loose or
unbalanced loads are dangerous.
WARNING
1. The upper hinge point is a hazardous pinch point. Do not use
fingers or hands to remove foreign materials.
2. Post safety warnings and barricade working area at dock level
and at ground level to prevent unauthorized use of the leveler
during maintenance/service.
3. Never leave the dock leveler unattended in the raised position.
4. Always make sure that the lip is seated inside the night lock after
putting the dock in the parked position.
5. Never leave loads sitting on the dock leveler.
6. Do not attempt to raise the dock leveler if someone is standing on
it.
7. Do not use the dock leveler if the lips full width is not fully
supported by the vehicle load bed.
8. Do not operate the dock leveler beyond its rated capacity.
9. Do not drive or walk onto the truck until it is parked against
the dock bumpers and the wheels are chocked, or the vehicle
restraint has been fully engaged.
10. Never attempt to lift or hold the lip out by hand. Serious personal
injury could occur.
11. Never remove the wheel chocks until loading/ unloading is
finished and the truck driver has been given permission to depart.
NOTICE
1. Do not ground welding equipment to any electrical components.
2. Do not attach welder as ground to leveler platform when welding
on base frame assembly. Attach welder ground to base frame
assembly only.
3. Do not allow the drill to go too deeply when drilling holes in the
control box. Damage to the control systems may occur.
4. Never use air to blow debris from control box. Use a vacuum to
remove debris from control box.
5. Do not connect green ground lead into control box until all
welding has been completed.
6. Always keep the work area clean and free of litter.
7. Always clean all side openings of dirt and debris.
8. Always clean all dirt and debris from the lip hinge.
9. Always clean up dry and liquid spills immediately after they occur.
10. Always maintain proper lighting in the work area.
11. If a procedure is not clearly defined in this manual, contact your
authorized Service Representative.
CAUTION
1. Only trained personnel should operate or service this equipment.
2. Do not operate the dock equipment until the transport vehicle is
parked against the dock bumpers.
3. Always park the dock equipment after use.
4. Conduct routine inspections and maintenance. Failure to do so
could cause equipment damage and or personal injury.
5. Always call your authorized service representative or
manufacturer immediately if a malfunction occurs.

4.0 LOCKOUT / TAGOUT PROCEDURE AND RULES
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 and procedures be utilized.
WARNING
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.
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.
D
OP O N
ER OT
AT
E
XX
XX XXX
XX XX
XX XX
XX XX
XX X
X
Approved way to lockout / tagout.

5.0 INSTALLATION WITH PIT TYPE DOCK LEVELERS
WARNING
Do not install, operate, or service this product unless you have read and followed the safety practices, warnings, and installation
instructions contained in this manual. Failure to do so could result in death or serious injury. Always use dock leveler support when
working under a dock leveler ramp or lip.
Place barricades around the pit on the dock floor and driveway while installing, maintaining or repairing dock leveler or vehicle
restraint.
Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury.
Inadequate lifting equipment or practices can cause a load to fall unexpectedly. Make sure the lifting chain or other lifting devices
are in good condition and have rated capacity of at least 500 lb. (227 kg) for the lifting angle used. Never allow anyone to stand
on or near the vehicle restraint when it is lifted or positioned. Stand clear of the vehicle restraint when it is positioned.
Use caution when unbinding the vehicle restraint. Keep hands clear of pinch points and wear appropriate safety attire: glasses,
gloves and work boots. Site conditions may require extra safety equipment such as hard hat and safety harness. Keep hands
and feet clear of vehicle restraint pinch points. Failure to follow this warning can allow the vehicle restraint to fall, tip, or swing into
people, causing death or serious injury.

5.1 INSTALLATION INSTRUCTIONS
Curb Angle
Adjacent to Hinge
Spools
Vertical Weld
(Both Ends)
Bumper And Extension

Bracket
Back Frame
Locate and Drill 5/8" (16mm) Hole

Into Concrete
Install (12) - 5/8" X 6" (16 X 152mm)

Concrete Wedge Anchors
5/32" (4mm)
Curb Angle
Back Frame

5.1 INSTALLATION INSTRUCTIONS CONT'D
WARNING
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.
Keep hands and feet clear of dock leveler pinch points.
1. Inspect the loading dock curb angle and verify that it is firmly
embedded and anchored in the concrete and is minimum 3"
x 8" x 1/4" (75 x 75 x 6mm) steel. If there is no curb angle, if
anchoring or embedding is questionable, or is not of minimum
size specified, proceed with advised installation mounting
types (Section 5.5)
WARNING
The EOD leveler must be welded to a firmly embedded
steel channel or other dock steel as describe in installation
instructions. Do not attempt to use only bolts or anchors to
attach the dock leveler to the concrete.
Use caution when removing strapping from the EOD leveler.
Keep hands clear of pinch points and wear appropriate safety
attire - glasses, gloves, and work boots.
2. Remove strapping from the EOD leveler and discard all

shipping material.
WARNING
Use caution when lifting or moving the EOD leveler. Do not
attempt to lift without suitable hoisting equipment capable of
lifting as much as 600 lb.
3. Locate and set aside the push-button control box and
hydraulic powerpack with mounting bracket. Remove the
bumper extensions and store outside the immediate work
area.
4. Tack weld top of back frame securely to curb angle.
10 ISSUE DATE: APRIL 10, 2015 REV.0 (PART # 411-254-0)
5. Ensure that the back frame is firmly against curb angle or dock
face concrete and plug-weld the back frame to the curb angle
at the four circular holes in the frame. If curb angle does not
overlap these holes, use the back plate as a template and drill
four holes 5/8" dia. x 6" (15mm x 150mm) deep, in the dock
face concrete. Clean out holes and insert and permanently
install appropriate concrete wedge anchors. Tighten enough
to secure the back frame.
6.
Finish weld the top of the back frame to the curb angle. Weld
1/4" x 5" (6mm x 125mm) long welds on both ends of the back
frame. Repeat the 1/4" (6mm) welds on 9" (225mm) centers
across the full length of the back frame.
7. Vertical weld both ends of back frame to curb angle, full length
of vertical contact. Tighten the wedge anchor nuts securely.
8. Position the left-hand bumper bracket (as viewed when
standing on the driveway in front of the dock leveler) so that
there is 1/2" (13mm) clearance between the bracket side and
the comfort grip handle pocket, and the bracket is level with
the top of the curb angle. Weld all horizontal and vertical
contact areas between bracket and curb angle and plug
weld mounting holes that overlap curb angle. Install concrete
wedge anchors 5/8" x 6" (15mm x 150mm) in mounting holes
that are not welded.
9. Position the right-hand bumper bracket so that there is a 1/2"
(13mm) clearance between the bracket and the dock leveler
deck plate. Weld all horizontal and vertical contact areas
between bracket and curb angle and plug weld mounting
holes that overlap curb angle. Install concrete wedge anchors
5/8" x 6" (15mm x 150mm) in mounting holes that are not
welded.
10. Lubricate all pivot points using SAE30 motor oil or equivalent.

5.2 SELF-CONTAINED POWERPACK (PER MOUNTED)
1. Enlist the services of a qualified electrician to have the electrical conduit and wiring installed between the push button control box
and the powerpack motor.
5.3 REMOTE POWERPACK INSTALLATION

1. Securely mount the hydraulic powerpack horizontally on an interior wall adjacent to the door opening, at approximately 8' (2438mm)
above floor level. Install 1-1/2" (38mm) conduit for hydraulic hose, from the lift cylinder up and through the exterior wall to the
hydraulic powerpack. Pull the hydraulic hose through the conduit and attach to the fitting on the powerpack center manifold and
the opposite end to the fitting located at the base of the lift cylinder. Repeat the same for the lip cylinder. Ensure that the hose is
free of kinks and clear of any obstructions. Secure the hose to the foundation structure using clips. Enlist the services of a qualified
electrician to have the electrical conduit and wiring installed between the push button control box and the powerpack motor.
5.4 INSTALLATION INSPECTION

1. Clean up the entire work area and apply touch-up paint to all welds, scratches, and burns.
2. Ensure all concrete wedge anchors have been securely tightened.
3. Test operate the unit through several full cycles of operation. Refer to Section 6.0 "Operating Instructions." If problems are noted,
refer to Section 11.0 "Troubleshooting."
4. Leave these instructions with the EOD leveler for use by the owner.
5.5 INSTALLATION MOUNTING INSTRUCTIONS

5.5.1 8" POUR-IN CHANNEL
8" Pour-In Channel
Anchor
Must be poured in with dock concrete

8" structural channel minimum. 11.5 lb. / ft.
Weld-on curb angle concrete anchors to be a minimum 5/8"
x 6" long (16 x 152mm) located on 12" (305mm) centers with
one anchor 3" (76mm) from each end
ISSUE DATE: APRIL 10, 2015 REV.0 (PART # 411-254-0) 11

5.5 INSTALLATION MOUNTING INSTRUCTIONS CONT'D
5.5.2 ONE PIECE ANGLE PLATE

Beveled Edge
(By Others)
Face Plate Types - For use on existing docks with no curb

steel
1/4" (6mm) minimum plate thickness. Top plate 13" (330mm)
wide, face plate 10" (254mm) wide. Lengthen to suit EOD
Leveler model
Place angle plate on existing dock as shown. Use drill as
template
Lag to sound concrete as follows:
Top Plate: Drill 3/4" dia. x 3-1/2" (19 x 89mm) deep holes.
Insert 5/8" (16mm) expansion sleeves (010-116). Install and
tighten 5/8" x 1-1/2" (16 x 38mm) button-head bolts (010-117)
using 3/8" (10mm) Allen key
Face Plate: Drill 5/8" dia. x 6" (16 x 152mm) deep holes. Insert
5/8" x 6" (16 x 152mm) long concrete anchor wedges
(010-108) and tighten
5.5.3 TWO PIECE ANGLE PLATE

1/4" (6mm) minimum plate thickness. Top plate 13" (330mm)

wide, face plate 10" (254mm) wide. Lengthen to suit EOD
Leveler model
Place top plate on top of existing dock, front edge flush with
dock face, full length
Drill 3/4" dia x 3-1/2" (19 x 89mm) deep holes using plate
as template. Insert 5/8" (16mm) expansion sleeves (010-116).
Install and tighten 5/8" x 1-1/2" (16 x 38mm) button-head bolts
(010-117) using 3/8" (10mm) Allen key
Place face plate in position as shown. Position top edge for
welding and tack-weld to top plate
Drill 5/8" dia. x 6" (16 x 152mm) deep holes using plate as a
template. Insert 5/8" x 6" (16 x 152mm) long concrete wedge
anchors (010-108) and tighten
Weld the two plates together as illustrated. 1/4" x 5" (6 x
127mm) long welds on 9" (229mm) centers
Beveled Edge
5.5.4 OPTIONAL APPROACH RAMP

Position ramp as illustrated. Outside edge of ramp flush with

outside edge of curb angle
Tack-weld ramp to curb angle
Drill 3/4" dia. (19mm) holes using ramp as template. Insert 5/8"
expansion sleeves (010-116). Install and tighten 5/8" x 1-1/2"
(16 x 38mm) button-head bolts (010-117) using 3/8" (10mm)
Allen key
Weld the ramp to the curb angle as illustrated. 1/4" x 5" (6 x
127mm) welds on 9" (229mm) centers
(By Others)
Weld
Ramp
Expansion
Sleeve
Button-Head
Bolt
Weld
Curb
Angle
Anchor

6.0 OPERATING INSTRUCTIONS - MD-CH SERIES EDGE-OF-DOCK LEVELER
WARNING
Do not install this leveler, operate, and/or service unless you have been trained and authorized to do so.
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 operate this leveler until you have checked its condition. Report the need for leveler repairs to your supervisor immediately and do not operate
leveler 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 dock leveler without using the comfort grip handle.
Keep hands and feet clear of dock leveler pinch points at all times. Never use hands to lift dock ramp and/or lip onto vehicle or to store the dock leveler.
Do not drive on leveler unless lip is securely on vehicle bed and has a minimum of 4" (100mm) projection on vehicle bed.
Do not exceed 3 MPH when driving over the dock leveler.
Do not drive over edges of the dock leveler and/or dock bumper blocks (bumper blocks are not structural).
6.1 FUNCTIONAL DESCRIPTION
No other means of support is provided when in this position
The MD-CH Series Hydraulic Edge-of-Dock (EOD) Leveler is

intended to be used as a bridge located between a loading dock
floor surface and the rear deck upper surface of a vehicle.
The EOD Leveler is restored to its original stored position by the

operator before the vehicle is allowed to depart.
The EOD Leveler upper deck plate complete with a hinged,

vertically hanging lip plate is located flush with the floor surface
and is permanently mounted on the outer edge of the loading
dock.
The rear deck surface of a vehicle is parked and blocked in place
against the dock bumpers that are integral components of the
EOD Leveler, in working alignment with the EOD Leveler. An EOD
Leveler, used in conjunction with a vehicle restraint are ideal for
this application. Consult your local Blue Giant dealer / distributor
for more details.
The EOD Leveler is operated by maintaining pressure on a push
button switch located on a control box. The push button activates a
hydraulic pump / motor that forces fluid into a hydraulic lift cylinder.
As the cylinder rod extends, the deck is rotated up into a vertical
position. When the lift cylinder reaches its maximum extension the
smaller lip cylinder begins to extend, forcing the lip plate into a
vertical position as well. The push button switch is then released.
As the operator releases the push button switch, the lip cylinder
remains extended while the lift cylinder retracts. This forces the
lip plate to remain in an extended position as the deck plate
moves forward. The lip plate moves forward horizontally until the
underside comes to rest on the load bed of the vehicle.
Lip Plate
Weldment
Deck Plate
Weldment
Back Frame
Weldment
Lip Cylinder
Assembly
Lift Cylinder
Assembly
Tension
Spring
Powerpack
Bumper
STANDARD OPERATION PROCEDURES

6.2 PRIOR TO USE: EQUIPMENT IN HOME POSITION
The restraint apparatus is in the home position and the dock leveler
lip is parked safely in the lip keepers.
6.3 TRAILER AT BAY

Transporter Vehicle
The vehicle driver reverses the vehicle into position firmly against
the dock bumper extensions.
Vehicle
Restraint
6.4 ENGAGING DOCK LEVELER

The EOD Leveler is operated by pushing and holding the "DOWN"
push button on the control box.
The dock operator assures that the vehicle is secured (using either
a vehicle restraint or wheel chock) to prevent forward creep or
unexpected departure.
Bumper
Extensions

6.5 RAISING DOCK LEVELER
WARNING
Do not attempt to operate the EOD Leveler while the comfort
grip handle (optional) is in use as a maintenance stand.
The operator maintains pressure on the "UP" push button to raise

the EOD Leveler to its most extended raised position.
6.6 EXTENDING DOCK LEVELER
WARNING
The lip plate must overlap the vehicle load bed by a minimum
of 4" (100mm) full width.
The lift cylinder will extend to its maximum length, raising the deck
plate to a near vertical position. When the lift cylinder has reached
its fullest extension the lip cylinder begins to extend.
6.7 LIP ON LOAD BED
WARNING
The vehicle should never be allowed to depart with the lip
plate resting on the load bed.
The lip plate will now be in full contact with the load bed.
PERFORM LOADING AND UNLOADING

6.8 STORING DOCK LEVELER
Deck Raised from

Load Bed
When the loading / unloading operation is completed, the operator

repeats Steps 3 and 4 to raise the lip plate off the vehicle load bed.
6.9 DISENGAGING VEHICLE RESTRAINT / REMOVING

WHEEL CHOCKS
The operator releases the vehicle restraint or removes the wheel
chocks to allow the vehicle to depart. The operator then indicates
to the vehicle driver that it is safe to depart.
The dock is once again available for use.
Vehicle
Restraint
Released

7.0 PLANNED MAINTENANCE
DANGER
When repairing or conducting maintenance procedures on electrical components, perform lockout / tagout steps according to OSHA
regulations and approved electrical codes.
DANGER
Prior to repairs, place adequate barriers to prevent unauthorized
personnel and vehicle from entering the work area.
WARNING
All repairs and maintenance work are to be conducted by
trained and authorized personnel ONLY.
7.1 ROUTINE SERVICING AND MAINTENANCE

Regular maintenance and care of the equipment is very important for cost and operation efficiency and more importantly operator safety.
Faulty equipment is potential source of danger to the operator, and to other personnel working near it. As with all quality equipment,
keep the equipment in good operating condition by following the recommended schedule of maintenance. Failure to do so will void the
manufacturer's warranty.
7.2 AUTHORIZE USAGE

The importance of this procedure is emphasized in this manual with a brief review and later with more detailed instructions. For more
information regarding authorize usage, contact the manufacturer.
Available support by dealer / distributor:
Equipment usage training and authorization
Workplace practical guide for safe use of this product
Ease of service; inspection and planned maintenance
Equipment daily inspection checklist
7.3 MAINTENANCE SEQUENCE

1.
2.
3.
4.
5.
Cleaning, including surrounding area

Visual inspection of all components
Lubrication (as required)
Test operate all functions
Adjustments (if required)

8.0 COMPONENT IDENTIFICATION
Lip Cylinder
Rod End
(Self-Lubricated)
Bushings (2)
Lift Cylinder
Rod End
(Self-Lubricated)
Bushings (2)
Lift Eye
Lip Plate
Hinge Points
Lip Cylinder
Housing End
(Self-Lubricated)
Bushings (2)
Powerpack
Fluid Level
Deck Plate
Hinge Points
Lift Cylinder
Housing End
(Self-Lubricated)
Bushings (2)

9.0 RECOMMENDED SPARE PARTS
11 12
19 3
9 10
15 14
Lubrication
Points
5 4
20 18 17 16 1
2 13
5 4
7
24 23 22 21
Model: MD-CH Series Hydraulic Edge-of-Dock Leveler

30,000 lb (13,608 kg) capacity
RSP FOR EOD LEVELER
RSP FOR EOD LEVELER

QTY
REQD
ITEM
NO.
PART NO.
Powerpack
14
010-059
Cap Screw
200-03114
Lifting Cylinder Assembly
15
011-530
Jam Nut
200-03115
Lip Cylinder Assembly
16
012-211
Flat Washer
300-5000-17
Hydraulic Hose
17
012-200
Lock Washer
034-601
Fitting
18
011-502
Nut
110-886
Bumper
19
018-006
Bushing
017-034
Tension Spring
20
027-006
Control Box - Push Button
013-616
Shackle
21
010-086
Cap Screw
010-168
Cap Screw
22
012-214
Washer
10
011-621
Lock Nut
23
011-510
Nut
11
010-131
Cap Screw
24
012-222
Lock Washer
12
011-554
Lock Nut
027-006
Control Station 115V
13
018-007
Bushing
027-007
Control Station 230V
ITEM
NO.
PART NO.
033-434
DESCRIPTION
DESCRIPTION
QTY
REQD
10.0 CONTROLS
5.28"
(135mm)
7.94"
(202mm)
DISCONNECT POWER
BEFORE OPENING.
.75"
(19mm)
READ AND FULLY UNDERSTAND

THE OWNERS MANUAL BEFORE
OPERATING THIS PRODUCT.
3.47"
(88mm)
5.81"
(148mm)
Front View
1.94"
(49mm)
Side View
Bottom View
COMPLETE CONTROL STATION SINGLE PUSH BUTTON SP1
COMPLETE CONTROL STATION SINGLE PUSH BUTTON SP1

WITH OVERLOAD
ITEM
ITEM
SINGLE PHASE
QTY.
PART NO.
DESCRIPTION
VOLTAGE RANGE
027-006-L
115V / 1PH / 50-60 Hz
110 - 130V
027-007-L
230V / 1PH / 50-60 Hz
208 - 240V
Decal included (part # 038-251E)
SINGLE PHASE
QTY.
PART NO.
DESCRIPTION
VOLTAGE RANGE
1
1
027-006-LO
115V / 1PH / 50-60 Hz
110 - 130V
027-007-LO
230V / 1PH / 50-60 Hz
208 - 240V
Decal included (part # 038-251E)

11.0 MD-CH SERIES HYDRAULIC EDGE-OF-DOCK LEVELER TROUBLESHOOTING
WARNING
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
Unit does not lower from fully
raised position when push
button is released.
Unit lowers from fully raised
position, but lip does not
remain horizontal as deck
plate rotates downward.
PROBLEM CAUSE AND SOLUTION

1. Lubricate all pivot points - SAE10 oil.
2. Check return spring tension (Part # 017-034), adjust or replace as required.
1. Deck stop chain required adjustment.

2. Do not operate EOD Leveler with stop chain removed.
3. Powerpack requires sequential pressure setting adjustment (consult factory).
- Lip does not deploy onto

load bed
Lip plate raises early causing
it to strike the rear of the
vehicle.
1. Powerpack requires sequential pressure setting adjustment (consult factory).

2. Deck / Lip Stop requires adjustment

12.0 WIRING DIAGRAM
REMOTE PUSH BUTTON STATION
MOTOR CONTACTOR
OPTIONAL
OVERHEAD DOOR
INTERLOCK
SWITCH (DS)
(NOTE: REMOVE
A1
JUMPER BETWEEN
#3 AND CONTACTOR
#5 WHEN INSTALLING
DOOR SWITCH)
(MC)
2
A2
95
RESET
96
THERMAL
OVERLOAD
(OL)
3
START
4
GND
POWER L1
SUPPLY
N OR L2
OPTIONAL
CYLINDER
SWITCH
(CS)
JUNCTION BOX
LIP CYLINDER
MOTOR
(M)
HYDRAULIC
GEAR PUMP
VELOCITY
FUSE
(FALLSAFE)
RESERVOIR
Above schematic is for 1HP, 115-230V/1/60 (dual voltage motor) for MDC Series Model MD-CH
Full load amps = 14.0 / 6.8
LIFT
CYLINDER

NOTES
Corporate 85 Heart Lake Road South

Brampton, ON, Canada L6W 3K2
t 905.457.3900 f 905.457.2313
USA 6350 Burnt Poplar Road

Greensboro, NC 27409
www.BlueGiant.com
If calling within North America: t 1.800.668.7078 f 1.888.378.5781 Copyright Blue Giant Equipment Corporation 2015

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What safety precautions should be taken when operating the hydraulic edge-of-dock leveler?

What safety precautions should be taken when operating the hydraulic edge-of-dock leveler?

INSTALLATION & OWNERS MANUAL

HYDRAULIC EDGE-OF-DOCK LEVELER

ACTUAL PRODUCT MAY NOT APPEAR EXACTLY AS SHOWN

ISSUE DATE: APRIL 10, 2015 REV.0 (PART # 411-254-0EI)

HYDRAULIC EDGE-OF-DOCK LEVELERINSTALLATION & OWNER'S MANUAL

ABOUT THE MD-CH SERIES HYDRAULIC EDGE-OF-DOCK LEVELER 3

OWNERS PURCHASE RECORD

SAFETY MESSAGE COLOR IDENTIFICATION 6

OPERATIONAL SAFETY WARNINGS

LOCKOUT / TAGOUT PROCEDURE AND RULES 7

INSTALLATION WITH PIT TYPE DOCK LEVELERS 8

SELF-CONTAINED POWERPACK (PER MOUNTED)

REMOTE POWERPACK INSTALLATION

INSTALLATION MOUNTING INSTRUCTIONS

8" POUR IN CHANNEL

ONE PIECE ANGLE PLATE

TWO PIECE ANGLE PLATE

OPTIONAL APPROACH RAMP

OPERATING INSTRUCTIONS - MD-CH SERIES EDGE-OF-DOCK LEVELER 13

PRIOR TO USE: EQUIPMENT IN HOME POSITION

ENGAGING DOCK LEVELER

RAISING DOCK LEVELER

EXTENDING DOCK LEVELER

LIP ON LOAD BED

STORING DOCK LEVELER

DISENGAGING VEHICLE RESTRAINT / REMOVING WHEEL CHOCKS

ROUTINE SERVICING AND MAINTENANCE

RECOMMENDED SPARE PARTS 19

ISSUE DATE: APRIL 10, 2015 REV.0 (PART # 411-254-0)

HYDRAULIC EDGE-OF-DOCK LEVELERINSTALLATION & OWNER'S MANUAL

1.1 OWNERS PURCHASE RECORD

ISSUE DATE: APRIL 10, 2015 REV.0 (PART # 411-254-0)

HYDRAULIC EDGE-OF-DOCK LEVELERINSTALLATION & OWNER'S MANUAL

2.1 WARRANTY INFORMATION

The following is a quick reference to important procedures that

Thank you for purchasing Blue Giant products. We appreciate your

The Occupational Safety and Health Act

To validate warranty on recently purchased equipment,

American National Standards Institute (ANSI)

Also a member of:

2.2 EXCLUSION OF LIABILITY

Loading Dock Equipment Manufacturers

The manufacturer assumes no liability for damage or injury to

2.3 MANUFACTURERS NOTE

ISSUE DATE: APRIL 10, 2015 REV.0 (PART # 411-254-0)

HYDRAULIC EDGE-OF-DOCK LEVELERINSTALLATION & OWNER'S MANUAL

8. Modifications or alterations of dock equipment shall be made

2. The owner should thoroughly familiarize themselves with

9. The owner or a trained and authorized representative shall

Upon receipt of any newly purchased dock equipment, the

3. Nameplates, cautions, instructions, and posted warnings shall

10. Unless specifically agreed to in writing by Blue Giant Equipment

2.5 INSTALLERS GUIDELINES

ISSUE DATE: APRIL 10, 2015 REV.0 (PART # 411-254-0)

HYDRAULIC EDGE-OF-DOCK LEVELERINSTALLATION & OWNER'S MANUAL

3.1 OPERATIONAL SAFETY WARNINGS