Hydraulic Edge of Dock Leveler 25EP78-HA

For specifiers and bid writers. Blank fields (____) require confirmation from the current Bluff cut sheet or approval drawing for the unit as ordered.

A. Manufacturer

1. Design is based on products manufactured by Bluff Manufacturing, 9201 South Freeway, Fort Worth, TX 76140.
2. Type: Loading dock leveler shall be a hydraulic edge of dock leveler: the mechanical EZ-Pull leveler fitted with the factory hydraulic package (AC power unit, 6" stroke tie-rod cylinder, flow control valve, and wall-mounted push-button control), retaining the latch and latch catch. The deck and lip are raised hydraulically and lower by gravity as fluid returns to the reservoir.

B. Product Characteristics

1. Product: Hydraulic edge of dock leveler — Model 25EP78-HA.
2. Size: 78" usable width (100" overall) with an overall span (dock to truck bed) of 27-3/4". Closed depth 17". Alternate usable widths of 72" and 78" available.
3. Capacity: 25,000 lbs. (25,000 and 30,000 lb. capacities also available).
4. Estimated weight: ____ lbs (approximately 631 lbs; confirm against current approval drawing).

C. Construction

Deck (center section) and front lip shall be 1/2" steel tread/safety plate, ____ minimum yield. Front lip shall project 15" with bumpers projecting 16-3/4" from the dock face. Lip hinge pin (____ diameter / ____ material) shall be supported by hinge tubes with grease fittings. Hinge tube I.D. ____.

D. Operation

A wall-mounted push-button station (forward / reverse) inside the building operates the leveler. With the truck backed in and the trailer door open, the reverse button is held until the deck rises and the latch falls into position; the forward button is then held and the front lip extends until it rests on the truck floor, or until the latch kicks off and the lip lowers onto the truck floor. To store the unit, the reverse button is held until the front lip clears the truck bed and rises to vertical; hydraulic fluid returns to the tank and the deck lowers slowly to its resting position, parallel to the dock face.

E. Power Unit

AC hydraulic power unit (MPOWERUNIT) with 1/2 HP, 1725 RPM, 115/208–230 V dual-voltage motor wired for 120 V single-phase service (8.4 A at 115 V); 6" stroke tie-rod hydraulic cylinder (MHYDCYLINDER) rated 3,000 PSI; flow control valve (YFCV) on the cylinder feed; two 30" hydraulic hoses; wall-mounted forward/reverse push-button station (MPUSHBUTTON) and electrical junction box (M442GANGBOX), both factory pre-wired. Customer supplies the 120 V single-phase incoming power and the push-button-to-junction-box run in #14 stranded wire and conduit per local electrical code. Units ship without hydraulic fluid: fill the reservoir with common-grade ISO 46 hydraulic fluid (ISO 32 for sub-freezing service). Reservoir capacity ____ (confirm against the current Bluff cut sheet).

F. Working Range

±5" above and below dock level with gas or propane forklifts; ±3" above and below dock level for electric forklifts, pallet jacks, and all other equipment.

G. Compliance

Leveler and warranty shall meet or exceed the performance requirements of ANSI MH30.2 and CS-202-55 (OSHA / US Dept. of Commerce).

H. Bumpers

Two (2) EPDM bumpers per leveler, included.

1. The driver reverses the vehicle firmly against the dock bumpers.
2. The dock operator confirms the trailer is chocked or restrained against forward creep or unexpected departure, and that the trailer door is open.
3. Press and hold the reverse button until the deck rises and the latch falls into position, then release it.
4. Press and hold the forward button. The front lip extends forward; keep holding until the lip rests on the truck floor, or until the latch kicks off and the lip lowers onto the truck floor.
5. Make sure the lip overlaps the truck bed by at least 8 inches before forklift entry.

1. Confirm loading is complete and all personnel and equipment have cleared the leveler.
2. Press and hold the reverse button until the front lip clears the truck bed and rises to a vertical position.
3. Release the button. The hydraulic fluid returns to the tank and the deck section lowers slowly to its resting position, parallel to the dock face.

When the leveler is not in use, keep it in the lowered, stored position. The unit cannot be worked manually during a power outage.

• Cleaning: clear debris from the hinge tube areas with a wire brush.
• Grease: grease the zerk fittings located underneath the deck.
• Latch & latch catch: inspect contact surfaces for wear; too much wear can reduce height-up allowance and keep the latch from disengaging.
• Hydraulic system: check the reservoir fluid level (ISO 46; ISO 32 for sub-freezing service); inspect the hoses, fittings, flow control valve, and cylinder for leaks; confirm the push-button station and junction-box wiring are secure.
• Structural: check welds, mount plate, anchors, and the 1/2" steel deck for wear or cracking.
  Read the full breakdown in the EOD Installation Guide (PDF)

Leveler will not pivot:

• No grease in the hinge and tube joints.
• No hydraulic fluid in the tank.
• Missing or broken component; check for an obstruction preventing operation.

Leveler will not extend forward:

• Latch installed incorrectly (reversed) or the latch did not engage.
• Leveler installed below dock level, so the unit cannot pivot back far enough for the latch to engage.
• No hydraulic fluid in the unit, or a leak in a hose.
• Broken or missing component.

Lip not returning to stored position:

• Latch not disengaging.
• Insufficient grease in the hinges; check for debris or obstructions.

Leveler not moving with the motor running:

• Check the fluid level.
• Wrong button pressed; travel direction can be reversed by swapping leads 4 and 5 or the connectors on the valve body.
• Faulty hose, damaged valve stem, wiring error, or damaged components.

Leveler will not move and the motor is not running:

• Check wiring and voltage; the unit requires 120 V single-phase service.
• Motor damaged, bad push-button switch, or power outage — the unit cannot be worked manually.

Always specify model number 25EP78-HA and your unit’s serial number when ordering parts.

Hydraulic package components

The hydraulic package ships in the pump/motor box with the cylinder assembly, push-button station, and junction box factory-assembled. Specify model and serial number when ordering. Request a quote using the form on this page, or call 1-800-741-1258.

• ANSI MH30.2 — Edge of Dock Leveler standards; manufactured and tested in compliance.
• CS-202-55 — US Department of Commerce / OSHA dock equipment standard.

Bluff Manufacturing warrants the unit free from defects in material and workmanship for one (1) year from shipping date to the original purchaser. EOD hydraulic power units (not including hoses) are warrantied for 90 days from shipping date. Coverage requires the product to be used and serviced per Bluff’s manuals and instructions, and is limited to repair or replacement of defective parts. A date-stamped photograph is required to initiate a claim. Warranty is void in cases of improper installation, unauthorized service or modification, operation outside rated capacity, abuse, neglect, or weather-related damage.