When using a dock leveler at your warehouse, there are several operating issues that can arise as with all equipment. It is important to identify issues with your dock equipment and resolve them quickly to prevent further downtime or bigger problems down the line. In this article, we’ll discuss common issues that are cause for a dock leveler repair. Note that all maintenance and service on dock equipment must be performed by a trained technician. For loading dock service (in Cleveland OH), please call us at 855-951-4499.
Dock Leveler Will Not Stay Down (Mechanical Leveler)
One sign of a needed repair is if your dock leveler will not stay down. This is common on mechanical dock levelers that are not connected to a power source. On a mechanical leveler, the main springs have power in the stored position. When the leveler rises, the power is exasperated and allows for the plate to rise. The only component holding the deck down is a hold-down, or ramp control. This ratcheted mechanism keeps the deck stored when not being used. If the teeth or mechanism is broken, the deck will not stay down and will keep coming up. The only solution to this problem is a replacement hold-down or the component on the hold-down that is not operating. This could be the ratch and pawl mechanism, or another component. Once this is replaced, your dock leveler should store as desired.
Dock Leveler Will Not Rise
If your mechanical dock leveler will not activate, one common issue is a broken main lifting spring. Lifting springs keep a dock leveler deck under power when stored. If a main spring is broken, there may not be enough power to lift the deck and lower onto a truck bed. For a powered dock leveler, there may be a power source issue, electrical or control panel issue, or a hydraulic system issue. If the dock leveler has sensors, switches, or is interlocked with other equipment, there may be a fault in one of these components or the sequence of operation preventing activation of equipment.
Dock Leveler Comes Up Too Slow or Fast
A mechanical dock leveler that is too slow or fast to rise may have too much or too little power on the main springs. Adjustments will need to be made under the dock leveler deck to add or decrease tension on the main lifting springs. On a powered unit, the hydraulic system may have a leak, not enough fluid moving through the system, or other hydraulic system failure(s).
Dock Leveler Lip Plate Issues
Common issues with dock leveler lips are either not activating or not staying out to reach a truck bed. Various lip activation systems exist, but common are a gas spring or shock absorber failure, a push out bar failure, a lip latch that is not releasing the lip to descend, or other lip assembly issues. It can also be that the lip assist has too little power to activate the lip plate. On a powered leveler, the lip cylinder may have failed or a related hydraulic system failure.
