Common Dock Leveller Problems and How to Fix Them Dock levellers are essential components of any loading bay, providing a smooth and secure transition between warehouse floors and delivery vehicles. However, like any mechanical or hydraulic system, dock levellers can develop problems over time. In this blog, we will explore common dock leveller issues, how to troubleshoot them, and when it is best to repair or replace a faulty dock leveller. Hydraulic vs. Mechanical Dock Leveller Issues Dock levellers come in two main types: hydraulic and mechanical. Each type has its own set of common problems that require specific solutions. Hydraulic Dock Leveller Issues Hydraulic dock levellers use powered hydraulic systems to raise and lower the platform. While they are generally more durable and require less manual effort, they can still encounter issues such as: ● Hydraulic Fluid Leaks – Over time, hydraulic hoses and seals can wear out, leading to fluid leaks. If you notice hydraulic fluid pooling near the dock leveller, inspect the hoses and seals for damage and replace them if necessary. ● Slow or Erratic Movement – If the dock leveller moves slower than usual or behaves unpredictably, the hydraulic fluid level may be low or contaminated. Check the fluid reservoir and refill or replace the hydraulic fluid as needed. ● Power Failure – Hydraulic dock levellers rely on electricity. If the leveller is unresponsive, check the power source, circuit breakers, and control panel for faults. Mechanical Dock Leveller Issues Mechanical dock levellers operate using springs, pull chains, and manual force. Common issues include: ● Broken or Stretched Springs – Springs play a crucial role in the operation of mechanical dock levellers. If the leveller is difficult to raise or does not stay in place, the springs may be worn out and need replacement. ● Damaged Lip Extension Mechanism – The lip of a dock leveller should extend smoothly. If it gets stuck or does not extend fully, inspect the lip hinge and clean or lubricate it as needed.
Common Dock Leveller Problems and How to Fix Them ● Rust and Corrosion – Mechanical dock levellers are more prone to rusting due to their exposed components. Regular maintenance, including lubrication and rust prevention treatments, can extend their lifespan. Troubleshooting Common Malfunctions Identifying and resolving dock leveller problems quickly can prevent costly downtime and safety hazards. Here are some common malfunctions and how to troubleshoot them: ● Dock Leveller Won't Raise or Lower – Check the power supply (for hydraulic systems) or inspect the spring and chain mechanism (for mechanical systems). Ensure there are no obstructions preventing movement. ● Uneven Platform – If the dock leveller is tilting to one side, there may be an issue with the hinges, springs, or hydraulic cylinders. Inspect these components and adjust or replace them as needed. ● Dock Leveller Lip Won't Extend – Lubricate the lip hinge and check for debris. If the issue persists, the extension mechanism may require servicing or replacement. ● Excessive Noise or Vibration – Unusual noises may indicate loose bolts, worn-out parts, or improper lubrication. Tighten loose components and apply lubricant to moving parts. When to Repair vs. When to Replace a Dock Leveller Deciding whether to repair or replace a dock leveller depends on factors such as the severity of the issue, the age of the leveller, and overall maintenance costs. When to Repair ● The problem is minor and can be resolved with routine maintenance. ● The leveller is relatively new and has no history of recurring issues. ● The repair cost is significantly lower than a full replacement. ● Components such as springs, hydraulic hoses, or hinges can be replaced without compromising the overall integrity of the dock leveller. When to Replace ● The dock leveller has reached the end of its lifespan and requires frequent repairs. ● Major components, such as the hydraulic system or platform structure, are severely damaged.
Common Dock Leveller Problems and How to Fix Them ● The cost of repairing the leveller is close to or exceeds the price of a new one. ● The leveller no longer meets safety or performance standards, posing a risk to workers and goods. Conclusion Regular inspection and maintenance of dock levellers can help prevent common problems and ensure smooth operations at loading bays. Whether dealing with hydraulic fluid leaks, worn-out springs, or a malfunctioning lip extension, addressing issues promptly can save time and money. If your dock leveller requires professional attention, BGS provides expert services to keep your equipment in optimal condition. For professional dock shelter repair in Edinburgh and other dock leveller services, contact BGS today!