How to install a dock leveler?

A dock leveller is used to bridge the difference in height and distance between the warehouse floor and vehicle in the most efficient way. It is a height-adjustable platform used to ensure smooth transition between dock and truck which helps prevent forklift accidents that can cause serious injuries and forklift damages. It is usually comprised of a simple metal plate that is raised from a stowed position and then lowered onto the back of the truck. The structure is reasonable, the lifting is stable, and the operation is simple. It is widely used in loading and unloading operations, installation and maintenance of factories, logistics and other departments, which can greatly improve work efficiency. Many customers care how to install it. Let me introduce it below.

Most importantly, measure. Make sure the new leveler will fit into the pit.

Place leveler into pit

You are now ready to install your new dock leveler. Guiding the new unit into the pit. Make sure you have even spacing on the sides. Normally, a dock leveler is 2″ smaller than the pit width, so there is a 1″ gap on either side. This allows for articulation of the top deck, and allows for any inconsistencies in the pit width. Shim under frame in corners and center to get leveler flush with top of pit. Make sure to weld shims to leveler. If you don’t, they will eventually work their way out.

Weld leveler rear-corner tack

Tack weld each corner and center of the rear leveler angle to curb angle. Make sure surfaces are as level as possible.

Weld leveler front

Tack weld the front bottom leveler angle to the curb angle. Normally, our levelers are built a little shorter than the pit depth, so shimming the leveler to the proper height is normal. Don’t forget to shim under the lift cylinder on a hydraulic dock lever or under the hold-down on a mechanical dock leveler.

Weld leveler rear-full

Once the leveler is tacked all around and is square and level, continue to weld across the back angles and the front angles. A full weld is ideal, but 6″ stitch welds on smaller and lower capacity levelers is acceptable. Grind all welds smooth.

Conduit-1

If there are no electrical you need to run conduit so we can feed wires from the control box to the leveler motor. Here, we drilled a hole in the face of the building, allowing the conduit to be snaked down the wall face and into the leveler pit.

Control box mounted

Here we finish up the wiring by running the conduit and wires into the bottom of control box. Once installed, review all your steps to make sure you did not overlook anything or forget a step. Once verifying that everything is installed correctly, operate your leveler several times to make sure it is working properly.