Installing a standard hinged-lip dock leveler requires specific precautions to ensure the safety of personnel and the proper operation of the equipment. Incorrect handling, connection errors or rushing the commissioning process can cause material damage or create dangerous situations.
To minimise these risks, it is essential to follow the manufacturer’s instructions and check every component before putting the dock leveller into operation.
What risks are involved when installing a dock leveller?
Installing a dock leveller involves working with heavy equipment that incorporates mechanical, hydraulic and electrical components. As a result, certain operations can create risks of crushing, impact or component damage.
Before carrying out any work, the working area must be secured and checked to ensure that no people or objects are underneath the platform or within its range of movement.
How to secure the work area
The first precaution is to ensure that the working area is clear and complies with the manufacturer’s instructions.
Never start or move the platform when a person or object is underneath it. The risk of crushing can result in serious or even fatal injuries.
During dock leveller operation, people should also remain at a safe distance to prevent impacts with the platform or other moving components.
Check the hydraulic system before use
The hydraulic system is essential for the operation of the dock leveller. Before commissioning the equipment, check that the hydraulic circuit is correctly filled and that there are no leaks.
After a prolonged period without use, the hydraulic circuit must also be refilled before operating the platform. Depending on the equipment instructions, it may be necessary to press and hold the «RAISE PLATFORM» button for 20 seconds.
Never force the hydraulic power unit or attempt to raise the platform manually or with auxiliary machinery.
Check the mechanical and electrical components
Before starting the dock leveller, several checks should be carried out to identify any possible faults.
These include:
- Install the safety arm before carrying out any adjustments.
- Check that there is no interference between components.
- Verify the direction of motor rotation.
- Do not operate the equipment if the motor is rotating in the wrong direction.
- Check that the electrical connections have been correctly made.
- Avoid remaining unnecessarily underneath the platform.
These checks help identify potential problems before the equipment is put into operation.
Precautions when carrying out welding work
When welding is required during installation, precautions must be taken to protect the dock leveller’s components.
The welding ground must not be connected to the cylinder, control cabinet or electrical components. It must be connected to the base of the platform in accordance with the manufacturer’s instructions.
This prevents the welding current from damaging the equipment’s electrical or hydraulic components.
Protect the control cabinet when drilling
When drilling the metal enclosure of the control cabinet, prevent metal shavings from falling onto the electrical components.
These particles can cause damage and lead to malfunctions in the control cabinet.
Once drilling is complete, remove the metal shavings with a vacuum cleaner before continuing with the installation.
Carry out checks before commissioning
Before using the dock leveller, a general inspection of the installation should be carried out to ensure that all its components are working correctly.
The following should be checked:
- The hydraulic circuit and absence of leaks.
- The direction of motor rotation.
- Platform movement.
- Absence of interference between components.
- Operation of the hydraulic power unit.
- Safety of the working area.
If any fault is detected, the dock leveller must not be used until the problem has been identified and resolved.
How can you ensure a safe installation?
A safe dock leveller installation is based on three key principles: following the manufacturer’s instructions, securing the working area and checking the different systems before commissioning.
Rushing should be avoided throughout the process. Adjustment, connection and maintenance operations must be carried out using the appropriate safety devices and by qualified personnel.
Dock leveller installation video
Below, you can watch a video showing the main stages involved in installing a dock leveller.
If you have any questions about installing or commissioning a dock leveller, contact Alapont Global. Our team can advise you on the most suitable solution for the specific characteristics of your facility.
