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Common Dock Leveller Problems and How to Solve Them

Dock leveller

A Dock Leveller plays a crucial role in the smooth operation of loading docks, thus ensuring efficient transfer of goods. This essential loading dock equipment come in various types, each with its unique set of components and operational mechanisms. For instance, this includes hydraulic dock levellers, mechanical dock levellers, and air-powered dock levellers.

However, like any mechanical system, dock levellers can encounter issues that hamper their functionality. As a result, this can lead to operational delays and safety concerns thus fracturing customer relationships.

In this article, Bridge Door Systems will discuss common dock leveller problems. To further this, we will provide troubleshooting tips to keep your loading dock equipment in top condition.


Fundamentals of a Dock Leveller and Equipment

Efficiency is the cornerstone of a successful logistics operation. High-quality dock levelling equipment significantly contributes to increased productivity by reducing loading and unloading times.

When trucks and warehouse floors are not aligned, manual labour is required to bridge the gap, leading to delays. In contrast, top-tier dock levellers create a smooth transition between the two surfaces. This thus enables forklifts and other equipment to move goods quickly and efficiently.

With this being said, you can imagine how incoherent a loading bay may be with any faults and problems. So BDS want to highlight common issues and exactly how to prevent them happening.

Uneven even with a Dock Leveller

One of the most frequent issues with dock levellers is uneven levelling. When the dock leveller platform does not align correctly with the truck bed, it can create safety hazards. This issue is often caused by misalignment or worn-out components.



  • Inspect the hydraulic or mechanical components for any signs of damage, wear, or misalignment.
  • Adjust the levelling mechanism to ensure proper alignment with the truck bed.
  • Replace damaged or worn parts, such as hinges, springs, or pivot points.

Slow Operation of the Dock Leveller

Another common problem is slow operation, which can lead to delays in the loading and unloading process. Slow operation may occur due to hydraulic or pneumatic issues, or from gradual wear and tear of the equipment.



  • Check the hydraulic or air-powered system for leaks, which may result in a loss of pressure and slower operation.
  • Regularly lubricate moving parts, such as pivot points and hinges, to ensure smooth and efficient operation.
  • Consult the manufacturer’s guidelines to determine if there are any specific adjustments that can speed up the leveller’s operation.


Platform Stuck or Jammed

A platform that gets stuck or jammed during operation can be a significant safety concern. This issue can be caused by debris, foreign objects, or malfunctioning components within the dock leveller.



  • Inspect the platform for any debris, such as dirt, gravel, or packaging materials, and remove them.
  • Examine the components for signs of wear, damage, or misalignment, as these issues can lead to jams.
  • Regularly clean the pit area to prevent debris from accumulating and causing obstructions.


Noisy Operation of a Dock Leveller

Excessive noise during operation can not only be irritating but also indicative of underlying problems with the dock leveller. Noisy operation can result from friction, loose components, or worn-out parts.



  • Lubricate all moving parts to reduce friction and minimise noise.
  • Tighten any loose bolts, nuts, or fasteners that may be causing the noise.
  • Replace any worn or damaged components that may contribute to the noise.


Hydraulic System Issues

Hydraulic dock levellers rely on hydraulic fluid and components to function correctly. Common issues with the hydraulic system include leaks, reduced lifting capacity, and slow operation.


  • Inspect the hydraulic system for any visible leaks and repair or replace damaged hoses or fittings.
  • Check the hydraulic fluid level and quality, ensuring it meets the manufacturer’s recommendations.
  • Regularly service the hydraulic system to maintain optimal performance.


Mechanical or Air-Powered System Problems

Mechanical dock levellers and air-powered dock levellers have their own sets of issues. For instance, misalignment, damaged springs, or air supply problems.



  • Inspect the mechanical or air-powered components for misalignment, wear, or damage.
  • Adjust or replace worn or damaged parts as needed.
  • Ensure that the air supply is consistent and that there are no obstructions in the air lines.


Dock Leveller Solutions from Bridge Door Systems

Maintaining your loading dock equipment, including dock levellers, is essential for both operational efficiency and safety. By regularly inspecting and troubleshooting common problems, such as uneven levelling, slow operation, platform jams, noise, and system-specific issues. Then you can ensure that your loading dock runs smoothly and safely.

Whether you have hydraulic or air-powered dock levellers, proper dock leveller installation is key to secure loading dock environment. Remember that prioritising loading dock safety and addressing issues promptly can prevent accidents and minimise downtime. This will ultimately lead to you saving time and resources, with the help of Bridge Door Systems.

In a world where every second counts, the importance of reliable dock levelling equipment thus cannot be underestimated. It’s not just about moving goods – it’s about moving your business forward. This is a guarantee with the help of Bridge Door Systems‘ loading bay equipment and commercial installations.