Project Overview

Upgrading an Old Mechanical Dock Leveler

The old mechanical dock was causing issues for Rubicon Organics in Delta. The steel frame and dock plate were still okay, but the mechanical mechanisms had reached the end of their lifespan.

Rather than replacing the entire dock leveler, Northern Dock Systems offered to upgrade the dock to a fully operational hydraulic system with a Hydraulic Conversion Kit. This involved the removal of outdated mechanical components, the installation of hydraulic mechanisms and several structural modifications to ensure optimal performance and safety.

Step 1: Removal of Mechanical Components

The project began with the careful removal of all unnecessary mechanical components. Using a torch, the team dismantled the outdated parts that were no longer required for the hydraulic system. This step cleared the way for the new hydraulic setup.

Step 2: Structural Modifications for Hydraulic Conversions

To accommodate the hydraulic system, several structural changes were made:

• Flat Stock Installation: Flat stock was fitted and welded to the header opening to reinforce the structure.
• Cylinder Mounts and Cross Brace: Main cylinder mounts and a cross brace were fitted and welded. Shims were used to ensure proper alignment before welding to the existing rear brace.
• Obstruction Removal: The steel mount from the mechanical hold-down bracket was cut away as it was obstructing the lip plate from stowing properly.
• Lip Cylinder Mounts: A square opening was cut into the header to fit and weld the lip cylinder mounts securely.
• Lip Latch Retainers: These were heated and bent on the front lower dock frame to allow the lip plate to stow with ease.
• Electrical Conduit Protection: A 3”x3”x¼”x4” steel angle was welded to the front lower dock frame to deflect the lip plate and prevent it from crushing the electrical conduit.
• Additional Guard: Another steel angle was cut and welded to serve as a guard deflector for the conduit when the dock is in the down position.

Step 3: Testing the New Hydraulic Dock Leveler

All heated and welded areas were painted black using spray paint for a clean, rust-resistant professional finish. All hydraulic hoses were connected and the hydraulic oil levels in the pump motor reservoir were checked and confirmed to be at optimal levels. A full operational test was conducted, confirming that the dock leveler was functioning smoothly and efficiently.

Hydraulic Dock Leveler Conversion for Increased Safety

The dock leveller was successfully converted from mechanical to hydraulic operation. The project not only improved the functionality and safety of the dock but also extended its service life. The client was highly satisfied with the results, noting the precision and professionalism of the work completed.