Mechanical Dock Hydraulic Conversion
Project Overview
Ongoing Issues with the Mechanical Dock
Tab Labs Inc. in Langley was facing frequent issues with its mechanical dock, including a recent pull chain failure. Rather than investing in another round of repairs, they decided to upgrade to a Hydraulic Dock Conversion Kit and contacted Northern Systems for the solution.
Before
Broken pull chain
Before
Bent frame
Scope of Work and Preparation for the Hydraulic Conversion
Our Installation Technician gathered the necessary parts and tools for the project and arrived at Tab Labs. After meeting with the site contact to review the scope of work, the plan was set: install a new 208V, 3-phase hydraulic dock conversion kit into the mechanical dock and add toe guards for safety.
Dock Preparation and Disassembly
Upon arrival, the technician used a forklift to open the dock and place it on safety stands. He then cleaned out the dock pit to ensure it was clear of debris before removing the old mechanical components. A torch was used to cut off the steel brackets supporting the outdated parts.
During
Cleaning out the dock pit
Building the Hydraulic Structure
The technician then focused on constructing the new hydraulic system structure. He cut 10-foot lengths of 3”x 3”x 1/4” angle steel to use as frame supports for the main lift cylinder. After marking the mount locations, he used a torch to cut openings in the front deck hinge plate for the new lip cylinder mounts, followed by welding the cylinders into place.
Reinforcing the Structure
To further strengthen the structure, the technician added additional steel angles in front of the main lift cylinder mount. He then welded all support brackets and hydraulic cylinder mounts, ensuring the integrity of the system. After welding, the steel components were cleaned and painted black for a finished appearance.
Installing the Hydraulic Power Pack
The next phase involved installing the hydraulic power pack. The technician bolted the power pack onto a steel mounting plate and welded it securely to the dock’s leg frame. He topped up the hydraulic oil and installed the hoses and fittings to connect the main lift and lip cylinders to the power pack.
After
New hydraulic cylinders
After
Added toe plates for safety
Addressing the Lip Plate Latch Issue
During testing, the technician discovered that the lip plate had no latches to secure the dock in the closed position. To resolve this, he fabricated new lip latches from 3” x 3”x 1/4” angle steel and welded them into place. Additional gusset supports were added using 2” x 1/4” flat bar pieces, and the new latches were painted black to match the dock’s finish.
After
Added a lip plate latch
Final Testing and Successful Installation
The technician then tested the dock’s functionality. The lip plate now securely locked into place with the new latches, and the dock sat flush with the floor when closed. With the system fully operational, the installation was complete.
Customer Satisfaction and Additional Orders
The hydraulic dock conversion was a success, transforming the mechanical system into a fully functional hydraulic dock. The installation was completed on time and to the highest standards, and the customer was so pleased with the results that they ordered hydraulic conversions for their other location.
“Your team did such a good job on our dock levelers I was asked to get the same thing done at our new building.”
Maintenance Manager, Tab Labs Inc.
Location
Langley, BC
Featured Products
Hydraulic Conversion Kit for Mechanical Dock Levelers
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