Dock Leveler Preventive Maintenance: 5 Tips To Keep Them Working
If your loading dock is the heartbeat of your facility, dock levelers are what keep it pumping.
When they’re working, everything flows. When they’re not, things back up fast — delays pile up, safety risks increase, and costs escalate.
“Dock levelers are one of those assets that quietly support every shipment,” says Tom Racer, project engineer for Engineered Solutions at Burwell Material Handling. “They’re small compared to everything else in your facility, however, they carry a lot of weight in keeping things moving and need regular attention to stay reliable.”
Why Preventive Maintenance Pays Off
Think about it this way: you wouldn’t want to wait for a forklift tire to blow before checking the tread. The same logic applies to dock levelers. A proactive maintenance program helps you avoid:
- Unexpected downtime that throws off your shipping schedule
- Safety risks from malfunctioning equipment
- Costly emergency repairs that could have been prevented
- Shortened equipment lifespan from unchecked wear and tear
- Energy loss from poor sealing or hydraulic inefficiencies
“Waiting for a dock leveler to fail is like waiting for your brakes to give out before you service your car,” Racer says. “If you don’t have a plan to prevent failure, you’ll end up with the headaches and costs that come with downtime.”
5 Smart Maintenance Moves for Dock Levelers
Building a preventive maintenance plan doesn’t have to be complicated. Start with these five essentials:
- Inspect Regularly
Look for wear, damage, or loose components. Catching small issues early prevents bigger problems later.
“The truth is, most breakdowns don’t come out of nowhere,” Racer says. “You’ll see the signs if you know where to look and check consistently.”
- Lubricate Moving Parts
Follow manufacturer guidelines to reduce friction, minimize wear, and extend the life of your dock leveler.
- Keep It Clean
Clear out debris, dirt, or buildup that can interfere with proper operation and create hazards.
- Check Hydraulic or Electrical Systems
Look for leaks, low fluid levels, or damaged wiring — especially in high-use environments.
- Schedule Professional Service
Trained technicians can provide deeper inspections, adjustments, and manufacturer-specific expertise.
“Having the right technician makes all the difference,” Racer says. “They’re able to spot things you’d never catch until it’s too late.”
Why This Matters to Operations Leaders
If you’re in a role like VP of operations, logistics, or facilities, preventive maintenance is about building long-term performance. Benefits include:
- Avoiding unplanned downtime that derails operations
- Extending equipment life and delaying costly replacements
- Improving safety and regulatory compliance
- Controlling costs with predictable service schedules
- Supporting automation and future upgrades
“Dock levelers are easy to overlook because they ‘just work’ … until they don’t,” Racer says. “But for operations leaders, the difference between a reliable dock and a failing one can be measured in lost shipments, lost time, and lost trust.”
Ready to Keep Your Dock Levelers Running Strong?
Let’s talk through a maintenance plan that fits your operation.