Facility
Commercial warehouse
All Case Studies
Case Study — Kelley Dock Leveler Repair
Two Kelley Dock Levelers Repaired and Back in Service the Same Day
A Sun Valley warehouse had two aging mechanical levelers with different component failures. Both were repaired, cleaned, lubricated, tested, and returned to service in about four hours.
Sun Valley, CA October 2026 Two Kelley Mechanical Levelers
Equipment
2 Kelley mechanical units
Time On Site
About 4 hours
Outcome
Same-day return to service
The Challenge
Two older levelers, two different warning signs
Two side-by-side Kelley mechanical dock levelers, each more than ten years old, had developed separate wear-related problems.
Dock #1 had a failing hold-down assembly, the mechanism that keeps the platform secure and properly positioned.
Dock #2 had a leaking lip shock, creating the risk that the lip could drop uncontrolled instead of lowering smoothly.
Neither dock had stopped completely, but both symptoms could have progressed into unplanned downtime or a safety event under load.
Project Gallery
The two dock positions and completed repairs
Our Solution
Component-level repair, cleaning, and verification
Dock #1 — Hold-Down Assembly
The failing assembly was removed. Manufacturer-supplied brackets were welded in place, the new universal hold-down was installed, and both pull chains were adjusted to the correct length.
Dock #2 — Kelley Lip Shock
The leaking lip shock was removed and replaced with a new Kelley unit and new cotter pins, restoring controlled lip movement instead of an uncontrolled drop.
Preventive Service
Both pits were cleared of debris, all moving and friction points were lubricated, and each leveler was cycled repeatedly before release back to the warehouse.
Parts installed: one universal hold-down assembly, one Kelley lip shock, new cotter pins, general-purpose lubricant, and 7018 welding rod.
The Result
Both docks ready for use the same day
Each leveler passed repeated operating tests with no issues. The full two-dock scope took about four hours on site.
Replacing only the worn components preserved two otherwise serviceable levelers while cleaning and lubrication addressed the maintenance conditions that accelerate future wear.
~4 Hours
Both dock repairs completed
Repeated Tests
Smooth, controlled operation confirmed
Related Expertise
Service, equipment, industry, and local coverage
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Inspection, preventive maintenance, component repair, and replacement for mechanical, hydraulic, and air-powered dock levelers across Southern California.