Most mechanical dock levelers use snubber mechanisms to lift the lips as they are raised, and they close slowly as shocks absorb the weight of the lip. In many of the Kelley dock levelers, however, a push bar and a yieldable rod are connected to a link assembly so that when the deck is raised, the push bar drops down. Then, as someone walks across to the outside of the dock leveler, the plate on the push bar catches on the middle bolt allowing the push bar to raise the lip.
Over time the mechanisms for these walkout levelers fail. Before replacing the push bar, however, we recommend eliminating four other possible causes of failure. One is that there is not enough spring tension. A simple adjustment will correct the problem. The second cause of failure is the spring in the power pack may be binding. This can be corrected by lubricating the spring. The third cause of failure is a worn half-inch bolt that the bar pushes. This can be replaced easily. Fourth, sometimes the push bar binds in the frame, and the bar will not drop when the deck is raised. The frame can be spread with a crowbar to correct this problem.
If the other possible causes are eliminated, then you will need to replace the push bar. In this tutorial, we show how to replace a worn Kelley push bar with a stronger aftermarket push bar assembly.
IMPORTANT NOTE REGARDING LOCAL PICKUPS: DDM is considered a life-sustaining company because we are an internet retail company that provides essential products. Due to the recent outbreak of Coronavirus, however, we are changing our local order pickup policy at our West Chicago location. To pick up an order you will need to order first. The quickest way is to order in advance through our online shopping cart. There you can select the local pickup option. Or, you can call 630-293-1337 for assistance, to confirm availability of parts, and to place your order. Once ordered, your parts will be available for pickup in the lobby of our north side front entrance. Longer items will be picked up on the south side loading dock. Please honor the six foot social distancing rule. Thank you for your patience and understanding as we all navigate this challenge together. More information is available on our blog titled DDM Adjusts to the COVID-19 Coronavirus. In the same article you will also find documentation and an answer to the question: "Is a garage door repair company a life sustaining business?"