Installation - Pit Pan Form & Pit Leveler

Pit Pan Installation Dimensions

Extended Pit Pan Dimensions

Pit Pan Form Kit - Installation Instructions

NOTE: The Pit Pan Form kit is not part of a dock leveler. The leveler requires separate installation by the manufacturer’s instructions to ensure proper operation with the necessary adjustments. Should the leveler have to be removed from the pit (i.e., relocation or major repair), it is a simple operation compared to removing the pour-in type levelers.

CHECK MEASUREMENTS OF PERMA PIT TO SEE THAT IT ADHERES TO MANUFACTURERS’ SPECIFICATIONS BEFORE POURING CONCRETE!

Phase 1: Measurement Confirmation & Site Planning

1. Confirm Dimensions

   Determine pit dimensions (A, B, C) from leveler manufacturers’ specifications.

2. Leave an opening in the foundation wall 12” wider than the finished pit width when pouring the foundation. The front curb angle should be set in the center of this opening.
3. The pit floor should be poured at the same time as, or before, the dock floor. Check pit depth to the leveler manufacturer’s specification to determine the correct position of the front curb angle (Dim. C).
4. Pour the pit floor 6” wider than the finished pit width (Dim. A) and 3” longer than the finished length including the foundation wall (Dim. B).

Phase 2: Pit Preparation & Setup

5. Set up the Perma Pit; the sides will bolt to the back member which has three holes on each side of it. The 3” angle will be at the top on all three members and to the outside of the pit. The top of the angles should be level with the dock floor. The side members must be placed flush with the outside face of the foundation wall.
6. Make sure the Perma Pit is square. Place a 2” x 4” or 2” x 6” brace at the middle top of the Perma pit, also at the front top. Nail some 2” X 4” cleats to the floor of the pit at the bottom of the Perma Pit to steady the pit when pouring concrete. (If necessary, you can drill holes in the bottom flange and nail this to the pit floor.)
7. Bulk head the front of the Perma Pit on each side.

Phase 3: Concrete Pour & Finishing

8. Pour concrete around the Perma Pit.
9. Remove bracing when concrete has hardened.

Pour in Pit Pan - Installation Guide

1. Step 1: Prepare the Opening and Pan Angle

   Leave an opening in the stem wall that is the appropriate width for the leveler. You can find the required width (Dimension "A") in the provided chart. Note that for 10-foot levelers, a 24.5-inch deep opening is required. Ensure a 3-inch by 3-inch angle is in place.

2. Step 2: Level the Pan and Ensure Drainage

   Place the pan and level it so the top of the pan angle is flush with the floor line. Use brick or concrete supports under the pan to achieve the correct height. Pitch the pan forward by 0.5 inches to allow for proper drainage.

3. Step 3: Secure the Pan

   Before pouring any concrete, tie down the pan using rebar. This is crucial to prevent the pan from shifting during the initial pour. Important: Do not unstrap the leveler or raise its deck until after the initial concrete pour is complete.

4. Step 4: Pour the Concrete and Finish

   Anchor the leveler with the initial concrete pour. Make sure the concrete fills in solidly under the leveler to ensure a solid pit floor. Once the initial pour is complete, you can pour the rest of the floor section and finish it up to the curb angle of the pan.

Step 1

Step 2

Step 3

Step 4

Pit Leveler Installation Guide

This guide provides a detailed, step-by-step process for the proper installation of a pit leveler. Adhering to these instructions ensures safety, operational efficiency, and longevity of the equipment. Please follow each step carefully for a successful installation.

Phase 1: Preparation and Inspection

1. Receiving and Unloading

   Upon receipt, the pit leveler can be handled in one of two ways: with a chain sling hooked into the designated holes, or by using the fork slots located at the front or rear of the unit. Select the safest method based on your equipment and workspace.

2. Initial Inspection and Documentation

   Immediately after unloading, conduct a thorough visual inspection of the leveler. Look for any signs of physical damage or missing components. If any damage or missing parts are found, it is critical to have the carrier's personnel sign the bill of lading to document the issue. This step is essential for filing any necessary claims against the carrier.

3. Site and Pit Preparation

   Ensure the dock area and the pit itself are clean and free of any debris that could obstruct the installation. Verify the pit's width, depth, and length against the leveler's specifications. If the pit depth is too shallow, a portion of the floor may need to be chipped out to ensure the leveler's rear is flush with the dock floor.

Phase 2: Placement and Shimming

4. Leveler Positioning

   Carefully position the leveler directly in front of the pit opening. Using a forklift, slowly maneuver the unit into the pit, taking care not to drag or wedge it against the pit walls. Having an assistant provide guidance from the dock floor can be very helpful in this process.

5. Initial Shimming

   You can either pre-place the shims in the pit or add them after the leveler is positioned. If pre-placing, refer to the owner's manual for the correct locations of the shim packs. Once the leveler is fully in the pit, use the forklift to push it securely against the back wall, maintaining approximately one inch of clearance between the leveler's sides and the pit walls.

6. Shimming Verification and Placement

   After placement, verify that the rear angle and deck of the leveler are flush with the dock floor. Ensure shim packs are correctly positioned under the rear uprights and both lip keepers at the front. Note that shimming under the ratchet or hold-down is unnecessary and should be avoided.

Phase 3: Welding, Bumper Installation, and Testing

7. Initial Welding

   Begin by welding the rear of the leveler to the embedded curb angle. Perform a weld at the center first, followed by welds at the ends. This provides initial stability and should be completed before welding the shims.

8. Release and Secure

   Cut and completely remove the restraining band from the lip. Pull and hold the ring at the rear of the deck until the lip fully extends and locks into position. Once the lip is locked, engage the maintenance strut to secure the leveler for the next steps.

9. Final Welding and Security

   Weld the shim packs together. Securely weld the front shim packs to both the base frame and the embedded curb angle. This is a crucial step, especially for mechanical levelers, as it prevents the base frame from lifting under the tension of the snubber spring, ensuring correct operation.

10. Bumper Installation

    Securely bolt or weld the dock bumpers to the dock face as close to the pit opening as possible. The bumpers should either be flush with the dock floor or at a height of 48 inches. If the bumpers are raised, ensure they are properly supported from behind.

11. Complete Final Welds

    Finish the welding process on the rear angle. Use a skip weld method to cover approximately 50% of the length of the rear angle. Place the welds directly behind the rear frame uprights and at the ends of the angle for maximum structural integrity.

12. Functional Testing and Finishing

    After all welding and bolting are complete, remove the maintenance strut and operate the leveler several times to confirm all functions are working properly. As a final step, spray paint the welds and any other areas that may have been marred during installation to prevent rust and maintain a professional appearance.