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use-V 01-en-2009-A-01.pub

1. Dhollandia Romania Bucharest 40 744 571 655 AUST Dhollandia Russia Moscow 7 916 531 36 00 Saudi Arabia Alaa Industrial Equipment Damman 966 1448 4482 Slovakia Dhollandia CE Predmier 421 41 500 10 80 South Africa Grenco 27 21 555 90 00 DAI Dhollandia Spain 4 34 91 877 16 50 Reder System 34 937 18 09 94 5 Dhollandia Sweden Alvesta 46 8 594 63 400 Switzerland Dhollandia Vertretung M llheim 41 52 762 77 00 Ukraine Dhollandia Ukraine 380 44 492 86 49 United Arab 5 Hytec DUDA 971 4 333 13 99 The national distributors can help you to locate the nearest Dhollandia service centre e See www dhollandia com for the latest update on the service network
2. Dhollandia UK Huntingdon 44 1480 435 266 Free service 0800 0855 141 Greece Smyrliadis Truck amp Trailer Athens 30 210 816 12 18 Hungary Liberatus 36 23 312 398 STAN Gs REE Balliniough Refrigeration Dublin 353 146 00 322 lsrae Amir Engineering Petach Tikva 972 39 222 750 Haly Dhollandia Italy Diegaro die Cesena 39 0547 347 615 KN er Bader al Mulla 965 48 15 077 Latvia Lithuania Dhollandia Latvia Riga 371 28 305 904 _ DHOLLANDIA C15 Malta Alexander Xerri QOrMi 356 21 470 900 Netherlands Dhollandia Netherlands Breda 31 765 81 14 55 Norway Dhollandia Norway Oslo 47 98221333 Dhollandia Poland Krakow 48 12 260 61 10 Portugal Dhollandia Plataformas Villa Franca de Xira 351 263 286 570 Romania
3. DHOLLANDIA e hydraulical OPEN CLOSE or steel cables Fig 3 2 Upper beam lift with steel cables amp 4 Fig 3 3 Fully hydraulical column lifts no chains Grease DHOLLANDIA 4 TESTING THE CABLE CHAIN RUPTURE DEVICE Fig 4 1 chains Fig 4 2 steel cables e The 1 deck column lifts driven by a lift cylinder plus a single cable or single chain system are equipped with a Load Safety Device LSD e These cable rupture devices or chain rupture devices are designed to block the platform inside the lift columns in case of failure of the suspension system and to protect the plat form the load and the operator from falling to the ground e The LSD is tested as follows Clean the lift columns Remove all foreign objects amp dirt from the inside of the columns and from the LSD With the platform in open position lower the platform to approx knee height Place a block of wood under each side of the platform near the front platform edge and LOWER the platform onto the blocks Continue to press the function LOWER until the chain or steel cable is physically slack underneath the lift runner If the chain or steel cable doesn t go slack remove the cov er of the cylinder beam and whilst pressing the function LOWER push the cylinder in by hand This will create slack chain or cable to continue the test Slack chain or cable is a necessity otherwise the LSD test can prove nega
4. minimum section of 150mm of the platform point should cover the loading dock see Fig 5 28 150 When loading unloading the loading floor of the vehicle might lower rise relative to the loading dock Use the electrical controls to adjust the platform when the point of the platform rises above or below the dock see Fig 5 29 Negligence to adjust the platform angle could cause severe damage to the tail lift It is forbidden to let the platform float and use a second articulated link bridge be tween its point and the loading dock see Fig 5 30 When loading unloading the platform point should always overlap a rigid underground over a minimum of 150mm see Fig 5 28 5 29 It is forbidden to use a folding platform as bridge plate In order to prevent damage the platform should always be closed in its travel position prior to driving away from the loading dock DHOLLANDIA a 6 LOADING DIAGRAMS e Hydraulic tail lifts are not designed to LIFT LOWER weights corresponding to their nomi nal capacity over the full surface of the platform The nominal capacity is valid at a certain distance or centre of gravity behind the vehicle body Behind that point that is marked on the platform the maximum safe working load diminishes according to the load diagrams below e When LIFTING the tail lift is normally protected against overload by the pressure relieve valve in the hydrau
5. 87 1 Introduction to the standard control box A26 Electrical amp hydraulic wiring diagrams B30 ment Regulations 1998 87 2 Option 5094 3 1 button control box A27 6 International distributor network C15 87 3 Option 5011 for lifts with manual closure only A28 87 4 Auxiliary controls A28 67 5 Operating instructions for column lifts with manual A30 closure 67 6 Operating instructions for column lifts with hydraulic A31 closure S7 7 use of stabilising legs A32 87 8 user of roll stops A33 87 9 Automatic tilt at ground level A35 8 Warranty conditions A36 Copyright O 2009 DHOLLANDIA NV This publication or parts thereof may not be reproduced or transmitted in any form or by any means electronically or physically for any purpose without the express written authorization of DHOLLANDIA NV DHOLLANDIA Identification of the tail lift _ DHOLLANDIA CE DECLARATION OF CONFORMITY Corresponding Directive 2006 42 EC annex 2 A A3 We hereby declare that the DHOLLANDIA ail lift identified above based on its design and its construction complies to the relevant fundamental health and safety requirements of the CE Directives and is destined to be mounted on a vehicle This declaration of conformity is only valid and the use of the tail lift is only permitted once the following conditions are met e The tail lift is fitted to a vehicle and the fitting complies with the conditions of the CE Directives with
6. Therefore always stand to one side of the lift when opening the platform and always keep your head hands and limbs clear of the moving platform or other moving parts of the lift e Remark for column lifts with manual closure Stay out of the operation radius of the platform Keep clear of moving parts Beware of hand foot and head traps at all times DHOLLANDIA 5 3 Danger zones risk of crushing amp sheerin Correct operator position HHA Danger zone e The operator should maintain a clear visual control over the platform the operation radius of the platform and the load on the platform at all times e The operator should stay out of the operation radius of the platform and stay clear of the moving parts at all times Beware at all times for potential risks of crushing or sheering fingers hands limbs feet or toes between the moving parts of the lift arms hydraulic cylinders and the moving platform A Beware of hand foot and head traps at all times Keep clear of moving parts e The main danger zones for the operator and occasional bystanders in traffic are the following the zone directly behind the platform and within the operation radius of the platform see Fig 5 4 the crushing zone between the lowering platform and the ground see Fig 5 5 the crushing zone between the lifting platform and the rear cross member of the vehi cle floor see Fig 5 6 the c
7. DHOLLAN DIA 1 DECK COLUMN LIFTS USER S MANUAL MAINTENANCE amp REPAIR COMPULSORY INSPECTIONS amp REPORTS Manufacturer DHOLLANDIAN V Zoomstraat9 9160 LOKEREN Belgium Tel 32 0 9 3490692 Fax 32 0 9 349 09 77 e mail info dhollandia be Advice to the user This user s manual must be kept in the immediate vicinity of the tail lift at all times as reference Order Ref MD005 EN for the vehicle driver and tail lift operator Advice to the driver and service personnel All maintenance amp repair works and periodic inspections must be duly recorded in this manual DHOLLANDIA 1 Doc USE V 01 2009 01 0 Origin 30 09 2009 Rev 0 16 07 2012 CE Declaration of Conformity A3 Chapter B Chapter C Disclaimer 4 MAINTENANCE amp REPAIR COMPULSORY INSPECTIONS amp REPORTS General introduction A4 1 Safety instructions for maintenance amp repair B2 Introductory remarks C2 Chapter A 81 1 General safety instructions B2 2 Inspections _ _ C2 USER S MANUAL 81 2 Hydraulic components B4 82 1 Put into service test amp Fitting Declaration C2 81 3 Electrical components B5 32 2 Periodic inspections C2 1 Intended use A6 2 Maintenance B6 823 Maintenance amp Repair Reports special inspections
8. Is the main fuse for the HTL near the vehicle batteries still functional Is the connection of the HTL to the vehicle batteries ok Are the batteries auxiliary batteries too weak Has the mechanical platform lock been released If all this has been verified and an approved service agent intervenes to repair the HTL it is very important that the fault analysis is executed in a logical and systematic way Too often components are replaced at random until the malfunction disappears Such method is very expensive however on labour hours and spare parts cost Therefore it is very important to identify quickly and precisely if a malfunction has an electrical a hydraulic or a mechanical cause For instance when a HTL doesn t LOWER it can be that The coil s of control valve H in the power pack or one of the safety valves D on the lift cylinders receive no current electrical fault one of the cartridges of the safety valves D on the lift cylinders has been hit and bent by a projecting stone or that one of the braking valves on the cylinders is blocked hy draulic fault one of the piston rods of the lift cylinders is bent by overload or accident mechanical fault The tables below can be used as guide during the further fault analysis e Some steps in the check list require special skills and specific knowledge see DHOLLANDIA Repair amp Maintenance training program In case of do
9. VOl2 MEG S POW R PACK ACTING VALVES SINGL ON LIFT H amp TILT S B39 CHAPTER C COMPULSORY INSPECTIONS amp REPORTS 4 _ DHOLLANDIA INTRODUCTORY REMARKS Since the 151 of Jan 1997 all tail lifts sold in one of the EC member states should comply with the European Machine Directives 89 392 EC and 98 37 EC and subsequent amend ment 2006 42 EC As a consequence all DHOLLANDIA tail lifts are designed and manufactured in accordance with these regulations and they are carrying the CE mark These regulations include the CE Machine Directive 89 392 CEE in its most recent version called CEMD hereaf ter the EN Standards derived from the Directives that enable manufacturers to prove conformity of their machines with the Directives the national norms that become applicable upon execution of the Machine Directives By means of a Declaration of Conformity see Chapter 1 the manufacturer confirms that the machines supplied comply with the regulations stated above INSPECTIONS All tail lifts should be subjected to a number of compulsory inspections as explained be low 2 1 Put into service test and Fitting Declaration All tail lifts are largely pre assembled and tested by the manufacturer and receive a CE Declaration of Conformity Annex II a covering the design and mode of construction Tail lifts are no stand alone application thou
10. Where applicable for lifts with tilt cylinders only not for lifts with manual OPEN CLOSE _ DHOLLANDIA A26 e Additional rotary switches are foreseen in case of more complex lifts The functions LEG IN LEG OUT in case of lifts with hydraulic stabilising legs See Fig 7 6 e In practice the functions on the exterior control box are actuated as follows To actuate LEG 1 actuate LIFT LOWER LEG OUT 7 use of safety switch not required on all lift models CLOSE OPEN 7 2 Option 094 3 1 button control box The option 5094 features a 1st control box with buttons plus a 2nd separate control box with 1 safety button A separate battery switch should be mounted during installation of the lift e This type is for instance used for mounting into the side panel of the vehicle body e The 3 buttons plus the safety button operate the 4 basic functions LIFT LOWER CLOSE amp OPEN See Fig 7 7 LIFT CLOSE Z _ 08 4 OG LOWER 1 OPEN Z Where applicable for lifts with tilt cylinders only not for lifts with manual closure ami OG N ne Q DHOLLANDIA 7 3 Option 011 for lifts with manual closure only e The option S011 features a single control box with 2 control buttons and an emergency cut out switch A separate battery switch should be mounted during installation of the lift e The 2 buttons operate the 2 basic
11. DHOLLANDIA 6 10 The HTL doesn t reach floor height e Insufficient quantity of oil in the reservoir Verify the oil level in the power pack and top up oil if necessary Rest the platform in work position on the ground The The lift columns and or lift runners are damaged causing the lift runners to jam correct oil level reaches to the MAX mark on the oil reservoir e The lift columns contain to much hardened grease are clogged up with debris and dirt The chain or steel cable length is incorrectly adjusted Check the position of the stops for lift runners and adjust them when required Check the lift columns and lift runners for visible damage and repair Clear all debris from the lift columns clean them with high pressure steam cleaner and apply grease Adjust the length of the chain or steel cable anchor or move to the next mounting position 6 11 The electric motor seemingly runs at normal speed but the platform doesn t move e Insufficient quantity of oil in the reservoir The hydraulic pump sucks air Verify the oil level in the power pack and top up oil if necessary Rest the platform in work position on the ground The The oil filter between the reservoir and pump is clogged up dirt or ice formation correct oil level reaches to the MAX mark on the oil reservoir e The drive shaft between the electric motor and the hydraulic pump is broken e The hydraulic pump is completely worn out Dismount the filte
12. E0188 C H INTERIOR CONTROL RE 2 oO lt 5 EXTERIOR CONTROL BOX REF E068 NO 5008 2 VB4 TESCO PIEK hydraulic closure 57278 9091403 43 41x Power pack GT LD L R 01 06 Valve V012 D V096 D Sch VB4 5727B 9091403 Tesco 2009 01 PK gt 2 EXTRA CTRL U gt 12 24V E GY gt CTRL BOX Date 22 10 2009 OLOUR CODE DIN 47100 ie DEOLLANDIA 00 2 lI lI lI f iO ES TH amp TILT DOUBLE ACTING VALV POWER PACK ON LI HYDR B37 Type Column lift DH VA manual closure Power pack G VAO1 7 02 Valve 018 Plan Sch 018 2008 01 5 1 BUTTON EXTERIOR CONTROL DH VA USE 5 N O Date 13 08 2008 PEOLLANDLA BATTERY 4000 STD L l gt CTRL gt 24 12 SHE SALE GN gt YE sl COLOUR CODE DIN 47100 D C1 C2 B38 Type Fully hydraulic column lift DH VH Power pack G LE L R 01 06 Valve Plan I 2 x lt 2 O 5008 B E068 Sch 012 5008 2009 01 772 2 5 75 55 4 2009 012 7 096 stats H Z Z L gt 2 5 gt 0 lt Z lt r I E V096
13. Dynamic test at 100 nominal capacity Verify if the lift has sufficient lift capacity Verify the general performance amp stability Verify the working speeds gt LIFT amp LOWER max 15 cm sec OPEN amp CLOSE max 10 sec gt AUTOMATIC TILT at ground level max 4 sec Overload test Limitation of the lift capacity Place the platform at rest on the ground Put a load of 1 nominal capacity at the centre of gravity adjust the hydraulic pressure on the pressure relief valve so that the nominal capacity is just reached Seal the pressure relief valve after final adjustment Put a load of 1 25x nominal capacity at the centre of gravity the platform should not be able to lift vertically _ DHOLLANDIA C5 4 8 European homologation of the bumper bars e Upon technical vehicle inspection compliance of the vehicle with the European Directive for rear bumper bars 2006 20 EG will be checked e In case of slider lifts the platform functions as bumper bar and it is homologated as such In case of cantilever or tuck away lifts an additional bumper bar with official ho mologation is available as an option e Remark DHOLLANDIA s homologations only cover the equipment in their original delivery format and mounted conform to DHOLLANDIA s fitting instructions If needed the homologations can be downloaded from the internet www dhollandia com gt Downloads gt Bumper certificates after 2007 IN
14. and after each replacement of hydraulic pipes or revision of hydraulic cylinders LI Starter solenoid electric motor e General condition correct amperage LI Electrical connection block in the power pack e Corrosion burn marks sparkles LI Control valves on the logical valve block e Fixation amp tightening of all cable amp wire connections LI Pressure relief valve e General condition e Verify the maximum oil pressure in function of the nominal capacity of the HTL and adjust if required HTL lifts too little or too much weight Max oil pressure 220 BAR 2 10 Hydraulic cylinders What to verify Execute service or repair if required All cylinders e General condition M3 e Hydraulic system is free from leaks both during operation amp at rest J1 e Fixation amp locking of all articulation pins DHOLLANDIA TE LI Electrical safety valves e General condition e Function amp operation of the manual emergency button e Clearance to the bumper mounting plates and other fixed parts e Condition of the electrical cable to the power pack LI Tilt cylinders on HTL with hydraulical closure e Condition of the springs used for function OPEN 2 11 Lift frame What to verify Execute service or repair if required LI Frame construction e General condition condition of the welds LI Toe guard at end of loading floor and or front edge of platform e Check for cracks amp deformation straightness o
15. from sand and dirt e Any grease job should include Greasing of the lift columns lift runners and their Teflon slide surfaces Lubrication of the Load Safety Device LSD steel cables or chains Greasing of the inside of the cylinder beam the pulleys pulley blocks sprockets Lubrication of the platform lock platform retaining catch hinged toe guards if applica ble articulation points of the safety gates Greasing of all articulation points equipped with grease nipples e Where grease nipples are used the greasing must be executed in such a way that all articulation points get a grease collar on both sides of the bearing or articulation protect ing it against ingress of water salt sand or dirt e Ensure all grease nipples function correctly and replace any defective nipples For articu lations that cannot be greased even after replacing the grease nipple the articulation pin must be dismounted and polished and its grease channel must be cleaned As ultimate solution the articulation pin must be renewed e Always use acid free grease The use of graphite grease is not allowed e Verify if the platform lock and or platform retaining catch operate smoothly and lubricate with oil if necessary e The various types of HTL should be greased according to the grease plans in Fig 3 3 and following I In case of special tail lifts deviating from these images contact DHOLLANDIA to obtain further instructions
16. to handle Even when the platform is closed there can still be significant force on the tor sion bar and the other components attached to it The components bar retain er articulation pins should not be altered while the bar is under torsion O e 0 l l l l W bm pr In case of doubt on any of the subjects in this chapter stop immediately and ask Z I advice from DHOLLANDIA prior to continuing _ DHOLLANDIA 1 2 Hydraulic components In normal working order a HTL is supported by the hydraulic pressure in the cylinders Therefore hydraulic components such as valves hydraulic pipes cylinders etc should not be removed before the platform and lift arms are secured against accidental falling by means of a hoist a forklift a gantry crane or by resting the platform on the ground Dismounting of hydraulic cylinders general release the oil pressure in the hydraulic circuit by pushing the control switches for LOWER for revision of the lift cylinders or OPEN for revision of the tilt cylinders for approx 20 sec Only when the oil pressure is released is it allowed to remove the corresponding articulation pins Dismounting of hydraulic TILT cylinders take into account that the some tilt cylinders are equipped with strong internal springs see Fig 1 9 generating a strong pull force on the articulation pins when th
17. Thorough Examination jointly called STE here after the expert competent person assesses the rate of deterioration of the equipment e Competent and regular maintenance is extremely important not only in order to maximise identifies any defects and certifies that the equipment is safe for continued use for the fol the life expectancy of the tail lift called HTL hereafter but also in order to guarantee the lowing period up to the next STE 6 months for UK 12 months in most other countries operational reliability and safety of the operator and potential bystanders across Europe e No maintenance or repair work is done during a STE The scope of STE therefore implies all points of the checklist below with exception of the actual greasing work 2 2 and the purging work 2 8 Other points are specially reserved for the STE and are marked as follows gt STE Statutory Thorough Examination or periodic inspection e Follow the scheme on the next pages verify point after point and tick off as you make progress some steps in the check list require special skills and specific knowledge see DHOLLANDIA Repair amp Maintenance training program In case of doubt on how to proceed DON T go any further but ask your local DHOLLANDIA distributor for professional advice e The HTL should work smoothly and quietly and at a fairly constant pace During LIFT and LOWER only the sound of the hydraulic power pack should be au
18. amp REPAIR DHOLLANDIA 1 SAFETY INSTRUCTIONS FOR MAINTENANCE amp REPAIR e During the maintenance amp repair works the service engineer should follow the general safety instructions for the use of the tail lift see Chapter A as well as the specific tech nical safety instructions described below 1 1 General safety instructions e Use appropriate working clothes Never wear loose fitting clothes that may be trapped in the moving parts of the tail lift called HTL hereafter Always wear safety goggles with side guards safe footwear with steel protection tips non flammable overalls protective gloves and ear plugs Wear a safety helmet when working under the HTL or vehicle chassis Avoid wearing rings bracelets necklaces watches etc See Fig 1 1 e Before releasing the mechanical platform lock check if the hydraulic system builds up pressure goes in overpressure and ensure that there is no visible oil leaks see Fig 1 2 e Take into account that a leak visible or not in one or more of the hydraulic components may cause a pressure loss causing the platform to fall open as soon as the mechanical lock is released see Fig 1 3 e Consider that in an emergency situation the platform might have been closed with use of external help forklift hoist gantry crane leaving the hydraulic cylinders empty instead of filled with oil and causing the platform to fall down as soon as the mechanical lock is re
19. carried out In case of important repair works with significant impact on the structural integrity of the lift or the safe working conditions the lift should be subjected to a special inspection by an expert competent person to evaluate if it is safe to continue to use it The findings of these inspections should be summarised in the relevant inspection certificates see pg amp following If a tail lift has failed to pass a periodic or special inspection it should be repaired and be subjected to a further inspection re inspection by an expert competent person to evaluate if it is safe to continue to use it after the latest repair The findings of these in spections should be summarised in the relevant inspection certificates see pg C6 amp fol lowing The content of these compulsory inspections is explained in Chapter B Point 2 2 4 Expert competent person The expert or competent person in UK law is a person appointed by the user or owner of the tail lift By his expert technical knowledge and experience and by his expertise in health and safety regulations he should be qualified to form an impartial judgement re garding the safety and reliability of a tail lift The British ACOP Approved Code of Practice Regulation 9 describes it as follows the owner should ensure that the person carrying out a thorough examination has such ap propriate practical and theoretical knowledge and experience of the lifting equ
20. identified in the Declaration of Conformity has been inspected on its YES LINO operational safety and reliability Place date Name amp function of the expert During this inspection no imperfections have been found or Name amp address of the inspection body L During this inspections the following shortcomings have been identified Follow up by the owner or fleet operator LI Shortcomings have been acknowledged Scope of the inspection LI Shortcomings have been repaired Place date Name amp signature of the owner or fleet operator Partial inspections to follow DHOLLANDIA INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION L SPECIAL INSPECTION RE INSPECTION Date of inspection Evaluation the tail lift is safe and suitable for further use The tail lift identified in the Declaration of Conformity has been inspected on its YES LINO operational safety and reliability Place date Name amp function of the expert During this inspection no imperfections have been found or Name amp address of the inspection body L During this inspections the following shortcomings have been identified Follow up by the owner or fleet operator LI Shortcomings have been acknowledged Scope of the inspection LI Shortcomings have been repaired P
21. of the lifting platform and the rear cross member of the vehicle floor or between the lowering platform and the ground For situations where no 4 button foot controls are used the Standard for tail lifts EN1756 1 describes a number of body design configurations and applications non exhaustive creating an acceptable level of safety see EN1756 1 2001 A1 2008 or our fitting in structions FIT ELEC_OPTION in its latest revision see also 5 4 e Fig 4 11 Marking of the centre of gravity Hydraulic tail lifts are not designed to LIFT LOWER weights corresponding to their nominal capacity over the full surface of the plat form The nominal capacity is valid at a certain distance or centre of gravity behind the vehicle body Behind that point that is marked on the platform the maximum safe working load diminishes according to the load diagrams see also Point 6 DHOLLANDIA rE e 4 12 Load safety device LSD mounted on each of the lift runners In the unlikely event of a steel rope or chain breaking the LSD will jam the lift runner and the platform in the lift column preventing the platform to drop more than 100mm from its position at the time of the failure see Chapter B e 4 13 Main battery fuse on the battery cable 15A fuse on the wires inside the control box both fuses are used to protect the electrical system of the tail lift and the vehicle against short circuits and amperage peaks e Fig 4 14 Signalling o
22. the data men tioned on the identification sticker in the exterior control box The safe working zone for the operator is clearly and permanently marked on the platform If applicable The foreseen foot protection conforms with the fitting in structions The platform is made sufficiently visible for the surrounding traffic platform lights flags reflective tape traffic cones A hand grip for the operator to hold when lifting lowering with the platform is mounted on the rear frame of the vehicle body _ DHOLLANDIA CA 4 7 General operation practical tests General operation with an empty platform execute all movements several times with ALL available control units The movements should be executed smoothly amp quietly without strange noises otatic test at 125 overload Test for deformation Position the platform at 1 2 height Note the distance and angle to the vehicle floor Put a load of 1 25 x nominal capacity at the centre of gravity and remove it again Verify the distance and angle to the vehicle floor No permanent deformation should be noted Static test at 125 overload Test on inclination e Position the platform at the level of the vehicle floor Put a load of 1 25 x nominal capacity at the centre of gravity Note the distance and angle to the vehicle floor Repeat the same measurements after 15 min The platform should not be lowered more than 15 mm and should not be tilted down more than 2
23. the fitting instructions of DHOLLANDIA and the Fitting and Body Build ing Instructions of the vehicle manufacturer e After the fitting of the lift the risk analysis the weight test and put into service test has been carried out with positive results and the fitting declaration see page C3 has been filled out completely and correctly This Declaration of Conformity and the responsibility of the manufacturer are no longer valid if any modification to the tail lift is made without the prior written permission of the manufacturer or if the maintenance instructions have been neglected and or the periodic inspections have not been executed Applicable CE Directives e 2006 42 EC Signature stamp manufacturer Belsele DHOLLANDIA NV Gentstraat 49 9111 BELSELE Tel 32 0 9 349 06 92 Fax 32 0 9 349 09 77 BTW 432 147 371 DISCLAIMER Warning The illustrations and information contained within this manual are not contractually binding and cannot lead to any form of legal action against DHOLLANDIA DHOLLANDIA tail lifts are constantly being adapted to new vehicle and chassis develop ments and specialised customer requirements Therefore DHOLLANDIA reserves the right to alter product specifications without prior notice and potentially modifications or new developments might not have been taken into account at the time of printing DHOLLANDIA agent for advice I If you require further information on non c
24. the instructions of this manual After weight testing with nominal capacity the hydraulic pressure has been at Remarks Signature of the inspector C3 CHECKLIST FOR THE PUT INTO SERVICE TEST 4 1 General inspection on the fitting parameters The vehicle is technically suitable for the type of lift and its nominal capacity The requirement for mechanical or hydraulic stabilising legs has been checked and been fulfilled if applicable The actual fitting dimensions don t exceed the theoretical maximum fitting dimen The position of the exterior control box conforms to the fitting instructions The power feed to all auxiliary controls is wired into the safety switch on the exte rior control panel When the exterior control box is alive non of the auxiliary con trol units is activated and vice versa The hold to run principle works on all control units any ongoing movement should immediately stop when one of the corresponding switches is released The cables going to the platform platform lights foot controls are properly sions mentioned in the fitting drawings routed and cannot be damaged during the various movements of the lift and the Fitting amp Body Building instructions from the vehicle manufacturer There are no visible oil leaks after the weight tests all cylinders are free from paint remainders The hydraulic circuits have been purged conform to the fitting instruct
25. 2 Gentiication ne 82 14 Checklist for maintenance amp inspection B 3 Description AG z 82 4 Expert competent person C2 4 Safety Devices 11 3 Grease plans B15 2 5 Initiative to organise inspections 2 5 Safety instructions for the use of the lift A15 4 Testing the cable chain rupture device B17 3 Validation of the manufacturer s warranty C3 85 1 Introduction A15 5 Ordering spare parts B18 4 Scope of the put into service test C3 85 2 General safety instructions A15 6 Fault finding amp repair B18 Fitting Declaration C3 5 3 Danger zones risk of crushing amp sheering A18 6 1 Summary activation of electrical solenoids per lift 4 1 85 4 Auxiliary controls Position of the operator on the 19 j ee i H Checklist for the put into service test C4 platform 7 Emergency operation B27 Inspection certificates C6 85 5 Instructions for loading amp unloading A21 87 1 Introduction and safety instructions B27 Maintenance amp Repair Reports C11 5 6 Importance of good maintenance A22 7 2 Operation of the SINGLE ACTING valves B28 5 PUWER amp LOLER in Great Britain C14 85 7 Instructions for working at loading docks A23 7 3 Operation of the DOUBLE ACTING valves B29 PUWER the Provision and Use of Work Equip 6 Loading diagrams A24 7 4 Manual override of the starter solenoid B29 99 1 ment Regulations 1998 014 7 Operating instructions 26 8759 Course of action _____ B30 552 LOLER the Lifting operations and Lifting Equip
26. 3 6 A warranty claim can only be admitted for further investigation when the following docu mentation is available e A fitting declaration from the hands of the installer of the HTL confirming that the HTL is correctly fitted according to the Fitting Instructions of DHO and the Body and Equipment Building Instructions of the manufacturer of the CV e A weight test and commissioning certificate with positive result e of the last inspection certificate relating the yearly inspection TUV inspec tion special inspection or repeated inspection e Acopy of the last maintenance and repair report as mentioned in the User s Manual 8 3 7 The final decision if a warranty claim is accepted and reimbursed by lies with DHO alone 8 3 8 The right of DHO to have specific warranty works carried out in specific workshops ap pointed by it doesn t entitle the user of the HTL in case of repetition or with another HTL under warranty to have works carried out in non DHO workshop This requires in all cases the prior approval of DHO Non observation of this clause annihilates the product warranty 8 3 9 Failing parts must be returned to DHO within 15 days after execution of the works free of transport port and package charges Upon positive recognition of the warranty claim only the cost of the most economical transport means is reimbursed 8 3 10 For the parts that DHO acquires from its own suppliers the wa
27. RL B33 pl GN gt EXTRA 5 Drit 1 0580417074 Type SIDE COLUMN LIFT DH VOCZ S802 automatic tilt at groundlevel Power pack G LD L R 03 Valve V012 D Plan N Sch VOCZ V012 D GS 5708 2008 01b OLOUR CO 6002 H tO O LM HYDRAULIC MEMORY BLACK BUTTON 5 2 L gt gt m ly N INS N XTR CTRL lermuiine lal D jej S S TW N SS 7 2 L 8M HYDR POWER PACK BATTERY 71412 XNV 742 LIL 3015 24 B34 Type SIDE COLUMN LIFT DH VOCZ Power pack G LD L R 03 Plan N m 5802 automatic tilt at groundlevel Valve VO12 D Sch 0 2 012 0 65 2007 01 Date 11 06 2007 DEOLLANDIA B35 Type COLUMN LIFT DH VB4 WITH HYDRAULICAL CLOSURE 5727 8 Power pack G SD L 01 02 Valve V012 D V096 D Plan Sch 4 012 0 5008 2009 01 01 12 2009 PEOLL ANDLA pes OLOUR COD DIN 47100 gt 1 I lI 1 11 f tO T EXTERIOR CONTROL BOX REF 2810 Ly 62 VOI2 D V096 D ES VARTE ACTING VALV ON LIFT H amp TILT S DOUBL HYDR B36 Type DH Plan
28. SPECTION CERTIFICATE for 1 PERIODIC INSPECTION L SPECIAL INSPECTION RE INSPECTION Date of inspection Evaluation the tail lift is safe and suitable for further use The tail lift identified in the Declaration of Conformity has been inspected on its YES LINO operational safety and reliability Place date Name amp function of the expert During this inspection no imperfections have been found or Name amp address of the inspection body L During this inspections the following shortcomings have been identified Follow up by the owner or fleet operator LI Shortcomings have been acknowledged Scope of the inspection LI Shortcomings have been repaired Place date Name amp signature of the owner or fleet operator Partial inspections to follow DHOLLANDIA R INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION L SPECIAL INSPECTION RE INSPECTION Date of inspection Evaluation the tail lift is safe and suitable for further use The tail lift identified in the Declaration of Conformity has been inspected on its YES LINO operational safety and reliability Place date Name amp function of the expert During this inspection no imperfections have been found or Name amp address of the inspection body L During this inspections the following shortcomings have been iden
29. adjust the hydraulic pressure on the pressure relief valve so that the nominal capacity is just reached Seal the pressure relief valve after final adjustment Put a load of 1 25x nominal capacity at the centre of gravity the platform should not be able to lift Remark 2 16 Administrative obligations What to verify Execute service or repair if required Freq _ 1 Maintenance amp repair reports e All works are duly documented in the corresponding report or certificate documents always LI Certificates for Periodic inspection Special Inspection Re inspection DHOLLANDIA 3 GREASE PLANS Fig 3 1 Lower beam lift with chains amp manual OPEN CLOSE e Grease schedule under normal conditions of use and a single labour shift the schedule can be limited to 3 thorough greasings per year e Incase of very intensive use multiple shift 24h operation or use a hostile environ lt J ment food industry frequent high pressure cleaning with strong detergents the fre Grease Lubricate with quency of greasing should be increased adjusted to the specific working conditions ac oil cording to practical experience In case of doubt contact your local DHOLLANDIA agent e Before greasing the HTL should be cleaned with a high pressure steam cleaner in order to clear the lift columns amp lift runners from hardened grease and debris and all articulation points and grease nipples if applicable
30. amp down 1 Floor extension optional extension of the vehicle floor between the lift columns till the front edge of the platform Platform carries the load during loading unloading Manufactured from steel or light weight aluminium and foreseen of a non slip working surface Travel lock mechanical lock mounted on the lift columns keeping the platform in its vertical travel position when not being used and holding the platform hard against the rubber buffers 44 Lift runners set of 2 profiles carrying the platform and its load They are lifted low ered by the lift cylinder s 45 Lift cylinder s hydraulic cylinders used to LIFT LOWER the lift runners the plat form and its load 46 Tilt cylinder s hydraulic cylinder used to OPEN CLOSE the platform or to change its angle when deployed in open position Fixed leading edge the fixed leading edge is the standard execution for all column lifts and provides a smooth access over the rear edge of the platform As an option various types of hinged ramps are available 48 Hydraulic power pack contains the electric motor driving the hydraulic pump the oil tank and the control valves Electric control box mounted in a fixed position under the vehicle chassis Contains the electrical switches allowing the operator to execute all tail lift functions Remark Pos 46 is only for lifts with hydraulic OPEN CLOSE On lifts with manual OPEN CLOSE they are rep
31. ance amp Repair Reports O Inspection Reports B 2 4 Identification marking amp satefy decals What to verify Execute service or repair if required LI Identification sticker serial number Pictograms on the various control units LI Decal with user s pictograms near the exterior control box LI Marking of the centre of gravity LI Marking of the safe working zone on the platform for wander lead with spiral cable amp fixed interior control LI Other originally applied safety decals amp signs Remark 2 5 Protection against unauthorized use 1 On off isolator switch for the HTL in the vehicle cabin LI Battery switch the exterior control box of the HTL LI Safety switch in the exterior control box Remark _ _ 7 e Readability e completeness e Fixation amp adhesion to the surface What to verify Execute service or repair if required W52 Jl W52 Jl e General condition e Function amp operation e General condition e Function amp operation automatic return to the neutral 0 position all switches B8 2 6 Electrical control devices What to verify Execute service or repair if required Exterior control box e General condition LI Joy stick push buttons rotary switches e Function amp operation L Protection rubbers on the buttons amp switches e Automatic return to the neutral 0 position all switch
32. asured at the incoming pole of the starter solenoid verify the 35mm battery cable to the battery switch in the exterior control box and measure if the battery switch itself passes through the current ER B20 6 4 Symptoms of weak batteries or damaged current supply continued If no 24V 12V is measured at the incoming pole of the battery switch check out the 35mm battery cable the 250A main fuse all plug connections if applicable and the complete power circuit up to the batteries of the vehicle Charge the batteries verify the function of the separate cells and renew the batteries if necessary Seek the reason for flat batteries damaged or corroded fuse under rated alternator and repair or adjust 6 5 The electric motor doesn t run but the downward functions OPEN LOWER work fine e The button switch or electric contacts are faulty or the connection to one of the contacts is loose e The electric cable is cut or damaged or there is a bad contact e The incoming or outgoing connection to the electrical distribution block in the power pack is faulty e The starter solenoid in the power pack is defective e The carbon brushes of the electric motor are worn out e The thermal fuse inside the electric motor earth of the starter solenoid is switched off by overheating caused by overload or insufficient battery tension e The 35mm battery earth cable is damaged or l
33. ated as follows Fig 7 14 Operation of column lifts with hydraulic OPEN CLOSE Opening the platform Consult the user s manual before getting started Observe all safety instructions Switch on the electrical power to the tail lift cabin switch in the driver s cabin and battery switch near the exterior control box If applicable LOWER the mechanical or hydraulic stabilising legs into work position 3 Whilst standing beside the platform not under LOWER the platform 150mm to disengage the mechanical travel lock 4 OPEN the platform 90 into the horizontal work position Loading amp unloading Select between exterior control box and auxiliary controls 5 Use any of the functions LOWER depicted in 7 1 to 7 5 to LOWER the platform to the ground Use any of the functions LIFT depicted in 7 1 to 7 5 to LIFT the platform to the ve hicle floor level Observe the loading diagrams amp instructions at all times Closing up in travel position 7 LIFT the platform up to a convenient height for closing LIFT the platform until the mechanical travel lock is engaged If applicable LIFT the mechanical or hydraulic stabilising legs into travel position Switch off the electrical power to the tail lift cabin switch in the driver s cabin and battery switch of the exterior control box Close the lid of the control box DHOLLANDIA CLOSE the platform until it reaches the closed vertical position and y
34. ately and ask advice from DHOLLANDIA prior to contin uing Identify the failure and repair High Override the starter solenoid as described above preference Apply an external auxiliary battery directly to the electric motor Use an external power pack to LIFT and CLOSE the platform back into its travel position Last help Identify the failure and repair Use the manual emergency operation on the valve to actuate the corre sponding function DHOLLANDIA Type COLUMN LIFT DH VOC A WITH MANUAL CLOSURE Power pack G RS L 03 04 Valve V005 Plan 1800 7 801 gt lt Z Q F068 5008 Sch VOC V005 5008 B 2009 01 2009 Date BATTERY 15 09 2009 F DHOLLANDIA S IN THE POWER PACK NO VALV B31 Type COLUMN LIFT DH VOC A WITH MANUAL CLOSURE 2009 Power pack G RS L 03 04 Valve V005 Plan N Sch VOC V005 EC5008 EC5010 2009 01 Date 15 09 2009 PHOLLANDLA Z Z ul gt gt gt m COLOUR CODES DIN 47100 C5010 H CONTROL BOX lt CONTROL Box EC5008 H J S IN THE POWER PACK MECH NO VALVE B32 Type COLUMN LIFT DH VOC WITH MANUAL CLOSURE 2007 Power pack G VH L 01 02 Valve V079 Plan Sch 0 079 2007 01 51 BATTERY EXTRA CT
35. atteries and verify if the power pack is properly earthed none of the electric valves starter solenoid electric motor can work without a good earth link 6 4 Symptoms of weak batteries or damaged current supply e The downward functions OPEN amp LOWER are working but the upward movements LIFT amp CLOSE are failing e The electric motor still runs but audibly slower and laboriously e The starter solenoid switches on but the electric motor doesn t react e The starter solenoid quickly switched on and off doorbelling e Nothing at all happens where 35mm is mentioned also other cable sections 25mm 50mm are implied _ DHOLLANDIA Remove the lid of the power pack and measure the tension at the incoming pole of the starter solenoid when the sys tem is under strain push the function LIFT If you measure 24V 12V check the working of the starter solenoid when pushing the function LIFT you should meas ure 24V 12V at the outgoing pole of the starter solenoid verify and measure the 35mm battery cable to the electric motor check the earth link of the starter solenoid and the earth link of the electric motor up to the vehicle batteries Also if you measure 24V 12V on the multimeter also check if there is sufficient Amp by using a test bulb If the bulb doesn t light check for poor connection at the 250A main fuse and the whole 35mm battery cable up to the power source If no 24V 12V is me
36. bly slightly above or below perfect horizontal level is automatically repeated upon every new LIFT cycle off the ground This angle is memorised Without tilt cylinders With tilt cylinders e Automatic tilt should be used with auxiliary controls featuring the functions LIFT LOWER only 4 button foot controls 2 button wander leads 2 button fixed interior controls The use of 3 or 4 button auxiliary controls including TILT results in confusion and errors It might cause damage to the tail lift and injuries to the operator or third parties near by DHOLLANDIA 8 WARRANTY CONDITIONS 8 1 Abbreviations DHOLLANDIA or her official national agent distributor HTL Hydraulic tail lift CV Commercial vehicle 8 2 Period 8 2 1 The warranty period lasts 12 months from the day that the HTL is taken into operation for the first time This point in time is determined by the date of the weight test and commis sioning of the HTL prescribed by and conform with the CE Machine Directive and the fitting instructions of DHO without exceeding however 3 months after the delivery date of the HTL concerned For this purpose the results of the weight test and commissioning must be duly reported and inscribed in the Fitting Declaration in the User s Manual issued with every HTL 8 2 2 The initial warranty period is not modified or influenced by occurring service repair or improvement works or by the r
37. ccess ramp when fully opened over 180 Floor extension optional extension of the vehicle floor between the lift columns till the front edge of the platform Hydraulic power pack contains the electric motor driving the hydraulic pump the oil tank and the control valves Electric control box mounted in a fixed position under the vehicle chassis Contains the electrical switches allowing the operator to execute all tail lift functions Remark Pos 26 is only for lifts with hydraulic OPEN CLOSE On lifts with manual OPEN CLOSE they are replaced by Pos 6 8 9 e The DH VA DH VH and Carco C series comprise of a range of fully hydraulic col umn lifts designed for a wide variety of trucks trailers and semi trailers and are availa ble with lift capacities of 500 to 3 000kg In its travel position the platform of the column lift is stowed vertically behind the vehicle body Before use the platform is lowered approx 20cm then tilted open 90 from the vertical travel position to a horizontal work position The functions OPEN amp CLOSE can be manual supported by torsion springs or actuated by a hydraulic tilt cylinder Main details amp terminology 9 _ DHOLLANDIA Fig 3 3 Fully hydraulic column lift Description Lift columns set of 2 columns mounted in a fixed position against the vehicle body They form the tracks in which the lift runners carrying the platform go up
38. concerned e g Remove the solenoid from the elec trovalve when this action doesn t end the malfunction the cause is not electrical e g dirt in the cartridge damaged sealing Disconnect the auxiliary control to further isolate the problem and narrow down the scope Measure the tension at the electrical distribution block in the power pack and repair the fault 86 3 HTL doesn t react on the exterior control nor on the auxiliary control 6 Isolator switch for the HTL in the vehicle cabin is not switched on e Main power plugs between the tractor unit and the semi trailer are defective or not plugged in e 250A main fuse is out of order corroded heated and burnt by bad connection e Battery switch in the exterior control box is not switched on or is out of order doesn t pass the current e 15A fuse in the control box is defective e The power pack is not properly earthed Switch on the isolator switch for the HTL in the vehicle cabin Plug in measure the tension and or repair the plugs between the tractor and semi trailer battery link earth link and the charging system Verify the 250A main fuse and repair or replace if necessary Switch on the battery switch in the exterior control box Measure if the switch passes current to the 2nd pole Verify the 15A fuse on the control panel of the exterior control box and repair or replace if necessary Establish a direct earth link to the HTL b
39. ctuated by a hydraulic tilt cylinder Main details amp terminology Fig 3 2 Overhead beam column lift with hydraulic OPEN CLOSE fw decir Lift columns set of 2 columns mounted in a fixed position against the vehicle body They form the tracks in which the lift runners carrying the platform go up amp down Cylinder beam horizontal beam mounted at vehicle roof level It contains the lift cyl inder and the drive mechanism consisting of steel ropes or chains plus pulleys Platform carries the load during loading unloading Manufactured from steel or light weight aluminium and foreseen of a non slip working surface _ DHOLLANDIA A8 _ DHOLLANDIA Travel lock mechanical lock mounted on the lift columns keeping the platform in its vertical travel position when not being used and holding the platform hard against the rubber buffers Lift runners set of 2 profiles carrying the platform and its load They are lifted low ered by the lift cylinder and the drive mechanism consisting of steel ropes or chains plus pulleys Lift cylinder hydraulic cylinder used to LIFT LOWER the lift runners the platform and its load Tilt cylinder optional hydraulic cylinder used to OPEN CLOSE the platform in case of a lift with hydraulic OPEN CLOSE Hinged ramps optional foldable ramps at the rear and or side of the platform serving as roll stop device when raised 90 in vertical position and as a
40. d the load itself are ade quately strong Tail lifts which lift people must be operated in a way that avoids risks to operators or pas sengers Employers should be sure that the lift has been installed properly and that in use the vehi cle and tail lift are positioned so as to ensure safe working conditions for operators and bystanders Lifting tasks must be planned supervised and carried out safely The tail lifts must be thoroughly examined after they have been installed on the vehicle and before they are first used In service they must be thoroughly examined at least every 6 months The content of these thorough examinations is defined not by the tail lift manufac turer but by a competent person appointed normally from outside the company by the user of the equipment He will report any defects and specify the time within which they must be rectified Whilst this examination may well include testing there is no legal requirement for a weight test to be performed every six months For more information refer to Safe Use of Lifting Equipment ACOP and guidance L113 HSE Books ISBN 0 7176 16282 Remark the particular and national character of the Puwer and Loler regulations don t liberate the users and owners of DHOLLANDIA tail lifts in any way of the full requirements with regards to periodic servicing and testing reporting described in the users manual DHOLLANDIA s own written instructions are of prime importance
41. dible Any other e Remark When checking on the correct tightening of the bolts the only accurate tool to use creaking grinding or shrieking noise should be carefully investigated to avoid dam is a torque wrench The following values are prescribed age Prescribed tightening moment M N m e The maintenance frequency depends on the intensity and conditions of use The mini Type of thread strength class mum frequency for the various works is given below 8 109 W52 52 x year weekly check by owner operator X I 3x year 4 monthly check by qualified DHOLLANDIA service agent O X 1 20 gt J1 yearly winter maintenance to be executed just before the winter so that any condensation water in the hydraulic circuit can be removed during the oil change and frost problems during the winter can be avoided e HTL are subject to compulsory periodic inspections by an expert competent person see 82 4 in chapter The frequency of these inspections is set at minimum 1 year for most countries in Europe In the United Kingdom the frequency of the LOLER examination or the Statutory Thorough Examination is set at minimum 2 year by the Health and Safety Executive HSE _ DHOLLANDIA BG _ DHOLLANDIA CHECKLIST FOR MAINTENANCE amp INSPECTION Legend W52 Weekly check by owner fleet operator STE Statutory Thorough Examination UK or Periodic inspection b
42. e electric cable to one of the safety valves O or S needed to OPEN is interrupted or has amp or open the safety valves manually via the emergency operation if the valves are opened manually and the platform a bad contact OPENS the cause is electrical for sure One of the solenoids O or S needed to OPEN is defective or the cartridge of one of the See explanation of the different techniques under 6 7 valves is mechanically defective e One of the braking valves on the cylinders or in the power pack is mechanically blocked by If one of the valves is not energized measure the current amp earth circuit to that solenoid into the control box and repair ice dirt or by mechanical malfunction The travel lock has not been opened lf the electrical operation of all solenoids is correct verify the cartridges of the valves for mechanical damage Dismount One of the tilt cylinders is blocked piston rod bent by accident interior spring or piston is the braking valves on the cylinders and in the power pack to verify if they work ok seized up er Finally verify the tilt cylinders and their spring for mechanical damage 86 9 The lift capacity is insufficient the HTL doesn t reach the full nominal capacity e The load is too heavy or removed too far from the centre of gravity Check the lift columns and lift runners for visible damage and repair Clear all debris from the lift columns clean them e The
43. e electric plugs of the main power supply to the HTL plus and earth de fects to the batteries defects to or caused by any type of low battery appliance alarm or anti theft device prescribed or mounted by the customer all other electrical failures to the electric motor the starter solenoid other switch elements caused by insufficient battery or power capacity 8 4 9 Damage caused by normal and natural wear and tear Damage or defects caused by inaccurate or faulty fitting unless mounted by DHO Damage or defects caused by negli gence and disregard of the DHO Maintenance and Repair instructions and by disregards of the prescribed maintenance intervals Damage or defects caused by negligent or improper use by negligence and disregard of the general or product specific DHO user s instructions by abuse or improper use of the HTL for any application other than its normal intended use as described in the DHO User s Manual by overload collision or any other form of accident and by all other influences as for as they cannot be attributed to a fault or mistake from DHO 8 4 10 Defects and damage caused by unauthorised modifications to the original construction or safety devices of the HTL without explicit prior written approval by DHO during the fitting process or afterwards e g during repair and maintenance works 8 4 11 As far as any given incident is not covered by the legislation on product liability and warranty a warra
44. e platform should hold to the hand grip mounted to the rear frame of the vehicle body See Fig 5 16 e f hinged foot protector see Fig 5 10 or safety cut out see Fig 5 11 is used the fixed interior control should only be used inside the vehicle body from a safe working zone of min 400x400 mm clearly and permanently marked at min 250 mm distance from the hazard zone between the platform and the rear of the vehicle floor See Fig 5 17 e In addition to having the safe working zones on the platform amp the vehicle floor perma nently marked it is recommended to mark the hazardous areas at the end of the vehicle floor and the front of the platform in a contrasting colour See Fig 5 18 e The safe working zones for the operator must be kept clear at all times It is prohibited to put load on these dedicated areas e The operator should always stand besides the load to prevent him from being crushed between the load and the rear side of the vehicle e To prevent injury when falling from heights it is compulsory to use safety gates along the exposed edges of the platform if the lifting height 2000mm prevent injury by tripping the operator should pay attention to protruding items on the platform surface at all times ex platform lights roll stops and their lever etc e tis prohibited to use the platform as elevated working platform e The power feed to any of the auxiliary controls shou
45. e platform stands in its closed position Consult the spare parts list to check the cylinder construction In order to remove the articulation pins of such cylinders the platform must be opened to 45 first to release the tension from the springs secure platform against accidental fall see For the revision of the tilt cylinders with internal spring make sure this spring is without tension before opening up the cylinder Consult the spare parts list to check the cylinder construction Negligence may lead to serious injury Before opening any hydraulic cylinder make sure that you manually open the safety valve via the manual emergency operation and you remove the hydraulic pressure from the system see Fig 1 10 Support the cylinders during dismounting to prevent them against free fall onto the ground upon extraction of the articulation pins Remounting hydraulic cylinders when the underside of the cylinder is connected to the frame with the corresponding pin the easiest way forward is to connect the hydraulic pipe to the cylinder first so that the cylinder can be extended to the correct length by means of the regular electrical controls Take into account that after a repair the cylinders are filled with air and that the piston rods will slide out with shocks when the cylinder is filled with oil Therefore when re mounting the articulation pins never check with your finger if the eye of the cylinder is lined up wi
46. ed on the right side of the vehicle For control boxes mounted to the left side of the vehicle the images should be mirrored e The standard control box contains a 4 way joystick operating the functions LIFT LOW ER CLOSE plus a safety switch e The safety switch can be a rotary switch with removable key see Fig 7 1 a standard rotary switch see Fig 7 2 7 3 or a push button see Fig 7 4 They function as follows Rotary switch as safety switch See Fig 7 5 Switch turned amp held clockwise 1 Activates the joy stick in the exterior control box and deactivates the auxiliary controls Switch turned counter clockwise 2 Activates the auxiliary controls and deactivates the joy stick in the exterior control box 1 Hold to run principle when the safety switch is released it will automatically return to the neutral position and deactivate the joy stick 2 Fixed position the auxiliary controls remain active as long as the safety switch is not manually returned to the neutral position choice for exterior control box 1 lt choice for gt gt auxiliary controls 2 Push button as safety switch Button pushed in Activates the joy stick in the exterior control box Button left idle Activates the auxiliary controls joy stick operates the 4 basic functions LIFT LOWER CLOSE amp OPEN See Fig f Symbol Joystick Symbol Joystick 7 5 LIFT 4 CLOSE N Z LOWER 1
47. eplacement of failing parts 8 3 Conditions 8 3 1 In case of a warranty claim DHO has the right to examine the defect or failure or to have it examined For this purpose the supplied object if mounted to a wheeled vehicle must be presented at the DHO workshop or any other workshop appointed by DHO to this respect The same is also valid for the warranty repair works themselves 8 3 2 Warranty can only be attributed to HTL which are maintained in the original delivery condition and specification Modifications to the construction or safety devices of Dhollandia HTL are strictly forbidden except in case of explicit prior written approval by DHO 8 3 3 Defects failures deficiencies in general that restrict the utility of the HTL due to faulty design construction material deficiencies or failing manufacture are solved by rectifying works or by substitution replacement and this at the discretion of DHO _ DHOLLANDIA A36 8 3 4 Upon becoming apparent defects failures deficiencies in general must be immediately reported to DHO via the fastest possible way Warranty claims which are older than 30 days will be declared inadmissible Parts replaced under warranty become the property of DHO 8 3 5 The warranty is only valid for HTL which are mounted serviced repaired and con served according to the relevant instructions from DHO and for which all works have been carried out using original DHO spare parts 8
48. es LI Lid over the control box e Conditions of electrical cables wires and protection rubbers O Position of the exterior control box e Conformity with the fitting instructions between 300 amp 600mm from centre line of the control box to the rear side of the vehicle body LI 15A fuse in the exterior control box e General condition LI Electrical contacts in the various control units e Moisture inside the control unit amp corrosion e Fixation amp tightening of all cable amp wire connections LI Foot controls optional e See points above e Condition routing amp guidance of the electrical cables from the platform over the lift arms to the connection point in the power pack or exterior control box O Safety issues on foot controls e Connection to the safety button in the exterior control box see fitting instructions e Compulsory 2 feet operation Wander lead with spiral cable optional e See points above LI Fixed interior control optional e Condition of the spiral cable condition of the plug connections e Position inside the vehicle body protection against damage by the load O Safety issues on these controls e Connection to the safety button in the exterior control box see fitting instructions e Marking of safe working zone on the platform and or on the loading floor inside the vehicle body e Conformity with fitting instructions re toe protection _ DHOLLANDIA 2 7 Electrical installation What to verif
49. f the columns e Corrosion Lift columns lift runners e General condition check for cracks amp deformation e Straightness of the columns and runners e Corrosion e Smooth sliding UP DOWN e Wear of bearings rollers pins and slide surfaces e Adequate LI Articulation pins e General condition deformation LI Articulation bearings e Locking of the articulation pins by locking pins bolts amp nuts e Wear of bearings rollers pins and slide surfaces if applicable e Presence of grease nipples correct and regular greasing LI Cylinder beam amp drive system steel cables chains pulley blocks pulleys and e General condition check for cracks amp deformation wear stretching their roller bearings sprockets e Alignment of pulleys chains or steel cables e Correct lubrication LI LSD Load Safety Device cable rupture device chain rupture device e General condition function amp operation correct lubrication M3 e Execute LSD test following Chapter 4 J1 LI Mounting plates fixation to the vehicle body e General condition check for cracks deformation M3 LI Mounting plates of the bumper bar e Presence condition amp correct tightening of all mounting bolts J1 Remark DHOLLANDIA 2 12 Platform What to verify Execute service or repair if required L Platform construction e General condition condition of the welds M3 e Check for cracks amp deformation J1 e Corrosion A
50. f the deployed platform any platform protruding beyond the ex tremities of the vehicle must be clearly visible from all approachable sides in daylight and at night Check the national regulations of the country where the vehicle will be registered as the se might be very strict on the application of platform lights and the size and type of the platform flags The impact of platform lights see Fig 4 14 a reflective flags see Fig 4 14 b and lateral reflecting tape see Fig 4 14 c on the visibility of the platform strongly depends on the direction of approach and the light conditions bright sunlight versus night darkness A combination of the 3 is ideal to cover all circumstances Outside the delivery scope of a tail lift it is good practice to encourage operators to mark the working area of the platform in the streets by means of traffic cones see Fig 4 14 d DHOLLANDIA e Fig 4 15 Roll stops on the platform optional any platform aimed to LIFT and LOWER rolling loads must be equipped with a device that prevents this load from rolling uninten tionally off the edge DHOLLANDIA roll stops can be fitted into the platform point or at intermediate distances further towards the front edge of the platform see Fig 4 15 As alternative on platforms equipped with hinged ramps these ramps can be opened and raised 90 in vertical position to serve as roll stops or opened over 180 to service as acce
51. f the operator is intoxicated or impaired in any way e Use extreme care in wet or slippery conditions e The tail lift should be used by means of original control units only DHOLLANDIA dis claims liability for any personal injury or property damage that results from operating a product that has been modified from the original design e In traffic always respect a safety distance of 5m to the following car and ask other driv ers to respect an equivalent distance when parking behind your tail lift see Fig 5 3 _ DHOLLANDIA A16 These platforms are often equipped with invisible torsion bars reinforcing the manual open close movement As a consequence depending on the setting of this torsion bar the platform might start to open close by itself from the mo ment that the corresponding lock is released These torsion springs incorporate a significant amount of energy and are po tentially dangerous Incorrect installation use or adjustment servicing may result in serious injury of the operator or service personnel Bear in mind that in case of mechanical failure the platform might have been closed with the help of external devices forklift gantry crane and that the platform might drop in free fall to the open position after disengaging the travel lock Don t attempt to control the opening speed of the platform just by human force The platform might be very heavy up to more than 100kg to handle
52. f the torsion bars manual closure lift or in case of accidental loss of hydraulic pressure hydraulic closure lift e Fig 4 3 Platform retaining catch mounted on the lift runners of tail lifts with manual closure When the platform is lowered out of the travel lock it prevents the platform from falling open in case of damage or incorrect setting of the torsion bars manual closure lift e 4 4 Braking valves flow control valves mounted to the hydraulic cylinders and the power pack Pressure compensating braking valves are used to align the speed of the functions LOW ER and OPEN with the legal requirements This is Vertical movements max 15cm sec OPEN amp CLOSE max 10 sec min 9 sec for the opening and closing cycles OPEN speed 40cm sec up to 500kg capacity max 30cm sec for other lifts at groundlevel max 4 sec Compensating means that the valve brakes less more if the load is lighter heavier to obtain similar speeds regardless of the load on the platform _ DHOLLANDIA 11 e Fig 4 5 Pressure relief valve permits the manufacturer and the installer to limit the final performance of the tail lift to its nominal capacity and protects it against overload during the LIFT cycle e Fig 4 6 2 hand exterior control box equipped with functional control switches and a safety or selection switch The compulsory use of the 2 hands to actuate the tail lift func tion
53. following obligations on owners fleet operators Operate safely Carry a risk assessment of your operation Set up a formal maintenance plan Ensure that both lift users and service personnel are trained and that they have writ ten instructions gt Ensure that lifts are safe Lifts provided after 1997 should meet the Machinery Direc tive gt Plan lifting operations and ensure they are supervised Appoint a competent person This appointed competent person should establish a thorough examination proce dure minimum every six months Rectify any reported defects 85 1 PUWER the Provision and Use of Work Equipment Regulations 1998 e Applies to all work equipment including tail lifts but also includes vehicles e Strengthens the requirements of the Management of Health and Safety at work Regula tions 1992 e Stipulates that vehicles and lifts must be maintained in a good state of repair e Only competent trained people should operate repair and service the equipment e Lifts supplied from 1993 1996 may require upgrading to meet the Essential Safety Re quirements of the Machinery Directive e For more information refer to Safe Use of Work Equipment ACOP and guidance L22 HSE Books 1998 ISBN 0 7176 16266 _ DHOLLANDIA C14 5 2 LOLER the Lifting Operations and Lifting Equipment Regulations 1998 Employers must ensure that the lifting equipment its mounting an
54. ft runners keeping the platform in closed vertical position once the platform is released from the travel lock DHOLLANDIA Open platform lock lock mounted on the lift runners keeping the platform in open horizontal position after being opened manually Otherwise torsion bar 8 would tilt up the platform Hinged ramps optional foldable ramps at the rear and or side of the platform serving as roll stop device when raised 90 in vertical position and as access ramp when fully opened over 180 Hydraulic power pack contains the electrical motor driving the hydraulic pump the oil tank and the control valves Electric control box mounted in a fixed position under the vehicle chassis Contains the electrical switches allowing the operator to execute all tail lift functions Remark Pos 6 8 9 are only for lifts with manual OPEN CLOSE On lifts with hydraulic OPEN CLOSE they are replaced by Pos 26 e The DH VB series comprises of a range of overhead beam column lifts designed for a wide variety of trucks trailers and semi trailers and is available with lift capacities of 500 to 2 000kg In its travel position the platform of the column lift is stowed vertically behind the vehicle body Before use the platform is lowered approx 20cm then tilted open 90 from the vertical travel position to a horizontal work position The functions OPEN amp CLOSE can be manual supported by torsion springs or a
55. functions LIFT LOWER the closure of the platform is done manually The emergency switch enables the operator or any bystander to cut off the power to the control unit is case of emergency See Fig 7 8 e When using this control to LIFT LOWER the platform the operator should ensure at all times to keep his hands and limbs clear from the moving parts of the tail lift A Keep clear of moving parts Beware of hand foot and head traps at all times i choice for 7 4 Auxiliary controls listo C gt auxiliary controls e The auxiliary controls should be used with full respect of the particular safety instructions of 5 4 e f the safety switch in the exterior control box is a rotary switch this switch should be turned counter clockwise to activate the auxiliary control See Fig 7 9 e The foot controls option 5006 or 5075 are equipped with 4 buttons 2 buttons to LIFT 2 buttons to LOWER Any of the 2 movements is stopped immediately if 1 of the 2 buttons is released or if a wrong combination of buttons is actuated See Fig 7 10 LOWER DHOLLANDIA a e The 2 button wander lead with spiral cable option S001 and the 2 button fixed interior controls option S003 S005 are equipped with 2 buttons 1 button to LIFT 1 button to LOWER See Fig 7 11 e The use of 3 button wander leads with spiral cable enabling the operator to additionally TILT the platform is disallo
56. gged up with debris and dirt e One of the piston rods of the lift cylinders tilt cylinders is bent by overload or by accident e The logical 3 way valve in the main valve block V012 or V096 in the power pack leaks and opens closes the return of oil to the reservoir alternately e The braking valve in the power pack or one of the braking valves in the banjo couplings on the lift cylinders tilt cylinders is blocked mechanical defect or blocked by dirt or ice Check the lift columns and lift runners for visible damage and repair Clear all debris from the lift columns clean them with high pressure steam cleaner and apply grease Verify if the piston rods of the lift tilt cylinders are straight and if they move freely and smoothly through the cylinder head Dismount the non return valve from the 3 way valve in the main valve block V005 V012 or V096 in the power pack Clean the seat of the bullet ball reshape it if required renew the bullet and reassemble the valve Dismount the braking valve in the power pack and the banjo couplings on the lift tilt cylinders Verify if all run freely and work correctly 6 14 The platform LOWERS slowly without any control being actuated the platform angle remains unchanged The safety valve D needed to LOWER on the lift cylinders or in the power pack is leaking The O ring of the cartridge is damaged or the valve is stuck in open position by dirty or ice e The seal o
57. gh and must be incorporated into a complete vehicle to become operational CEMD regards the complete vehicle including the tail lift and any other ancillary equipment as one single machine The manufacturer s Declaration of Conformity and the authorisation to put the equipment into service must be reinforced by a put into service test by an expert and must be validated by a Fitting Declaration The content of this compulsory put into service test is explained in Chapter C Point 4 2 2 Periodic inspections Once in service every tail lift should be inspected periodically at least once per year by an expert competent person to evaluate its condition and suitability for continued use or if a Specific repair or maintenance is required The findings of these inspections should be summarised in the relevant inspection certificates see pg C6 amp following In Great Britain these periodic inspections are called Statutory Thorough Examinations and they require a frequency of min 2 times per year The content of this compulsory periodic inspection is explained in Chapter B Point 2 _ DHOLLANDIA C2 2 3 Maintenance amp Repair Reports special inspections re inspections All maintenance amp repair works performed on the tail lift should be reported in the Main tenance amp Repair Reports see pg C11 amp following to provide any service agent or safety officer intervening on the lift with a full history of the works
58. hanical components articulation points lift arms frames or platforms cylinders etc In case of damage or failure these components must be replaced by original spare parts e Remark for column lifts with manual closure A These platforms are often equipped with invisible torsion bars reinforcing the manual open close movement The torsion bar is preset during manufacturing and is housed in the 1st section at the front of the platform see Fig 1 8 Short aluminium platforms may have only 1 torsion bar Heavier platforms with hinged ramps longer depth platform in steel often have 2 bars running from either articulation point to a bar retainer inside the platform These torsion springs incorporate a significant amount of energy and are po tentially dangerous Incorrect installation use or adjustment servicing may result in serious injury of the operator or service personnel Therefore the tension in the bar should only be adjusted by someone who has been specifically trained to do so It is NOT a user serviceable part Bear in mind that in case of mechanical failure the platform might have been closed with the help of external devices forklift gantry crane and that the platform might drop in free fall to the open position after disengaging the travel lock Don t attempt to control the opening speed of the platform just by human force The platform might be very heavy up to more than 100kg
59. hardened grease are clogged up with debris and dirt e The LSD is engaged due to bad greasing or too much debris in the lift columns or by genu ine rupture of the suspension system steel cable or chain pulleys and sprockets If one of the valves is not energized measure the current amp earth circuit to that solenoid into the control box and repair lf the electrical operation of all solenoids is correct verify the cartridges of the valves for mechanical damage Dismount the braking valves on the cylinders and in the power pack to verify if they work ok Verify if the LSD is engaged Check the steel cables or chains pulleys and sprockets for mechanical damage and re pair Clear all debris from the lift columns clean them with high pressure steam cleaner and apply grease Finally verify the lift cylinder s themselves for any mechanical damage _ DHOLLANDIA B22 6 8 The platform doesn t OPEN the other functions work ok for HTL with hydraulical OPEN CLOSE e The button switch or electric contact are faulty or the connection to one of the contacts is Verify if the travel lock is open loose e The incoming or outgoing connection to the electrical distribution block in the power pack is Verify if the electrical operation of the safety valves O or S needed to OPEN on cylinders or in power pack is ok faulty e with a magnetic tester a solenoid generates a magnetic field when it is electrically activated e Th
60. he outgoing main pole of the starter solenoid also check if there is sufficient Amp by using a test bulb If the bulb doesn t light check for poor connection at the 250A main fuse and the whole 35mm battery cable up to the power source Also if you measure 24V 12V at the outgoing main pole of the starter solenoid verify the earth of the electric motor lf the earth of the electric motor is ok revise the motor or replace it B21 6 6 The electric motor doesn t switch off e The button or switch for LIFT in the exterior control box or auxiliary control doesn t return to Remove the plug of the control power to the starter solenoid if this action doesn t remove the fault the starter solenoid the neutral 0 position is burnt and remains activated e The button or switch returns to 0 position but one of the electric contacts behind the switch is stuck or burnt If the fault lies with the control circuit uncouple the auxiliary controls to narrow down the scope e Short circuit between the various wires in one of the electrical cables The contacts of the starter solenoid are burnt and remain activated Measure the electrical distribution block in the power pack and repair the electric fault If the control circuit isn t at fault switch off the battery switch in the exterior control box or cut the power in a different way e g remove the 250A main fuse and replace the starter solenoid Check the battery voltage when
61. if required LI General operation with empty platform e Execute all movements several times with ALL available control units The movements should W52 be executed smoothly amp quietly without strange noises M3 e Verify occurrence of any play or deformation in the articulation points when driving over the plat 1 form and when OPENING CLOSING the platform O Static test at 125 overload test on DEFORMATION Position the platform at 1 2 height STE Note the distance and angle to the vehicle floor Put a load of 1 25 x nominal capacity at the centre of gravity and remove it again Verify the distance and angle to the vehicle floor No permanent deformation should be noted O Static test at 125 overload test on INCLINATION Position the platform at the level of the vehicle floor STE Put a load of 1 25 x nominal capacity at the centre of gravity Note the distance and angle to the vehicle floor Repeat the same measurements after 15 min The platform should not be lowered more than 15 mm and should not be tilted down more than 2 Dynamic test at 100 nominal capacity Verify if the lift has sufficient lift capacity J1 Verify the general performance amp stability Verify the working speeds LIFT amp LOWER max 15 cm sec OPEN amp CLOSE max 10 sec AUTOMATIC TILT at ground level max 4 sec O Overload test Place the platform at rest on the ground STE Put a load of 1x nominal capacity at the centre of gravity
62. ilt at ground level See 7 9 Platform accessed by fork lifts is allowed only when the platform is at full rest on the ground The combined weight of the fork lift and the load should not exceed 150 of the nominal capacity of the tail lift see Fig 5 23 When unloading the platform at the ground always push the load off the platform don t pull By pushing the load from a higher position the operator avoids that the load would roll or fall over him or hit him Loads must be protected against shifting position and unintentional rolling off the plat form For loads that have no natural resistance against slipping the use of original DHOLLANDIA roll stops see 7 8 or alternative fixation devices ex ratchet straps is compulsory The gravity point of the load should not be able to move during the move ments of the platform _ DHOLLANDIA 21 5 6 Importance of good maintenance operate correctly and that no urgent maintenance or damage repair is required If any unsafe condition exists or unusual noises or movements are noticed DO NOT use the lift and contact an authorised DHOLLANDIA service agent for repair e Prior to use inspect the tail lift to ensure that all safety systems and all functions e Missing worn or illegible warning decals must be immediately replaced e Competent and regular maintenance is very important for the operational reliability and the safety of the operator and occasional third
63. inged ramps at the rear edge of the platform see Fig 7 19 5701 5 5 Hinged ramps at the sides of the platform The hinged ramps can be manually raised into 90 vertical position to serve as roll stop device or swung over 180 to serve as access ramp OPEN Pull the rear side of the ramp towards you raise and lock it into 90 verti cal position CLOSE Lift up the ramp and swing it further to the 180 open position where it can service as loading unloading ramp RANT 54 L r FER J 412 LL DHOLLANDIA 7 9 Automatic tilt at ground level e Some column lifts are equipped with a conical platform and automatic tilt at ground level This means When the platform touches the ground its point automatically See tilts down when the buttons for LOWER remain pushed in Fig 7 20 When the buttons for LIFT are pushed in and the platform See rises off the ground it will first tilt up to a preset horizontal posi Fig 7 21 tion then lift further in this setting to the vehicle floor e These and other types of lifts are equipped with tilt cylinders which allow the operator to TILT adjust the angle of the platform to the slope UP of the underground see Fig 7 22 OG e The automatic tilt incorporates a memory the angle of the platform set by the operator upon opening the platform possi
64. ions During the various movements of the lift the flexible oil pipes stay clear from the the vehicle chassis amp body They cannot be damaged by rubbing squeezing All safety decals amp labels identification sticker decal with user s pictograms decal with load diagram have been fitted conform with the fitting instructions 84 2 Inspection of the mechanical part The size number and spread of mounting bolts and or welding seams conform with the fitting instructions All mounting bolts are fastened to the prescribed torques Check for potential deformation after weight testing All welding has been performed by qualified welders All articulation pins are properly fastened and locked The lift columns are adequately greased End stops have been mounted to stop the lift runners and the platform flush with the vehicle loading floor 4 3 Inspection of the electrical part Voltage of the lift is compatible with voltage of the vehicle The foreseen batteries amp alternator suit the lift capacity application amp frequency of use The cabin switch in the driver s cabin and the battery switch of the exterior control box function OK The main fuse the battery and earth cables are fitted correctly and conform to the fitting instructions all bolted connections of cables and fuses are properly tight 84 5 Inspection of the platform The centre of gravity is correctly marked and corresponds with
65. ipment to be thoroughly examined as will enable them to detect defects or weaknesses and to as sess their importance in relation to the safety and continued use of the lifting equipment The expert competent person should read and use the content of this user s manual of the technical documentation of the tail lift and all other information required to execute the various inspections in a professional way The expert competent person should perform all inspections with due diligence fill out all points of the relevant inspection certificates and sign 2 5 Initiative to organise inspections The initiative to choose an expert and organise the inspections described above lies with the owner of the vehicle or fleet operator 3 VALIDATION OF THE MANUFACTURER S WARRANTY e The safety reliability and durability of any tail lift and its components depends on the qual ity of the fitting works e Therefore the manufacturer s warranty can only be activated and validated if it has been mounted correctly and professionally to conform with the fitting instructions if a put into service test has been executed with an affirmative result and if the findings of this test have been duly reported in the relevant inspection certificates 4 SCOPE OF THE PUT INTO SERVICE TEST e The put into service test see also 2 1 comprises of a visual inspection on the fitting work of the tail lift on the vehicle chassis and of the various a
66. ir power pack e This emergency operation enables the operator to execute certain movements by hand e g LOWER OPEN when the regular electrical controls fail and help the service agent in fault finding to distinguish between electrical and hy draulic malfunctions e Switch off the isolator switch in the vehicle cabin remove the key from the battery switch in the exterior control box or disconnect main fuse on the battery to avoid unsafe injudi cious or unauthorized use also by strangers in traffic of the HTL See Fig 7 1 e Stay out of the operation radius of the platform and stay clear of the moving parts at all times Beware at all times for potential risks of crushing or sheering fingers hands limbs feet or toes between the moving parts of the lift arms hydraulic cylinders and the moving platform See Fig 7 2 e Work from a position beside the HTL frame or over the front side of the HTL frame Nev er behind the HTL frame or under the lift arms See Fig 7 3 e Refer to the summary in 6 1 to determine which valves on the cylinders and also in the power pack in case of Double Acting valves need to be opened in order to actuate the functions OPEN or LOWER and proceed accordingly DHOLLANDIA gt e For HTL with Double Acting valves in the power pack If the power pack is mounted on the side of the HTL frame manipulate the valves on the cylinders first and open the valve in the power
67. k situation e g health amp safety regulations road traffic regulations company procedures Driver Periodic Training according to 2003 59 CE etc e The operator should have passed the minimum age of 18 years 5 2 General safety instructions e The operator should use appropriate working clothes Never wear loose fitting clothes that may be trapped in the moving parts of the tail lift Always wear safe footwear with steel protection tips and a good non slip sole and protective gloves See Fig 5 1 e Prior to releasing the mechanical platform lock and using the lift check if the lift can be used safely Take precautions to guarantee your own safety and the safety of occasional bystanders or third parties in traffic Clear the working area of any objects that could po tentially impede the movements of the lift Make sure the platform is clearly visible from all approach directions flashing platform lights platform flags traffic cones etc and that the working zone is sufficiently illuminated e The vehicle must be safely parked the parking brake applied and the engine must be switched off Lock the rear doors and fasten all other moving parts of the vehicle body DHOLLANDIA ae e For trailers amp semi trailers ensure that the vehicle cannot tip over when putting heavy weights on the platform If the vehicle or the tail lift are equipped with mechanical or hydraulic stabilising legs de ploy these bef
68. l times e The option list features 4 types of roll stop systems 215 M Manual roll stops operated by torsion springs see Fig 7 16 OPEN Press the lever on the side of the roll stop flap CLOSE Step on the roll stop flap When driving a load from the ground onto the platform the roll stop will automatically close 215 A Automatic roll stops operated by torsion springs see Fig 7 17 Kick the lever on the side of the roll stop flap sideways from position 1 to position 2 215 A will now function as a manual roll stop S215 M When stepping on the roll stop flap or when driving load from the ground onto the platform the roll stop will automatically close OPEN Kick the lever on the side of the roll stop flap sideways rearward from position 1 to position 3 S215 A will now function as automatic roll stop AUTOMATIC MODE When stepping on the roll stop flap or when driving a load from the ground onto the platform the flap automatically jump back to the open position after releasing it or when the load is passed over it CLOSE Kick the lever into position 1 Step on the roll stop flap _ DHOLLANDIA A33 215 V Vertical roll stops no springs see Fig 7 18 OPEN Kick the button on the side of the roll stop flap in the direction of the plat form point CLOSE Step on the roll stop flap When driving a load from the ground onto the platform the roll stop will automatically close 701 H
69. lace date Name amp signature of the owner or fleet operator Partial inspections to follow DHOLLANDIA ar MAINTENANCE amp REPAIR REPORTS DATE NATURE OF THE REPAIR OR MAINTENANCE IDENTIFICATION OF SERVICE AGENT DHOLLANDIA C11 MAINTENANCE amp REPAIR REPORTS DATE NATURE OF THE REPAIR OR MAINTENANCE IDENTIFICATION OF SERVICE AGENT DHOLLANDIA C12 MAINTENANCE amp REPAIR REPORTS DATE NATURE OF THE REPAIR OR MAINTENANCE IDENTIFICATION OF SERVICE AGENT DHOLLANDIA C13 5 PUWER amp LOLER IN GREAT BRITAIN e The CE Machine Directives apply to the manufacturers of all kinds of machines including tail lifts and require that machines are designed and manufactured to be safe e The Government of Great Britain has complemented these CE Directives with a legisla tion called PUWER The Provision and Use of Work Equipment Regulations 1998 and LOLER The Lifting Operations and Lifting Equipment Regulations 1998 which focuses on the users of the same machinery e PUWER and LOLER fall under UK criminal law and neglect or failure to comply with the previsions can lead to financial penalties or imprisonment e This legislation imposes
70. laced by Pos 6 8 9 gt gt gt gt cO I NO 10 For all tail lift models above the electric control box and the hydraulic power pack connected to the vehicle battery or auxiliary battery during fitting according to the fitting instructions of DHOLLANDIA and the requirements imposed by the vehicle manufac turer the batteries their charging system the battery and earth cables and fuses are dimensioned sufficiently strong and fitted with care following above mentioned instructions Insufficient battery tension will cause harm and irreparable damage to the electrical components of the lift starter solenoid electric motor electric switches etc e To ensure the reliability of the lift over many years it is extremely important that As most vehicles are supplied with power supplies that cover the primary needs of the original equipment only the vehicle owner amp his contractors should consider upgrading the battery capacity and charging system in function of the additional needs of all auxiliary equipment tail lift but also extra heating system refrigeration units etc The alternator of the vehicle should have a min rating of 14V 45A for 12V vehicles and 28V 80A for 24V vehicles In case of long journeys and short periods of tail lift use the existing alternator and batteries will probably suffice In case of long journeys and long periods of intensive tail lift
71. latform lights cable connections inside the exterior control box e General condition insulation of the separate wires M3 L All cable connections inside the power pack e Moisture inside the control unit amp corrosion J1 LI All cable connections inside the auxiliary controls e Fixation amp tightening of all cable amp wire connections Limit switches pressure switches reed sensors optional e General condition W52 e Function amp operation automatic return to the neutral 0 position Ji 2 8 Hydraulic pipes flexible hoses hydraulic couplings What to verify Execute service or repair if required ES L1 Hydraulic pipes amp flexible hoses e General condition outside rubber coat is intact inside steel braids are not visible LI Flexible hoses in the energy track between lift columns and platform for HTL e Routing amp guidance protection against squeezing sheering or rubbing with hydraulical closure e Fragility amp porosity e Age to be replaced every 4th year fill out the Maintenance amp Repair Report LI Couplings e General condition LI Fixed hydraulic pipes in steel e Corrosion fixation e Hydraulic system is free from leaks both during operation amp at rest Remark DHOLLANDIA 2 9 Hydraulic power pack What to verify Execute service or repair if required LI Oil reservoir casing of the power pack 4 lid e General condition no cracks or deformation i
72. ld be connected to the safety switch in the control box Activation of the auxiliary controls should deactivate the functions on the exterior control box It is prohibited to bypass any of the safety features of the tail lift DHOLLANDIA a 5 5 Instructions for loading amp unloading Follow the loading diagrams amp explanatory comments see Point 6 at all times Never try to scoop loose substance ex sand gravel rocks etc from the ground to move it by means of the platform or to lift lower it on the platform See Fig 5 19 5 20 Never use the platform to level the ground surface or to push or pull loads or substances by means of the platform See Fig 5 20 Never drop any load on the platform ex by means of a forklift gantry crane etc Due to the kinetic effect the impact of dropping a load is far greater than the nominal weight of this load might deceivingly suggest initially See Fig 5 21 Never step or climb on a load Prior to putting load on the platform its angle should be inclined a few degrees upwards to compensate for the compression of the vehicle suspension and the minimal play in the articulations of the lift Doing so the platform will find itself in a perfect horizontal position after placing the load onto it Never adjust the angle of the platform when it is loaded Do so only when the platform is empty see Fig 5 22 For lifts with conical platform always use the automatic t
73. leased see Fig 1 3 1 4 e When opening the platform always stand to one side of the vehicle Never behind the platform Always avoid the area directly behind and within reach of the moving platform see Fig 1 3 If the nature of the works require that you enter this danger zone neverthe less make sure that you secure the platform against accidental falling by means of hoists forklifts gantry crance etc see Fig 1 5 Ideally rest the platform on the ground before _ DHOLLANDIA B2 Landkleppen Hayons www freda starting the works see Fig 1 6 e Avoid to stand on or sit between the open platform and the rear side of the vehicle see Fig 1 7 e If the nature of the works require that you enter into one of the danger zones see 5 3 Chapter A or between the movable parts of the HTL make sure that you switch off the power source to the HTL Switch off the isolator switch in the vehicle cabin remove the key from the battery switch in the exterior control box or disconnect main fuse on the battery to avoid unsafe injudicious or unauthorized also by strangers in traffic use of the HTL see Fig 1 7 e When dismounting amp remounting articulation pins make sure these pins are remounted in the original way and are duly secured by means of locking pins bolts amp nuts e It is prohibited to modify straighten heat up weld lengthen or shorten etc the con struction of the mec
74. lers and shall be used exclusively to load and unload the goods transported on this vehicle with obedience of the load chart and the user s and safety instructions described in this Chapter A 2 IDENTIFICATION Every DHOLLANDIA tail lift is identified by and labelled with a unique serial number Use this reference for any inquiry on this particular lift or when ordering spare parts Apart from the lift type and serial number the main identification sticker in the control box also mentions the nominal lift capacity the centre of gravity and the date of construction see Fig 2 1 Additional identification stickers are used on various components see Fig 2 2 3 DESCRIPTION DHOLLANDIA tail lifts are developed and manufactured using state of the art technology high quality materials and components and comply with the European CE safety regulations mentioned in the Declaration of Conformity unless agreed otherwise upon ordering export outside CE region _ DHOLLANDIA AG e The DH VOC series comprises of a range of lower beam column lifts designed for a wide variety of factory built panel vans trucks trailers and semi trailers and is available with lift capacities of 500 to 2 000kg In its travel position the platform of the column lift is stowed vertically behind the vehicle body Before use the platform is lowered approx 20cm then tilted open 90 from the vertical travel position to a horizontal work
75. lic circuit Most of the overload and consequential damage happens when LOWERING loads e The nominal capacity NC is the maximum weight that the tail lift should carry under the best possible circumstances the centre of gravity of the load stands no further than the nominated centre of gravity of the tail lift marked on the platform surface always place the load as close as possi ble to the rear side of vehicle and the load stands centrally between the lift columns this is at equal distance from both platform sides e Beyond these best possible circumstances the maximum safe working load SWL goes down according to the load diagrams amp instructions below see Fig 6 1 6 2 e The load should never protrude beyond the side edges or front edge of the platform _ DHOLLANDIA A24 NOT OK load positioned too close to the platform point NOT OK load positioned too far off centre SWL 50 of NC OK load positioned as close as possible to the rear of the vehicle OK load positioned centrally be tween the lift columns e Be aware that the centre of gravity of the load doesn t necessarily correspond with its physical middle point The weight can be spread very unevenly e Unilateral loading on 1 side of the platform should be avoided Restrict the load to a maxi mum safe working load of 50 of the nominal capacity see Fig 6 1 gt U e Pay attention to avoid co
76. lves and where they are fitted Verify if the ring of the cartridge is damaged or the valve is stuck in open position by dirty or ice control valves in the power pack are single acting or double acting e The seal on the piston of the tilt cylinder s is are leaking e HTL with hydraulic tilt at ground level the seal of the hydraulic memory cylinder is leaking For most types of HTL multiple valve system there must be a combination of different defects if the platform falls open Spontaneously safety valve leaking on one cylinder and the cylinder seal leaking on the other or the safety valves on both cylinders leaking and the control valve in the power pack leaking A single malfunction wouldn t be enough if the hydraulic circuit counts more than 1 safety valve Verify if the manual emergency operation on the electro valves is firmly closed Test and verify if the tilt cylinders and hydraulic memory are not leaking internally See RMT HB 6b Revise the cylinders if required Flush purge the cartridge of the safety valves on the tilt cylinders and if applicable the control valve in the power pack see RMT HB5 revise replace O rings or replace the part DHOLLANDIA 7 EMERGENCY OPERATION 7 1 Introduction and safety instructions e Most types of DHOLLANDIA tail lifts called HTL hereafter are equipped with a manu al emergency operation on the electrovalves used on their cylinders and in the
77. m to disengage the mechanical travel lock Whilst standing beside the platform not under open the platform retaining catch and manually open the platform 90 into the horizontal work position For platforms with torsion bars fitted ensure the platform is locked in horizontal posi tion Loading amp unloading Select between exterior control box and auxiliary controls Use any of the functions LOWER depicted in 7 1 to 7 5 to LOWER the platform to the ground Use any of the functions LIFT depicted in 7 1 to 7 5 to LIFT the platform to the ve hicle floor level Observe the loading diagrams amp instructions at all times Closing up in travel position LIFT the platform up to a convenient height for closing I Stand to the side of the platform press it down by hand disengage the open platform lock and manually close the platform into vertical travel position 10 Check that the platform retaining catch is automatically closed 1 LIFT the platform until the mechanical travel lock is engaged If applicable LIFT the mechanical or hydraulic stabilising legs into travel position DHOLLANDIA Switch off the electrical power to the tail lift cabin switch in the driver s cabin and battery switch of the exterior control box Close the lid of the control box 7 6 Operating instructions for column lifts with hydraulic closure e The column lifts with hydraulic closure should be oper
78. n the mechanical parts amp mounting brackets M3 LI Fixation of the power pack to the HTL frame or to the chassis e Protection against corrosion sealing of all the holes J1 e Condition of the lid amp the rubber locking straps e Hydraulic system is free from leaks both during operation amp at rest e Tightness of the collars of the suction hose and return hose Hydraulic oil e Check oil level amp refill if required M3 e Oil type ISO 22 as standard other types used as option check before refill J1 e Oil level rest the platform in work position on the ground The correct oil level reaches to the MAX mark on the oil reservoir e Change oil amp clean filter To remove all the oil lift the rear of the vehicle off the ground so that the lift amp tilt cylin ders can contract fully and no oil remains in the cylinders LI Hydraulic functions e Hydraulic system is free from leaks during execution of all functions 6 f oil needs to be refilled search for reason and repair e Purge the hydraulic system 1 OPEN the platform completely below horizontal level until the tilt cylinders are fully retracted and continue to push the function OPEN for another 20 sec See Fig 2 1 2 Tilt the platform back up to horizontal position and LOWER the platform completely further down below normal ground level until the lift cylinders are fully retracted and continue to push the function LOWER for another 20 sec See Fig 2 2
79. n the piston of the lift cylinder s is are leaking e HTL with hydraulic tilt at ground level the seal of the hydraulic memory cylinder is leaking Remark Take into account the quantity of cylinders the quantity of safety valves and where they are fitted Verify if the control valves in the power pack are single acting or double acting For most types of HTL multiple valve system there must be a combination of different defects if the platform lowers Spontaneously safety valve leaking on one cylinder and the cylinder seal leaking on the other or the safety valves on both cylinders leaking and the control valve in the power pack leaking A single malfunction wouldn t be enough if the hydraulic circuit counts more than 1 safety valve Verify if the manual emergency operation on the valves is firmly closed Test and verify if the lift cylinders and hydraulic memory are not leaking internally See RMT HB 6a 6b Revise the cylinders if required Flush purge the cartridge of the safety valves on the cyllinder and if applicable the control valve in the power pack _ DHOLLANDIA see RMT 5 revise replace O rings or replace the part B25 6 15 The platform falls open the point of the platform tips down for HTL with hydraulical OPEN CLOSE The safety valve needed to OPEN on tilt cylinder or in power pack is leaking The O Remark Take into account the quantity of cylinders the quantity of safety va
80. ncealed overload situations such as Platform squeezed in the storage pocket of a loading dock unexpected forces can apply to the lifting mechanism causing severe damage see Fig 5 26 Platform and lifting mechanism damaged by hard reversing of the vehicle against the loading dock see Fig 5 25 Platform accessed by fork lifts is allowed only when the platform is at full rest on the ground The combined weight of the fork lift and the load should not exceed 150 of the nominal capacity of the tail lift see Fig 5 23 Fork lifts offloading merchandise on the platform point standing at the floor level of the vehicle the kinetic effects of the descend speed amp the additional weight of the forks masts of the forklift often lead to significant overload Load over the side edge of the platform place the merchandise centrally between the 2 lift columns at equal dis tance from both platform sides See Fig 5 21 6 3 and applicable load diagram see Fig 6 2 are supplied with the lift The op e Note stickers indicating the nominal capacity the centre of gravity see Fig erator should take note of this information prior to using the lift www DHOLLANDIA com DHOLLANDIA s 7 OPERATING INSTRUCTIONS 7 1 Introduction to the standard control box e All the symbols in this chapter represent left hand drive vehicles continental Europe with the control box mount
81. ng unloading activity Ensure the legs are completely lifted in travel position before sliding the lift in out slider lifts or before moving the vehicle gt DHOLLANDIA stabilising legs should be used to stabilise the vehicle only They are not suitable to lift the vehicle not empty not fully loaded In order to ascertain this the height of the stabilising legs should be adjusted during loading unloading to adapt them to the variation in the vehicle suspension In case of mechanical legs be very careful when releasing the mechanical lock to store the legs in travel position If the vehicle has been loaded the extra weight in the vehicle body might induce significant tension on the sliding foot of the leg and its lock ing mechanism DHOLLANDIA 7 8 The use of roll stops e Any platform aimed to lift and lower rolling loads must be equipped with a roll stop sys tem to prevent the load from rolling unintentionally off the edge to protect the load against shifting position and its centre of gravity to move during the LIFT LOWER movement e As part of the ordering process of the lift it is important that the vehicle owner and his contractors choose the position of the roll stops in function of the intended application pallets trolleys and the loading diagrams applicable to the nominal capacity chosen The loading diagrams amp instructions of chapter 6 should be observed at al
82. nty case cannot lead to a damage claim of any kind Remark full conditions includ standard repair times and description of procedures available on request WARRANTY CLAIM REPORT als DHOLLANDIA for DHOLLANDIA tail lifts ID of service agent claimant ID of operator owner Procedure for the initiation and management of a warranty claim Vehicle reg Date of repair SIN type of lift Description of defect O See pictures enclosed Diagnosis work required or performed Description Code Price EUR nette Allowed by DHO mileage Important contact info Central service Department Tel 32 0 9 340 49 67 Fax 32 0 9 340 49 69 To be filled in by Dhollandia O Claim is accepted Retum parts to Dhollandia copy of warranty claim 24h service O Claim is accepted in modified form Scrap parts Mob 32 0 496 90 27 O Claim is not accepted the parts but keep them for inspection for 3 l months Mob 32 0 496 56 90 22 GATENS asp Dhollandia will replace parts Dhoallandia will credit you for the items Central Ker Spare parts department Tel 32 0 9 340 49 66 32 0 9 340 49 94 N V Zoomstraat 9 8 2160 Lokeren Belgium Tel 32 019 349 06 92 Fax 32 0 9 249 09 77 Infogdhollandla be DHOLLANDIA DHOLLANDIA aa CHAPTER B MAINTENANCE
83. onforming parts contact your official The illustrations shown in this manual represent tail lifts prepared for left hand drive countries Unless otherwise agreed upon ordering export outside CE region DHOLLANDIA tail lifts continental Europe The operators of tail lifts prepared for right hand drive countries comply with the European CE safety regulations mentioned in the Declaration of Conformity UK Ireland South Africa Australia shall consider that their equipment if ordered with the They have been designed and manufactured with the greatest care to guarantee a safe and correct option number is executed mirror wise reliable operation GENERAL INTRODUCTION This manual explains e chapter A how the DHOLLANDIA tail lift is manufactured what safety devices are incorporated in its design and how to use the tail lift in a correct way that guarantees the integrity of the machine over the intended life time and the safety of the operator and any bystanders e chapter B how to maintain and service the tail lift in an appropriate way that can guaran tee its reliability over the intended life time e chapter C what legal requirements re periodic testing and certification must be ob served DHOLLANDIA 7 CHAPTER A USER S MANUAL DHOLLANDIA 1 INTENDED USE DHOLLANDIA tail lifts are designed to be fitted to commercial vehicles factory built panel vans commercial trucks trailers and semi trai
84. oose at the connection to the battery pole e Insufficient battery tension where 35mm is mentioned also other cable sections 25mm 50mm are implied _ DHOLLANDIA Remove the lid of the power pack and feel the temperature of the electric motor If the motor feels hot the thermal fuse inside the motor probably has interrupted the earth of the starter solenoid This can be verified by giving the starter solenoid a direct connection to the earth After a cooling period of approx 15 min the thermal fuse automatically re stores the earth of the starter solenoid and the electric motor becomes operational again If not measure the tension at the incoming poles of the starter solenoid main power amp control power If no 24V 12V is measured measure and verify the main power circuit and the control power circuit Earth via thermal fuse PP Control power IN 6 a Main pole OUT Main power IN If 24V 12V is measured at both incoming poles measure the tension at the outgoing main pole of the starter solenoid If no 24V 12V is measured here and the electric motor doesn t feel overheated the thermal fuse or the starter solenoid itself is defective or the electric motor containing the earth of the starter solenoid is badly earthed as a whole The failure of the thermal fuse can be verified by replacing the thermal fuse by a direct earth connection If you measure 24V 12V with the multimeter at t
85. ore opening the platform Ensure that the stabilising legs are positioned on solid even ground In case of soft terrain sand gravel solid support blocks must be used under the stabilising legs see Fig 5 2 e Ensure that the operator can overview and keep visual control over the whole working area of the lift and its platform at all times e The operation of the lift should be confined to a single operator Upon deployment amp use of the lift the operator should not accept anybody except himself to stand in the immedi ate vicinity of the lift and its platform Ensure at all times that nobody stands under or with in reach of the moving platform Always stand to one side of the lift when opening the platform never under or behind the platform e Inspect the lift prior to each use If any unsafe condition exists or unusual noises or A movements are noticed DO NOT use the lift and contact an authorised DHOL LANDIA service agent for repair e Read and comply with all warning decals pictograms and instructions affixed to the lift e Never leave the lift behind in open position Before leaving the vehicle behind unattended Store the lift away and close the doors of the vehicle e Don t move the vehicle with the lift in open position Stow the lift away and close the doors of the vehicle before moving position Never move the vehicle while a person stands on the platform or inside the vehicle body e The lift should not be used i
86. ou hear the hy draulic system turn in overpressure m T m CO m B 7 7 The use of stabilising legs e DHOLLANDIA tail lifts are available with 2 types of stabilising legs Mechanical stabilising legs are deployed and restored manually by the operator They are only suitable for light commercial vehicles up to 3 5T GVW and support maximum 3T total weight Hydraulic stabilising legs are operated via the exterior control box They are available in capacities of 2 5 4T and 10T and are therefore suitable for a much wider range of commercial vans and trucks See page 27 on the practical operation of the functions LEGS IN LEGS OUT e The purpose of the stabilising legs is to prevent the vehicle from tipping over e g central axle trailers or to support the chassis of the vehicle during loading unloading e g vehi cles with very long overhang with relatively weak chassis or in case of extreme lift ca pacities e The use of stabilising legs is compulsory on certain vehicles Consult the user s manual and or the Fitting and Body Building Instructions from the vehicle manu facturer e When using the stabilising legs the operator should observe following points Ensure that the stabilising legs are positioned on solid even ground In case of soft terrain sand gravel solid support blocks must be used under the stabilising legs see Fig 7 15 Use the legs upon every loadi
87. pack afterwards If the power pack is mounted in the middle of the frame between the lift arms it is saf er to manipulate the valve in the power pack first and open the valves on the cylin ders afterwards e After use don t forget to close the buttons for the manual emergency operation again and the mount the protective cap again on top of the cartridge of the valve 7 2 Operation of the SINGLE ACTING valves e Refer to the summary in 6 1 to determine which valves are Single Acting and can be manipulated as described in this Except for OMM3 wiring diagrams these valves V036 V037 or V036 H V037 H are mounted on all hydraulic lift amp tilt cylinders Depending on the wiring diagram they are also mounted in the power pack See Fig 7 4 e First remove the protective cap from the top of the cartridge of the valve See Fig 7 5 Under this cap sits a bronze coloured button that can be screwed unscrewed e Unscrew this button counter clockwise to OPEN the valve manually See Fig 7 6 e The flow of oil through the valve and the speed of the downward movement can be ad justed by opening the valve more faster or less slower e After use screw the button in clockwise to CLOSE the valve manually See Fig 7 6 Lock it hand tight in closed position e Toend mount the protective cap again on top of the cartridge of the valve _ DHOLLANDIA B28 V036 H V037 H open close 7 3 O
88. parties in traffic e All maintenance and repair works should be executed by authorised DHOLLANDIA service agents and using original spare parts only DHOLLANDIA 5 7 Instructions for working at loading docks e When working at loading docks it is recommended to store the platform safely away and to drive the goods directly from the dock onto the vehicle floor and vice versa Platform stored vertically under the vehicle floor when reversing into to dock make sure there is enough clearance between the underside of the platform and the ground Reverse at low speed and make sure not to hit the platform against the dock to pre vent mechanical damage see Fig 5 25 Min 200 mm Platform stored horizontally in a storage pocket under the loading dock make sure there is sufficient clearance under and above the platform taking into account all ex pected positions of the vehicle suspension The platform shouldn t touch either the Min 50 mm ceiling or the bottom of the storage pocket in the loading dock see Fig 5 26 Min 200 mm Min 200 mm e When using the tail lift platform as bridge plate between the loading floor of the vehicle and the loading dock follow the instructions below Fig 5 28 gt KG lt Nom capacity The total weight of the load and the lifting device forklift electric or manual transpallet truck etc shouldn t exceed the nominal capacity of the lift see Fig 5 27
89. peration of the DOUBLE ACTING valves e Refer to the summary in 6 1 to determine which valves are Double Acting and can be manipulated as described in this For OMM3 wiring diagrams these valves V071 V072 or V071 H V072 H are mounted on all hydraulic lift amp tilt cylinders Depending on the wir ing diagram they are also mounted in the power pack See Fig 7 7 Fig 7 7 V071 V072 V071 H V072 H e For V071 H V072 H the protective caps on the cartridge of the valve are equipped with an elastic skin covering an emergency button that can be pushed in by the finger These valves can be operated manually without dismounting anything e Push in the button under the protective rubber cap to OPEN the valve manually See Fig 7 8 e Release the button under the protective rubber cap to CLOSE the valve manually See Fig 7 8 S7 4 Manual override of the starter solenoid e When the main pole IN of the starter solenoid see 6 5 receives normal 24V 12V ten sion but the electric motor doesn t function the starter solenoid can be overridden as follows e Switch off the isolator switch in the vehicle cabin remove the key from the battery switch in the exterior control box or disconnect the main fuse on the battery See Fig 7 1 e Connect the main poles IN amp OUT of the starter solenoid with 2 spanners of the same Main pole IN string of a starter cable Ensure non of the spanners touches the earth s
90. position The functions OPEN amp CLOSE can be manual supported by torsion springs or actuated by a hydraulic tilt cylinder Main details amp terminology Fig 3 1 Lower beam column lift with manual OPEN CLOSE 1 Lift columns set of 2 columns mounted in a fixed position against the vehicle body They form the tracks in which the lift runners carrying the platform go up amp down lift cylinder and the drive mechanism consisting of steel ropes or chains plus pul 2 Cylinder beam horizontal beam mounted at or below the vehicle floor It contains the leys 3 Platform carries the load during loading unloading Manufactured from steel or light weight aluminium and foreseen of a non slip working surface 4 Travel lock mechanical lock mounted on the lift columns keeping the platform in its vertical travel position when not being used and holding the platform hard against the rubber buffers 5 Lift runners set of 2 profiles carrying the platform and its load They are lifted low ered by the lift cylinder and the drive mechanism consisting of steel ropes or chains plus pulleys This catch doesn t hold the platform hard against the rubber buffers 1 Lift cylinder hydraulic cylinder used to LIFT LOWER the lift runners the platform and its load Torsion bar spring device assisting the manual OPEN CLOSE of the platform in case lift with manual closure Platform retaining catch mechanical lock mounted on the li
91. pressure relief valve is set too low with high pressure steam cleaner and apply grease e The pressure relief valve is polluted or mechanically blocked in open position The pump sucks insufficient oil the oil or filter are polluted clogged up with ice or dirt or Fit a pressure gauge to the power pack and measure the maximum pressure delivered by the pump see RMT HB1 the oil is too viscous after refilling with oil of incorrect specifications e The hydraulic pump is worn out If set too low try to adjust the pressure relief valve to max 220 bar and only as far as required See RMT HB3 e The seal of one of the lift cylinder is leaking e HTL with hydraulic tilt at ground level the seal of the hydraulic memory cylinder is leaking e The lift columns and or lift runners are damaged causing the lift runners to jam e The lift columns contain to much hardened grease are clogged up with debris and dirt If the adjustment of the pressure relief valve doesn t show any result try first to purge this valve See RMT HB4 If no result dismount the oil filter and clean it dirt or ice when freezing If also without result the pump is probably worn out A worn out pump heats up quickly lf the oil pressure can be raised but the lift capacity remains insufficient possibly one of the seals of the lift cylinders or the hydraulic memory cylinder is leaking Verify if the cylinders are free of internal leaks See RMT
92. r and clean it Replace the filter if a complete rinse is not possible The seals of the cylinder s are heavily damaged or torn off by incorrect manipulation Feel the temperature of the pump worn out pump heats up quickly Dismount the pump off the electric motor and verify the condition of the drive shaft Test and verify the tightness of the hydraulic cylinders See RMT HB 6a 6b 6 12 The platform LIFTS and CLOSES simultaneously when the function LIFT is actuated for HTL with hydraulical OPEN CLOSE e The solenoid of the control valve S CLOSE is electrically activated while it should remain Remove the solenoid of control valve S If the fault remains the cartridge of the valve is probably leaking stuck in open without tension position e The cartridge of the control valve S CLOSE is polluted or stuck in open position or defec tive in another way Flush purge the valve or replace See RMT 5 If the fault disappears after removal of solenoid S the cause is electrical Measure the control circuit of the function CLOSE switches electrical contacts electrical distribution block in power pack to identify the origin of the malfunc tion DHOLLANDIA 6 13 The platform LOWERS OPENS with shocks when the function LOWER OPEN is actuated The lift columns and or lift runners are damaged causing the lift runners to jam e The lift columns contain to much hardened grease are clo
93. rranty supplied and en sured by DHO is limited to the specific warranty conditions given by these suppliers to DHO 8 3 11 Outgoing spare parts are temporarily invoiced for administrative reasons As soon as the failing parts have been returned and the warranty claim has been positively recognized the invoice is credited 8 3 12 Except in case of different contractual agreement the warranty is always limited to the free replacement of the failing parts Labour and mileage costs relating to a roadside repair are only reimbursed if the CV is physically blocked due to the nature of the tail lift failure and according to the agreed labour rates and standard or agreed repair times See document C GAR 02 EN In case of different contractual agreement whereby full warranty is guaranteed the labour cost is only taken into consideration at the standard repair times prescribed by DHO which represent an average time required to repair specific problems by trained tail lift technicians and at the standard hourly labour rates foreseen in the DHO network 58 4 NOT covered under warranty conditions 8 4 1 Except for the cases described under Pt 3 12 labour cost and mileage are excluded from the warranty coverage Also excluded in all cases and under all circumstances are con sequential damage loss such as immobility tractor or other transport logistic costs all transport costs to and from the DHO workshop driver s waiting ho
94. rticulation points e General condition check for cracks deformation elliptic deformation M3 1 Articulation pins e Locking of the articulation pins by locking pins bolts amp nuts J1 e Presence of grease nipples correct and regular greasing LI Load restraints roll stops hinged ramps e General condition function amp operation M3 Platform lights flags traffic cones e Condition routing amp guidance of the electrical cables from the platform over the lift arms to the J1 LI Foot controls connection point in the power pack or exterior control box LI Travel lock amp platform retaining catch O Visibility of the platform in public traffic e The platform is clearly visible in surrounding traffic from all approachable angles STE W52 Ji LI Torsion bar s in the platform HTL with manual OPEN CLOSE e General condition function amp operation e Required effort to open close the platform is within normal limits LI Safety gates e General condition function amp operation W52 LI Toe guard at end of loading floor and or front edge of platform M3 Jl J1 LI Synthetic platform rollers if applicable e General condition replace when damaged or worn out e Presence amp condition of end stops for LIFT movement e Alignment of platform flush with the loading floor Platform at loading floor Remark DHOLLANDIA Sm 2 15 Practical tests What to verify Execute service or repair
95. rushing zone between the closing platform and the rear frame of the vehicle body 300 lt L lt 600 mm see Fig 5 7 the danger zone between the load on the platform and the rear frame of the vehicle the danger zone between the platform and fixed obstacles like walls loading docks etc e The prescribed position of the exterior control box see Fig 5 8 and the compulsory use of 2 hands to actuate the tail lift functions see Fig 4 6 aim to protect the operator from crushing his head between the closing platform and the rear frame of the vehicle body Therefore never try to look inside the body when closing the platform DHOLLANDIA Fr 5 4 Auxiliary controls Position of the operator on the platform e The issue of the choice and position of the auxiliary controls deals with the protection of the toes feet and limbs of the operator working on or around the platform It deals with the risk that the operator might squeeze crush or injure his toes or limbs between the edge of the rising or closing platform and the rear cross member of the loading floor of the vehicle or between the lowering platform and the ground e tis generally accepted that the foot control with compulsory 2 feet operation provides an efficient remedy against this risk since it immobilises both feet of the operator on a predetermined and safe location on the platform the buttons of the foot control see Fig 5 9 should only be used
96. s protects the operator from crushing his head or limbs between the rear frame of the body and the lifting or closing platform Fig 4 7 Emergency stop this stop is formed by a battery switch or selection switch with removable key integrated in the control box see Fig 4 7 a or mounted by the installer at another location that is clearly visible and easily accessible to the operator As option the control box can be equipped with a genuine emergency button see Fig 4 7 b The emer gency stop allows to cut the electrical power in case of danger e Fig 4 8 Cabin switch mounted on the dashboard in the driver cabin optional this switch enables the operator to switch the electrical power to the tail lift on off and con tains a signal as to whether the platform is correctly stowed in its travel position or not e Fig 4 9 4 button foot controls mounted to the platform option S006 The compulsory use of the 2 feet to actuate the functions LIFT and LOWER immobilises the feet of the operator on a safe location the buttons of the foot controls and protects him from crushing or squeezing his toes feet or limbs between the edge of the lifting platform and the rear cross member of the vehicle floor See also 5 4 e 4 10 Protection of toes feet amp limbs The choice and position of any type of auxiliary controls influences strongly on the risk that the operator might squeeze crush or injure his toes or limbs between the edge
97. spects determining the operational safety of the tail lift aseries of static and dynamic weight tests e Most points of the visual inspection will be executed through practical tests without load The test shall allow the expert to evaluate if the tail lift has been incorporated on the vehi cle chassis in accordance to the manufacturer s fitting instructions if the tail lift is safe to be used if it can be operated safely amp correctly from all existing controls if it can execute all functions smoothly without unexpected movements or sounds e content of this compulsory put into service test is explained hereunder _ DHOLLANDIA FITTING DECLARATION by installer of the tail lift Name amp address of the fitting company Name amp function of the inspector By means of this Fitting Declaration declare that the tail lift identified in the Declaration of Conformity in this manual has been fitted conform to the fitting instructions from the manufacturer and that the put into service test has been executed with affirmative re sult As a consequence the tail lift has been found suitable for use in its fitted condition The following results have been noted The vehicle is technically suitable for the installation and 4 yes use of the tail lift concerned The installation has been executed conform to the fitting instructions of Dhollandia and the put into service test has been executed following
98. ss ramp These ramps are available for the rear edge and for the sides of the platform for applications where side loading is required see Fig 4 15 b e Fig 4 16 Safety gates optional safety gates should be fitted for all applications where a significant risk exists that the operator could be injured when falling off the platform UK Work at Heights Regulation 2005 Safety gates are available in a wide range of execu tions to suit the particular needs of the operator see examples Fig 4 16 e Fig 4 17 Warning decals apart from the identification stickers see Point 2 every tail lift is supplied with one or more warning decals They cover the applicable load chart a sim plified set of instructions for use and other decals warning the operator for specific haz ards Note the images above right are examples The exact execution might vary in function of the type of lift and the application If required contact your official DHOLLANDIA agent for further advice DHOLLANDIA NT 5 SAFETY INSTRUCTIONS FOR THE USE OF THE LIFT 5 1 Introduction e DHOLLANDIA tail lifts shall be exclusively used to load the goods transported on the carrying vehicle with obedience of the applicable load chart the user s and safety instruc tions described in Chapter A of this manual A Warning e Simultaneously the operator should follow all other precautions and instructions applica ble to his wor
99. teel casing of the starter solenoid electric motor or power pack itself See Fig 7 9 e Re establish the electric power to the power pack switch on the isolator switch in the vehicle cabin insert the key from the battery switch in the exterior control box or recon nect the main fuse on the battery If the starter solenoid is the failing part the electric mo tor will now start to run e Alternatively you can maintain the electric power on the power pack and link the 2 main poles IN amp OUT of the starter solenoid with an old screw driver or other metal object Again ensure not to make any connection to the earth See Fig 7 10 DHOLLANDIA TF 7 5 Course of action 8 ELECTRICAL amp HYDRAULIC WIRING DIAGRAMS e The table below shows which courses of action can be taken in case of a breakdown e The following pages contain the main wiring diagrams for DHOLLANDIA tail lifts as sup resulting from a failure on one of the solenoids R D O H S The actions are ranked plied in their standard execution from high preference if relevant parts and professional labour skills are available down to last help if parts or professional labour skills are not available if a correct diagnosis e In case of special lifts should the original wiring diagram joined to the lift be lost or for definitive repair cannot be established quickly unavailable contact DHOLLANDIA for further help case of doubt stop immedi
100. th the holes of the articulations on the platform pulley blocks or frame see Fig 1 11 _ DHOLLANDIA B4 F 1 9 Tilt cylinder with internal sprin open close e Only when all articulation pins are mounted and secured is it allowed the build up full pressure in the hydraulic system by means of the regular electric controls e And only after assuring that the hydraulic system generates over pressure and no oil leaks are visible is it allowed to remove the mechanical devices supporting the platform hoist gantry crane forklift e For dismounting and remounting hydraulic valves safety valves on the cylinders control valves in the power pack the same safety precautions apply Stay out of the operation radius of the platform Keep clear of moving parts Beware of hand foot and head traps at all times 1 3 Electrical components e Before dismounting and remounting electrical components ensure that the components are without tension e It might be insufficient to just switch off the battery switch in the exterior control box or the isolator switch on the dashboard in the vehicle cabin For certain works the main fuse or the connection to the battery will need to be disconnected e First define clearly which area you need to work on then interrupt the circuit at a point which is nearer to the battery or power source _ DHOLLANDIA 25 2 MAINTENANCE e During this periodic inspection or Statutory
101. the system is under load push the function LIFT Insufficient battery voltage doorbelling is a frequent cause of starter solenoid failure 6 7 The platform doesn t LOWER the other functions work ok e The button switch or electric contact are faulty or the connection to one of the contacts is Check the lift columns and lift runners for visible damage and repair loose e The incoming or outgoing connection to the electrical distribution block in the power pack is Verify the electrical operation of the safety valves D needed to LOWER on cylinders or in power pack faulty e with a magnetic tester a solenoid generates a magnetic field when it is electrically activated e The electric cable to one of the safety valves D needed to LOWER is interrupted or has a bad contact e One of the solenoids D needed to LOWER is defective or the cartridge of one of the valves is mechanically defective e or open the safety valves manually via the emergency operation if the valves are opened manually and the platform One of the braking valves on the cylinders or in the power pack is mechanically blocked by LOWERS the cause is electrical for sure ice dirt or by mechanical malfunction gt EE One of the lift cylinders is blocked piston rod bent by accident badly open close e The lift columns and or lift runners are damaged causing the lift runners to jam e The lift columns contain to much
102. tified Follow up by the owner or fleet operator LI Shortcomings have been acknowledged Scope of the inspection LI Shortcomings have been repaired Place date Name amp signature of the owner or fleet operator Partial inspections to follow _ DHOLLANDIA C7 INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION L SPECIAL INSPECTION RE INSPECTION Date of inspection Evaluation the tail lift is safe and suitable for further use The tail lift identified in the Declaration of Conformity has been inspected on its YES LINO operational safety and reliability Place date Name amp function of the expert During this inspection no imperfections have been found or Name amp address of the inspection body L During this inspections the following shortcomings have been identified Follow up by the owner or fleet operator LI Shortcomings have been acknowledged Scope of the inspection LI Shortcomings have been repaired Place date Name amp signature of the owner or fleet operator Partial inspections to follow DHOLLANDIA INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION L SPECIAL INSPECTION RE INSPECTION Date of inspection Evaluation the tail lift is safe and suitable for further use The tail lift
103. tive Manually lever one side of the platform upwards and remove the blocks then release the platform The LSD should engage within 100mm drop If the LSD has not been activated check if the various components of the LSD can move freely To disengage the LSD press the function LIFT to raise the platform to the floor level of the vehicle You will hear the LSD disengage Repeat the same test on the other side of the platform _ DHOLLANDIA B17 5 ORDERING SPARE PARTS e The following information must be confirmed when ordering spare parts Type year of construction amp serial number of the tail lift Spare parts reference consult the spare parts lists The desired quantity of each item Your administrative data company name invoice address VAT number purchase order number delivery address and expected delivery time e The type year of construction amp serial number of the tail lift can be found on the identifica tion stickers see point 2 in Chapter Al _ DHOLLANDIA B18 6 FAULT FINDING amp REPAIR In case of a malfunction the operator can verify a number of points himself before calling an approved DHOLLANDIA service agent Is the isolator switch for the tail lift called HTL hereafter in the vehicle cabin switched on Are the main power plugs between the tractor unit and the trailer properly connect ed Is the battery switch in the exterior control box switched on
104. to comply with the overall CE Safety Directives with DHOLLANDIA s code of good practice re maintenance and with the validation of the product warranty 6 INTERNATIONAL DISTRIBUTOR NETWORK Australia Tieman Industries PTY LTD Melbourne 61 3 9469 6700 Austria Dhollandia Austria Neuhofen im Innkreis 43 7752 70 270 Belgium amp Luxemburg Dhollandia Service 32 9 349 06 92 ER Dhollandia Brasil Sumar 55 19 3832 4000 Dhollandia Bulgaria 5 359 2 870 42 76 Czech Republic Dhollandia Czech Republic Troubsko 420 545 232 603 Denmalk IKJ DK A S 45 45 70 0201 Estonia Widni Baltic Tallinn 372 6532 431 Finiand EEE Widni Vantaa 358 9751 80 500 France Dhollandia France Argenteuill 33 134 11 74 00 Free service number 33 825 042 966 Dhollandia Germany Hamburg 49 40 76 11 96 0 Great Britain
105. ubt on how to proceed DON T go any further but ask your local DHOLLANDIA distributor for professional advice These cross references to the training program are marked for example see RMT HB3 see Repair amp Maintenance Training Hydraulic Base techniques N 3 6 1 Summary activation of electrical solenoids per lift movement Scheme DH VA DH VOC DH VOC MECH E Fully DH VB4 DH VB4 MECH SA hydraulical MECH Single Acting OPEN CLOSE hydraulic hydraulic are double acting SA single acting electrovalve DA double acting electrovalve R starter solenoid of the electric motor H control valve LIFT in the power pack D safety valve LOWER on the lift cylinders or in the power pack control valve CLOSE in the power pack O safety valve OPEN on the tilt cylinders Other special ref s for specific applications check the wiring diagrams DHOLLANDIA a 6 2 HTL moves at normal speed without any control switch being operated e Button or switch of the exterior control or auxiliary control doesn t return to the neutral 0 position e Button or switch does return to the 0 position but one of the electrical contacts behind the switch is stuck or burnt e Short circuit between the various wires in one of the electrical cables Typically a malfunction at normal speed is usually caused by an electrical failure Determine this by isolating the power source from the solenoid
106. under the safe working conditions described in the Europe an Standard EN1756 1 2001 A1 2008 and the latest issue of the DHOLLAN DIA fitting instructions FIT ELEC_OPTION e Other auxiliary controls wander lead with spiral cable fixed interior control sure that the installation of the tail lift has passed a risk analysis with positive result and complies with the above mentioned documents In case of doubt consult with DHOLLANDIA before proceeding further e Before putting the tail lift in operation the vehicle owner or employer should en f hinged foot protector see Fig 5 10 or safety cut out see Fig 5 11 is used the wander lead with spiral cable can only be used If the end of the loading floor is executed with a toe guard profile according to Fig 5 12 see Fig 5 12 On the platform from a safe working zone of min 400x400 mm clearly and perma nently marked at min 250 mm distance from the hazard zone between the platform and the rear of the vehicle floor See Fig 5 13 Inside the vehicle body from a safe working zone of min 400x400 mm clearly and permanently marked at min 250 mm distance from the hazard zone between the plat form and the rear of the vehicle floor See Fig 5 4 On the ground from a safe working zone min 500 mm away from the side edge of the platform See Fig 5 15 DHOLLANDIA NE e When lifting lowering the operator standing on th
107. urs rental costs for re placement CV opportunity cost and missed sales 8 4 2 All administrative costs and start forfeits unless different contractual agreement with the service agent concerned 8 4 3 Consumables and serviceable parts subject to wear and tear such as rubber and synthetic parts hydraulic flexible hoses platform flags hydraulic oil defects to foot con trols caused by loss of or damage to the protection rubbers defects to platform lights caused by impact or abuse with pallets pallet trucks or other foreign objects defects to wander leads their spiral cables and plugs 8 4 4 The normal regular HTL activities with relation to service maintenance and paint finish conservation and the different types of inspections according to the CE Machine Di rective or DHO User s Manual 8 4 5 HTL problems caused by the subsequent use of polluted oil or oil with technical or hydraulic characteristics that are not compatible with the original oil foreseen by DHO 8 4 6 The adjustment of the hydraulic cylinders after the first period of use and the checking and retightening of bolt connections made during the fitting process 8 4 7 All additional components added to the HTL construction after delivery of the HTL to the body builder or the installer of the lift All defects failures deficiencies caused by the use and implementation of non original DHO spare parts _ DHOLLANDIA A37 8 4 8 Defects to th
108. use the batteries will probably need upgrading to heavier duty ones In case of short journeys and long periods of intensive tail lift use both the alternator and the batteries will probably need upgrading Alternator of 14V 80A or 28V 135A The following min battery equipment is recommended in function of the tail lift capacity 750 1 140Ah 1500 1 1 180Ah DV 2000kg 2x 135Ah 2000kg Not recommended 2x 180Ah 4 SAFETY DEVICES DHOLLANDIA tail lifts are equipped with a wide range of safety devices in order to en sure that goods can be loaded unloaded with a maximum degree of safety for both the oper ator and the load The following safety devices are incorporated or recommended on most tail lifts e Fig 4 1 Electrical safety valves mounted to all lift and tilt cylinders A safety valve locks the hydraulic oil inside the cylinder as long as its solenoid is not activated by a control switch Its purpose 15 to hold the platform in its travel position during driving or in a fixed position in case of the failure of a hydraulic pipe as soon as the control button is released DHOLLANDIA valves are equipped with a manual emergency control allowing the operator to open the valve in case of electrical power failure see chapter B e Fig 4 2 Mechanical travel lock mounted on the lift columns When stowed in the travel position it prevents the platform from falling open in case of damage or incorrect setting o
109. wed under the European CE Safety Directives e The selection switch selection between exterior amp auxiliary controls that is normally fitted in the exterior control box see Fig 7 1 7 5 can also be mounted in the fixed interior controls option S004 C see Fig 7 12 Selection switch on fixed interior control box See Fig 7 12 Switch turned clockwise 1 choice for interior controls 1 Switch turned counter clockwise 2 choice for e When using the auxiliary controls to LIFT LOWER the platform the operator should en Too exterior control box 2 sure at all times to keep his hands and limbs clear from the moving parts of the tail lift Keep clear of moving parts Beware of hand foot and head traps at all times DHOLLANDIA T 7 5 Operating instructions for column lifts with manual closure e The column lifts with manual closure possibly supported by torsion springs should be operated as follows Fig 7 13 Operation of column lifts with manual OPEN CLOSE Opening the platform 1 Consult the user s manual before getting started Observe all safety instructions Switch on the electrical power to the tail lift cabin switch in the driver s cabin and battery switch of the exterior control box Ensure that the platform retaining catch is fully engaged before commencing If applicable LOWER the mechanical or hydraulic stabilising legs into work position LOWER the platform 150m
110. y Execute service or repair if required LI Batteries e General condition LI 35mm BATTERY cable to the battery 1 e Good mounting amp fixation of electrical cable amp wire connections see fitting instructions LI 35mm EARTH cable to the battery or earth point 1 e Technical maintenance of the batteries power circuit battery charging circuit and earth circuit LI Electrical plug connections between truck amp trailer Harrisson Rema e Apply grease or Vaseline to all connections to protect them against corrosion 1 where 35mm is mentioned also other cable sections 25mm 50mm are implied 1 250 300A main fuse near the battery e General condition M3 Battery switch the exterior control box and or near the battery e Corrosion burn marks arcing J1 e Good tight fixation of the 35mm BATTERY amp EARTH cables e Apply grease or Vaseline to all connections to protect them against corrosion LI 35mm BATTERY amp EARTH cables e Routing amp guidance protection against squeezing sheering or rubbing M3 LI Cables between exterior control box and power pack e Damage good insulation amp protection J1 LI Cables to the safety valves on the cylinders 6 Sufficient fixation to the vehicle body or chassis LI Cables to the auxiliary controls e Clearance from dangerous vehicle components exhaust braking circuit drive amp engine parts LI Cables to the platform foot controls amp p
111. y expert competent person M3 4 monthly check 3x year by a qualified DHOLLANDIA service agent LI To be verified during maintenance AND periodic inspection STE J1 Yearly winter maintenance by a qualified DHOLLANDIA service agent O Additional points only to be verified during periodic inspection STE 2 1 High pressure cleaning What to verify Execute service or repair if required 1 Complete HTL at the rear under the vehicle chassis incl lift columns e Clean the HTL thoroughly to make all greasing points welding seams bolt and pin connections hydraulic pipes and couplings tidy and clearly visible for inspection All articulation points with grease nipples e Grease thoroughly with acid free grease according to the grease plans under Point 3 LI Inside of lift columns amp slide pads on lift runners LI Inside of cylinder beam LI Mechanical platform lock platform retaining catch e Lubricate with chain or steel cable oil M3 LI Chains steel cables of the lift system LSD J1 O Correct and complete greasing e Verify correct and complete greasing according to the points above Remark 2 3 Documents amp reports What to verify Execute service or repair if required CE Declaration of Conformity e Presence in the driver s cabin O Fitting Declaration by the installer e Readability O User s manual in the correct language e Completeness reports duly filled out after each intervention O Mainten

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