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1. Follow up by the owner or fleet operator L Shortcomings have been acknowledged Scope of the inspection L Shortcomings have been repaired Place date Name amp signature of the owner or fleet operator Partial inspections to follow DHOLLANDIA a 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 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 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 th
2. 44 1480 435 266 Free service 0800 0855 141 Smyrliadis Truck Trailer Athens 30 210 816 12 18 Liberatus 36 23 312 398 Ballinlough Refrigeration Dublin 353 146 00 322 Amir Engineering Petach Tikva 972 39 222 750 c Dhollandia Italy Diegaro die 39 0547 347 615 KUWAI rot edt Bader al Mulla Kuwait 965 48 15 077 Latvia Lithuania Dhollandia Latvia 371 28 305 904 DHOLLANDIA Alexander Xerri 356 21 470 900 Netherlands Dhollandia Netherlands 31 765 81 14 55 NOWAY Trailer Pro As Kjeller 4T 982 213 33 Poland Dhollandia Poland Krakow 48 12 260 61 10 Pruga Dhollandia Plataformas Villa Franca de Xira 351 263 286 570 Romania Dhollandia Romania Bucharest 40 744 571 655 Dhollandia Russia Moscow
3. 0178 08 H08 2008 01 Date 22 05 2008 DIEOILILNIDIUR mm HYDRAUILC TILT LSU LSP SP SV LE 4000 mm OPTIONS 5094 5 1 amp S094 H 541 Z USE I S N 5 Lu COLOUR COD DIN 47100 OPTIONS 5094 5 1 8 5094 5 1 7 MECHANLICAL TILT LM LMP LC USE 4000 mm 7x1 m STD L E0178 M08 B44 Connection 2 button wander lead spiral cable 5001 Power pack n a Valve n a Plan Sch Extra 5001 2009 02 Date 02 06 2009 DEOLLANDIA las 95 lex ua N J 0785 EXTRA CONTROL I LL gt w gt S mE AM l UO 0785 IN POWER PACK d O L EXTRA CONTROL OPTION CONNECTION IN CTRL BOX 300A 1 LI 4 E068 300A 45 Di of H XTERIOR CONTROL BOX FEF B45 Connection 4 button foot controls 5006 Plan Sch Extra 5006 2009 02 Date 02 06 2009 E068 300A d gt gt lt Ls CO TH 24 gt lt z c 4 gt lt
4. BU gt EART gt gt D gt 24 12V EXTRA CTRL GY AR gt 24 12 WH gt 0 NONNV2 0 05 CTRL STANDARD MOD 006 CONNECTION 5006 FOOT CONTROLS BASIC CONFIGURATION APPLICATION POSSIBLE ON ALL LIFT TYPES BATTERY 46 Connection 075 foot controls with reed sensor 5090 platform lights Sch Extra 5075 5090 5070 2009 01 29 08 2008 BATTERY RIOR CONTROL BOX REF EXT 068 008 7 NO 47 OS CABLE P gt gt e lt eu e O 8 4 5070 CANNON PLUG ARTH gt 24 12V CONNECTION Pos CABLE N S076 CANNON PLUG r NOT INCLUDED 075 Foor CTRL S090 PLATFORM LIGHTS REED SENOR CONNECTION OF 5075 4 BUTTON FOOT CONTROLS REED SENSOR 5090 PLATFORM LIGHTS APPLICATION ALL DH L wiTH 075 FOOT CONTROLS INTEGRATED REED SENSOR Connection 075 foot controls with reed sensor 5090 platform lights Plan N Sch Extra 5090 5070 5070 2009 01 CIXXX EXTERIOR CONTROL BOX REF E068 NO 5008 2 PLUG E N CONNECTION x Pos CABLE N CTION OS CABL CANNON
5. 7 916 531 36 00 Saudi Arabia Alaa Industrial Equipment Damman 966 1448 4402 Dhollandia CE Predmier 421 41 500 10 80 South Africa Grenco 27 21 555 90 00 Dhollandia Spain Madrid 34 91 877 16 50 Reder System 34 937 18 09 94 5 Dhollandia Sweden AB Alvesta 46 8 594 63 400 Switzerland Dhollandia Vertretung M llheim 41 52 762 77 00 Ukraine Dhollandia Ukraine Kiev 380 44 492 86 49 United Arab Emirates DUDAT sca aep ctun RR MT 971 4 333 13 99 The national distributors can help you to locate the nearest Dhollandia service centre www dhollandia com for the latest update on the service network
6. First remove the protective cap from the top of the cartridge of the valve See Fig 6 5 Under this cap sits a bronze coloured button that can be screwed unscrewed Unscrew this button 7 counter clockwise to OPEN the valve manually See Fig 6 6 The flow of oil through the valve and the speed of the downward movement can be ad justed by opening the valve more 7 faster or less 7 slower After use screw the button in 7 clockwise to CLOSE the valve manually See Fig 6 6 Lock it hand tight in closed position To end mount the protective cap again on top of the cartridge of the valve DHOLLANDIA Fig 6 4 V036 V037 B27 V036 H V037 H e open close i 56 3 Operation of the DOUBLE ACTING valves Refer to the summary in 55 1 to determine which valves are Double Acting and can be manipulated as described in this For 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 6 7 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 Push in the button under the protective rubber cap to OPEN the valve manually See Fig 6 8 Release the button
7. 24 Expert competent person 2 4 Safety Devices A11 3 Grease plans B13 2 5 Initiative to organise inspections C2 9 Safety instructions for the use of the lift A14 4 Ordering spare parts B16 3 Validation of the manufacturer s warranty C3 5 1 Introduction A14 5 Fault finding amp repair B16 4 Scope of the put into service test C3 85 2 General safety instructions A14 951 Summary activation of electrical solenoids per tail B17 Fitting Declaration C3 5 3 Danger zones risk of crushing amp sheering A16 lift function 84 1 Checkli mI ecklist for the put into service test C4 854 Auxiliary controls Position of the operator on the 17 6 operation 26 _ platform 6 1 Introduction and safety instructions B26 ij Inspection certificates C6 5 5 Instructions for loading amp unloading A19 6 2 Operation of the SINGLE ACTING valves B27 Maintenance amp Repair Reports C11 5 6 Importance of good maintenance A20 6 3 Operation of the DOUBLE ACTING valves B28 5 PUWER amp LOLER Great Britain C14 5 7 Instructions for working at loading docks A21 64 Manual override of the starter solenoid 28 85 1 PUWER the Provision and Use of Work Equip C14 85 8 Moving loads between 2 vehicles with cantilever tail A22 6 5 Course of action B29 ment Regulations 1998 5 T Electrical amp hydraulic wiring diagrams B29 852 LOLER the Lifting operations and Lifting Equip C14 6 Loading diagrams A23 ment Regulations 19
8. DHOLLAN DIA USER S MANUAL MAINTENANCE amp REPAIR COMPULSORY INSPECTIONS amp REPORTS Manufacturer DHOLLANDIA N 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 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 A1 Doc USE TRAD EN 2009 A 01 0 Origin 30 06 2008 Rev 0 5 09 2009 CE Declaration of Conformity A2 Chapter B Chapter C Disclaimer A3 MAINTENANCE amp REPAIR COMPULSORY INSPECTIONS amp REPORTS General introduction A3 1 Safety instructions for maintenance amp repair B2 1 Introductory remarks C2 Chapter A 911 General safety instructions B2 2 Inspections C2 USER MANUAL 81 2 Hydraulic components B3 921 Putinto service test amp Fitting Declaration C2 1 3 Electrical components B4 22 Periodic inspections C2 1 Intended use A6 2 Maintenance B5 Maintenance amp Repair Reports special inspections 92 3 C2 2 a 21 Checklist for maintenance amp inspection B6 3 Description A6
9. This is Vertical movements 15cm sec OPEN amp CLOSE max 10 sec min 9 sec for the opening and closing cycles OPEN speed max 40cm sec up to 500kg capacity max 30cm sec for other lifts TILT at groundlevel 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 A11 1 m Mm mm Fig 4 4 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 5 2 hand exterior control box equipped with functional control switches and safety or selection switch The compulsory use of the 2 hands to actuate the tail lift func tions protects the operator from crushing his head or limbs between the rear frame of the body and the lifting or closing platform e Fig 4 6 Emergency stop this stop is formed by a battery switch or selection switch with removable key integrated in the control box see Fig 3 6 a or mounted by the installer at another location that is clearly visible and easily accessible to the operator see Fig 3 6 b The emergency stop allows to cut the electrical power in case of danger e Fig 4 7 Cabin switch mounted on the dashboard in the driver cabin o
10. 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 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 All maintenance amp repair works performed on the tail lift should be reported 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 carried out e n 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 evaluat
11. n mrtm m H H H H H ON H io O lt DEPENDING ON LIFT TYP COLOUR CODES DIN 47100 MECH A B31 STANDARD LIFT DH LM 068 068 2009 Power pack GT LX motor pump Valve VO12 X V096 X V141 Plan Sch 096 2009 10 Date 25 03 2009 CI23K0 TO XTERIOR CONTROL BOX REF ECIOSKO TO XTRA H CTRL gt 24 12V RD gt mis Lu 2 1 N 7 CONNECTION Pos CABLE N 5070 CANNON PLUG 5070 12 I2M 4 5 NOT INCLUDED S090 PLATFORM LIGHTS 5075 Foor CTRL REED SENOR DH LM STANDARD LIFT MECHT TILT FOR TRUCKS FROM AUGUST ZZ 2 AS d m 76 4 7 a CONNECTION Pos CABLE N S076 CANNON PLUG N 0 DOUBLE ACTING VALVE ON TILT S POWER PACK SINGLE ACTING VALVE ON LIFT H MECH 2009 ONWARDS B32 STANDARD LIFT DH LM E068 2009 Power pack G LX moftor pump Plan Sch LM V096 X S008 B 2009 BIOS RIOR CONTROL BOX REF EXT E cn 2 Valve 01 VO12 X 096 V141 Date 31 03 2009 BATTERY DROLLANDIJA S
12. switches etc 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 use the batteries will probably need upgrading by heavier duty ones 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 e The following min battery equipment is recommended in function of the tail lift capacity Capacity 750 1000kg Battery 1x 140Ah 2x 88Ah 21090 2x 135Ah 2000kg Not recommended 2x 180Ah 1500 1x 180Ah DHOLLANDIA T 4 SAFETY DEVICES DHOLLANDIA tail lifts are equipped with a wide range of safety devices in order to effec tuate that goods can be loaded unloaded with a maximum degree of safety for bot
13. 2 S008 Z no E068 Valve 2009 VO12 X 096 Date 0 2 OR I2XIMM 2 CTRL I2XIM 2 gt 2 Y gt V0l2 X V096 25 03 2009 DEHOLLANDIA ON LIFT H ON TILT S R _ R PACK R S x N 5 0 SINGLE ACTING VALV DOUBLE ACTING VALV POW EN R MECH t B36 SLIDER DH SM80 E068 STABIL LEGS 2009 Power pack 5 pump Valve VO12 X V096 X V093 Plan Sch SM80 ST V096 X V093 2009 10 EC233K0 TO 215 0 TO EF ERIOR CONTROL BOX R 068 5008 2 20 GY PK 2 RD BU L BATTERY 2 V0I2 X V096 DEPENDING ON THE LIFT TYPE SINGLE ACTING VALVE ON LIFT H DOUBLE ACTING VALVE ON TILT S POWER PACK pus M scd MEGHA mo V 837 SLIDER DH SM80 E068 HYDROMOTOR GEARWHEEL 2009 Power pack GT SX moftor Valve 012 096 Plan Sch 5 80 096 5008 2009 01 Date 31 03 2009 PEOLLANDIA BATTERY EXTERIOR CONTROL BOX REF EB205 mi C Co 62
14. 2006 01 Date 01 11 2006 BATTERY EXTRA CTRL C EXTRA CTRL 2 11 lift cylinder on DH RC lift cylinders DH RM B41 Type VAN LIFT DH LSP 05 HYDR 2006 Power pack 6 15 01 02 Valve VO12 D Plan Sch 15 05 012 0 2008 01 bes OLOUR CODES DIN 47100 C 0178 08 x m E 2 x 2 OF EXT GITE x J zi XTRA CTRL ARTH PK E U gt 24 12V p Date 05 01 2009 gt DHOLLANDIA BATTERY ACTING VALVES ON LIFT H amp TILT S DOUBL DIS 42 0783 gt 8 0783 gt 8 oN ed J 10 8002 8H 8W 8403 9 4IX3 eA DA 1 4100 mm 4x1 mr MdAH Pub 5 04 2 1005 4100 4x 1 E0075 4x EXTRA CTRL COLOUR copes DIN 47100 8002 5S0 Fr 1 T duum II I I DD lt o HU CAxMZZI Po 43 5094 3 1 341 panel controls MECH HYDR Hit Plan N
15. 2l ON LIFT H ON TILT S SINGLE ACTING VALV DOUBLE ACTING VALV POWER PACK X MECH B38 SLIDER LIFT DH SSU80 HYDR HYDROMOTOR amp GEARWHEEL 2008 Power pack GT SD L R 01 06 Valve VO12 D VO96 D Plan Sch 550 80 096 0 2008 10 068 5008 2 NO 221 0 TO C20IKO TO F RIOR CONTROL BOX R EXTRA CTRL ap ae SO S EXTRA CTRL 24 12V Z Z ul gt x lI I II lI CQ DM f 100 OLOUR COD DIN 87100 D lt i HN V0I2 D V096 B39 SLIDER LIFT 0 507 8 HYDR TILT RETRACT Power pack G SOC3 5 Plan N SO7 V095 DW 2006 01 2006 Valve V095 01 11 2006 gt 0711 61 x m BATTERY EXTRA CTRL 7 H2 5 Ei 4 3 2 I 7 i Laum nono Pump pressure Slide out 40 TUCK AWAY LIFT DH RM MECH TILT OPTION S419 2006 Power pack 6 51 4 Valve V005 AUNDDJIUR 005 1800 5419
16. Damage or defects caused by inaccurate or faulty fitting unless mounted by Damage 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 unauthorized 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 warranty case cannot lead to a damage claim of any kind Remark full conditions includ standard repair times and description of procedures available on request T miai LL ie ri 1 se cei een LIII LIEU LE ___ orrie ether care l Tam Lalo EF Fax 22 018 24D
17. LIFT and LOWER rolling loads must be equipped with a device that prevents this load from rolling unintentionally off the edge DHOLLANDIA roll stops can be fitted into the platform point or at inter mediate distances further towards the front edge of the platform e Fig 4 14 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 qn Fig 4 14 DHOLLANDIA um 5 SAFETY INSTRUCTIONS FOR THE USE OF THE LIFT 85 1 Introduction 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 Warning In order to ensure the safety of the operator and occasional bystanders the use of the lift is strictly reserved to skilled operators who have been duly trained who know and understand the full content of this manual Negligence can put the operator and third parties at great risk Simultaneously the operator should follow all other prescriptions and instructions applica ble to his work situation e g health amp safety regulations road traffic regulations company procedures Driver Periodic Training according
18. PLUG 070 CANNON ARTH SWITCH IN CABIN gt E T INCLUDED BN BU gt CAB SWITCH E l CTRL VEHICI D SENSOR 5090 PLATFORM LIGHTS ON PLATFORM RE CONNECTION OF 5090 PLATFORM LIGHTS S0 0 R REED SENSOR APPLICATION ALL DH L WITH 070 REED SENSOR 2 22 lt PLUG 48 Platform lights 090 on control box WITHOUT battery switch E068 Power pack n a Plan Sch Extra 5090 2009 01 Date 15 03 2009 BATTERY 5008 2 NO E068 B EXTRA CTRL REF 84 o De Q H BU gt CAB SWITCH el ARTH SS BN D SENSOR IN PLATFORM POINT RE 5090 PLATFORM LIGHTS CONNECTION 5090 PLATFORM LIGHTS BASIC CONFIGURATION APPLICATION ALL CONTROL BOXES ECIXXX oPTION 5008 2 WITHOUT BATTERY SWITCH 49 Platform lights 5090 on control box E1xxx WITH battery switch E068 Power pack n a Plan Sch Extra 5090 2007 01 15 03 2009 DISIOTLILRUNIDIUR WITH E068 S008 B BATTERY XXX gt o m i o a o x o a gt S090 PLATFORM LIGHTS CONNECTION OF S090 PLATFORM LIGHTS BASIC CONFIGURATION APPLICATION ALL CONTROL BOXES E XXX OPTION 5008 WI
19. be executed smoothly amp quietly without strange noises e Verify occurrence of any play or deformation in the articulation points when driving over the plat form and when OPENING CLOSING the platform Static test at 125 overload test on 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 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 down more than 2 0 Dynamic test at 100 nominal capacity Verify if the lift has sufficient lift capacity 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 Put a load of 1x 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 nomina
20. be searched in this long tilt cylinder Verify if the manual emergency operation on the valves is firmly closed Test and verify if the long tilt cylinder is not leaking internally See RMT HB 6a 6b Revise the cylinders if required Flush purge the cartridge of the safety valve and or of the control valve S in the power pack see RMT HB5 re vise replace O rings or replace the part Verify if the control valve in the power pack works ok Verify if the manual emergency operation on the valve U is firmly closed Remove the solenoid of valve U and verify if it is without tension If valve U is open the oil from the pump flows directly back to the oil reservoir Verify the mechanical fixation of the retraction cylinder on both sides Repair if necessary Uncouple the hydraulic pipe for SLIDE OUT at the retraction cylinder and try to SLIDE IN If large quantities of oil con tinuously leak from the pipe and the piston rod doesn t move the cylinder seals are worn out or the piston is broken loose Dismount the retraction cylinder and revise it Verify the oil pressure if the system turns in overpressure and the HTL doesn t SLIDE IN the slide blocks or rollers are probably worn out or the slider system is deformed B24 e The control U in the power pack is not activated e The control valve is mechanically blocked in the open position The O ring of the cartridge is damaged or the valve is stuck in open
21. between the open platform and the rear side of the vehicle see Fig 1 7 If the nature of the works require that you enter into one of the danger zones see 5 3 in 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 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 It is prohibited to modify straighten heat up weld lengthen or shorten etc the con struction of the mechanical 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 81 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 press
22. capacity chosen The loading diagrams amp instructions of chapter 6 should be observed at all times The standard position is in the platform point but customized positions can be ordered The option list features 3 types of roll stop systems 215 Manual roll stops operated by torsion springs see Fig 7 23 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 Automatic roll stops operated by torsion springs see Fig 7 24 Kick the lever on the side of the roll stop flap sideways from position 1 to position 2 5215 will now function as a manual roll stop 5215 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 5215 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 A35 215 V Vertical roll stops no springs see Fig 7 25 OPEN Kick the button on the side of the roll stop flap in the directi
23. infor mative decals EF0501 supplied with the lift which should be applied to the vehicle body within eye sight of the operator Fig 7 17 Exterior control box for slider lifts Opening the platform Consult the user s manual before getting started Switch on the electrical power to the tail lift cabin switch in the driver s cabin and battery switch of the exterior control box Observe all safety instructions and open the platform lock 4 LOWER the foldable platform approx 20cm except for mountings with platform slides see Fig 7 19 where the lift frame hits the end at the end the ui tubes tance LOWER tno mechanical or yea sailing cs irto work posto _ 5 Uomepohetkobepom _ Ne Exterior control box use the depicted combination of joy stick and safety button to LIFT amp LOWER At the ground use the automatic tilt at ground level S Obemeteiwingdayans mstuondalims 0 Ue Closing ypintovelpositon 00002 appa e mechanical or hydraulic spitsng egs vavel postion where the lift frame hits the end stops at the front of the sliding tubes Close the platform lock See also Fig 7 18 DHOLLANDIA 25 7 8 Operating instructions for slider lifts with double folded platform e The exterior control box on slider lifts with double folded platform should be operated as follows See also the informative decals EF0509 supplied with the lift which
24. instructions are of prime importance 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 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 Lokeren 32 9 349 06 92 Brazil arusi nen ana 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 Nolako Naestved 45 55 70 0201 Estonia Widni Baltic Tallinn 372 6532 431 pu mna Widni Vantaa 358 9751 80 500 France Dhollandia France Argenteuil 33 134 11 74 00 Free service 33 825 042 966 Dhollandia Germany Hamburg 49 40 76 11 96 0 Great Britain Dhollandia UK Huntingdon
25. is of course the unload the U vehicle via the ground then proceed to reload the L vehicle of the ground in a second phase If only 1 of 2 vehicles is equipped with a tail lift transferring loads is only allowed if a mini mum section of 150mm of the platform point can cover the loading floor of the other vehi cle See also Fig 5 24 Again when loading unloading the loading floor of one vehicle might lower rise rela tive to the other vehicle Use the electrical controls to tilt the platform down when its point rises above the loading floor of the other vehicle Never drive onto the platform when its point doesnt lay flat on the ground DHOLLANDIA A22 Min 200 mm Min 200 mm Max 200 mm Min 200 mm 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 When LIFTING the tail lift is normally protected against overload by the pressure relieve valve in the hydraulic circuit Most of the overload and consequential damage happens when LOWERING loads order to ensure the safety of the operator and occasional bystanders and pro tect the structural int
26. liability for any personal injury or property damage that re sults from improper use The manufacturer s product liability and the warranty are voided in case of disregard in this respect 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 e DH L series comprises of a range of cantilever lifts designed for wide variety of factory built panel vans trucks trailers and semi trailers and is available with lift capaci ties of 300 to 9 000kg In its travel position the platform of the cantilever lift is stowed vertically behind the vehi cle body Before use the platform is tilted open 90 from the vertical travel position to a horizontal work position Main det
27. 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 free moving flexible oil pipes of the retraction cylinder stay clear from the ve The main fuse the battery and earth cables are fitted correctly and conform to the hicle chassis amp body They cannot be damaged by rubbing squeezing fitting instructions all bolted connections of cables and fuses are properly tight The end stops at the rear end of the sliding tubes are fitted correctly and the plat ened forms arrives flush with the loading floor when LIFTING DHOLLANDIA C4 The retraction cylinder if applicable stays clear from the vehicle chassis amp body includ air pipes brake conducts etc during all movements of the lift and for all positions of the vehicle suspension 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 Static test at 12596 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 12596 overload Test on inclination Position the platform a
28. plat form and its load Tilt cylinders 1 or 2 hydraulic cylinders used to change the angle of the platform when deployed in work position Hydraulic power pack contains the electric motor driving the hydraulic pump the oil tank and the control valves 3 DHOLLANDIA 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 A8 DH R series comprises of a range of tuck away lifts designed for a wide range of trucks trailers and semi trailers and is available with lift capacities of 500 to 2 000kg In its travel position the foldable platform of the tuck away lift is safely stored underneath the vehicle chassis Before use the platform is tucked out from its travel position under the vehicle chassis to its work position behind the vehicle body and then unfolded Main details amp terminology Fig 3 3 Tuck away lift Description 0 Lift frame mounted in a fixed position under the vehicle chassis It bears the plat form and its load via intermediation of the lift arms and hydraulic cylinders Mounting plates used to mount the lift frame to the vehicle chassis Foldable platform carries the load during loading unloading Available in steel execution with aluminium point and in full aluminium execution Foreseen of a non slip working surface Roller arm arm with synthe
29. possible see Fig 1 12 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 with the holes of the articulations on the platform lift arm or frame see Fig 1 13 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 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 For dismounting and remounting hydraulic valves safety valves on the cylinders control valves in the power pack the same safety precautions apply 81 3 Electrical components DHOLLANDIA Before dismounting and remounting electrical compone
30. should be where the lift frame hits the end stops at the front of the sliding tubes applied to the vehicle body within eye sight of the operator Switch off the electrical power to the tail lift cabin switch in the driver s cabin and Opening the platform battery switch of the exterior control box Close the lid of the control box 1 Consult the user s manual before getting started Switch on the electrical power to the tail lift cabin switch in the driver s cabin and battery switch of the exterior control box Observe all safety instructions open the platform lock and LOWER the foldable plat form approx 20cm Use the central rotary switch to SLIDE OUT the platform to the rear end of the sliding tubes This is where the lift frame hits the end stops at the end of the sliding tubes Lower the platform to just above the ground Unfold the 2 parts of the double folded platform Use the central rotary switch to SLIDE IN the platform into the work position If applicable LOWER the mechanical or hydraulic stabilising legs into work position Loading amp unloading Select between exterior control box and auxiliary controls Exterior control box use the depicted combination of joy stick and safety button to LIFT amp LOWER At the ground use the automatic tilt at ground level 0 Observe the loading diagrams amp instructions at all times Closing up in travel position If applicable LIFT the mechanical or hydraulic stabilisi
31. solid support blocks must be used under the stabilising legs see Fig 5 2 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 within reach of the moving platform Inspect the lift prior to each use If any unsafe condition exists or unusual noises or movements are noticed DO NOT use the lift and contact an authorized DHOL LANDIA service agent for repair Read and comply with all warning decals pictograms and instructions affixed to the lift 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 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 When available close the mechanical platform lock after closing the platform in its travel position The lift should not be used if the operator is intoxicated or impaired any way Use extreme care in wet or slippery conditions e The tail lift Sho
32. vehicle body within eye sight of the operator Fig 7 15 Optional control box for cantilever lifts option S094 Opening the platform Consult the user s manual before getting started Switch on the electrical power to the tail lift cabin switch in the drivers cabin and battery switch near the exterior control box 3 Observe all safety instructions and open the platform lock If applicable LOWER the mechanical or hydraulic stabilising legs into work position OPEN the platform approx 90 into the desired horizontal position Don t LOWER before the horizontal work position has been reached to LIFT amp LOWER At the ground use the automatic tilt at ground level 10 Close the platform lock see also Fig 7 16 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 CLOSE the platform until it reaches the closed vertical position and you hear the hy draulic system turn in overpressure DHOLLANDIA 87 7 Operating instructions for slider lifts 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 e The exterior control box on slider lifts should be operated as follows See also the
33. 47 69 erra fa do DHOLLANDAA Mob 32 0 484 56 90 27 wan site M ciel l impe Mob 32 03436 66 PO 22 C _ __ few d _ ar orem crore El Pes ceu ew gem NIB a R _ __ rupe ms aam T pam Fax 192 0 9 240 84 te m DHOLLANDIA DHOLLANDIA MAINTENANCE 4 REPAIR DHOLLANDIA 1 SAFETY INSTRUCTIONS FOR MAINTENANCE amp REPAIR n order to ensure the safety of the technical personnel the operator of the tail lift and occasional bystanders the execution of maintenance and repair works is strictly re served to skilled and authorised service agents who have been duly trained who know and understand the content of this manual and master the safety aspects involved in their job Negligence can put the technical personnel the operator and third parties at great risk 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 techni cal safety instructions described below 61 1 General safety instructions Use appropriate working clothes Never wear loose fitting clothes that may be trapped in the moving parts of t
34. 98 7 Operating instructions A25 6 International distributor network C15 7 1 Introduction to the standard control box A25 87 2 Option 094 3 1 button control box A26 7 3 Auxiliary controls 27 7 4 Automatic tilt at ground level A28 7 5 Operating instructions for cantilever lifts A29 87 6 2 instructions for cantilever lifts Option A30 7 7 Operating instructions for slider lifts A31 87 8 RE instructions for slider lifts with double A32 olded platform 7 9 Operating instructions for tuck away lifts A33 87 10 The use of stabilising legs A34 87 11 user of roll stops A35 8 Warranty conditions A36 Copyright 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 m Identification of the tail lift CE DECLARATION OF CONFORMITY Corresponding Directive 98 37 EC annex 2 A We hereby declare that the DHOLLANDIA tail lift identified above based on its design and its construction complies to the relevant fundamental safety and health 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
35. A INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION SPECIAL INSPECTION 1 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 LJ NO operational safety and reliability Place date Name amp function of the expert L During this inspection no imperfections have been found or Name amp address of the inspection body LI 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 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 LI YES LINO operational safety and reliability Place date Name amp function of the expert L 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
36. A Hydraulical mixed system Open With Motor 3 MECH Double Acting MECH Single Acting Year of 2002 2002 2009 2008 2003 2007 construction 2008 2009 2008 Tilt at ground level Mechanical tilt Hydraulical tilt Mechanical tilt Mechanical tilt All types mechanical amp hydraulical tilt HTL types DH LM LC SM SMR DH LSP LSP6 LSU DH LM LC SM SMR DH LM All types DH L DH S DH R SMP SMO RM RC SSU SV SO SMP SMO RM RC LIFT UP I All valves H 0 5 H DA S DA O D DA H S U DA U IS US SA B I U IS US SA H D 1 U IS US SA S 4 2 way valve D O B SA w single acting electrovalve control valve CLOSE in the power pack DA double acting electrovalve O 7 safety valve OPEN on the tilt cylinders control valve SLIDE IN in the power pack or on the hydromotor R 7 starter solenoid of the electric motor U control valve SLIDE OUT in the power pack or on the hydromotor H control valve LIFT in the power pack IS control valve LEG IN in the power pack or on the stabilising leg D safety valve LOWER on the lift cylinders US control valve LEG OUT in the power pack or on the stabilising leg DHOLLANDIA B17 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 bu
37. Directives with 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 09 392 EC e and subsequent modifications 98 37 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 DHOLLANDIA n A3 DISCLAIMER 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
38. INGLE ACTING VALVE ON LIFT H POWER PACK MECH DOUBLE ACTING VALVE ON TILT S B33 Type STANDARD LIFT DH LE LSU no E068 HYDR tilt 2008 Power pack 10 pump Valve VO12 D VO96 D Plan Sch 150 096 0 2008 11 Date OLOUR COD DIN 47100 X EXTRA CTRL O e O du EXTRA CTRL eM LU oO x QO Li gt lt m Y Z O x ei Y gt EXTRA CTRL gt 24 2V NO E068 S008 7 ES ACTING VALV ER PACK POW DOUBL ON LIFT H amp TILT S HYDR B34 STANDARD DH LE LSU HYDR Power pack GT LD moftor pump Plan Sch LSU V096 D S008 B 2009 01 pes OLOUR COD DIN 47100 p EXTERIOR CONTROL BOX REF EBIOI 5008 2068 E068 2008 VO12 D VO96 D Date BATTERY oO A gt EXTRA GN gt 01 04 2009 DHOLLANDIA ES ACTING VALV R PACK DOUBL ON LIFT H amp TILT S HYDR B35 SLIDER LIFT DH SM80 Power pack GT SX motor Plan Sch 5 80 096 2009 10 Z Zulsl gt gt n lt SOO 2 non H H Ho H H H H EXTERIOR CONTROL BOX REF 205 0 TO 225 0 TO C
39. Incl also DH SO 1500 2000 kg 15 grease points DH SO8 2 extra grease poiints gt 15grease points DHOLLANDIA E The following information must be confirmed when ordering spare parts e In case of a malfunction the operator can verify a number of points himself before calling Type year of construction amp serial number of the tail lift an approved DHOLLANDIA service agent Spare parts reference consult the spare parts lists 15 the isolator switch for the tail lift called HTL hereafter in the vehicle cabin switched desired quantity of each item on Are the main power plugs between the tractor unit and the trailer properly con Your administrative data company name invoice address VAT number purchase nected 15 the battery switch in the exterior control box switched on order number delivery address and expected delivery time Is the main fuse for the HTL near the vehicle batteries still functional Is the connection of the HTL to the vehicle batteries ok The type year of construction amp serial number of the tail lift can be found on the identifica Are the batteries auxiliary batteries too weak tion stickers see point 2 in Chapter Has the mechanical platform lock been released e lf 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 w
40. LANDIA POWER SINGLE ACTING VALVE ON LIFT H MECH X DOUBLE ACTING VALV knew Kees ee s gt F ON TILT S 5008 7 NO E068 EART EXT EXTERIOR CONTROL BOX REF ECIO3KO TO ECI25KO TO eec EXTRA CTRL Ubid yond CODES DIN 47100 85 01 6002 X 960A WT 49S L f pm mm LEE ji oo W Po Hood Ho gp 0g lt GO UJ C lt M 2454 6002 60 62 VINY TIOM B30 _ 100 1 19 8A DA IFLA X 960A X Z10A ed J 8903 ou X HO3W W1 HG 141 GM vGNVIS 6002 E068 HYDR STABILISING LEGS 2009 Power pack pump Valve 012 V096 X V141 093 Plan Sch 57 096 093 2009 10 Date 25 03 2009 F TO 5 TO 2 2 2 EXTERIOR CONTROL BOX D RII pl 1 EXTRA CTRL 1 2 2 VT 2 gt 28112 Y gt 5 C N 62 ON LIFT H ACTING VALVE ON TILT S R PACK SINGLE ACTING VALV POW DOUBL Z Z ul gt lt gt n 9 gt
41. SE amp OPEN See Fig iuh Joystick Symbol 7 5 LIFT t CLOSE 7 ah Du ymbol DHOLLANDIA Additional rotary switches foreseen in case of more complex lifts The functions SLIDE IN SLIDE OUT in case of slider lifts The functions LEG IN LEG out in case of lifts with hydraulic stabilising legs See Fig 7 6 e n practice the functions on the exterior control box are actuated as follows To actuate SLIDE IN SLIDE OUT LEG IN LEG OUT use of safety switch not required on all lift models CLOSE Dutton controi DOX The option 5094 features a 1st control box with 3 buttons plus a 2nd separate control box with 1 safety button A separate battery switch should be mounted during installation of the lift This type is for instance used for mounting into the side panel of factory built panel vans e The 3 buttons plus the safety button operate the 4 basic functions LIFT LOWER CLOSE amp OPEN See Fig 7 7 DHOLLANDIA w A26 SLIDE IN 7 IN t gt SLIDE tem OUT 7 3 Auxiliary controls e The auxiliary controls should be used with full respect of the particular safety instructions xm of 85 4 lt WO choice for auxiliary controls e the safety switch in the exterior control box is a rotary switch this switch should be turned counter clockwise to activate the auxiliary
42. TH BATTERY SWITCH B50 MAINTENANCE amp INSPECTION REPORTS 1 E i ka rn z3 DHOLLANDIA Since the 1st 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 All tail lifts should be subjected to a number of compulsory inspections as explained be low All tail lifts are largely pre assembled and tested by the manufacturer and receive CE Declaration of Conformity Annex covering the design and mode of construction Tail lifts are no stand alone application though and must be incorporated into a complete vehicle to become operational CEMD regards the complete vehicle including the tail lift
43. ace to verify the result B25 6 56 1 Introduction and safety instructions Most types of DHOLLANDIA tail lifts called HTL hereafter are equipped with a man ual emergency operation on the electrovalves used on their cylinders and in their 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 Prior to manipulating the manual emergency operation on the valves take maximum safety precautions and take notice of the safety instructions for use for repair amp main tenance and the ones included in this section n case of doubt stop immediately and ask advice from DHOLLANDIA prior to con tinuing Negligence can put the technical personnel the operator and third parties at great risk 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 6 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 bet
44. acement 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 88 4 NOT covered under DHO 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 hours 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
45. ails amp terminology Fig 3 1 Cantilever lift DAL NN Lift frame mounted in a fixed position under the vehicle chassis It bears the platform and its load via intermediation of the lift arms and hydraulic cylinders ua Mounting plates used to mount the lift frame to the vehicle chassis Platform carries the load during loading unloading Manufactured from steel or light weight aluminium and foreseen of a non slip working surface Equipped with syn thetic rollers to protect it from scraping on the ground 4 Lift arms actuated by the hydraulic lift cylinders used to LIFT LOWER the platform and its load Lift cylinders 1 or 2 hydraulic cylinders used to LIFT LOWER the lift arms the plat form and its load Tilt cylinders 1 or 2 hydraulic cylinders used to OPEN CLOSE the platform or to change its angle when opened in work position T 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 9 Bumper bar under run protection device certified conform to CE legislation DHOLLANDIA The DH S series comprises of range of slider lifts designed for wide range of trucks trailers and semi trailers and is available with lift capacities of 400 to 3 000kg In its trave
46. anufacturer 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 e The Declaration of Conformity the manufacturer s product liability and the warranty are voided in case of disregard in this respect 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 H YES has been executed following the instructions of this e The put into service test see also 2 1 comprises of manual a visual inspection on the fitting work of the tail lift on the vehicle chassis and of the After weight testing with nominal capacity the hydraulic various aspects determining the operational safety of the tail lift pressure has been at a series of static and dynamic weight tests Most points of the visual inspection will be executed through practical tests without load Remarks 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
47. ase of breakdown The following pages contain the main wiring diagrams for DHOLLANDIA tail lifts as sup resulting from a failure on one of the solenoids D H 5 U The actions are plied in their standard execution ranked 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 diag e In case of special lifts should the original wiring diagram joined to the lift be lost or nosis for definitive repair cannot be established quickly unavailable contact DHOLLANDIA for further help n case of doubt stop immediately and ask advice from DHOLLANDIA prior to con tinuing 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 Identify the failure and repair Use the manual emergency operation on the valve to actuate the corre sponding function retraction cylinder Open the valve manually or mechanically disconnect the retraction cylinder or gear wheel system and use a forklift to push the platform slowly and gently back into its travel position DHOL
48. asure the centre distance between lift arm and tilt cylinder on the frame and on the platform compare both values and compare with the fitting data Grease the HTL thoroughly and verify the clearance of all pins in the articulation bearings Verify the general condition of the articulation points pins and bearings for deformation 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 block V012 of V096 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 Remark Take into account the quantity of cylinders and their safety valves and whether the control valves in the power pack are single acting or double acting For most types of HTL with 4 cylinders there must be a combination of different defects if the platform lowers sponta neously 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 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 inter
49. ay Too often components are replaced at random until the malfunction disappears Such method is very expensive however on labour hours and spare parts cost e 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 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 7 hy draulic fault one of the piston rods of the lift cylinders is bent by overload or accident 7 mechanical fault e The tables below can be used as guide during the further fault analysis 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 These cross references to the training program are marked I Some steps the check list require special skills and specific knowledge see as for example see RMT HB3 see Repair amp Maintenance Training Hydraulic Base techniques 3 DHOLLANDIA 85 1 Summary activation of electrical solenoids per tail lift function 2 Scheme MECH E HYDR MECH X OMM3 MECH DA MECH S
50. batteries damaged or corroded fuse under rated alternator and repair or adjust 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 Main power IN Earth thermal fuse Control power IN nl i Main pole OUT 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 the outgoing main pole of the starter solenoid also check if there is sufficient Amp by using a test bulb If th
51. chapter represent left hand drive vehicles continental Europe with the control box mounted 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 LOWER OPEN CLOSE plus a safety switch 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 amp exterior control box 1 choice for D gt auxiliary controls 2 I Push button as safety switch Button pushed in Activates the joy stick in the exterior control box Button left idle Activates the auxiliary controls e The joy stick operates the 4 basic functions LIFT LOWER CLO
52. control See Fig 7 8 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 9 e The 2 button wander lead with spiral cable option S001 and the 2 button fixed interior controls option S003 5005 are equipped with 2 buttons 1 button to LIFT 1 button to LIFT t t e The use of 3 button wander leads with spiral cable enabling the operator to additionally TILT the platform is disallowed under the European CE Safety Directives Pu L OWER 1 1 waq ili DHOLLANDIA 87 4 Automatic tilt at ground level e All tail lifts with a conical platform are equipped with 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 11 t 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 12 tion then lift further in this setting to the vehicle floor Most types of lifts are equipped with tilt cylin To actuate ders which allow the operator to adjust the TILT angle of the platform to the slope of the un UP 2 derground see Fig 7 13 Other types have fixed stabilis
53. d to execute maintenance and STE Statutory Thorough Examination or periodic inspection repair works Follow the scheme on the next pages verify point after point and tick off as you make The warranty and product liability are only valid for HTL which are maintained in good progress working condition according to the instructions in this manual DHOLLANDIA disclaims liability for any personal injury or property damage that re sults from operating a product that has been modified from the original design that hasn t been serviced repaired according to the instructions in this manual or when non R 4 Some steps in the check list require special skills and specific knowledge see DHOLLANDIA Repair 8 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 original components or spare parts are used 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 audible Any other 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 e The maintenance frequency depends on the intensity and conditions of use The mini Type of thread Size Stren
54. draulic pump is broken e The hydraulic pump is completely worn out e The seals of the cylinder s are heavily damaged or torn off by incorrect manipulation e HTL is badly greased the pins seize up in the articulation bearings e HTL is deformed in one of the articulation points pins or bearings e One of the piston rods of the lift cylinders tilt cylinders is bent by overload or by accident 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 e By frosty weather ice formation in the hydraulic pipes valves e The braking valve in the power pack or the braking valves on the lift cylinders tilt cylinders are dimensioned too small DHOLLANDIA Verify the oil level in the power pack and top up oil if necessary Rest the platform in work position on the ground The correct oil level reaches to the MAX mark on the oil reservoir Check the position of the stops for the lift arms and adjust them when required Verify and compare the fitting height and vehicle dimensions with the fitting instructions Verify the general condition of the HTL frame lift arms and articulation points pins amp bearings Verify the oil level in the power pack and top up oil if necessary Rest the platform in work position on the ground The correct oil level reaches to the MAX mark on the oil reservoir Dismo
55. e is open the oil from the pump flows directly back to the oil reservoir Verify the mechanical fixation of the retraction cylinder on both sides Repair if necessary Verify the oil pressure if the system turns in overpressure and the HTL doesn t SLIDE OUT the slide blocks or rollers are probably worn out or the slide system is deformed Verify if the electrical operation of the solenoid on valve l is ok e g magnet tester If not measure the current amp earth circuit to that solenoid until the control box switches and contacts and repair Replace the solenoid if necessary Verify the various parts of the retraction system hydromotor gear wheels tooth racks and slide blocks rollers on the slide plates for deformation or damage Repair or replace if necessary Dismount the cartridge of the 4 2 way valve on the hydromotor try to clean it and loosen it up or replace to verify the result Verify if the electrical operation of the solenoid on valve U is ok e g magnet tester If not measure the current amp earth circuit to that solenoid until the control box switches and contacts and repair Replace the solenoid if necessary Verify the various parts of the retraction system hydromotor gear wheels tooth racks and slide blocks rollers on the slide plates for deformation or damage Repair or replace if necessary Dismount the cartridge of the 4 2 way valve on the hydromotor try to clean it and loosen it up or repl
56. e The content of this compulsory put into service test is explained hereunder Signature of the inspector DHOLLANDIA 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 The vehicle is technically suitable for the type of lift and its nominal capacity tro units Is activated and vice versa The hold to run principle works on all control units any ongoing movement The requirement for mechanical or hydraulic stabilising legs has been checked should inimedistely stop when cone ot the corie ponding swilches is released and been fulfilled if applicable The cables going to the platform platform lights foot controls are properly The actual fitting di i t the theoretical maxi fitting dimen 22 men routed and cannot be damaged during the various movements of the lift sions mentioned in the fitting drawings The lift has been fitted to conform with the fitting instructions of DHOLLANDIA and the Fitting amp Body Building instructions from the vehicle manufacturer There no visible oil leaks after the weight tests all cylinders are free from paint All safety decals amp labels identification sticker decal with user s pictograms decal remainders with load diagra
57. e 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 If the earth of the electric motor is ok revise the motor or replace it B19 e The button or switch for LIFT the exterior control box or auxiliary control doesn t return to the neutral 0 position e The button or switch returns to 0 position but one of the electric contacts behind the switch is stuck or burnt e Short circuit between the various wires in one of the electrical cables e The contacts of the starter solenoid are burnt and remain activated e The button switch or electric contact are faulty or the connection to one of the contacts is loose e The incoming or outgoing connection to the electrical distribution block in the power pack is faulty e The electric cable to one of the safety valves D is interrupted or has a bad contact e Solenoid H LIFT LOWER is defective Or the cartridge of the valve is mechanically blocked only for the schemes HYDR and MECH DA not for MECH SA nor for MECH X e One of the solenoids D lift cylinders is defective or the cartridge of one of the valves is mechanically defective e One of the braking valves on the cylinders or in the power pack is mechanically blocked by ice dirt or by mechanical malfunction e One of the lift cy
58. e if it is safe to continue to use it The findings of these inspections should be summarised in the relevant inspection certificates see pg C6 amp following e 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 summarized in the relevant inspection certificates see pg C6 amp fol lowing e The content of these compulsory inspections is explained in Chapter B Point 2 e 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 equipment 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 e The expert competent person should read and use the content of this user s man
59. e 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 e Fig 4 11 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 vehi cle against short circuits and amperage peaks e Fig 4 12 Signalling of 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 these 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 12 a reflective flags see Fig 4 12 b and lateral reflecting tape see Fig 4 12 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 HTL 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 12 d e Fig 4 13 Roll stops on the platform any platform aimed to
60. e platform 7 the buttons of the foot control see Fig 5 9 should only be used under the safe working conditions described in the Euro pean Standard 1756 1 2001 1 208 and the latest issue of the DHOLLAN DIA fitting instructions FIT ELEC OPTION 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 Before putting the tail lift in operation the vehicle owner or employer should en f no 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 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 12 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 13 the ground from a safe working zone min 500 mm away from the side edge of the platform See Fig 5 14 DHOLLANDIA UE e When lifting lowering the operator standing on the platform should hold to the hand grip
61. e users of the same machinery PUWER and LOLER fall under UK criminal law and neglect or failure to comply with the previsions can lead to financial penalties or imprisonment This legislation imposes following obligations on owners fleet operators safely Carry out 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 Ensure that lifts are safe Lifts provided after 1997 should meet the Machinery Direc tive 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 Applies to all work equipment including tail lifts but also includes vehicles Strengthens the requirements of the Management of Health and Safety at work Regula tions 1992 Stipulates that vehicles and lifts must be maintained in a good state of repair Only competent trained people should operate repair and service the equipment Lifts supplied from 1993 1996 may require upgrading to meet the Essential Safety Re quirements of the Machinery Directive For more information refer to Safe Use of Work Equipment ACOP and guidance L22 HSE Books 1998 ISBN 0 7176 16266 DHOLLANDIA C14 Employers must ensure that t
62. egrity of the lift fore lying loading instructions and diagrams should be followed with great care Negligence can put the operator and third parties at great risk or cause premature wear or damage to the tail lift DHOLLANDIA disclaims liability for any personal injury or property damage that re sults from overload practices 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 arms this is at equal distance from both plat form sides 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 A23 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 arms e Be aware that the centre of gravity of the load doesn t necessarily correspond with its physical middle point The weight can be
63. en 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 22 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 11 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 A19 0 Importance qood maintenance Prior to use inspect the tail lift to ensure that all safety systems and all functions A operate correctly and that no urgent maintenance or damage repair is required any unsafe condition exists or unusual noises or movements are noticed DO NOT use the lift and contact an authorized DHOLLANDIA service agent for repair Missing worn or illegible warning decals must be immediately replaced Competent and regular maintenance is very important for the operational reliability and the safety of the operator and occasional third parties in traffic All maintenance and repair works should be executed b
64. ers with a fixed non adjustable platform angle Tilt cylinders Tilt cylinders DH LSP DH LM DH LSU DH SM DH SSU DH SO DH SV DH SK DH RMC DH RCC Fixed stabiliser rods DH RC DH RM DH SKS DH SC The automatic tilt incorporates a memory the angle of the platform set by the operator upon opening the platform possibly slightly above or below perfect horizontal level is automatically repeated upon every new LIFT cycle off the ground This angle is memorised 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 might cause damage to the tail lift and injuries to the operator or third parties near by DHOLLANDIA n 87 5 Operating instructions for cantilever lifts e The standard exterior control box on cantilever lifts should be operated as follows See also the informative decals EF0500 supplied with the lift which should be applied to the vehicle body within eye sight of the operator Fig 7 14 Standard exterior control box for cantilever lifts Opening the platform Consult the user s manual before getting started Switch on the electrical power to the tail lift cabin switch in the driver s cabin and battery switch of the exterior control box Observe all safety in
65. gth class mum frequency for the various works is given below 8 8 10 9 W52 52 xlyear weekly check by owner operator Standard M6 x 1 10 14 gt 4 monthly check by a qualified DHOLLANDIA service agent M8 x 1 25 24 33 gt J 1x year yearly winter maintenance to be executed just before the winter M10 x 1 5 47 68 so that any condensation water in the hydraulic circuit be removed during the oil M12 x 1 75 82 115 change and frost problems during the winter be avoided M14 x2 123 185 M16 x 2 195 285 e HTL are subject to compulsory periodic inspections by an expert competent person see Fine M14 x 1 5 135 195 2 4 in chapter C The frequency of these inspections is set at minimum 1 year for most M16 x 1 5 208 300 countries in Europe In the United Kingdom the frequency of the LOLER examination or M20 x 1 5 360 the Statutory Thorough Examination is set at minimum 2 year by the Health and Safety M24 x 2 450 Executive HSE DHOLLANDIA B5 W52 Weekly check by owner fleet operator STE Statutory Thorough Examination UK or Periodic inspection by expert competent person 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 Additional points only to be verified during periodic inspection STE 0 Complete HTL at the rear under
66. h the op erator 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 is 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 platform lock mounted as supplement to the safety valves on the cylinders Although not compulsory in all CE countries it is strongly recommended to se cure the platform in its travel position by means of such additional lock to prevent it from falling in case of accidental loss of hydraulic pressure If the platform needs to function as load restraint device in the meaning of DIN EN 12195 1 or DIN EN 12642 Code XL the lock might be compulsory depending on the pay load of the vehicle and the type of tail lift Ask DHOLLANDIA for further advice e Fig 4 3 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 LOWER and OPEN with the legal requirements
67. he lifting equipment its mounting and 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 user s manual DHOLLANDIA s own written
68. he 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 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 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 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 released see Fig 1 3 1 4 e 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 nevertheless 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 starting the works see Fig 1 6 DHOLLANDIA Avoid to stand on or sit
69. ibution block in the power pack and repair the fault 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 batteries 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 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 who
70. icient clearance under and above the platform taking into account all expected positions of the vehicle suspension The platform shouldn t touch either the ceiling or the bottom of the storage pocket in the loading dock see Fig 5 29 next page DHOLLANDIA gt KG S Nom capacity Fig 5 24 Min 150 mm A21 55 6 Moving loads between 2 vehicles with cantilever tail lifts When transferring loads between 2 vehicles equipped with a cantilever platform proceed as follows see Fig 5 30 Open the platform of the vehicle that should be loaded L vehicle fully below horizontal level until it cannot be opened any further Open the platform of the vehicle that should be unloaded 7 U vehicle to horizontal level and reverse until the platform point arrives at 200mm from the rear frame of the body of the L vehicle Tilt the platform of the U vehicle down and make sure it rests on the platform of the L vehicle When loading unloading the loading floor of one vehicle might lower rise rela tive to the other vehicle Use the electrical controls to tilt the platform of the U vehicle down when its point rises above the platform of the L vehicle Prior to adjusting the plat form angle make sure the platform is empty 7 no load no operator on the platform If the vehicles are too different in size to follow the instructions above it is not permitted to transfer loads in this way The safest way to transfer loads
71. in the power pack or exterior control box 0 Foot controls Platform lock O Visibility of the platform in public traffic e platform is clearly visible in surrounding traffic from all approachable angles 0 Synthetic platform rollers e General condition replace when damaged or worn out M3 J1 LI Slide plates slide blocks rollers e General condition check for cracks amp deformation L Sliding tubes in steel or aluminium e Smooth SLIDING IN OUT Wear to the slide blocks and or rollers e Correct amp regular greasing if required check the grease plans LI End stops in the sliding tubes e The end stops at the rear of the sliding tubes are positioned correctly when LIFTING the plat form arrives flush with the loading floor of the vehicle 0 Hydromotor gear wheel assembly e General condition of the hydromotor the gear wheel and the tooth racks LI Retraction cylinder e General condition of the retraction cylinder its mounting to the lift frame and to the vehicle chas sis e Check for cracks damage amp deformation 0 Roller arm for deployment of the platform e General condition check for cracks amp deformation M3 e Smooth folding in out J1 L Torsion traction springs e General condition M3 Adequate tension effective but not too strong J1 Remark DHOLLANDIA WT LI General operation with empty platform e Execute all movements several times with ALL available control units The movements should
72. inal delivery format and mounted conform to DHOLLANDIA fitting instructions If needed the homologations can be downloaded from the internet See 3 www dhollandia com gt Downloads gt Bumper certificates after 2007 INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION 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 LI YES LINO operational safety and reliability Place date Name amp function of the expert L 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 L Shortcomings have been acknowledged Scope of the inspection L Shortcomings have been repaired Place date Name amp signature of the owner or fleet operator Partial inspections to follow DHOLLANDIA a INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION 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 LJ NO operational safety and reliability Place date Na
73. inder to the HTL frame or vehicle chassis is broken e The seals on the piston of the retraction cylinder are worn out or pulled off the piston by an accident e The piston is broken loose of the piston rod by an accident e The slide blocks or rollers are worn out or the slide system is deformed DHOLLANDIA Remark Take into account the quantity of cylinders and their safety valves and whether the control valves in the power pack are single acting or double acting For most types of HTL with 4 cylinders there must be a combination of different defects if the platform falls open spon taneously 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 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 HB 6b Revise the cylinders if required Flush purge the cartridge of the safety valves O and or of the control valve S in the power pack see RMT HB5 revise replace O rings or replace the part Remark most of the cantilever HTL from 1500kg onwards have a short tilt cylinder type EDS left side and a long tilt cylinder type SKS right side If the platform falls open to 45 but not further to horizontal level the malfunction must
74. ing platform and the rear cross member of the vehi cle floor see Fig 5 6 ig 5 300 L 600 mm the crushing zone between the closing platform and the rear frame of the vehicle body 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 5 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 T 55 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 th
75. ions 0 Frame construction e General condition condition of the welds Lift arm construction e Check for cracks amp deformation e Corrosion 0 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 HTL with mechanical tilt at ground level brackets for the mechanical tilt e General condition check for cracks amp deformation M3 e Operation amp function of the automatic tilt at ground level J1 0 Mounting plates fixation to the vehicle chassis e General condition check for cracks amp deformation M3 e Presence condition amp correct tightening of all mounting bolts J1 Remark Platform construction e General condition condition of the welds e Check for cracks amp deformation e Corrosion 0 Articulation points e General condition check for cracks deformation elliptic deformation 0 Articulation pins e Locking of the articulation pins by locking pins bolts amp nuts e Presence of grease nipples correct and regular greasing DHOLLANDIA Continued e General condition function amp operation LI Load restraints roll stops e Condition routing amp guidance of the electrical cables from the platform over the lift arms to the LI Platform lights flags traffic cones connection point
76. l capacity at the centre of gravity the platform should not be able to lift Remark 0 Maintenance amp repair reports e All works are duly documented in the corresponding report or certificate documents always 0 Certificates for Periodic inspection Special Inspection Re inspection DHOLLANDIA 3 GREASE PLANS All DHOLLANDIA tail lifts called HTL hereafter are equipped with low maintenance bearings Therefore under normal conditions of use and a single labour shift the greas ing frequency can be limited to 3 thorough greasings per year In case of very intensive use multiple shift 24h operation or use in a hostile environ ment food industry frequent high pressure cleaning with strong detergents the fre quency of greasing should be increased adjusted to the specific working conditions ac cording to practical experience In case of doubt contact your local DHOLLANDIA agent Before greasing the HTL should be cleaned with a high pressure steam cleaner in order to clear all articulation points and grease nipples from sand and dirt The greasing must be executed in such a way that all articulation points get a grease col lar on both sides of the bearing or articulation protecting it against ingress of water salt sand or dirt 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 articu
77. l position the foldable platform of the slider lift is safely stored underneath the vehicle chassis Before use the lift frame is rolled out from its travel position at the front side of its sliding tubes to a work position at the other extremity of the sliding tubes then the platform is unfolded Main details amp terminology Fig 3 2 Slider lift Description Sliding tubes tubes mounted to the vehicle chassis used to roll retract the lift frame and its platform from a travel position underneath the vehicle chassis to a work position at the end of the vehicle chassis Hydromotor or retraction cylinder hydraulic system propelling the lift frame in out along the sliding tubes Lift frame suspended in the sliding tubes mounted to the vehicle chassis It bears the platform and its load via intermediation of the lift arms and hydraulic cylinders 21 Slide plates suspends the lift frame in the sliding tubes Is equipped with rollers to facilitate the retraction movement Foldable platform carries the load during loading unloading Available in steel exe cution with aluminium point and in full aluminium execution Foreseen of a non slip working surface Equipped with synthetic rollers to protect it from scraping on the ground Lift arms actuated by the hydraulic lift cylinders used to LIFT LOWER the platform and its load Lift cylinders 1 or 2 hydraulic cylinders used to LIFT LOWER the lift arms the
78. lation pin must be dismounted and polished and its grease channel must be cleaned As ultimate solution the articulation pin must be renewed Always use acid free grease The use of graphite grease is not allowed Verify if the platform lock and the locking pins under the lift arm if applicable operate smoothly and lubricate with oil if necessary For slider HTL with rectangular synthetic slide blocks see Fig 3 1 the sliding tubes must be cleaned by high pressure steam cleaner min 4 times year and subsequently greased with light grease i e spray grease over their full length For slider HTL with slide rollers see Fig 3 2 the slide tubes mustn t be greased It can be required though in function of the conditions and environment of use to clean the slid ing tubes regularly by means of a high pressure steam cleaner The various types of HTL should be greased according to the grease plans in Fig 3 3 and following DHOLLANDIA B13 Fig 3 3 DH LC 500 750kg 5 10 grease points In case of special tail lifts deviating from these images contact DHOLLANDIA to obtain further instructions Fig 3 4 DH LSP 300 500kg Fig 3 6 DH LSP4 6 500 1000kg DH LSU 2000 4000k Incl also DH LE 1500 2000 kg 12 grease points DHOLLANDIA Fig 3 7 DH SM R 20 1500 2000kg DH SM R 30 2000 3000k Fig 3 8 DH SV SP 20 1500 2000kg DH SSU 2000 3000k Incl also DH SMP 1500 2000 kg DH SMO 750 1000kg
79. le 35mm battery cable up to the power source If no 24V 12V is measured 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 gt 18 continued 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 7 earth of the starter solenoid is switched off by overheating caused by overload or insufficient battery tension e The 35mm battery or earth cable is damaged or loose at the connection to the battery pole e Insufficient battery tension where 35mm is mentioned also other cable sections 25mm 50 are implied DHOLLANDIA 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
80. linders is blocked piston rod bent by accident badly greased DHOLLANDIA Remove the plug of the control power to the starter solenoid if this action doesn t remove the fault the starter solenoid is burnt and remains activated If the fault lies with the control circuit uncouple the auxiliary controls to narrow down the scope 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 e g remove the 250A main fuse and replace the starter solenoid Check the battery voltage when the system is under load push the function LIFT Insufficient battery voltage doorbelling is a frequent cause of starter solenoid failure Verify the electrical operation of the safety valves D on the lift cylinders e with a magnetic tester a solenoid generates a magnetic field when it is electrically activated g e or open the safety valves manually the emergency operation if the valves are opened manually and the platform LOWERS the cause is electrical for sure If the electrical operation of the safety valves D is ok verify the control valve H in the power pack in a similar way If one of the valves is not energized measure the current amp earth circuit to that solenoid into the control box and repair If the electrical operation of all sole
81. m have been fitted conform with the fitting instructions The hydraulic circuits have been purged conform to the fitting instructions 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 The size number and spread of mounting bolts conform with the fitting instruc tions All mounting bolts are fastened to the prescribed torques Check for poten tial deformation after weight testing The centre of gravity is correctly marked and corresponds with the data men All welding has been performed by qualified welders tioned on the identification sticker in the exterior control box All articulation pins are properly fastened and locked 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 All articulation pins are equipped with grease nipples and are duly greased structions Cantilever lifts the stroke of the tilt cylinders has been adjusted 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 Voltage of the lift is compatible with voltage of the vehicle The foreseen batteries mounted on the rear frame of the vehicle body amp alternator suit the
82. me amp function of the expert L During this inspection no imperfections have been found or Name amp address of the inspection body LI 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 C7 INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION 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 LI YES LINO operational safety and reliability Place date Name amp function of the expert L 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 L Shortcomings have been acknowledged Scope of the inspection L Shortcomings have been repaired Place date Name amp signature of the owner or fleet operator Partial inspections to follow DHOLLANDI
83. mounted to the rear frame of the vehicle body See Fig 5 15 f no 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 16 e n addition to having the safe working zones on the platform 8 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 17 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 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 gt 2000mm To 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 The power feed to any of the auxiliary controls should be connected to safety switch in the control box Activa
84. n bearings e HTL is deformed in one of the articulation points pins or bearings 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 e The safety valve D on the lift cylinders is are leaking The O ring of the cartridge is dam aged or the valve is stuck in open position by dirty or ice e The control valve H in the power pack is leaking The O ring of the cartridge is damaged or the valve is stuck in open position by dirt or ice e The seal on 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 DHOLLANDIA Remove the solenoid of control valve S If the fault remains the cartridge of the valve is probably leaking stuck in open position Flush purge the valve or replace See RMT HB 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 to identify the origin of the malfunc tion Me
85. nally See RMT HB 6a 6b Revise the cylinders if required Flush purge the cartridge of the safety valves D and or of the control valve in the power pack see RMT HB5 revise replace O rings or replace the part B23 The safety valve on the tilt cylinders is leaking O ring of the cartridge is dam aged or the valve is stuck in open position by dirty or ice e The control valve S 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 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 e The seal on the piston or the seal between the piston and the piston rod of the long tilt cylinder mostly on right hand side is leaking e Safety valve O on the long tilt cylinder is leaking and the control valve S in the power pack is leaking in case of double acting valve The O ring of the cartridge is damaged or the valve is stuck in open position by dirty or ice The control valve in the power pack is not activated e The control valve U is mechanically blocked in the open position The O ring of the car tridge is damaged or the valve is stuck in open position by dirty or ice e The solenoid of control valve U is electrically activated while it should remain without ten sion e The fixation of the retraction cyl
86. nder the stabilising legs see Fig 7 22 Use the legs upon every loading unloading activity Ensure the legs are completely lifted in travel position before sliding the lift in out slider lifts or before moving the vehicle 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 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 m 87 11 The use of roll stops DHOLLANDIA 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 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
87. ng legs into travel position Use the central rotary switch to SLIDE OUT the platform to the rear end of the sliding tubes 2 Fold the 2 parts of the foldable platform back into travel position DHOLLANDIA im N 1 D P 57 9 Operating instructions for tuck away lifts The exterior control box on tuck away lifts should be operated as follows See also the infor mative decals EF0502 supplied with the lift which should be applied to the vehicle body within eye sight of the operator Fig 7 21 Eexterior control box for tuck away lifts Opening the platform Consult the user s manual before getting started Switch on the electrical power to the tail lift cabin switch in the driver s cabin and battery switch of the exterior control box Observe all safety instructions and open the platform lock LOWER the foldable platform to the ground Simultaneously it will stand up in almost vertical position to make the manual deployment easier ra Exterior control box use the depicted combination of joy stick and safety button to LIFT amp LOWER At the ground use the automatic tilt at ground level LOWER above ard aose tre patom ot Fl be wq atom teok into verica poston past he ols on te mr Switch off the electrical power to the tail lift cabin switch in the driver s cabin and ba
88. noids 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 Finally verify the lift cylinders themselves for mechanical damage or bad greasing B20 e The button switch or electric contact are faulty or the connection to of the contacts is loose e The incoming or outgoing connection to the electrical distribution block in the power pack is faulty e The electric cable to one of the safety valves O is interrupted or has a bad contact e Solenoid 5 OPEN CLOSE is defective Or the cartridge of the valve is mechanically blocked only for the schemes HYDR MECH DA and not for MECH SA e One of the solenoids tilt cylinders is defective or the cartridge of one of the valves is mechanically defective e One of the braking valves on the cylinders or in the power pack is mechanically blocked by ice dirt or by mechanical malfunction e The platform lock has not been opened or for cantilever lifts the platform is squeezed or blocked in the rear frame of the vehicle body e For cantilever lifts with short tilt cylinder type EDS the traction spring or its fixation bolt is broken e One of the tilt cylinders is blocked piston rod bent by accident interior spring or piston is seized up for type SKSV badly greased e The load is too heavy or removed too far from the centre of gravity e The
89. nts ensure that the compo nents are without tension 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 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 B4 e open close During this periodic inspection or Statutory Thorough Examination jointly called STE here after the expert competent person assesses the rate of deterioration of the equipment 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 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 82 2 and the purging work 2 8 Other points are specially reserved for the STE and are marked as follows Only original DHOLLANDIA spare parts should be use
90. nue to push the function LOWER for another 20 sec See Fig 2 2 and after each replacement of hydraulic pipes or revision of hydraulic cylinders 0 Starter solenoid electric motor e General condition correct amperage 0 Electrical connection block in the power pack e Corrosion burn marks sparkles 0 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 LJ 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 0 Piston rods e Surface should be free of paint dirt amp scratches M3 J1 DHOLLANDIA B9 continued General condition gaiters are supple amp dry free from cracks amp damage 0 Rubber gaiters Positioning free evacuation of air out of the gaiters Electrical safety valves e General condition e Function amp operation of the manual emergency button Clearance to the bumper mounting plates and other fixed parts e Condition of the electrical cable to the power pack LI Tilt cylinders on cantilever HTL e Condition of the springs used for function OPEN e Setting amp locking of the adjustable extension see fitting instruct
91. of printing If you require further information on non conforming parts contact your official DHOLLANDIA agent for advice The illustrations shown in this manual represent tail lifts prepared for left hand drive countries continental Europe The operators of tail lifts prepared for right hand drive countries UK Ireland South Africa Australia shall consider that their equipment if ordered with the correct option number is executed mirror wise This manual explains Chapter 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 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 4 This manual must be kept with the tail lift at all times as reference book for the operators and technical service personnel In order to ensure the safety of the operator and occasional bystanders the use of the lift is strictly reserved to skilled operators who have been duly trained who know and understand the full content of this manual Negligence can put the operator and third parties at great risk Unless o
92. of the power pack amp lid e General condition no cracks or deformation in the mechanical parts amp mounting brackets M3 0 Fixation of the power pack to the HTL frame or to the chassis e Protection against corrosion sealing of all the holes J1 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 1 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 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 0 Hydraulic functions e Hydraulic system is free from leaks during execution of all functions e 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 Tiltthe 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 conti
93. on of the plat form point Step on the roll stop flap When driving a load from the ground onto the platform the roll stop will automatically close 8 WARRANTY CONDITIONS 88 1 Abbreviations DHOLLANDIA or her official national agent distributor HTL Hydraulic tail lift CV Commercial vehicle 56 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 replacement of failing parts 88 3 Conditions 8 3 1 In case of a warranty claim 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
94. ondition of the spiral cable condition of the plug connections Position inside the vehicle body protection against damage by the load 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 B7 0 Batteries e General condition 0 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 0 Electrical plug connections between truck amp trailer Harrisson Apply grease or Vaseline to all connections to protect them against corrosion 1 where 35mm is mentioned also other cable sections 25 50 are implied 250 300A main fuse near the battery e General condition 0 Battery switch in the exterior control box and or near the battery e Corrosion burn marks arcing Good tight fixation of the 35mm BATTERY amp EARTH cables Apply grease or Vaseline to all connections to protect them against corrosion L 35mm BATTERY 4 EARTH cables e Routing amp guidance protection against squeezing sheering or rubbing LI Cables between exterior control box and po
95. opy of the last inspection certificate relating the yearly inspection inspec tion special inspection or repeated inspection 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 DHO 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 a 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 warranty 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 repl
96. position by dirty or ice The solenoid of control valve is electrically activated while it should remain without ten sion e The fixation of the retraction cylinder to the HTL frame or vehicle chassis is broken e The slide blocks or rollers are worn out or the slide system is deformed e The control valve on the hydromotor is not activated or the electrical wiring to the solenoid is defective e The solenoid of the control valve is defective e The cartridge of the 4 2 way valve on the hydromotor is blocked or clogged up with dirt e One of the gear wheels or the drive system of the gear wheels is deformed or broken e One of the tooth racks is deformed or broken e The slide blocks or rollers are worn out or the slide system is deformed e The control valve U on the hydromotor is not activated or the electrical wiring to the sole noid is defective e The solenoid of the control valve U is defective e The cartridge of the 4 2 way valve on the hydromotor is blocked or clogged up with dirt e One of the gear wheels or the drive system of the gear wheels is deformed or broken e One of the tooth racks is deformed or broken e The slide blocks or rollers are worn out or the slide system is deformed DHOLLANDIA Verify if the control valve U in the power pack works ok Verify if the manual emergency operation on the valve is firmly closed Remove the solenoid of valve and verify if it is without tension If valv
97. pressure relief valve is set too low e The pressure relief valve is polluted or mechanically blocked in open position e The pump sucks insufficient oil the oil or filter are polluted clogged up with ice or dirt or the oil is too viscous after refilling with oil of incorrect specifications e The hydraulic pump is worn out 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 DHOLLANDIA Verify if the platform lock is open and for cantilever lifts if the platform is not squeezed or blocked in the rear frame of the vehicle body Verify if the electrical operation of the safety valves O on the tilt cylinders is ok e with a magnetic tester a solenoid generates a magnetic field when it is electrically activated e or open the safety valves manually via the emergency operation if the valves are opened manually and the platform OPENS the cause is electrical for sure See explanation of the different techniques under 55 7 If the electrical operation of the safety valves O on the cylinders is ok verify the control valve S in the power pack in a similar way If one of the valves is not energized measure the current amp earth circuit to that solenoid into the control box and repair If the electrical operation of all solenoids is correct verify the cartridges of the valves for mechanical damage Dismount the braking valves on the c
98. ptional 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 8 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 7 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 65 41 e 4 9 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 of the lifting platform and the rear cross member of the vehicle floor or between the lowering platform and the ground For situations where 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 1756 1 2001 1 2008 or our fitting in structions FIT ELEC OPTION in its latest revision e Fig 4 10 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 Th
99. rnt e Short circuit between the various wires in one of the electrical cables e 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 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 Typically a malfunction at normal speed is usually caused by an electrical failure Determine this by isolating the power source from the solenoid concerned e g Remove the solenoid from the electro valve 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 distr
100. 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 Direc tive 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 the 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
101. spread very unevenly e Unilateral loading on 1 side of the platform should be avoided Restrict the load to maxi mum safe working load of 5096 of the nominal capacity see Fig 6 1 e Pay attention to avoid concealed overload situations such as Platform squeezed the storage pocket of a loading dock unexpected forces can apply to the lifting mechanism causing severe damage see Fig 5 29 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 22 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 arms at equal distance from both platform sides See Fig 5 20 Note stickers indicating the nominal capacity the centre of gravity see Fig 6 3 and applicable load diagram see Fig 6 2 are supplied with the lift The operator should take note of this information prior to using the lift www DH rr o LLANDI LIA IA cc PL DHOLLANDIA 7 OPERATING INSTRUCTIONS 57 1 Introduction to the standard control box All the symbols in this
102. structions and open the platform lock If applicable LOWER the mechanical or hydraulic stabilising legs into work position OPEN the platform approx 90 into the desired horizontal position Dont LOWER before the horizontal work position has been reached Loading amp unloading 5 Select between exterior control box and auxiliary controls Exterior control box use the depicted combination of joy stick and safety button to LIFT amp LOWER At the ground use the automatic tilt at ground level Observe the loading diagrams amp instructions at all times Closing up in travel position LIFT the platform up to the level the vehicle floor prior to closing the platform CLOSE the platform until it reaches the closed vertical position and you hear the hy draulic system turn in overpressure 10 Close the platform lock see also Fig 7 16 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 Um 7 6 Operating instructions for cantilever lifts option 5094 optional control box with 3 1 control buttons option 5094 on cantilever lifts should be op erated as follows See also the informative decals EF0525 supplied with the lift which should be applied to the
103. t 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 22 Dynamic test at 10096 nominal capacity Verify if the lift has sufficient lift capacity Verify the general performance amp stability Verify the working speeds LIFT amp LOWER max 15 cm sec OPEN CLOSE max 10 sec 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 1x 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 e Upon technical vehicle inspection compliance of the vehicle with the European Directive for rear bumper bars 2006 20 EG will be checked n 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 Remark DHOLLANDIA s homologations only cover the equipment in their orig
104. terior control box of the HTL e General condition W52 0 Safety switch in the exterior control box e Function amp operation automatic return to the neutral 0 position all switches M3 J1 0 Exterior control box 0 Joy stick push buttons rotary switches 0 Protection rubbers on the buttons 4 switches 0 Lid over the control box O Position of the exterior control box 15A fuse in the exterior control box 0 Electrical contacts in the various control units 0 Foot controls optional O Safety issues on foot controls 0 Wander lead with spiral cable optional LI Fixed interior control optional O Safety issues on these controls DHOLLANDIA e General condition e Function amp operation e Automatic return to the neutral 0 position all switches e Conditions of electrical cables wires and protection rubbers 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 e General condition e Moisture inside the control unit amp corrosion e Fixation amp tightening of all cable amp wire connections 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 e Connection to the safety button in the exterior control box see fitting instructions e Compulsory 2 feet operation e See points above C
105. the vehicle chassis e Clean the HTL m to make all greasing points welding seams bolt and pin connections hydraulic pipes and couplings tidy and clearly visible for inspection 0 All articulation points with grease nipples e Grease thoroughly with acid free grease according to the grease plans under Point 3 LI Slider lift sliding tubes excl hydromotor systems 0 Mechanical platform lock O Correct and complete greasing e Verify correct and complete greasing according to the points above Remark O 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 Repair amp Maintenance Reports O Inspection Reports Remark L Identification sticker serial number Readability LI Pictograms on the various control units e completeness Decal with user s pictograms near the exterior control box e Fixation amp adhesion to the surface 0 Marking of the centre of gravity 0 Marking of the safe working zone on the platform for wander lead with spiral cable amp fixed interior control 0 Other originally applied safety decals amp signs Remark DHOLLANDIA B6 What to verify Execute service or repair if required LI On off isolator switch for the HTL in the vehicle cabin e General condition W52 e Function amp operation M3 J1 0 Battery switch in the ex
106. therwise agreed upon ordering export outside CE region DHOLLANDIA tail lifts comply with the European CE safety regulations mentioned in the Declaration of Conformity They have been designed and manufactured with the greatest care to guarantee a safe and reliable operation is strictly forbidden to modify the construction of the lift and its safety devices in any Way DHOLLANDIA disclaims liability for any personal injury or property damage that re sults from operating a product that has been modified from the original design without explicit written approval from the manufacturer The Declaration of Conformity the manufacturer s product liability and the warranty are voided in case of disregard in this respect and when non original components or spare parts are used to service or repair the lift USER 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 trailers 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 It is strictly forbidden to use the tail lift in a different way or for different purposes than foreseen in fore lying user s manual Negligence can put the operator and third parties at great risk DHOLLANDIA disclaims
107. tic rollers mounted on the lift frame Guiding the folded platform during the tuck in tuck out movement 4 Lift arms actuated by the hydraulic lift cylinders used to LIFT LOWER the plat form and its load 45 Lift cylinders 1 or 2 hydraulic cylinders used to LIFT LOWER the lift arms the platform and its load m Tilt cylinders or fixed stabilisers 2 hydraulic cylinders or fixed rods defining the 42 43 4 angle of the platform in work position 4T 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 Con tains the electrical switches allowing the operator to execute all tail lift functions Bumper bar under run protection device certified conform to CE legislation DHOLLANDIA A9 e 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 electric components of the lift starter solenoid electric motor electric
108. tion 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 T 55 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 17 5 18 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 19 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 20 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 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 21 At the ground always use the automatic tilt at ground level See 8 7 4 Platform accessed by fork lifts is allowed only wh
109. to 2003 59 CE etc e The operator should have passed the minimum age of 18 years 85 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 FT e For trailers amp semi trailers ensure that the vehicle cannot tip over when putting heavy weights on the platform e vehicle or the tail lift are equipped with mechanical or hydraulic stabilising legs de ploy these before opening the platform Ensure that the stabilising legs are positioned on solid even ground In case of soft terrain sand gravel
110. 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 0 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 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 c
111. tric or manual transpallet truck etc shouldn t exceed the nominal capacity of the lift ee Fig 5 23 minimum section of 150mm of the platform point should cover the loading dock see Fig 5 24 When loading unloading the loading floor of the vehicle might lower rise relative to the loading dock Use the electrical controls to tilt the platform when the point of the platform rises above or below the dock see Fig 5 25 Negligence to adjust the platform angle could cause severe damage to the tail lift e tis forbidden to let the platform float and use a second articulated link bridge between its point and the loading dock When loading unloading the platform point should always overlap a rigid underground over a minimum of 150mm see Fig 5 24 e tis forbidden to use a folding platform example platform of slider or tuck away lift as bridge plate see Fig 5 27 The folding platform should remain stored in its travel posi tion and form no further obstruction at the loading dock see Fig 5 28 e n order to prevent damage the platform should always be closed in its travel position prior to driving away from the loading dock For cantilever lifts where ever the loading dock is equipped with a storage pocket for tail lift platforms it is strongly recommended to store the platform away in this area Before revers ing into the dock check if it is deep enough for the depth of the platform Ensure there is suf f
112. ttery switch of the exterior control box Close the lid of the control box m D DHOLLANDIA 87 10 use of stabilising legs 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 5T 4T and 10T and are therefore suitable for a much wider range of commercial vans and trucks See page 26 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 The use of stabilising legs is compulsory on certain vehicles Consult the user s manual or the Fitting and Body Building Instructions from the vehicle manu facturer 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 u
113. ual of the technical documentation of the tail lift and all other information required to execute the various inspections in a professional way e The expert competent person should perform all inspections with due diligence fill out all points of the relevant inspection certificates and sign The initiative to choose an expert and organise the inspections described above lies with the owner of the vehicle or fleet operator The safety reliability and durability of any tail lift and its components depends on the qual ity of the fitting works Name amp address of the fitting company Name amp function of the inspector 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 A Warning DHOLLANDIA disclaims liability for any personal injury or property damage that re sults from operating a product that has not been fitted according to the fitting instruc tions or if the put into service test has been omitted or its findings falsified 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 m
114. uld 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 DHOLLANDIA A15 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 55 3 Danger zones risk of crushing sheering Correct operator position HH 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 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 Stay out of the operation radius of the platform Keep clear of moving parts Beware of hand foot and head traps at all times 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 lift
115. under the protective rubber cap to CLOSE the valve manually See Fig 6 8 56 4 Manual override of the starter solenoid When the main pole IN of the starter solenoid see 5 5 receives normal 24V 12V ten sion but the electric motor doesn t function the starter solenoid can be overridden as follows 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 6 1 Connect the main poles IN amp OUT of the starter solenoid with 2 spanners of the same string of a starter cable Ensure non of the spanners touches the earth steel casing of the starter solenoid electric motor or power pack itself See Fig 6 9 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 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 6 10 DHOLLANDIA V071 V072 B28 V071 H V072 H Main pole IN Main pole OUT e The table below shows which courses of action be taken in c
116. unt the filter and clean it Replace the filter if a complete rinse is not possible Feel the temperature of the pump a 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 6b Grease the HTL thoroughly and verify the clearance of all pins in the articulation bearings Verify the general condition of the articulation points pins and bearings for deformation 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 braking valve in the power pack and the banjo couplings on the lift tilt cylinders Verify if all run freely and work correctly If the free movement is ok adjust the diameter of the plunger in consultation with the official DHO service agent By frosty weather renew the oil store the vehicle in a warm atmosphere and try to melt occurring ice with a hot air blower B22 e The solenoid of the control S CLOSE is electrically activated while it should remain without tension e The cartridge of the control valve 5 CLOSE is polluted or stuck in open position or defec tive in another way e Error in delivery the centre distance between the lift arm and tilt cylinder is different on the lift frame than on the platform e HTL is badly greased the pins seize up in the articulatio
117. ure in the hydraulic circuit by pushing the control switches for LOWER for revision of the lift cylinders 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 on cantilever HTL take into account that the long tilt cylinders are often equipped with strong internal springs see Fig 1 8 and that the short tilt cylinders are often equipped with strong external springs inside a tubular extension see Fig 1 9 generating a strong pull force on the articulation pins when the platform stands in its closed position 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 above see Fig 1 10 For the revision of the long tilt cylinders type SKSV with internal spring keep in mind that the internal springs execute a strong push force on the cylinder head when the piston rod DHOLLANDIA B3 Fig 1 8 Type SKSV is stroked out causing the cylinder head to shoot when being unscrewed from the inder tube see Fig 1 11 Therefore before opening a cylinder make sure that you manually open the safety valve via the manual emergency operation and that the piston rod is retracted inside the cylin der tube as far as
118. ween the moving parts of the lift arms hydraulic cylinders and the moving platform See Fig 6 2 e Work from a position beside the HTL frame or over the front side of the HTL frame Never behind the HTL frame or under the lift arms See Fig 6 3 e Refer to the summary in 55 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 m HTL with Double Acting valves 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 pack afterwards the power pack is mounted in the middle of the frame between the lift arms it is safer to manipulate the valve in the power pack first and open the valves on the cylin ders afterwards 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 56 2 Operation of the SINGLE ACTING valves Refer to the summary in 55 1 to determine which valves are Single Acting and can be manipulated as described in this 8 Except for wiring diagrams these valves 036 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 6 4
119. wer pack e Damage good insulation amp protection LI Cables to the safety valves the cylinders e Sufficient fixation to the vehicle body or chassis L Cables to the auxiliary controls e Clearance from dangerous vehicle components exhaust braking circuit drive amp engine parts L Cables to the platform foot controls amp platform lights pu All cable connections inside the exterior control box e General condition insulation of the separate wires All cable connections inside the power pack Moisture inside the control unit amp corrosion 0 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 M3 J1 Remark 0 Hydraulic pipes amp flexible hoses e General condition outside rubber coat is intact inside steel braids are not visible LI Flexible hoses of the retraction cylinder between the chassis beams e Routing amp guidance protection against squeezing sheering or rubbing e Fragility amp porosity e Age to be replaced every 4th year fill out Maintenance Report 0 Couplings e General condition Fixed hydraulic pipes in steel e Corrosion fixation e Hydraulic system is free from leaks both during operation amp at rest Remark DHOLLANDIA B8 LI Oil reservoir casing
120. y authorized DHOLLANDIA service agents and using original spare parts only e tail lift cannot be repaired immediately in case of breakdown it must be put out of operation and secured against unauthorized use e A lift put into its travel position with the help of external devices forklift gantry crane is not supported by its hydraulic cylinders After releasing the mechanical platform lock the platform and lifting mechanism will drop in free fall to the start point of the breakdown without any possibility to stop the fall by means of the regular control box This can result in the unaware operator and third parties being at great risk To avoid any risk close the mechanical platform lock and apply additional means to immobilise the platform eg by additionally securing the original platform lock by means of ratchet straps Signal the hazard in a clearly visible way To re open the lift use again an external device forklift gantry crane for additional support Or repair the breakdown first bring the hydraulic system under pressure and release the platform locks after satisfactory testing of the lift functions DHOLLANDIA m mn A20 85 7 Instructions for working loading docks When using the tail lift platform as bridge plate between the loading floor of the vehicle and the loading dock follow the instructions below e The total weight of the load and the lifting device forklift elec
121. ylinders and in the power pack to verify if they work ok Finally verify the tilt cylinders and their spring for mechanical damage or bad greasing Fit a pressure gauge to the power pack and measure the maximum pressure delivered by the pump see RMT HB1 If set too low try to adjust the pressure relief valve to max 220 bar and only as far as required See RMT HB3 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 If the oil pressure can be raised but the lift capacity remains insufficient probably 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 HB6a B21 e The HTL is mounted too steeply or the end stops for the lift arm have not been fitted cor rectly e The vehicle body has been moved backwards e The frame is twisted by overload or accident e The lift arm or one of the articulation points is deformed by overload or accident e Insufficient quantity of oil in the reservoir e Insufficient quantity of oil in the reservoir The hydraulic pump sucks air e The oil filter between the reservoir and pump is clogged up dirt or ice formation e The drive shaft between the electric motor and the hy

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