Home

multi-deck column lifts user`s manual maintenance

1. B NY el of 2 0 oll 750 kg o m 0 to IN he he po 10 cable detection ma height detection es eee ie hes 5 4 5 6 7 8 Cable rupture detection 1 2 WVj38el 3dNI 142 MIVd YIMOd B47 e Type Removal lif DH VO5 hydraulic Power pack 6 505 Plan Sch VO5 HYDR 2010 02 m DH VOS 5881 STAB LEGS stabilising legs Valve VO12 E 48 COMPULSORY INSPECTIONS amp REPORTS 4 _ DHOLLANDIA Ci INTRODUCTORY REMARKS 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
2. cal 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 distribu tor for professional advice These cross references to the training program e Some steps in the check list require special skills and specific knowledge see marked as for example see RMT HB3 see Repair amp Maintenance Training Hydraulic Base tech niques N 3 DHOLLANDIA 87 2 HTL moves at normal speed without any control switch being operated 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 15 stuck or burnt e Short circuit between the various wires in one of the electrical cables Typically a malfunction at normal speed is usually caused by an electrical failure Determine this by isolating the power source from the solenoid concerned 0 Remove the solenoid from the electro valve when this action doesn t end the malfunction the cause is not electrical 0 dirt in the cartridge damaged sealing Disconnect the auxiliary control to further isolate the problem and narrow down the scope Measure the tension at the electrical distribution block in the power pac
3. Dhollandia UK Huntingdon 44 1480 435 266 Free service 0800 0855 141 Ukraine Dhollandia Ukraine Kiev 380 44 492 86 49 omyrliadis Truck amp Trailer Athens 30 210 816 12 18 United Arab Emirates Hytec DUDA 971 4 333 13 99 Liberatus Budapest 36 23 312 398 The national distributors can help you to locate the nearest Dhollandia service centre Ballinlough Refrigeration Dublin 353 146 00 322 IJ RR Amir Engineering Petach Tikva 972 39 222 750 e www dhollandia com for the latest update on the service network Dhollandia Italy Diegaro die Cesena 39 0547 347 615 6 1 51 Bader al Mulla 965 48 15 077 DHOLLANDIA
4. Platform stored vertically under the vehicle floor when reversing into to dock make sure there is enough clearance between the underside of the platform and the ground Min 200 mm Reverse at low speed and make sure not to hit the platform against the dock to pre vent mechanical damage see Fig 5 31 Platform stored horizontally in a storage pocket under the loading dock make sure there is sufficient clearance under and above the platform taking into account all ex pected positions of the vehicle suspension The platform shouldn t touch either the ceiling or the bottom of the storage pocket in the loading dock see Fig 5 32 Min 50 mm Min 200 mm Min 200 mm e When using the tail lift platform as bridge plate between the loading floor of vehicle and the loading dock follow the instructions below Fig 5 34 total weight of the load and the lifting device forklift electric or manual transpallet 2 KG S Nom capacity truck etc shouldn t exceed the nominal capacity of the lift see Fig 5 33 A minimum section of 150mm of the platform point should cover the loading dock see Fig 5 34 Min 150 mm When loading unloading the loading floor of the vehicle might lower rise relative to the loading dock Use the electrical controls to adjust the platform when the point of the platform rises above or below the dock see Fig 5 35 Negligence to adjust the platform angle could cause seve
5. joy stick operates the 4 basic functions LIFT LOWER CLOSE 4 See Fig 1 5 Where applicable for lifts with tilt cylinders only not for lifts with manual OPEN CLOSE DHOLLANDIA x LOWER i choice for exterior control box choice for auxiliary controls 2 e Additional rotary switches foreseen in case of more complex lifts The functions LEG IN LEG OUT in case of lifts with hydraulic stabilising legs See Fig 7 6 e n practice the functions on the exterior control box are actuated as follows To actuate To actuate LIFT LOWER LEG asi 117 CLOSE use of safety switch not required on all lift models OPEN e Most of the DHOLLANDIA control boxes are equipped with a removable key function ing 5 an emergency switch This emergency switch allows to cut the electrical power in case of danger see Fig 7 7 Where not implemented the European Standard foresees other means to disconnect the power such as disconnecting the battery connections UHOLLARNDIA 113 p Where applicable for lifts with tilt cylinders only not for lifts with manual closure DHOLLANDIA rem Stop 87 2 Option 5094 3 1 button control box e The option 5094 features a 1st control box with 3 buttons plus a 2nd separate control box with 1 saf
6. DHOLLAN DIA MULTI DECK COLUMN LIFTS USER S MANUAL MAINTENANCE amp REPAIR COMPULSORY INSPECTIONS amp REPORTS Manufacturer DHOLLANDIAN V Zoomstraat9 9160 LOKEREN Belgium Tel 32 0 9 3490692 Fax 32 0 9 349 09 77 e mail info dhollandia be website www dhollandia com 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 V 02 EN 2010 A 01 RevO Origin 01 01 2002 Rev 1 26 10 2010 CE Declaration of Conformity A3 Chapter B Chapter C Disclaimer 4 MAINTENANCE amp REPAIR COMPULSORY INSPECTIONS amp REPORTS General introduction A4 1 Safety instructions for maintenance amp repair B2 Introductory remarks C2 Chapter A 1 1 General safety instructions B2 2 Inspections _ _ C2 USER S MANUAL 1 2 Hydraulic components B4 2 1 Put into service test amp Fitting Declaration C2 1 3 Electrical components B5 82 2 Periodic inspections _ C2 1 Intended use A6 Maintenance B6 82 3 Maintenance amp
7. This declaration of conformity is only valid and the use of the tail lift is only permitted once the following conditions are met e The tail lift is fitted to a vehicle and the fitting complies with the conditions of the CE Directives with the fitting instructions of DHOLLANDIA and the Fitting and Body Build ing Instructions of the vehicle manufacturer e After the fitting of the lift the risk analysis the weight test and put into service test has been carried out with positive results and the fitting declaration see page C3 has been filled out completely and correctly This Declaration of Conformity and the responsibility of the manufacturer are no longer valid if any modification to the tail lift is made without the prior written permission of the manufacturer or if the maintenance instructions have been neglected and or the periodic inspections have not been executed Applicable CE Directives e 2006 42 EC Signature stamp manufacturer Belsele DHOLLANDIA NV Gentstraat 49 9111 BELSELE Tel 32 0 9 349 06 92 Fax 32 0 9 349 09 77 BTW 432 147 371 _ DHOLLANDIA DISCLAIMER Warning The illustrations and information contained within this manual are not contractually binding 4 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
8. x H x a VHZ o 04 HYDR RAMP 5 706 S094 5 5 DH HYDR RAMP 2010 02 Valve Date BATTERY OPTIONAL 01 04 2011 inn DE y IDIBIOJLILAUNTDIUA PLATFORM 45 e Type Hydraulic column lift DH VH30 32 hydraulic ramp S764 Power pack per project Valve 012 1xDA valve Plan Sch VH32 s764 2010 02 Date _ VHOZ 5764 RAMP 5708 50942545 DH 211 A ZHR X D WA Ln Fa n 01 04 2011 VOI2 IX DA IDIEIOILILJAUNIDIUA B46 e Type Removal lift DH VO5 hydraulic stabilising legs 2002 Power pack 6 505 Valve 012 Plan Sch 05 5881 2010 02 Date 01 04 2011 24 12V EXTRA CTRL GY PK y uw y How d Colour codes 47100 11 12 RD BU L Las M REMOVAL LIFT DH VOS HYDRAULIC STABILISING LEGS MAX 5 ABOVE ROOF BATTERY MECH SA 0176 05 4 5 s 1 9 XTERIOR CONTROL 2135145 6 8 9 2 3 1 of of ofl z af 12 7 12 2 i
9. 2 4 in chapter C The frequency of these inspections is set at minimum 1 year for most countries in Europe In the United Kingdom the frequency of the LOLER examination or the Statutory Thorough Examination is set at minimum 2 year by the Health and Safety Executive HSE _ DHOLLANDIA B6 CHECKLIST FOR MAINTENANCE amp INSPECTION Legend W52 Weekly check by owner fleet operator STE Statutory Thorough Examination UK or Periodic inspection by expert competent person M12 monthly 12x year by the owner operator or service agent LI To be verified during maintenance AND periodic inspection STE M3 4 monthly check 3x year by a qualified DHOLLANDIA service agent O Additional points only to be verified during periodic inspection STE J1 Yearly winter maintenance by a qualified DHOLLANDIA service agent 2 1 High pressure cleaning What to verify Execute service or repair if required EX L1 Complete HTL at the rear under the vehicle chassis incl lift columns e Clean the HTL thoroughly to make all greasing points welding seams bolt and pin connections hydraulic pipes and couplings tidy and clearly visible for inspection x 82 2 Greasing What to verify Execute service or repair if required Freq All articulation points with grease nipples e Grease thoroughly with acid free grease according to the grease plans under Point 3 Inside of lift columns amp slide pads on lift
10. VOI2 E ejpq 1102 0 0 lt EPENDING LIFT ae Lew XK ees Wee Cem saa 4 42 YIAN TIOR LO SA 9 wieysks e qpo XA OA 411 uwnjog edA e Type Fully hydraulic column lift DH VH Power pack G LD L R 01 06 Valve Plan Sch 012 0 5008 2011 02 ES COLOUR COD DIN 47100 0 02 0 7 EDIZ2 TO RIOR CONTROL BOX RE EXT O i O N VH FULL HYDR COLUMN LIFT DH D ell ES VO12 D gt Date 13 05 2011 DEIOILILANIDIUR BATTERY MECH DW 43 e Type Fully hydraulic column lift DH VH Power pack G LE L R 01 06 Valve Sch VH V012 E S008 B 2011 01 ES XTRA CTRL COLOUR COD 4 ii EXTERIOR CONTROL BOX REF EDIOO TO 7 0120 0 Nm A 111 m m 2 UN DH VH FULL HYDR COLUMN LIF VO12 E 096 BATTERY 01 04 2011 44 e Type Hydraulic column lift DH VH30 32 hydraulic ramp S764 VO12 1xDA valve Power pack per project Plan N ES Sch VH32 5764 COLOUR COD DIN 47100 0795 55 0 00l 2 o
11. have been fitted conform with the fitting instructions 4 2 Inspection of the mechanical part The size number and spread of mounting bolts and or welding seams conform with the fitting instructions All mounting bolts are fastened to the prescribed torques Check for potential deformation after weight testing All welding has been performed by qualified welders BEEN All articulation pins are properly fastened and locked The lift columns are adequately greased End stops been mounted to stop the lift runners and the platform flush with the vehicle loading floor The lift columns are equipped with locking pins under the platform 54 3 Inspection of the electrical part Voltage of the lift is compatible with voltage of the vehicle The foreseen batteries amp alternator suit the lift capacity application amp frequency of use The cabin switch in the driver s cabin and the battery switch of the exterior control box function OK _ DHOLLANDIA C4 The main fuse the battery and earth cables are fitted correctly and conform to the fitting instructions all bolted connections of cables and fuses are properly tight ened The power feed to all auxiliary controls is wired into the safety switch on the exte rior control panel When the exterior control box is alive non of the auxiliary con trol units is activated and vice versa The hold to run principle works on all control units any on
12. Closing up in travel position 10 Close and lock the safety rails LIFT or LOWER the platform to approx 15cm above the normal height of the platform in it s travel position 11 CLOSE the platform until it reaches the closed vertical position and you hear the hydraulic system turn in overpressure LOWER the platform until the platform hooks are engaged LEG IN If applicable lift the stabilising legs into travel position Switch off the electrical power to the lift Close the lid of the control box m E DHOLLANDIA m 7 7 Operating instructions for interior lifts e Interior mounted column lifts should be operated as follows Fig 7 18 Operation of interior column lifts Opening the platform Consult the user s manual before getting started Observe all safety instructions Switch on the electrical power to the tail lift cabin switch in the driver s cabin and battery switch of the exterior control box 3 LIFT the platform approx 50mm to take the platform weight off the locking pins Dismount the locking pins I Loading amp unloading Select between exterior control box and auxiliary controls 7 Observe the loading diagrams amp instructions at all times Use any of the functions LOWER depicted in 87 1 to 7 4 to LOWER the platform to the ground Use any of the functions LIFT depicted in 87 1 to 7 4 to LIFT the platform to the ve hicle floor
13. Repair Reports special inspections C2 2 Identification A6 82 1 Checklist f amp re inspections 3 Description AG ecklist for maintenance amp inspection T 824 Expert competent person C2 4 Safety Devices 10 2 Grease plans B16 2 5 Initiative to organise inspections C2 5 Safety instructions for the use of the lift A15 4 Testing the cable chain rupture device Big 8 Validation of the manufacturer s warranty 55 1 Introduction 15 5 Double cable systems B19 4 Scope of the put into service test C3 5 2 General safety instructions A16 6 Ordering spare parts B20 Fitting Declaration C3 85 3 Danger zones risk of crushing amp sheering A18 7 Fault finding amp repair B21 4 1 Checklist for the put into service test C4 5 4 Additional risk of lifting heights gt 2m A19 7 1 Summary activation of electrical solenoids per tail B21 55 5 Auxiliary controls Position of the operator on the aag liftfunction Inspection certificates C6 platform 8 Emergency operation B31 Maintenance amp Repair Reports C11 9 6 Instructions for loading amp unloading A22 58 1 Introduction and safety instructions B31 9 PUWER amp LOLER in Great Britain C14 85 7 Other important user s info A23 582 Operation of the SINGLE ACTING valves TIMER 30 05 MET 55 8 Instructions for working at loading docks A24 58 3 Operation of the DOUBLE ACTING valves B33 ment Regulations 1998 _ 85 0 Importance of good maintenance A25 584 Manual overr
14. also check if there is sufficient Amp by using a test bulb If the bulb doesn t light check for poor connection at the 250A main fuse and the whole 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 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 Way 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 B24 56 7 The platform doesn t LOWER the other functions work ok e The button switch or electric contact are faulty or the connection to one of the contacts is Check the lift columns and lift runners for visible damage and repair loose The incoming or outgoing connection to the electrical distribution block in the power pack
15. amp operation e Required effort to open close the platform is within normal limits LI Safety rails e General condition function amp operation LI Toe guard at end of loading floor and or front edge of platform Toe guard switch at end of loading floor and or front edge of platform e Automatic stop of the LIFT function from all controls when the toe guard flap is pressed down and its switch activated LI Synthetic platform rollers if applicable e General condition replace when damaged or worn out M3 J1 LI Platform at loading floor e Presence amp condition of end stops for LIFT movement M3 J1 e Alignment of platform flush with the loading floor DHOLLANDIA 82 15 Practical tests What to verify Execute service or repair if required Freq LI General operation with empty platform e Execute all movements several times with ALL available control units The movements should W52 be executed smoothly amp quietly without strange noises M3 e Verify occurrence of any play or deformation in the articulation points when driving over the plat J1 form and when OPENING CLOSING the platform O Static test at 125 overload test on DEFORMATION Position the platform at 1 2 height STE Note the distance and angle to the vehicle floor Put a load of 1 25 x nominal capacity at the centre of gravity and remove it again Verify the distance and angle to the vehicle floor No permanent deformation shou
16. carrying vehicle with obedience of the applicable load chart the user s and safety instruc tions described in Chapter A of this manual A Warning e Simultaneously the operator should follow all other precautions and instructions applica ble to his work situation e g health amp safety regulations road traffic regulations company procedures Driver Periodic Training according to 2003 59 CE etc e The operator should have passed the minimum age of 18 years _ DHOLLANDIA A15 55 2 General safety instructions 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 safety footwear with steel protection tips and a good non slip sole and protective gloves See Fig 5 1 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 See Fig 4 17 a d The vehicle must be safely parked the parking brake applied and the engine must be switched off Lock the rear doors and faste
17. clean them with high pressure steam cleaner and apply grease 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 possibly one of the seals of the lift cylinders or the hydraulic memory cylinder is leaking Verify if the cylinders are free of internal leaks See RMT HB6a For DH VO5 Remove the solenoid from the electrovalve Z controlling the 2nd pressure valve and determine of the cause is electri cal or hydraulic If electrical check the condition amp function of the limit switch in the cylinder beam incl its wiring When hydraulic flush purge the cartridge of the valve to evacuate any pollution revise replace O rings or replace the part Fit a pressure gauge to the power pack and measure the maximum pressure delivered by the pump see RMT HB1 If set too low adjust the pressure relief valve to max 200 bar and only as far as required to reach 500kg See RMT HB3 Check the lift columns
18. deformation e otraightness of the columns and runners e Corrosion e Smooth sliding UP DOWN e Wear of bearings rollers pins and slide surfaces e Adequate LI Articulation pins e General condition deformation LI Articulation bearings e Locking of the articulation pins by locking pins bolts amp nuts e Wear of bearings rollers pins and slide surfaces if applicable e Presence of grease nipples correct and regular greasing LI Cylinder beam amp drive system steel cables chains pulley blocks pulleys and General condition check for cracks amp deformation wear stretching their roller bearings sprockets e Alignment of pulleys chains or steel cables E e Correct lubrication e Horizontal alignment of the platform with the loading floor adjustment of the steel cables or chains if required e Vertical alignment of the platform in the rear frame of the vehicle body adjustment of the steel cables or chains if required e Fitting amp position of the retainers for the steel cables on the pulley blocks sprockets See pho tos LSD Load Safety Device cable ante device chain m device for General condition function amp operation correct lubrication M3 HTL with single cable system e Execute LSD test following Chapter 4 J1 LI Electrical cable rupture detection for HTL with double cable system e General condition function amp operation of the switches M3 e Adequate adjustment of the lift and safety cable
19. 25mm 50mm are implied 1 250 300A main fuse near the battery e General condition M3 Battery switch in the exterior control box and or near the battery e Corrosion burn marks arcing J1 e Good tight fixation of the 35mm BATTERY amp EARTH cables e Apply grease or Vaseline to all connections to protect them against corrosion LI 35mm BATTERY amp EARTH cables e Routing amp guidance protection against squeezing sheering or rubbing M3 LI Cables between exterior control box and power pack e Damage good insulation amp protection J1 LI Cables to the safety valves on the cylinders e Sufficient fixation to the vehicle body or chassis LI Cables to the auxiliary controls e Clearance from dangerous vehicle components exhaust braking circuit drive amp engine parts LI Cables to the platform foot controls amp platform lights L All cable connections inside the exterior control box e General condition insulation of the separate wires M3 All cable connections in the connection box on the platform e Moisture inside the control unit amp corrosion J1 L All cable connections inside the power pack e Fixation amp tightening of all cable amp wire connections LI All cable connections inside the auxiliary controls Limit switches pressure switches reed sensors optional e General condition W52 e Function amp operation automatic return to the neutral 0 position J1 Remark 82 8 Hy
20. Fig 5 5 the crushing zone between the lowering platform and the ground see Fig 5 6 the crushing zone between the lifting platform and the rear cross member of the vehi cle floor see Fig 5 7 300 L 600 mm the crushing zone between the closing platform and the rear frame of the vehicle body see Fig 5 8 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 9 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 c 55 4 Additional risk of lifting heights gt 2m e The nature of loading unloading at heights above 2m leads to additional hazards When ever working with the lift pay special attention to the following issues e To prevent injury when falling from heights it is compulsory to use safety rails along the exposed edges of the platform if the lifting height 2 2000mm see examples Fig 5 10 Protect your toes feet and limbs when standing on the lifting platform stay away from the hazardous crushing zone at the front edge of the platform see Fig 5 11
21. afterwards If 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 e After use don t forget to close the buttons for the manual emergency operation again and the mount the protective cap again on top of the cartridge of the valve 8 2 Operation of the SINGLE ACTING valves e Refer to the summary in 7 1 to determine which valves are Single Acting and can be manipulated as described in this Except for wiring diagrams these valves V036 V037 or V036 H V037 H are mounted on all hydraulic lift amp tilt cylinders Depending on the wiring diagram they are also mounted in the power pack See Fig 8 4 e First remove the protective cap from the top of the cartridge of the valve See Fig 8 5 Under this cap sits a bronze coloured button that can be screwed unscrewed e Unscrew this button counter clockwise to OPEN the valve manually See Fig 8 6 e The flow of oil through the valve and the speed of the downward movement can be ad justed by opening the valve more faster or less slower e After use screw the button in clockwise to CLOSE the valve manually See Fig 8 6 Lock it hand tight in closed position Toend mount the protective cap again on top of the cartridge of the valve _ DHOLLANDIA B32 V036 H V037 H open close 88 3 Oper
22. as soon as the control button is released DHOLLANDIA valves are equipped with a manual emergency control allowing the operator to open the valve in case of electrical power failure see chapter B e Fig 4 2 Mechanical travel lock preventing the stowed platform to lower or fall open unintentionally while driving It consists of 2 systems 1 A set of platform hooks preventing the platform from falling open in case of accidental pressure loss in the tilt circuit see 1 in Fig 4 2 2 A set of locking pins through the lift columns to remove prior to each use and the refit back in place after each use preventing the platform from creeping down in case of accidental pressure loss in the lift circuit see 2 in Fig 4 2 e 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 This is Vertical movements max 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 at groundlevel max 4 sec Compensating means that the valve brakes less more if the load is lighter heavier to obtain similar speeds regardless of the load on the platform _ DHOLLANDIA A10 e Fig 4 4 Pressure relief valve permits the manu
23. been repaired Place date Name amp signature of the owner or fleet operator Partial inspections to follow DHOLLANDIA ar DATE MAINTENANCE amp REPAIR REPORTS NATURE OF THE REPAIR OR MAINTENANCE IDENTIFICATION OF SERVICE AGENT _ DHOLLANDIA C11 MAINTENANCE amp REPAIR REPORTS DATE NATURE OF THE REPAIR OR MAINTENANCE IDENTIFICATION OF SERVICE AGENT DHOLLANDIA C12 MAINTENANCE amp REPAIR REPORTS DATE NATURE OF THE REPAIR OR MAINTENANCE IDENTIFICATION OF SERVICE AGENT DHOLLANDIA C13 5 PUWER amp LOLER GREAT BRITAIN e The CE Machine Directives apply to the manufacturers of all kinds of machines including tail lifts and require that machines are designed and manufactured to be safe e The Government of Great Britain has complemented these CE Directives with a legisla tion called PUWER The Provision and Use of Work Equipment Regulations 1998 and LOLER The Lifting Operations and Lifting Equipment Regulations 1998 which focuses on the users of the same machinery e PUWER and LOLER fall under UK criminal law and neglect or failure to comply with the previsions can lead to financial penalties or imprisonment e This
24. certification must be ob served DHOLLANDIA 7 4 P m dri D gt NE by v T 7 A e 1 t 2 a USER S MANUAL AS _ 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 this Chapter 113 ares pu Num DHOLLANDIA Zoomstraat9 BE 9160 Lokeren Latham Road G amp B HUNTINGDON CAMBS PE29 6YG 1009 0931 C DHOLLANDIA 1009 0931 B 2 IDENTIFICATION DHVO3 1500 kg 1800 mm 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 DHOLLANDIA also mentions the nominal lift capacity the centre of gravity and the date of construction see 1009 0931 P Fig 2 1 Additional identification stickers are used on various components see Fig 2 2 DHVO3 1500 kg 1800 mm 3 DESCRIPTION DHOLLANDIA tail lifts are developed a
25. com gt Downloads gt Bumper certificates after 2007 INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION L SPECIAL INSPECTION RE INSPECTION Date of inspection Evaluation the tail lift is safe and suitable for further use The tail lift identified in the Declaration of Conformity has been inspected on its O 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 E INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION L SPECIAL INSPECTION RE INSPECTION Date of inspection Evaluation the tail lift is safe and suitable for further use The tail lift identified in the Declaration of Conformity has been inspected on its O 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 inspecti
26. cylinder is leaking e The lift columns and or lift runners are damaged causing the lift runners to jam e The lift columns contain to much hardened grease are clogged up with debris and dirt For DH VO5 e The electrovalve controlling the 2nd pressure relief valve lift capacity limited to 500kg above roof level is electrically activated while it shouldn t be e The electrovalve controlling the 2nd pressure relief valve is polluted or mechanically blocked in open position 6 9 b DH VO5 the lift capacity is insufficient above the vehicle roof level DH VO5 are equipped with a safety circuit that limits the lift capacity to 500kg above the vehicle floor level This circuits consists of a electrovalve Z in the power pack and an 2nd pressure relief valve set at 500kg lift capacity If the lift capacity is fine below the roof level but not above the roof possible causes are e The 2nd pressure relief valve is set too low e The lift columns and or lift runners are damaged causing the lift runners to jam e The lift columns contain to much hardened grease are clogged up with debris and dirt adjust the 2nd pressure relief valve to a lower value Disregard can potentially lead If the lift capacity doesn t diminish above the roof level it is very important to re to damage and hazardous situations _ DHOLLANDIA Check the lift columns and lift runners for visible damage and repair Clear all debris from the lift columns
27. in the Declaration of Conformity in this manual has been fitted conform to the fitting instructions from the manufacturer and that the put into service test has been executed with affirmative re sult As a consequence the tail lift has been found suitable for use in its fitted condition The following results have been noted The vehicle is technically suitable for the installation and use of the tail lift concerned The installation has been executed conform to the fitting instructions of Dhollandia and the put into service test has been executed following the instructions of this manual After weight testing with nominal capacity the hydraulic pressure has been at Remarks Signature of the inspector C3 CHECKLIST FOR THE PUT INTO SERVICE TEST 4 1 General inspection on the fitting parameters The vehicle is technically suitable for the type of lift and its nominal capacity requirement for mechanical or hydraulic stabilising legs has been checked and been fulfilled if applicable The actual fitting dimensions don t exceed the theoretical maximum fitting dimen 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 All safety decals amp labels identification sticker decal with user s pictograms decal with load diagram
28. incoming pole of the battery switch check out the battery cable the 250A main fuse all plug connections if applicable and the complete power circuit up to the batteries of the vehicle Charge the batteries verify the function of the separate cells and renew the batteries if necessary Seek the reason for flat batteries damaged or corroded fuse under rated alternator and repair or adjust 7 5 The electric motor doesn t run but the downward functions OPEN LOWER work fine For HTL with double cable system For HTL with double cable system push the emergency button in the power pack the function LIFT or CLOSE If the e Failure of one of the steel lift cables electric motor starts to run possible causes are e Defect in the detection circuit for the cable rupture defect in the wiring circuit from the earth pole of the starter solenoid over the cable ruptures in the cylinder Reason the earth of the starter solenoid runs over min 2 cable rupture switches mounted beam to the thermal fuse inside the electric motor serially inside the cylinder beam see also defect in one of the cable rupture switches rupture of one of the lift cables with activation of one of the cable rupture switches as consequence Conventional points Dismount the cover of the cylinder beam check if one of the cable rupture switches is activated check the steel cables e The button switch or electric contacts are fau
29. level Closing up in travel position normal height of the platform in it s travel position I 5 Raise and lock the safety rails into vertical position if applicable DHOLLANDIA n 7 8 Operating instructions for DH VO5 removal lifts Removal lifts type DH VO5 are equipped with telescopic lift runners and can reach to heights between 5 and 6m above ground level to load unload goods at a 1st or 2nd building floor e Since this platform lifts well above the roof level of any commercial vehicle the risk of falling from extreme heights exists on all 4 platform sides There fore safety rails should be used on all exposed sides at all times and opera tors should follow the safety instructions of this manual with due diligence 6m POSITION FERMETURE CLOSURE e On top of the standard safety features the 5 is equipped with Hydraulic stabilising legs to stabilise the vehicle and the platform when working at extreme heights The use of the stabilising legs is obliged for all activities above roof level and generally for all circumstances where the stability of the vehicle and the load on the platform as well as the safety of the operator standing on the platform is compromised without the legs in place Detection on the stabilising legs the platform cannot be closed before the stabilising Function legs are fully retracted Safety rails on all sides hinged
30. of the Machine Directives By means of a Declaration of Conformity see Chapter 1 the manufacturer confirms that the machines supplied comply with the regulations stated above INSPECTIONS All tail lifts should be subjected to a number of compulsory inspections as explained be low 82 1 Put into service test and Fitting Declaration All tail lifts are largely pre assembled and tested by the manufacturer and receive a CE Declaration of Conformity Annex a 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 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 82 2 Periodic inspections Once in service every tail lift should be inspected periodically at least once per year by an expert competent person to evaluate its condition and suitability for continued use or if a specific repair or maintenance is required The findings of these inspections should be summarised in the relevant inspection certificates see pg C6 amp following In Great Britain t
31. power pack e This emergency operation enables the operator to execute certain movements by hand e g LOWER OPEN when the regular electrical controls fail and help the service agent in fault finding to distinguish between electrical and hy draulic malfunctions e Switch off the isolator switch in the vehicle cabin remove the key from the battery switch in the exterior control box or disconnect main fuse on the battery to avoid unsafe injudi cious or unauthorized use also by strangers in traffic of the HTL See Fig 8 1 e Stay out of the operation radius of the platform and stay clear of the moving parts at all times Beware at all times for potential risks of crushing or sheering fingers hands limbs feet or toes between the moving parts of the lift arms hydraulic cylinders and the moving platform See Fig 8 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 8 3 e Refer to the summary in 7 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 e For HTL with Double Acting valves in the power pack If the power pack is mounted on the side of the HTL frame manipulate the valves on the cylinders first and open the valve in the power pack
32. reserves the right to alter product specifications without prior notice and potentially modifications or new developments might not have been taken into account at the time of printing 7 If you require further information on non conforming parts contact your official 4 DHOLLANDIA agent for advice The illustrations shown in this manual represent tail lifts prepared for left hand drive countries Unless otherwise agreed upon ordering export outside CE region DHOLLANDIA tail lifts continental Europe The operators of tail lifts prepared for right hand drive countries comply with the European CE safety regulations mentioned in the Declaration of Conformity UK Ireland South Africa Australia shall consider that their equipment if ordered with the They have been designed and manufactured with the greatest care to guarantee a safe and correct option number is executed mirror wise reliable operation GENERAL INTRODUCTION This manual explains e chapter A how the DHOLLANDIA tail lift is manufactured what safety devices are incorporated in its design and how to use the tail lift in a correct way that guarantees the integrity of the machine over the intended life time and the safety of the operator and any bystanders e chapter B how to maintain and service the tail lift in an appropriate way that can guaran tee its reliability over the intended life time e chapter C what legal requirements re periodic testing and
33. runners LI Inside of cylinder beam LI Mechanical platform lock platform retaining catch e Lubricate with chain or steel cable oil M3 LI Chains steel cables of the lift system LSD J1 O Correct and complete greasing e Verify correct and complete greasing according to the points above Remark 82 3 Documents amp reports What to verify Execute service or repair if required E 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 Maintenance amp Repair Reports O Inspection Reports DHOLLANDIA 82 4 Identification marking amp satefy decals What to verify Execute service or repair if required LI Identification sticker serial number Pictograms on the various control units LI Decal with user s pictograms near the exterior control box LI Marking of the centre of gravity LI Marking of the safe working zone on the platform for wander lead with spiral cable amp fixed interior control LI Other originally applied safety decals amp signs e Readability e completeness e Fixation amp adhesion to the surface 82 5 Protection against unauthorized use What to verify Execute service or repair if required 1 On off isolator switch for the HTL in the vehicle cabin e General condition W52 e Function amp o
34. safety rails on the sides a fixed safety rail with plinth I1 2 Ww at the rear edge and a telescopic safety rail at the front edge of the platform Limitation of the lift capacity at 500kg above the roof level E0I76 VO5 LOWER ome pet _ TRIS e The DH VO5 is available with 1 type of control box only The different functions are actu CLOSE 1 S42 w ated as show in Fig 7 19 see Fig 7 19 2 2 w OPEN 1 The function CLOSE only works if the stabilising legs are fully pulled in So in order to 998 2 w CLOSE the platform U2 2 Use the function Height detection to CLOSE to LIFT LOWER the platform to the Change over to suitable height for closing the platform into it s travel position auxiliary controls Use the function LEG IN to raise the left amp right stabilising legs into their travel posi Height detection to H 4 tion CLOSE D 4 Use the function CLOSE to close the platform until it reaches the closed vertical posi tion and you hear the hydraulic system turn in overpressure TILT UP when w qi Use the function LIFT until the platform hooks are engaged legs are out 2 S 2 T L 2 Still with the stabilising legs on the ground the angle of the platform can be ad TILT DOWN O 2 justed to the slope of the ground Use the functions TILT TILT DOWN to do so DHOLLANDIA FER DH VO5 should be operated as follows Fig 7 20 Operation of removal l
35. see Fig 1 3 If the nature of the works require that you enter this danger zone neverthe less make sure that you secure the platform against accidental falling by means of hoists forklifts gantry crance etc see Fig 1 5 Ideally rest the platform on the ground before _ DHOLLANDIA B2 Landkleppen Hayons e ww starting the works see Fig 1 6 e Avoid to stand on or sit between the open platform and the rear side of the vehicle see Fig 1 7 e fthe nature of the works require that you enter into one of the danger zones see 55 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 e When dismounting amp remounting articulation pins make sure these pins are remounted in the original way and are duly secured by means of locking pins bolts amp nuts e tis 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 case of damage or failure these components must be replaced by original spare parts e Remark for column lifts w
36. steel cables or chains pulleys to avoid hand injuries e f no hinged foot protector see Fig 5 15 or safety cut out see Fig 5 16 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 22 and only if the front edge of the platform is equipped with a hinged toe guard flap accord ing to Fig 5 11 e n addition to having the safe working zones on the platform amp the vehicle floor perma nently marked it is recommended to mark the hazardous areas at the end of the vehicle floor and the front of the platform in a contrasting colour See Fig 5 23 e he safe working zones for the operator must be kept clear at all times It is prohibited to put load on these dedicated areas The operator should always stand beside the load to prevent him from being crushed between the load and the rear side of the vehicle e 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 foreign objects etc DHOLLANDIA 55 6 Instructions for loading amp unloading Follow the loading diagrams amp explanatory comments see Point 6 at all times Never try to scoop loose substance e
37. stop flap When driving a load from the ground onto the platform the roll stop will automatically close 215 A Automatic roll stops operated by torsion springs see Fig 7 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 _ DHOLLANDIA A39 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 direction of the plat form point CLOSE Step on the roll stop flap When driving a load from the ground onto the platform the roll stop will automatically close 701 S R Hinged ramps at the rear edge of the platform see Fig 7 26 9701 5 5 Hinged ramps at the sides of the platform The hinged ramps can be manually raised into 90 vertical position to serve as roll stop device or swung over 1
38. the fitting works e Therefore the manufacturer s warranty can only be activated and validated if it has been mounted correctly and professionally to conform with the fitting instructions if a put into service test has been executed with an affirmative result and if the findings of this test have been duly reported in the relevant inspection certificates 4 SCOPE OF THE PUT INTO SERVICE TEST e The put into service test see also 2 1 comprises of visual inspection on the fitting work of the tail lift on the vehicle chassis and of the various aspects determining the operational safety of the tail lift series of static and dynamic weight tests Most points of the visual inspection will be executed through practical tests without load The test shall allow the expert to evaluate if the tail lift has been incorporated on the vehi cle chassis in accordance to the manufacturer s fitting instructions if the tail lift is safe to be used if it can be operated safely amp correctly from all existing controls if it can execute all functions smoothly without unexpected movements or sounds e content of this compulsory put into service test is explained hereunder _ DHOLLANDIA FITTING DECLARATION by installer of the tail lift Name amp address of the fitting company Name amp function of the inspector By means of this Fitting Declaration declare that the tail lift identified
39. the foot of the op erator protrudes beyond the platform or vehicle floor the opposite toe guard flap hinges up and clears the way DHOLLANDIA m e Fig 4 15 Roll stops on the platform optional any platform aimed to LIFT and LOWER rolling loads must be equipped with a device that prevents this load from rolling uninten tionally off the edge DHOLLANDIA roll stops can be fitted into the platform point or at intermediate distances further towards the front edge of the platform see Fig 4 15 a As alternative on platforms equipped with hinged ramps these ramps can be opened and raised 90 in vertical position to serve as roll stops or opened over 180 to service as access ramp These ramps are available for the rear edge and for the sides of the platform for applications where side loading is required see Fig 4 15 0 e Fig 4 16 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 17 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 th
40. the hydraulic power pack are e The following min battery equipment is recommended in function of the tail lift capacity 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 MIN battery capacity 1x 180Ah e To ensure the reliability of the lift over many years it is extremely important that 2x 180Ah A the batteries their charging system the battery and earth cables and fuses are 2000 9 12V Not recommended dimensioned sufficiently strong and fitted with care following above mentioned instructions Insufficient battery tension will cause harm and irreparable damage 24V 2x 225Ah semi traction to the electrical components of the lift starter solenoid electric motor electric switches etc e if lifts are used very intensely e g to load or unload a full multi deck vehicle it is ex a tremely important to use sufficiently strong semi traction batteries and a powerful re lt I Specifically because of the long cycle times typical for multi deck lifts it is charging system that will keep the performance of the batteries high during the whole strongly recommended to sufficiently upgrade the battery capacity and recharg activity ing system and to install a battery guard system e As most vehicles are supplied with power supplies that cover the primary needs of the original equipment only the v
41. the lift columns and the platform keeping the platform in its vertical travel position when not being used and holding the plat form hard against the rubber buffers Lift runners set of 2 profiles carrying the platform and its load They are lifted low ered by the lift cylinder and the drive mechanism consisting of steel ropes or chains plus pulleys Safety rails rails to protect the operator against falling from heights and incurring serious injuries They should be used on all exposed platform sides and are compul sory above 2m lifting height see also Fig 4 11 Auxiliary controls LIFT LOWER controls integrated in one of the safety rails Toe guard protection flap detection switch protection the toes amp limbs of the op erator in the dangerous crushing zone between the moving platform and the loading floors of the vehicle Lift cylinder s hydraulic cylinder s used to LIFT LOWER the lift runners the plat form and its load 10 Tilt cylinder s hydraulic cylinder s used on external lifts to OPEN CLOSE the plat form i 11 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 _ DHOLLANDIA e For all tail lift models above the electric control box and
42. to the floor level of the vehicle You will hear the LSD disengage Repeat the same test on the other side of the platform DHOLLANDIA m 5 DOUBLE CABLE SYSTEMS e Many types of column lifts are driven by a double cable system the lift cylinder actuates a pulley block with 2 lift cables left amp right and 2 safety cables left amp right See Fig 3 2 5 1 e Incase of failure of one of the lift cables 1 if Fig 5 1 the platform is caught by the safety cable 2 to protect the platform the load and the operator from falling on the ground Then when one of the safety cables 2 is put under tension the corresponding cable rupture switch 3 is activated the earth of the starter solenoid in the power pack inter rupted and the function LIFT disabled The various cable rupture switches 3 normally 2 are wired serially so that the safety is activated in case of failure in any of the 2 sus pension systems left or right See also Fig 5 2 e In function of the intensity of use the steel lift cables 1 might stretch even unequally on the right and left side As a consequence the platform might get out of horizontal align ment with the vehicle floor or out of vertical alignment with the vehicle body and the steel i ITZ cables might need adjustment in the cylinder beam see also 2 11 V n 2 e Dismount the cover from the cylinder beam To lift lower the platform in rest position on one si
43. transport the transport or race cars the col lection of waste containers the transport of live stock etc e he columns lifts can be mounted on the outside or on the inside see Fig 3 2 or can be combined with each other Fig 3 2 Mounting position 5 Externallift 15 mounted at the rear of the vehicle body and is stowed vertically behind the vehicle body in it s travel position This lift has all func UN 7 tions LIFT LOWER and CLOSE OPEN X X X X Internal lift Is mounted inside the vehicle body When it is stowed in it s travel and locked it forms an integral part of one of the vehicle floors When used it works as a moving deck This lift only has the func tions LIFT LOWER no tilt DHOLLANDIA e Main details amp terminology Fig 3 3 Lower beam column lift DH VO 1 Lift columns set of 2 columns mounted in a fixed position against the vehicle body They form the tracks in which the lift runners carrying the platform go up amp down us al XS S th o MS MUTA VHE Cylinder beam horizontal or vertical beam mounted according to different configura tions see Fig 3 1 It contains the lift cylinder s and if applicable the drive mechanism steel ropes or chains plus pulleys Platform carries the load during loading unloading Manufactured from steel or light weight aluminium and foreseen of a non slip working surface Travel lock mechanical lock mounted on
44. when standing inside the vehicle body stay away from the hazardous crushing zone between rear edge of the loading floor and the lowering platform see Fig 5 11 Make adequate and consistent use of the available load restraints roll stop en d systems hinged ramps trolley brakes straps amp latches to prevent under vehicle floor goods from falling or rolling unintentionally off the platform Solution 1 toe guard flap Solution 2 double toe guard switch 7 standard on multi deck flap on platform and floor lifts N h e Oversee and keep visual control over the whole working area of the lift and its platform at all times INCLUDING the area UNDER the platform see Fig 5 12 96 Risk operator on vehicle floor crushes foot under lowering platform Solution toe guard flap on Solution toe guard flap platform flips up automatically platform flips up automatically 4 n H uu DHOLLANDIA s 55 5 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 moving platform and the r
45. 6 in the power pack leaks and Verify if the piston rods of the lift tilt cylinders are straight and if they move freely and smoothly through the cylinder opens closes the return of oil to the reservoir alternately head e The braking valve 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 Dismount the non return valve from the 3 way valve in the main valve block V005 V012 or V096 in the power pack Clean the seat of the bullet ball reshape it if required renew the bullet and reassemble the valve Dismount the braking valve in the power pack and the banjo couplings on the lift tilt cylinders Verify if all run freely and work correctly DHOLLANDIA m 6 14 The platform LOWERS slowly without any control being actuated the platform angle remains unchanged e The safety valve D needed to LOWER on the lift cylinders or in the power pack is leaking Remark Take into account the quantity of cylinders the quantity of safety valves and where they are fitted Verify if the The O ring of the cartridge is damaged or the valve is stuck in open position by dirty or ice control valves in the power pack are single acting or double acting e The seal on the piston of the lift cylinder s is are leaking e HTL with hydraulic tilt at ground level the seal of the hydraulic memory cylinder
46. 80 to serve as access ramp OPEN Pull the rear side of the ramp towards you raise and lock it into 90 verti position CLOSE Lift up the ramp and swing it further to the 180 open position where it can service as loading unloading ramp P f gt TEE Bj d KT i y m J ap 35 b DHOLLANDIA m 87 11 Automatic tilt at ground level e Some column lifts are equipped with a conical platform and automatic tilt at ground level This means When the platform touches the ground its point automatically See tilts down when the buttons for LOWER remain pushed in Fig 7 27 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 28 tion then lift further in this setting to the vehicle floor e These and other types of lifts are equipped with tilt cylinders which allow the operator to TILT adjust the angle of the platform to the slope x of the underground see Fig 7 29 e 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 Without tilt cylinders With tilt cylinders e Automatic tilt should be
47. ANDARD MODEL B39 e Type Column lift DH VB VO VX double cable system Power pack 6 5 01 Valve VO12 E Plan Sch VO 012 5008 2010 02 ES XTRA CTRL COLOUR COD DIN 47100 BATTERY DI20 TO DIOO TO 7 F R p Sq rn EN o x s 22 oO E o 11 x D B ell Hi 2007 S008 B VX es Ur MECH SA R H X R S t 40 e Type Column lift DH VB VO VX double cable system Power pack 6 5 Valve VO12 E Plan Sch VO VB VO12 E S094 2010 02 ES EXTRA CTRL COLOUR COD DIN 47100 OPTIONAL gt NO ND C x 8 44 22 O Tm kK x XTRA CTRL 12 24V VX M DH VO BATTERY Date 20 03 2011 cmm DRIOLLANDIJA MECH B41 TYPE DH VB VBV VO EXTERNAL LIFT HYDRAULIC CLOSURE Moly 2 5 hn WS L Pa a TYPE DH VB VO EXTERNAL LIFT HYDRAULIC CLOSURE HYDRAULIC STABILISING LEGS oN Ubid 0 0 Moly 2 ZO OL0Z YGAH GA OA 25 S
48. DIA Dynamic test at 100 nominal capacity e Verify if the lift has sufficient lift capacity e Verify the general performance amp stability e DH VOS5 verify if the lift capacity is limited to 500kg above roof level e 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 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 84 8 European homologation of the bumper bars Upon technical vehicle inspection compliance of the vehicle with the European Directive for rear bumper bars 2006 20 EG will be checked e n case of slider lifts the platform functions as bumper bar and it is homologated as such In case of cantilever tuck away or column lifts an additional bumper bar with offi cial homologation is available as an option e Remark DHOLLANDIA 5 homologations only cover the equipment in their original delivery format and mounted conform to DHOLLANDIA 5 fitting instructions e f needed the homologations can be downloaded from the internet See www dhollandia
49. OLLANDIA 7 Also take into account that the tilt cylinders type VS many column lifts work in op posite way as cylinders on conventional cantilever lifts when filled with oil the piston rod slides in and the platform closes The safer way to extend them to the correct stroke in order the remount them into the platform is to loosen the hydraulic pipe open the safety valve on the cylinder by hand and to push pull the piston rod by hand e Don t try to CLOSE the platform before all articulation pins are mounted and secured by their locking bolt See Fig 1 12 1 13 e Only when all articulation pins are mounted and secured is it allowed the build up full pressure in the hydraulic system by means of the regular electric controls e And only after assuring that the hydraulic system generates over pressure and no oil leaks are visible is it allowed to remove the mechanical devices supporting the platform hoist gantry crane forklift e For dismounting and remounting hydraulic valves safety valves on the cylinders control valves in the power pack the same safety precautions apply A e Stay out of the operation radius of the platform e Keep clear of moving parts e Beware of hand foot and head traps at all times 81 3 Electrical components e Before dismounting and remounting electrical components ensure that the components are without tension e t might be insufficient to just switch off the battery sw
50. OLLANDIA tail lifts ID of service agent claimant ID of operator owner Procedure for the initiation and management of a warranty claim Vehicle reg Date of repair SN type af lift Description of defect See pictures enclosed Diagnosis work required or performed Description Code Price EUR netto Allowed by DHO bm 0 SL mileage Important contact info Central Service Department Tel 32 0 9 340 49 67 Fax 32 0 9 340 49 69 To be filled in by Dhollandia O Claim is accepted Retum parts Dhollandia copy of warranty claim 24h Service Li Claim is accepted in modified form Scrap parts Mob 32 0 496 56 90 27 O Claim is not accepted rom the parts but keep them for inspection for 3 l months Mob 32 0 496 56 90 22 Doro nip ENSE T Dhollandia wil replace pars Dhoallandia will credit you for the items Central Uu MDM Spare parts department Tel 32 0 9 340 49 66 Fax 32 0 9 440 49 94 Zoomstraat 9 B 5160 Lokeren Belgium Tel 32 0 9 249 06 92 Fax 32 0 9 249 09 77 E mall infogdivollandia_be DHOLLANDIA DHOLLANDIA T MAINTENANCE amp REPAIR DHOLLANDIA 7 1 SAFETY INSTRUCTIONS FOR MAINTENANCE amp REPAIR e During the maintenance amp repair works the service engineer should follow the general safety instructions for t
51. ONTROL GUARD XTRA CTRL BU 12 24V gt H gt gt 4 VXA I0 Da B36 e Type Column lift type DH VXA S708 platform lights Power pack 6 5 01 Valve VO12 E Plan Sch 012 5094 5090 2010 03 ES COLOUR COD DIN 47100 MECH 95A 0795 5 0 M 0178 08 RIOR CONTROL 10 DH EXTRA CTRL BATTERY 4 lt o kK a 2010 Date 30 03 2011 PLATFORM LIGHTS 5708 B37 oN Ubid UN O Qv viz orga moz pesca 571 8 NM 5 S pee o 10 110Z 4p4Q AgA IGA VXA 425 ejbpq 1102 0 10 YIANY TIOR B38 oN 101495 AGA 2HA VXA HG adh e Type Container lift DH VBC2 5006 5090 Power pack 6 5 01 Serial N Valve Plan Sch VBC2 V012 E S008 B 2010 01 24 12 EXTRA CTRL Colour DIN 47100 2 RD BU BATTERY EDIOO TO EDI20 TO XTERIOR CONTROL BOX REF gt EXTRA CTRL EARTH O eo 5008 4 0 3 222 MECH SA S090 PLATFORM LIGHTS VO12 E 1 5 Date 01 04 2011 DIBIOILILJANIDIA 5006 Foor CTRL ST
52. OSE are disabled In order to allow the operator to stow the platform in it s travel position to reach a skilled service agent for further repair the power pack is equipped with an emergency push button see Fig 5 4 This allows to by pass the safety system and enables the functions LIFT and CLOSE temporarily until the button is released again tion and make the vehicle mobile for repair only They should not be used to en able regular loading unloading The functions automatically return to the neutral position after being released It is strictly forbidden and potentially dangerous to temper with the safety devices or to try and overrule them permanently The emergency functions should be used to stow the platform in it s travel posi e The cable rupture protection is tested as follows Rn Default Dismount the cover from the cylinder beam 18mm Turn the nut 5 on Fig 5 1 on the threaded fitting of the lift cable 1 counter clockwise so that the platforms slants one side and is caught by the correspond ing safety cable 2 Check if the cable rupture switch 3 is activated correctly with X Y see Fig 5 3 Adjust the position of the round nut 7 and its pawl 8 if necessary Check if the function LIFT is disabled The functions LOWER and OPEN should still work Check the function of the emergency button in the power pack Recondition the lift cable 1 in the original work stat
53. afety cut out see Fig 5 16 is used the wander lead with spiral cable can only be used If the end of the loading floor is executed with a toe guard profile according to Fig 5 17 see Fig 5 17 On the platform from a safe working zone of min 400x400 mm clearly and perma DHOLLANDIA nently marked at min 250 mm distance from the hazard zone between the platform e tis prohibited to use the platform as elevated working platform and the rear of the vehicle floor See Fig 5 18 _ Inside the vehicle body from a safe working zone of min 400x400 mm clearly and power feed to any of the auxiliary controls should be connected to the safety switch the control box Activation of the auxiliary controls should deactivate the functions on the exterior control box It is prohibited to bypass any of the safety features of the tail lift 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 19 and only if the front edge of the platform is equipped with a hinged toe guard flap according to Fig 5 11 On the ground from a safe working zone min 500 mm away from the side edge of the platform See Fig 5 20 e When lifting lowering the operator standing on the platform should hold on to the safety rail mounted on the platform See Fig 5 21 The operator should keep his hands clear of the lift runners lift columns
54. and lift runners for visible damage and repair Clear all debris from the lift columns clean them with high pressure steam cleaner and apply grease B27 86 10 The HTL doesn t reach floor height e Insufficient battery power e Insufficient quantity of oil in the reservoir e The lift columns and or lift runners or the pulleys sprockets are damaged causing the lift runners to jam e The lift columns contain to much hardened grease are clogged up with debris and dirt e The chain or steel cable length is incorrectly adjusted e Too much cable stretch Listen to the sound of the electric motor in the power pack measure the evolution of the voltage when trying to reach the higher positions If the sound of the electric motor drops dead or you measure a voltage drop below 21V 10V there is insufficient battery tension see also 7 4 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 lift runners and adjust them when required Check the lift columns lift runners pulleys and sprockets for visible damage and repair Clear all debris from the lift columns clean them with high pressure steam cleaner and apply grease Adjust the length of the chain or steel cable anchor or move to the next mounting position 6 11 The electric motor seemingly run
55. ation of the DOUBLE ACTING valves e Refer to the summary in 7 1 to determine which valves are Double Acting and can be manipulated as described in this 5 For OMMS 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 8 7 Fig 8 7 V071 V072 V071 H V072 H e For V071 H V072 H the protective caps on the cartridge of the valve are equipped with an elastic skin covering an emergency button that can be pushed in by the finger These valves can be operated manually without dismounting anything e Push in the button under the protective rubber to OPEN the valve manually See Fig 8 8 e Release the button under the protective rubber cap to CLOSE the valve manually See Fig 8 8 88 4 Manual override of the starter solenoid e When the main pole IN of the starter solenoid see 7 5 receives normal 24V 12V ten sion but the electric motor doesn t function the starter solenoid can be overridden as follows e Switch off the isolator switch in the vehicle cabin remove the key from the battery switch in the exterior control box or disconnect the main fuse on the battery See Fig 8 1 e Connect the main poles IN amp OUT of the starter solenoid with 2 spanners of the same Main pole string of a starter cable Ensure non of the spanners touches the earth ste
56. ble parts subject to wear and tear such as rubber and synthetic parts hydraulic flexible hoses platform flags hydraulic oil defects to foot con trols caused by loss of or damage to the protection rubbers defects to platform lights caused by impact or abuse with pallets pallet trucks or other foreign objects defects to wander leads their spiral cables and plugs 6 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 A43 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 el
57. c vehicle execution 12 CLOSE the platform until it reaches the closed vertical position and you hear the hydraulic system turn in overpressure y UFT he patom unti te patom roosaeenagd 000 vounte ocra 005 5 Swtan of tne cil poner to the 8 Cose tre 14 ofthe _ DHOLLANDIA rm 7 6 Operating instructions for cattle lifts DH VBV DH VXV e The lifts for cattle transport types DH VBV and are equipped with inverted platform locks and should be operated as follows Fig 7 17 Operation of cattle lifts with inverted platform hooks N Opening the platform 1 Consult the user s manual before getting started Observe all safety instructions Switch on the electrical power to the tail lift cabin switch in the driver s cabin and battery switch of the exterior control box LEG OUT if applicable lower the stabilising legs into work position LIFT the platform approx 150mm to disengage the platform hooks OPEN the platform 90 into the horizontal work position Raise and lock the safety rails into vertical position Loading amp unloading Select between exterior control box and auxiliary controls Observe the loading diagrams amp instructions at all times Use any of the functions LOWER depicted in 7 1 to 87 4 to LOWER the platform to the ground Use any of the functions LIFT depicted in 87 1 to 7 4 to LIFT the platform to the ve hicle floor level
58. cle only They are not suitable to lift the vehicle not empty not fully loaded In order to ascertain this the height of the stabilising legs should be adjusted during loading unloading to adapt them to the variation in the vehicle suspension In case of mechanical legs be very careful when releasing the mechanical lock to store the legs in travel position If the vehicle has been loaded the extra weight in the vehicle body might induce significant tension on the sliding foot of the leg and its lock ing mechanism DHOLLANDIA 87 10 The use of roll stops e Any platform aimed to lift and lower rolling loads must be equipped with a roll stop sys tem to prevent the load from rolling unintentionally off the edge to protect the load against shifting position and its centre of gravity to move during the LIFT LOWER movement e As part of the ordering process of the lift it is important that the vehicle owner and his contractors choose the position of the roll stops in function of the intended application pallets trolleys and the loading diagrams applicable to the nominal capacity chosen The loading diagrams amp instructions of chapter 6 should be observed at all times e option list features 4 types of roll stop systems 215 M 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
59. d applications 2000mm with a significant risk of falling from heights the platform is equipped with safety rails on all exposed edges 4 6 Inspection of the suspension system For lifts with a single cable or single chain system test the LSD see Pt 4 in Chapter B For lifts with a double cable system 1 set of lift cables 1 set of safety cables test the cable rupture detection switches see Pt 5 in Chapter B The emergency push button for the cable rupture switches mounted on the power pack functions OK 4 7 General operation practical tests General operation with an empty platform execute all movements several times with ALL available control units The movements should be executed smoothly amp quietly without strange noises Static test at 125 overload Test for deformation Position the platform at 1 2 height Note the distance and angle to the vehicle floor Put a load of 1 25 x nominal capacity at the centre of gravity and remove it again Verify the distance and angle to the vehicle floor No permanent deformation should be noted otatic test at 12596 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 tilted down more than 2 _ DHOLLAN
60. de turn the nut 5 on the threaded fitting of the steel cable resp clockwise counter clockwise e The corresponding safety cable s 2 must be adjusted as well Adjust their tension so that it is possible to pull the safety cable s 30 to 40mm away from the lift cable s by hand without coming out of the columns The tension of the safety cable s 2 is again 4 w Joseon _ increased decreased by turning the nut 6 on the threaded fitting of the steel cable resp TM clockwise counter clockwise The round nut 7 and pawl 8 for the cable rupture switch es must be readjusted so that distance X distance Y at all times See Fig 5 3 Safety cable e Execute the adjustment of safety cables 2 the round nut 7 and pawl 8 with due diligence as they determine the good function of the cable rupture safety Cable anchor feature Negligence can put the operator the technical service personnel and Nutonthreaded third parties at great risk Nut on threaded end of safety cable e f Y gt X the pawl 8 on the round nut 7 will hit the switch 3 very hard in case of a cable Round nut of the cable rupture detection rupture and the switch 3 might be damaged need replacement If X gt Y the pawl 8 will not reach the switch 3 in case of a cable rupture and the safety will fail to work Pawl of the cable rupture detection Lift cylinder DHOLLANDIA Ex e n case of a cable rupture the functions LIFT and CL
61. draulic pipes flexible hoses hydraulic couplings What to verify Execute service or repair if required HE 1 Hydraulic pipes amp flexible hoses e General condition outside rubber coat is intact inside steel braids are not visible LI Flexible hoses in the energy track between lift columns and platform for HTL e Routing amp guidance protection against squeezing sheering or rubbing with hydraulical closure e Fragility amp porosity e Age to be replaced every 4th year fill out the Maintenance amp Repair Report LI Couplings e General condition LI Fixed hydraulic pipes in steel e Corrosion fixation e Hydraulic system is free from leaks both during operation amp at rest DHOLLANDIA e 82 9 Hydraulic power pack What to verify Execute service or repair if required Freq LI Oil reservoir casing of the power pack amp lid e General condition no cracks or deformation in the mechanical parts amp mounting brackets M3 LI Fixation of the power pack to the HTL frame or to the chassis e Protection against corrosion sealing of all the holes J1 e Condition of the lid amp the rubber locking straps e Hydraulic system is free from leaks both during operation amp at rest e Tightness of the collars of the suction hose and return hose Hydraulic oil e Check oil level amp refill if required M3 e Oil type ISO 22 as standard other types used as option check before refill J1 e Oil level rest the platfo
62. e platform flags The impact of platform lights see Fig 4 17 a reflective flags see Fig 4 17 b and lateral reflecting tape see Fig 4 17 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 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 17 d e 4 18 Audible alarm due to their lifting height above 2m multi deck column lifts are equipped with an audible alarm warning accidental bystanders of the lowering platform and the potential hazard of getting trapped under the platform DHOLLANDIA e Fig 4 19 Warning decals 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 simplified set of instructions for use and other decals warning the operator for specific hazards Note all images above are examples The exact execution might vary in function of the type of lift and the application If required contact your DHOLLANDIA agent for further advice _ DHOLLANDIA 14 5 SAFETY INSTRUCTIONS FOR THE USE OF THE LIFT 5 1 Introduction e DHOLLANDIA tail lifts shall be exclusively used to load the goods transported on the
63. e operator see Fig 7 21 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 see Fig 7 22 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 A31 on the practical op eration of the functions LEGS IN LEGS OUT e The purpose of the stabilising legs is to prevent the vehicle from tipping over e g central axle trailers or to support the chassis of the vehicle during loading unloading e g vehi cles with very long overhang with relatively weak chassis or in case of extreme lift ca pacities e The use of stabilising legs is compulsory on certain vehicles Consult the user s p manual and or the Fitting and Body Building Instructions from the vehicle manu facturer e When using the stabilising legs the operator should observe following points Ensure that the stabilising legs are positioned on solid even ground case of soft terrain sand gravel solid support blocks must be used under 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 vehi
64. e suspension system Prior to unload LIFT the platform and remove the locking pins so that the platform can lower to the ground e Sufficient battery tension is vital to protect the electric components of the lift battery switch starter solenoid electromotor against overheating or burning See also pg A9 The time needed to LIFT the platform strongly depends on the condition of the power source and the weight on the platform e n most cases the electric motor is fan cooled and equipped with a thermal fuse In case of intensive use or a low voltage issue the motor will heat up and might be automatically stopped by this thermal fuse This is no reason to call out for a service agent Normally this fuses resets itself after the motor has cooled down this is approx 20 min e Overheating can be avoided by lightening the work and inserting pauses and by assuring a sufficiently strong power source giving min 23V constant output If overheating hap pens frequently the condition and capacity of the batteries amp the battery charging system and the dimension of battery cables earth cables and fuses must be checked the imple mentation of a battery guard evaluated DHOLLANDIA E 55 6 Instructions for working at loading docks e When working at loading docks it is recommended to store the platform safely away and to drive the goods directly from the dock onto the vehicle floor and vice versa
65. e tightness of the hydraulic cylinders See RMT HB 6a 6b B28 6 12 The platform LIFTS and CLOSES simultaneously when the function LIFT is actuated for HTL with hydraulical OPEN CLOSE e The solenoid of the control valve S CLOSE is electrically activated while it should remain Remove the solenoid of control valve S If the fault remains the cartridge of the valve is probably leaking stuck in open without tension position e The cartridge of the control valve S CLOSE is polluted or stuck in open position or defec tive in another way Flush purge the valve or replace See RMT 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 pack to identify the origin of the malfunc tion 6 13 The platform LOWERS OPENS with shocks when the function LOWER OPEN is actuated e The lift columns and or lift runners are damaged causing the lift runners to jam Check the lift columns and lift runners for visible damage and repair Clear all debris from the lift columns clean them e The lift columns contain to much hardened grease are clogged up with debris and dirt with high pressure steam cleaner and apply grease 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 V09
66. ear cross member of the loading floor of the vehi cle or between the lowering platform and the ground e he standard delivery specification comprehends a 2 button control for LIFT LOWER mounted to the safety rail on the platform in combination with one of the toe guard solu tions shown in 55 4 see Fig 5 13 This provides an efficient remedy against the risk of crushing and sheering of the toes feet or limbs e Itis strictly forbidden to use any other configuration of auxiliary controls without W explicit risk assessment by the installer of the lift and the safety executive of the company operating the vehicle and the lift The summary further in this can be used as a guide only and cannot lead to any form of legal complaint against N DHOLLANDIA Contact your national DHOLLANDIA distributor in case of doubt e tis generally accepted that the foot control with compulsory 2 feet operation provides an efficient remedy against this risk since it immobilises both feet of the operator on a predetermined and safe location on the platform the buttons of the foot control see Fig 5 14 Other auxiliary controls wander lead with spiral cable fixed interior control should only be used under the safe working conditions described in the Euro pean Standard 1756 1 2001 1 2008 and the latest issue of the DHOL LANDIA fitting instructions FIT ELEC_OPTION f no hinged foot protector see Fig 5 15 or s
67. ectrical failures to the electric motor the starter solenoid other switch elements caused by insufficient battery or power capacity 8 4 9 Damage caused by normal and natural wear and tear Damage or defects caused by inaccurate or faulty fitting unless mounted by 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 6 4 10 Defects and damage caused by unauthorised modifications to the original construction or safety devices of the HTL without explicit prior written approval by DHO during the fitting process or afterwards e g during repair and maintenance works 8 4 11 As far as any given incident is not covered by the legislation on product liability and warranty a warranty case cannot lead to a damage claim of any kind M Remark full conditions includ standard repair times and description of procedures available on request WARRANTY CLAIM REPORT PERENNI DHOLLANDIA for DH
68. eet operation LI Auxiliary control mounted to the safety rail e See points above L1 Wander lead with spiral cable optional e Condition of the electrical cable from the safety rail to the platform LI Fixed interior control optional e Condition of the spiral cable condition of the plug connections e Position inside the vehicle body protection against damage by the load O Safety issues on these controls e Connection to the safety button in the exterior control box see fitting instructions e Marking of safe working zone on the platform and or on the loading floor inside the vehicle body e Conformity with fitting instructions re toe protection LI Sound alarm on function LOWER e General condition amp function M3 e Audibility from within the working range of the platform J1 _ DHOLLANDIA B9 82 7 Electrical installation What to verify Execute service or repair if required EX LI Batteries e General condition LI 35mm BATTERY cable to the battery 1 e Good mounting amp fixation of electrical cable amp wire connections see fitting instructions LI 35mm EARTH cable to the battery or earth point 1 e Technical maintenance of the batteries power circuit battery charging circuit and earth circuit LI Electrical plug connections between truck amp trailer Harrisson e Apply grease or Vaseline to all connections to protect them against corrosion 1 where 35mm is mentioned also other cable sections
69. ehicle 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 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 to heavier duty ones In case of short journeys and long periods of intensive tail lift use both the alternator and the batteries will probably need upgrading Alternator of 14V 80A or 28V 1354A _ DHOLLANDIA A9 4 SAFETY DEVICES DHOLLANDIA tail lifts are equipped with a wide range of safety devices in order to en sure that goods can be loaded unloaded with a maximum degree of safety for both the 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 15 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
70. el casing of the starter solenoid electric motor or power pack itself See Fig 8 9 e he establish the electric power to the power pack switch on the isolator switch in the vehicle cabin insert the key from the battery switch in the exterior control box or recon nect the main fuse on the battery If the starter solenoid is the failing part the electric mo tor will now start to run e Alternatively you can maintain the electric power on the power pack and link the 2 main poles IN amp OUT of the starter solenoid with an old screw driver or other metal object Again ensure not to make any connection to the earth See Fig8 10 DHOLLANDIA m 8 5 Emengency push button the power pack Fig 8 11 e The emergency push button mounted on the side of the power pack enables the operator or service agent to overrule some of the safety features incorporated on the HTL in case of failure of the relevant switch or its wiring circuit e The emergency functions should be used to stow the platform in it s travel posi A tion and make the vehicle mobile for repair only They should not be used to en able regular loading unloading The functions automatically return to the neutral position after being released It is strictly forbidden and potentially dangerous to tamper with the safety devices or to try and overrule them permanently Upon use of the emergency button the safety instructions of this manual must be
71. ety button A separate battery switch should be mounted during installation of the lift e This type is for instance used for mounting into the side panel of the vehicle body e 3 buttons plus the safety button operate the 4 basic functions LIFT LOWER CLOSE amp OPEN See Fig 7 8 AN 09 87 3 Interior lifts with fixed platform and lifts with manual closure only ig 7 e Interior lifts with fixed platform and lifts with manual closure only have the functions LIFT LIFT t N LOWER and no tilt functions They can be controlled by the standard control box or the yy HN 3 1 button control box see Fig 7 9 0 c DHOLLANDIA ES e The option 5011 features single control box with 2 control buttons and an emergency cut out switch A separate battery switch should be mounted during installation of the lift e The 2 buttons operate the 2 basic functions LIFT LOWER the closure of the platform is done manually The emergency switch enables the operator or any bystander to cut off the power to the control unit is case of emergency See Fig 7 10 e These lifts can also be operated by any of the auxiliary controls below But whatever con figuration the operation of the lift should be subject to an explicit risk assessment by the installer of the lift and the safety executive of the company operating the vehicle and the lift See Pt 5 safety instructio
72. facturer 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 a 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 4 6 a or mounted by the installer at another location that is clearly visible and easily accessible to the operator As option the control box can be equipped with a genuine emergency button see Fig 4 6 b The emer gency 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 optional this switch enables the operator to switch the electrical power to the tail lift on off and con tains a signal as to whether the platform is correctly stowed in its travel position or not e Fig 4 8 Marking of the centre of gravity Hydraulic tail lifts are not designed to LIFT LOWER weights corresponding to their nominal capacity over the full surface of the plat form The nominal capacity is valid at a certain distance or centre of gravity behind the vehicle body Behind
73. fts driven by a lift cylinder plus a single cable or single chain system are equipped with a mechanical Load Safety Device LSD e These cable rupture devices or chain rupture devices are designed to block the platform inside the lift columns in case of failure of the suspension system and to protect the plat form the load and the operator from falling to the ground The LSD is tested as follows Clean the lift columns Remove all foreign objects amp dirt from the inside of the columns and from the LSD With the platform in open position lower the platform to approx knee height Place a block of wood under each side of the platform near the front platform edge and LOWER the platform onto the blocks Continue to press the function LOWER until the chain or steel cable is physically slack underneath the lift runner If the chain or steel cable doesn t go slack remove the cover of the cylinder beam and whilst pressing the function LOWER push the cylin der in by hand This will create slack chain or cable to continue the test Slack chain or cable is a necessity otherwise the LSD test can prove negative Manually lever one side of the platform upwards and remove the blocks then release the platform The LSD should engage within 100mm drop the LSD has not been activated check if the various components of the LSD can move freely To disengage the LSD press the function LIFT to raise the platform
74. going movement should immediately stop when one of the corresponding switches is released The cables going to the platform platform lights foot controls are properly routed and cannot be damaged during the various movements of the lift The function LOWER is signalled by a well audible sound alarm 84 4 Inspection of the hydraulic part There are no visible oil leaks after the weight tests all cylinders are free from paint remainders The hydraulic circuits have been purged conform to the fitting 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 84 5 Inspection of the platform The centre of gravity is correctly marked and corresponds with the data men tioned on the identification sticker in the exterior control box The safe working zone for the operator is clearly and permanently marked on the platform If applicable The platform is equipped with a suitable toe guard protection according to Chapter 65 4 In case of a toe guard flap switch the platform stops the LIFT function as soon as the toe guard flap is pushed in The emergency push button for the toe guard switch mounted on the power pack functions OK The platform is made sufficiently visible for the surrounding traffic platform lights flags reflective tape traffic cones For all lifting heights 22000mm an
75. he use of the tail lift see Chapter A as well as the specific techni cal safety instructions described below 1 1 General safety instructions e Use appropriate working clothes Never wear loose fitting clothes that may be trapped the moving parts of the tail lift called HTL hereafter Always wear safety goggles with side guards safe footwear with steel protection tips non flammable overalls protective gloves and ear plugs Wear a safety helmet when working under the HTL or vehicle chassis Avoid wearing rings bracelets necklaces watches etc See Fig 1 1 e Before releasing the mechanical platform lock check if the hydraulic system builds up pressure goes in overpressure and ensure that there is no visible oil leaks see Fig 1 2 e Take into account that a leak visible or not in one or more of the hydraulic components may cause a pressure loss causing the platform to fall open as soon as the mechanical lock is released see Fig 1 3 e Consider that in an emergency situation the platform might have been closed with use of external help forklift hoist gantry crane leaving the hydraulic cylinders empty instead of filled with oil and causing the platform to fall down as soon as the mechanical lock is released see Fig 1 3 1 4 When opening the platform always stand to one side of the vehicle Never behind the platform Always avoid the area directly behind and within reach of the moving platform
76. hese 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 82 3 Maintenance amp Repair Reports special inspections re inspections All maintenance amp repair works performed on the tail lift should be reported in the Main tenance amp Repair Reports see pg C11 amp following to provide any service agent or safety officer intervening on the lift with a full history of the works carried out In case of important repair works with significant impact on the structural integrity of the lift or the safe working conditions the lift should be subjected to a special inspection by an expert competent person to evaluate if it is safe to continue to use it The findings of these inspections should be summarised in the relevant inspection certificates see pg C6 amp following If a tail lift has failed to pass a periodic or special inspection it should be repaired and be subjected to a further inspection 7 re inspection by an expert competent person to evaluate if it is safe to continue to use it after the latest repair The findings of these in spections should be summarised in the relevant inspection certificates see pg C6 amp fol lowing The content of these compulsory inspections is explained in Chapter B Point 2 82 4 Expert competent pers
77. ide of the starter solenoid EX one 6 Loading diagrams A26 58 5 Emergency push button the power pack B34 ment Regulations 1998 7 Operating instructions A28 8 6 Course of action B35 6 International distributor network C15 7 1 Introduction to the standard control box A28 9 Electrical amp hydraulic wiring diagrams B35 7 2 Option 5094 3 1 button control box A30 87 3 Interior lifts with fixed platform and lifts with manual A30 closure only 74 Auxiliary controls A31 87 5 instructions for standard exterior column A33 87 6 n s instructions for cattle lifts DH VBV DH A34 97 7 Operating instructions for interior lifts A35 87 8 Operating instructions for DH VO5 removal lifts A36 87 23 The use of stabilising legs A38 7 10 The use of roll stops A39 87 11 Automatic tilt at ground level A41 8 Warranty conditions 42 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 CE DECLARATION OF CONFORMITY Corresponding Directive 2006 42 EC annex 2 A Identification of the tail lift We hereby declare that the DHOLLANDIA ail lift identified above based on its design and its construction complies to the relevant fundamental health and safety requirements of the CE Directives and is destined to be mounted on a vehicle
78. idge of one of the See explanation of the different techniques under 6 7 valves is mechanically defective e One of the braking valves on the cylinders or in the power pack is mechanically blocked by If one of the valves is not energized measure the current amp earth circuit to that solenoid into the control box and repair ice dirt or by mechanical malfunction e The travel lock has not been opened If the electrical operation of all solenoids is correct verify the cartridges of the valves for mechanical damage Dismount e One of the tilt cylinders is blocked piston rod bent by accident interior spring or piston is the braking valves on the cylinders and in the power pack to verify if they work ok seized up Finally verify the tilt cylinders and their spring for mechanical damage DHOLLANDIA 86 9 The lift capacity is insufficient the HTL doesn t reach the nominal capacity e The load is too heavy or removed too far from the centre of gravity e The 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
79. ifts DH VO5 Opening the platform Consult the user s manual before getting started Observe all safety instructions Switch on the electrical power to the tail lift cabin switch in the driver s cabin and battery switch of the exterior control box LEG OUT lower the hydraulic stabilising legs into work position 7 Select between exterior control box and auxiliary controls Observe the loading diagrams amp instructions at all times LOWER the platform to the ground to load unload 10 LIFT the platform to the vehicle floor level to load unload Above the roof level the lift capacity is reduced to 500 kg Closing up in travel position Close and lock the safety rails LIFT or LOWER the platform to approx 15cm under the vehicle floor or use the function Height detection to CLOSE to find the suitable height 12 LEG IN lift the hydraulic stabilising legs into their travel position 3 CLOSE the platform until it reaches the closed vertical position and you hear the hydraulic system turn in overpressure 3 m oo g 11 4 LIFT the platform until the platform hooks are engaged 15 Switch off the electrical power to the lift Close the lid of the control box DHOLLANDIA 87 9 The use of stabilising legs e DHOLLANDIA tail lifts are available with 2 types of stabilising legs Mechanical stabilising legs are deployed and restored manually by th
80. in the exterior control box see Fig 7 1 7 5 can also be mounted in the auxiliary con trols mounted on the side gate option S004 C or in the fixed interior controls option 9015 see Fig 7 15 Selection switch on the auxiliary controls See Fig 7 15 Switch turned clockwise 1 Activates the LIFT LOWER buttons in the auxil lary controls and deactivates the exterior control choice for interior controls 1 Keep clear of moving parts Beware of hand foot head traps at all times choice for exterior control box 2 DHOLLANDIA T 7 5 Operating instructions for standard exterior column lift e Standard exterior column lifts should be operated as follows Fig 7 16 Operation of standard exterior column lifts Opening the platform Consult the user s manual before getting started Observe all safety instructions Switch on the electrical power to the tail lift cabin switch in the driver s cabin and battery switch of the exterior control box Remove the locking pins through the columns Use any of the functions LOWER depicted 7 1 to 87 4 to LOWER the platform to the ground 0 Use any of the functions LIFT depicted in 87 1 to 87 4 to LIFT the platform to the ve hicle floor level Closing up in travel position Close and lock the safety rails LIFT or LOWER the platform to approx 15cm under the vehicle floor or any suitable height in function of the specifi
81. is Verify the electrical operation of the safety valves D needed to LOWER on cylinders or in power pack faulty e with a magnetic tester a solenoid generates a magnetic field when it is electrically activated e The electric cable to one of the safety valves D needed to LOWER is interrupted or has a bad contact e One of the solenoids D needed to LOWER is defective or the cartridge of one of the valves is mechanically defective e or open the safety valves manually via the emergency operation if the valves are opened manually and the platform e One of the braking valves on the cylinders or in the power pack is mechanically blocked by LOWERS the cause is electrical for sure ice dirt or by mechanical malfunction e One of the lift cylinders is blocked piston rod bent by accident badly greased e The lift columns and or lift runners are damaged causing the lift runners to jam e The lift columns contain to much hardened grease are clogged up with debris and dirt e The LSD is engaged due to bad greasing or too much debris in the lift columns or by genu ine rupture of the suspension system steel cable or chain pulleys and sprockets open close 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 Dism
82. is leaking For most types of HTL multiple valve system there must be a combination of different defects if the platform lowers Spontaneously safety valve leaking on one cylinder and the cylinder seal leaking on the other or the safety valves on For DH VB DH VO both cylinders leaking and the control valve in the power pack leaking A single malfunction wouldn t be enough if the e The check valve on the pressure pipe of the lift cylinder is leaking hydraulic circuit counts more than 1 safety valve Verify if the manual emergency operation on the valves is firmly closed Test and verify if the lift cylinders and hydraulic memory are not leaking internally See RMT 6b Revise the cylinders if required Flush purge the cartridge of the safety valves on the cyllinder and if applicable the control valve in the power pack see RMT 155 revise replace O rings or replace the part For DH VB DH VO These HTL have separate hydraulic pipes for LIFT and LOWER in order to accelerate the function LOWER The pipe for LIFT is equipped with a check valve Check this valve for leakage See RMT HB 6b Try to clean the check valve or replace the part 6 15 The platform falls open the point of the platform tips down for HTL with hydraulical OPEN CLOSE e The safety valve needed to OPEN on tilt cylinder or in power pack is leaking The O Remark Take into account the quantity of cylinders the quantity of safety
83. itch in the exterior control box or the isolator switch on the dashboard in the vehicle cabin For certain works the main fuse or the connection to the battery will need to be disconnected e First define clearly which area you need to work on then interrupt the circuit at a point which is nearer to the battery or power source _ DHOLLANDIA B5 2 MAINTENANCE e During this periodic inspection or Statutory Thorough Examination jointly called STE after the expert competent person assesses the rate of deterioration of the equipment e Competent and regular maintenance is extremely important not only in order to maximise identifies any defects and certifies that the equipment is safe for continued use for the fol the life expectancy of the tail lift called HTL hereafter but also in order to guarantee the lowing period up to the next STE 6 months for UK 12 months in most other countries operational reliability and safety of the operator and potential bystanders across Europe e No maintenance or repair work is done during a STE The scope of STE therefore implies all points of the checklist below with exception of the actual greasing work 2 2 and the purging work 2 8 Other points are specially reserved for the STE and are marked as follows STE Statutory Thorough Examination or periodic inspection e Follow the scheme on the next pages verify point after point and tick off as you make progre
84. ith manual closure These platforms often equipped with invisible torsion bars reinforcing the manual open close movement The torsion bar is preset during manufacturing and is housed in the 1st section at the front of the platform see Fig 1 8 Short aluminium platforms may have only 1 torsion bar Heavier platforms with hinged ramps longer depth platform in steel often have 2 bars running from either articulation point to a bar retainer inside the platform These torsion springs incorporate a significant amount of energy and are po tentially dangerous Incorrect installation use or adjustment servicing may result in serious injury of the operator or service personnel Therefore the tension in the bar should only be adjusted by someone who has been specifically trained to do so It is NOT a user serviceable part Bear in mind that in case of mechanical failure the platform might have been closed with the help of external devices forklift gantry crane and that the platform might drop in free fall to the open position after disengaging the travel lock Don t attempt to control the opening speed of the platform just by human force The platform might be very heavy possibly more than 100kg to handle Even when the platform is closed there can still be significant force on the tor sion bar and the other components attached to it The components bar re tainer articulation pins sho
85. ity of the load doesn t necessarily correspond with its physical middle point The weight can be spread very unevenly e Unilateral loading on 1 side of the platform should be avoided Restrict the load to a maxi mum safe working load of 50 of the nominal capacity see Fig 6 1 e Pay attention to avoid concealed overload situations such as Platform squeezed in the storage pocket of a loading dock unexpected forces apply to the lifting mechanism causing severe damage see Fig 5 32 Platform and lifting mechanism damaged by hard reversing of the vehicle against the loading dock see Fig 5 31 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 28 Fork lifts offloading merchandise on the platform point standing at the floor level of the vehicle the kinetic effects of the descend speed amp the additional weight of the forks masts of the forklift often lead to significant overload Load over the side edge of the platform place the merchandise centrally between the 2 lift columns at equal dis tance from both platform sides See Fig 5 26 6 3 and applicable load diagram see Fig 6 2 are supplied with the lift The op erator should take note of this information prior to using the lift 1 e Note stickers indicating the
86. k and repair the fault 87 3 HTL doesn t react on the exterior control nor on the auxiliary control e solator 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 15 fuse in the control box is defective e The power pack is not properly earthed Switch on the isolator switch for the HTL in the vehicle cabin Plug in measure the tension and or repair the plugs between the tractor and semi trailer battery link earth link and the charging system Verify the 250A main fuse and repair or replace if necessary Switch on the battery switch in the exterior control box Measure if the switch passes current to the 2nd pole Verify the 15A fuse on the control panel of the exterior control box and repair or replace if necessary Establish a direct earth link to the HTL 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 87 4 Symptoms of weak batteries or damaged current supply e The downward functions OPEN amp LOWER are working but the upward movements LIFT amp CLOSE are failing e The electric
87. l Inspection Re inspection DHOLLANDIA m Fig 3 1 Columns on ALL lifts e Grease schedule under normal conditions of use and a single labour shift the schedule DH VB VO VX can be limited to 12 thorough greasings per year e Incase 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 e Before greasing the HTL should be cleaned with high pressure steam cleaner in order to clear the lift columns amp lift runners from hardened grease and debris and all articulation points and grease nipples if applicable from sand and dirt e Any grease job should include Greasing of the lift columns lift runners and their Teflon slide surfaces Lubricate with Lubrication of the Load Safety Device LSD steel cables or chains oil of the inside of the cylinder beam the pulleys pulley blocks sprockets Lubrication of the platform lock platform retaining catch hinged toe guards if applica ble articulation points of the safety rails Greasing of all articulation points equipped with grease nipples Grease e Where grease nipples are used the greasing must be executed in such a wa
88. ld be noted O Static test at 125 overload test on INCLINATION Position the platform at the level of the vehicle floor STE Put a load of 1 25 x nominal capacity at the centre of gravity Note the distance and angle to the vehicle floor Repeat the same measurements after 15 min The platform should not be lowered more than 15 mm and should not be tilled down more than 27 LI Dynamic test at 100 nominal capacity Verify if the lift has sufficient lift capacity J1 L1 Dynamic test with 500kg above roof level DH VO5 Verify the general performance amp stability DH VO5 verify if the lift capacity is limited to 500kg above roof level Adjust if necessary Verify the working speeds LIFT amp LOWER max 15 cm sec OPEN amp CLOSE max 10 sec AUTOMATIC TILT at ground level max 4 sec O Overload test Place the platform at rest on the ground STE Put a load of 1x nominal capacity at the centre of gravity 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 82 16 Administrative obligations What to verify Execute service or repair if required LI Maintenance amp repair reports e All works are duly documented in the corresponding report or certificate documents always LI Certificates for Periodic inspection Specia
89. le for further use The tail lift identified in the Declaration of Conformity has been inspected on its O 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 INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION L SPECIAL INSPECTION RE INSPECTION Date of inspection Evaluation the tail lift is safe and suitable for further use The tail lift identified in the Declaration of Conformity has been inspected on its O 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
90. legislation imposes following obligations on owners fleet operators Operate 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 85 1 PUWER the Provision and Use of Work Equipment Regulations 1998 e Applies to all work equipment including tail lifts but also includes vehicles e Strengthens the requirements of the Management of Health and Safety at work Regula tions 1992 e Stipulates that vehicles and lifts must be maintained in a good state of repair e Only competent trained people should operate repair and service the equipment e Lifts supplied from 1993 1996 may require upgrading to meet the Essential Safety Re quirements of the Machinery Directive e For more information refer to Safe Use of Work Equipment ACOP and guidance L22 HSE Books 1998 ISBN 0 7176 16266 _ DHOLLANDIA C14 5 2 LOLER the Lifting Operations and Lifting Equipment Regulations 1998 Employers must ensure that the lifting equipment it
91. lifts as sup resulting from a failure on one of the solenoids R D O H S The actions are ranked plied in their standard execution from high preference if relevant parts and professional labour skills are available down to last help if parts or professional labour skills are not available if a correct diagnosis e In case of special lifts should the original wiring diagram joined to the lift be lost or for definitive repair cannot be established quickly unavailable contact DHOLLANDIA for further help e 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 DHOLLANDIA ess e Type Column lift type DH VXA Power pack 6 5 01 Valve VO12 E Plan Sch 012 5094 2010 02 Date 30 03 2011 DHOLILANDIA ES EXTRA CTRL gt DA gt 8 OOF I I 1 Il Il 1 Ee a COLOUR COD DIN 47100 BATTERY 4 gers o amp e 0703 251 04M 0178 MO8 XTERIOR C
92. lty or the connection to one of the contacts and pulleys and repair if necessary Adjust the cable length the position of the cable nut and its pawl if necessary is loose Check the condition and function of the cable rupture switches and repair if necessary e The electric cable is cut or damaged or there is a bad contact 6 The incoming or outgoing connection to the electrical distribution block in the power pack is Conventional points faulty Remove the lid of the power pack and feel the temperature of the electric motor If the motor feels hot the thermal fuse e The starter solenoid in the power pack is defective inside the motor probably has interrupted the earth of the starter solenoid This can be verified by giving the starter e The carbon brushes of the electric motor are worn out solenoid a direct connection to the earth After a cooling period of approx 15 min the thermal fuse automatically re e The thermal fuse inside the electric motor earth of the starter solenoid is switched off by Stores the earth of the starter solenoid and the electric motor becomes operational again overheating caused by overload or insufficient battery tension h hei ein T f no 24 12 e The battery or earth cable is under dimensioned damaged or loose at the connec not measure the tension at the incoming poles of the starter solenoid main power amp control power If no is tion to the battery pole measured
93. me importance to comply with the overall CE Safety Directives with DHOLLANDIA code of good practice re maintenance and with the validation of the product warranty 6 INTERNATIONAL DISTRIBUTOR NETWORK Alexander Xerri 356 21 470 900 Australia Tieman Industries PTY LTD Melbourne 61 3 9469 6700 Netherlands Dhollandia Netherlands Breda 31 765 81 14 55 AUSTA Dhollandia Austria Neuhofen im Innkreis 43 7752 70 270 Dhollandia Norway 47 98221333 Baltic states Dhollandia Latvia 371 28 305 904 Polan Dhollandia Poland Krakow 48 12 260 61 10 Estonia Latvia Lithuania Portugal Dhollandia Plataformas Villa Franca de Xira 351 263 286 570 Belgium amp Luxemburg Dhollandia Service Lokeren 32 9 349 06 92 Romania Dhollandia Romania Bucharest 40 744 571 655 zr Dhollandia Brasil Sumar 55 19 3832 4000 RUSSIA uena Dhollandia Russia Moscow 7 916 531 36 00 Bulgaria Dhollandia B
94. measure and verify the main power circuit and the control power circuit e Insufficient battery tension PS 7 Main power IN Remark For multi deck column lifts min 50mm cable section is recommended for the Earth via thermal fuse battery and earth cables Control power TE Main pole OUT DHOLLANDIA 87 5 The electric motor doesn t run but the downward functions OPEN LOWER work fine 86 6 The electric motor doesn t switch off e The button or switch for LIFT in the exterior control box or auxiliary control doesn t return to the neutral 0 position e The button or switch returns to O 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 _ DHOLLANDIA 4 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
95. 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 Remark For multi deck column lifts min 50mm cable section is recommended for the battery and earth cables DHOLLANDIA Remove the lid of the power pack and measure the tension at the incoming pole of the starter solenoid when the sys tem is under strain push the function LIFT If you measure 24V 12V check the working of the starter solenoid when pushing the function LIFT you should meas ure 24V 12V at the outgoing pole of the starter solenoid verify and measure the battery cable to the electric motor check the earth link of the starter solenoid and the earth link of the electric motor up to the vehicle batteries Also if you measure 24V 12V on the multimeter also check if there is sufficient Amp by using a test bulb If the bulb doesn t light check for poor connection at the 250A main fuse and the whole battery cable up to the power source If no 24V 12V is measured at the incoming pole of the starter solenoid verify the battery cable to the battery switch in the exterior control box and measure if the battery switch itself passes through the current QE B22 87 4 Symptoms of weak batteries or damaged current supply 4 If no 24V 12V is measured at the
96. n all other moving parts of the vehicle body Ensure that the vehicle cannot tip over when putting heavy weights on the platform See Fig 5 2 a If the 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 solid support blocks must be used under the stabilising legs see Fig 5 2 b Ensure that the operator can overview and keep visual control over the whole working area of the lift and its platform at all times The operation of the lift should be confined to a single operator Upon deployment amp use of the lift the operator should not permit anyone 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 Always stand to one side of the lift when opening the platform never under or behind the platform See Fig 5 3 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 authorised DHOL LANDIA service agent for repair Read and comply with all warning decals pictograms and instructions affixed to the lift _ DHOLLANDIA A16 e Never leave the lift behind unattended in the open position Before leaving the vehicle behind unattended sto
97. nd manufactured using state of the art technology high quality materials and components and comply with the European CE safety regulations mentioned in the Declaration of Conformity unless agreed otherwise upon ordering export outside CE region _ DHOLLANDIA AG e column lift range DH V comprises of a wide variety of constructions with vastly different lifting mechanisms but sharing many functional components such as platform safety rails roll stop amp ramp options safety devices etc These lifts are designed for a wide variety of trucks trailers and semi trailers and are available with lift capacities of 1000 to 5 000kg XIX e main types are as follows Fig 3 1 Main types of column lifts 1 DH VB Operated by a single lift cylinder and a set of steel cables cylinder beam is mounted horizontally at roof level DH VO Operated by a single lift cylinder and a set of steel cables cylinder X X X X X X X beam is mounted horizontally at or below the vehicle floor level 3 DH VX Operated by a single lift cylinder and a set of steel cables cylinder beam is mounted vertically in the right side column Operated by 2 hydraulic lift cylinders mounted in the left and right side columns No cables or chains involved By adding specific options these multi functional lifts can be adapted to suit specific appli cations such as the intensive distribution
98. nominal capacity the centre of gravity see Fig DHOLLANDIA 7 OPERATING INSTRUCTIONS 7 1 Introduction to the standard control box e All the symbols in this chapter represent left hand drive vehicles continental Europe with the control box 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 e The safety switch can be a rotary switch with removable key see Fig 7 1 a standard rotary switch see Fig 7 2 7 3 or a push button see Fig 7 4 They function as follows Rotary switch as safety switch See Fig 7 5 Switch turned amp held clockwise 1 Activates the joy stick in the exterior control box and deactivates the auxiliary controls Switch turned counter clockwise 2 Activates the auxiliary controls and deactivates the joy stick in the exterior control box 1 Hold to run principle when the safety switch is released it will automatically return to the neutral position and deactivate the joy stick 2 Fixed position the auxiliary controls remain active as long as the safety switch is not manually returned to the neutral position 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
99. ns 7 4 Auxiliary controls PAN choice for WY auxiliary controls e The auxiliary controls should be used with full respect of the particular safety instructions of 5 5 the safety switch in the exterior control box is a rotary switch this switch should be turned counter clockwise to activate the auxiliary control See Fig 7 11 e The standard auxiliary control mounted to the side gate is equipped with 2 buttons 1 button to LIFT 1 button to LOWER In case the lift is equipped with a hydraulic ramp option 5764 5765 the side gates is equipped with 2 more buttons 1 button for RAMP UP 1 button for RAMP DOWN See Fig 7 12 LOWER 4 DHOLLANDIA The foot controls option 5006 5075 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 13 The 2 button wander lead with spiral cable option S001 and the 2 button fixed interior ee t 1 controls option 5003 5005 equipped with 2 buttons 1 button to LIFT 1 button to The use of 3 button wander leads with spiral cable enabling the operator to additionally a TILT the platform is disallowed under the European CE Safety Directives The selection switch selection between exterior amp auxiliary controls that is normally fitted
100. oil pressure 220 BAR Emergency push button overriding the safety devices e General condition amp function of the button see also When the button is pushed in platform LIFTS when toe guard detection on platform is activated platform LIFTS when one or more switches of the cable rupture detection is are activated Platform LOWERS when or more switches of the slack cable detection is are acti vated DH VO5 DHOLLANDIA Te 82 10 Hydraulic cylinders What to verify Execute service or repair if required EX LI All cylinders e General condition e Hydraulic system is free from leaks both during operation amp at rest e Fixation amp locking of all articulation LI Electrical safety valves e General condition e Function amp operation of the manual emergency button e Clearance to the bumper mounting plates and other fixed parts Condition of the electrical cable to the power pack LI Tilt cylinders on HTL with hydraulical closure e Condition of the springs used for function OPEN Remark DHOLLANDIA m 2 11 Lift frame What to verify Execute service or repair if required LI Frame construction e General condition condition of the welds LI Toe guard at end of loading floor and or front edge of platform e Check for cracks amp deformation straightness of the columns e Corrosion Lift columns lift runners e General condition check for cracks amp
101. on 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 The expert competent person should read and use the content of this user s manual of the technical documentation of the tail lift and all other information required to execute the various inspections in a professional way The expert competent person should perform all inspections with due diligence fill out all points of the relevant inspection certificates and sign 82 5 Initiative to organise inspections The initiative to choose an expert and organise the inspections described above lies with the owner of the vehicle or fleet operator 3 VALIDATION OF THE MANUFACTURER S WARRANTY e The safety reliability and durability of any tail lift and its components depends on the qual ity of
102. ons 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 C7 INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION L SPECIAL INSPECTION RE INSPECTION Date of inspection Evaluation the tail lift is safe and suitable for further use The tail lift identified in the Declaration of Conformity has been inspected on its O 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 INSPECTION CERTIFICATE for 1 PERIODIC INSPECTION L SPECIAL INSPECTION RE INSPECTION Date of inspection Evaluation the tail lift is safe and suitab
103. ount the braking valves on the cylinders and in the power pack to verify if they work ok Verity if the LSD is engaged Check the steel cables or chains pulleys and sprockets for mechanical damage and re pair Clear all debris from the lift columns clean them with high pressure steam cleaner and apply grease Finally verify the lift cylinder s themselves for any mechanical damage DHOLLANDIA m 6 7 b DH VO5 the platform doesn t LOWER the other functions work ok Only for the lift type DH VO5 Visually check the slack cable detection switches on the fixed steel lift columns left amp right If one of them is activated e Lift runners and platform are jammed in the lift columns the lift runners and platform are mechanically blocked in the lift columns Search for the cause of the block and repair e Defect in the detection circuit for the slack cables clean the 2 column sets by means of a high pressure cleaner and grease again LOWER by means of the regular con Reason the power of the electrovalve for LOWER run over 2 detection switches mounted trols serially on the fixed steel lift columns left amp right Their purpose is to prevent the lift cables to go slack if the function LOWER would be activated and the platform lift runners would be If the detection switches are not visibly activated but the platform lowers when you push the emergency push button jammed mechanically in the lift columns by deformation di
104. peration J1 LI Battery switch the exterior control box of the HTL LI Safety switch in the exterior control box Remark _ DHOLLANDIA e General condition e Function amp operation automatic return to the neutral O position all switches B8 W52 Ji 82 6 Electrical control devices What to verify Execute service or repair if required L Exterior control box e General condition LI Joy stick push buttons rotary switches e Function amp operation L Protection rubbers on the buttons amp switches e Automatic return to the neutral 0 position all switches LI Lid over the control box e Conditions of electrical cables wires and protection rubbers O Position of the exterior control box e Conformity with the fitting instructions between 300 amp 600mm from centre line of the control box to the rear side of the vehicle body LI 15A fuse in the exterior control box e General condition LI Electrical contacts in the various control units e Moisture inside the control unit amp corrosion e Fixation amp tightening of all cable amp wire connections LI Foot controls optional e See points above e Condition routing amp guidance of the electrical cables from the platform over the lift runners to the connection point in the power pack or exterior control box O Safety issues on foot controls e Connection to the safety button in the exterior control box see fitting instructions e Compulsory 2 f
105. platform might have been closed with the help of external devices forklift gantry crane and that the platform might drop in free fall to the open position after disengaging the travel lock Don t attempt to control the opening speed of the platform just by human force The platform might be very heavy possibly more than 100kg to handle Therefore always stand to one side of the lift when opening the platform and always keep your head hands and limbs clear of the moving platform or other moving parts of the lift DHOLLANDIA E 5 3 Danger zones risk of crushing amp sheerin Correct operator position HHA Danger zone e The operator should maintain a clear visual control over the platform the operation radius of the platform and the load on the platform at all times e The operator should stay out of the operation radius of the platform and stay clear of the moving parts at all times Beware at all times for potential risks of crushing or sheering fingers hands limbs feet or toes between the moving parts of the lift arms hydraulic cylinders and the moving platform A e Stay out of the operation radius of the platform e Keep clear of moving parts e Beware of hand foot and head traps at all times e 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
106. rder 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 e For the revision of the tilt cylinders with internal spring make sure this spring is without tension before opening up the cylinder Consult the spare parts list to check the cylinder construction Negligence may lead to serious injury e Before opening any hydraulic cylinder make sure that you manually open the safety valve via the manual emergency operation and you remove the hydraulic pressure from the system see Fig 1 10 e 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 e into account that after a repair the cylinders are filled with air and that the piston rods will move with shocks when the cylinder is filled with oil Therefore when remounting 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 pulley blocks or frame see Fig 1 11 DH
107. re damage to the tail lift It is forbidden to let the platform float and use a second articulated link bridge be tween its point and the loading dock see Fig 5 36 When loading unloading the platform point should always overlap a rigid underground over a minimum of 150mm see Fig 5 34 5 35 It is forbidden to use a folding platform as bridge plate In order to prevent damage the platform should always be closed in its travel position prior to driving away from the loading dock DHOLLANDIA Y 5 9 Importance of good maintenance operate correctly and that no urgent maintenance or damage repair is required If any unsafe condition exists or unusual noises or movements are noticed DO NOT use the lift and contact an authorised DHOLLANDIA service agent for repair e Prior to use inspect the tail lift to ensure that all safety systems and all functions e Missing worn or illegible warning decals must be immediately replaced e Competent and regular maintenance is very important for the operational reliability and the safety of the operator and occasional by standers in traffic e All maintenance and repair works should be executed by authorised DHOLLANDIA service agents and using original spare parts only DHOLLANDIA n 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 pla
108. re the lift away and close the doors of the vehicle Dont move the vehicle with the lift in open position Stow the lift away and close the doors of the vehicle before moving position Never move the vehicle while a person Stands on the platform or inside the vehicle body e The lift should not be used if the operator is intoxicated or impaired in any way e Use extreme care in wet or slippery conditions e The tail lift should be used by means of original control units only DHOLLANDIA dis claims liability for any personal injury or property damage that results from operating a product that has been modified from the original design e n 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 4 Remark for column lifts with manual closure These platforms are often equipped with invisible torsion bars reinforcing the manual open close movement As a consequence depending on the setting of this torsion bar the platform might start to open close by itself from the mo ment that the corresponding lock is released These torsion springs incorporate a significant amount of energy and po tentially dangerous Incorrect installation use or adjustment servicing may result in serious injury of the operator or service personnel Bear in mind that in case of mechanical failure the
109. rm in work position on the ground The correct oil level reaches to the MAX mark on the oil reservoir e Change oil amp clean filler To remove all the oil lift the rear of the vehicle off the ground so that the lift amp tilt cylin ders can contract fully and no oil remains in the cylinders LI Hydraulic functions e Hydraulic system is free from leaks during execution of all functions 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 Tilt the platform back up to horizontal position and LOWER the platform completely further down below normal ground level until the lift cylinders are fully retracted and continue to push the function LOWER for another 20 sec See Fig 2 2 7 and after each replacement of hydraulic pipes or revision of hydraulic cylinders LI Starter solenoid electric motor e General condition correct amperage LI Electrical connection block in the power pack e Corrosion burn marks sparkles LI Control valves on the logical valve block e Fixation amp tightening of all cable amp wire connections LI Pressure relief valve e General condition e Verify the maximum oil pressure in function of the nominal capacity of the HTL and adjust if required HTL lifts too little or too much weight Max
110. rt the power pack the function LOWER possible causes are gt defect in the earth circuit of the electrovalve D for LOWER on the lift cylinder in the cylinder beam running over the 2 slack cable detection switches to the earth gt Defect in one of the slack cable switches Check the condition and function of both switches incl their wiring Don t use the emergency switch when the switches are visibly activated and the platform is physically blocked Disregard can potentially lead to damage and hazardous situations 6 8 The platform doesn t OPEN the other functions work ok for HTL with hydraulical OPEN CLOSE e The button switch or electric contact are faulty or the connection to one of the contacts is Verify if the travel lock is open loose 6 The incoming or outgoing connection to the electrical distribution block in the power pack is Verify if the electrical operation of the safety valves O 5 needed to OPEN on cylinders or in power pack is ok faulty e with a magnetic tester a solenoid generates a magnetic field when it is electrically activated e The electric cable to one of the safety valves or S needed to OPEN is interrupted or has e or open the safety valves manually via the emergency operation if the valves are opened manually and the platform a bad contact OPENS the cause is electrical for sure 6 One of the solenoids or 5 needed to OPEN is defective or the cartr
111. s at normal speed but the platform doesn t move The switch on the toe guard flap at the front edge of the platform is activated interrupting the circuit of electrovalve H for function LIFT Insufficient quantity of oil in the reservoir The hydraulic pump sucks air The oil filter between the reservoir and pump is clogged up dirt or ice formation The drive shaft between the electric motor and the hydraulic pump is broken The hydraulic pump is completely worn out The seals of the cylinder s are heavily damaged or torn off by incorrect manipulation _ DHOLLANDIA The power to valve H for function LIFT runs over the switch under the toe guard flap on the platform Ensure that the toe guard flap is not pressed down and try again to LIFT If no push the emergency button in the power pack function LIFT If the platform now starts to lift possible causes are defect or short circuit in the wiring circuit for the toe guard switch defect of the toe guard switch itself 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 Dismount 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 th
112. s 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 instructions are of pri
113. see Chapter 5 J1 LI Slack cable detection for DH VO5 e General condition function amp operation of the switches J1 LI Mounting plates fixation to the vehicle body e General condition check for cracks amp deformation M3 LI Mounting plates of the bumper bar e Presence condition amp correct tightening of all mounting bolts J1 Remark DHOLLANDIA 2 12 Platform What to verify Execute service or repair if required Freq LI Platform construction e General condition condition of the welds M3 e Check for cracks amp deformation J1 e Corrosion LI Articulation points e General condition check for cracks deformation elliptic deformation M3 LI Articulation pins e Locking of the articulation pins by locking pins bolts amp nuts J1 e Presence of grease nipples correct and regular greasing LI Load restraints roll stops hinged ramps e General condition function amp operation M3 Platform lights flags traffic cones e Condition routing amp guidance of the electrical cables from the platform over the lift arms to the J1 LI Foot controls connection point in the power pack or exterior control box LI Travel lock amp platform retaining catch O Visibility of the platform in public traffic e The platform is clearly visible in surrounding traffic from all approachable angles STE W52 M3 J1 W52 M3 J1 LI Torsion bar s in the platform HTL with manual OPEN CLOSE e General condition function
114. ss some steps in the check list require special skills and specific knowledge see DHOLLANDIA Repair amp Maintenance training program In case of doubt on how to proceed DON T go any further but ask your local DHOLLANDIA distributor for professional advice e he 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 e Remark When checking on the correct tightening of the bolts the only accurate tool to use creaking grinding or shrieking noise should be carefully investigated to avoid dam is a torque wrench The following values are prescribed age Prescribed tightening moment M N m e maintenance frequency depends on the intensity and conditions of use mini Type of thread otrength class mum frequency for the various works is given below 100001088 109 W52 52 xl year weekly check by owner operator 12 12x year monthly by the owner operator or service agent O X 1 20 3x year 4 monthly check by a qualified DHOLLANDIA service agent J1 1x year yearly winter maintenance to be executed just before the winter so that any condensation water in the hydraulic circuit can be removed during the oil change and frost problems during the winter can be avoided Livy e HTL are subject to compulsory periodic inspections by an expert competent person see
115. strictly followed e Working principle Safety device Effect upon activation of the safety device Effect of pushing the emergency button Switch on the under side of the toe guard flap at the The power circuit of electrovalve H for the function LIFT is The electrovalve for the function receives direct front edge of the platform interrupted The platform doesn t LIFT any more current from the emergency button The platform can LIFT but the toe guard protection is inactive Cable rupture switches on the HTL with double cable The earth circuit of the starter solenoid is interrupted The The starter solenoid is directly earthed over the emer system normally 2 mounted serially Platform doesn t LIFT any more gency button The electric motor can run again the plat form can LIFT and CLOSE in order to stow it in its travel position DH VO5 slack cable switches on the lift columns 2 The power circuit of electrovalve D for LOWER is inter The electrovalve D for the function LOWER receives direct mounted serially rupted The platform doesn t LOWER any more current from the emergency button The platform can LOWER but the slack cable protection is inactive _ DHOLLANDIA B34 58 6 Course of action 9 ELECTRICAL amp HYDRAULIC WIRING DIAGRAMS e The table below shows which courses of action can be taken in case of a breakdown e The following pages contain the main wiring diagrams for DHOLLANDIA tail
116. t the load would roll or fall over him or hit him See Fig 5 29 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 87 10 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 A22 5 7 Other important user s info e Exterior lifts are equipped with a set of platform hooks preventing the platform from fal ling open and a set of locking pins through the lift columns preventing the platform from lowering in case of accidental pressure loss See also Fig 4 2 in Pt 4 The operator should ensure that this mechanical travel lock is released when putting the tail lift in use and re installed when putting it out of service See Fig 5 30 e Interior lifts are equipped with a set of locking pins through the lift columns only or equivalent system made by the installer of the lift In order to protect the lift ing mechanism against overload and premature failure it is very important that the platform and its weight don t put any stress on the suspension system steel cables or chains pulleys sprockets Therefore Before driving off mount the locking pins through the lift columns and LOWER the platform onto them to remove the stress from th
117. tform The nominal capacity is valid at a certain distance or centre of gravity behind the vehicle body Behind that point that is marked on the platform the maximum safe working load diminishes according to the load diagrams below e When LIFTING the tail lift is normally protected against overload by the pressure relieve valve in the hydraulic circuit Most of the overload and consequential damage happens when LOWERING loads e The nominal capacity NC is the maximum weight that the tail lift should carry under the best possible circumstances the centre of gravity of the load stands no further than the nominated centre of gravity of the tail lift marked on the platform surface always place the load as close as possi ble to the rear side of vehicle and the load stands centrally between the lift columns this is at equal distance from both platform sides 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 A26 NOT OK load positioned too close to the platform point NOT OK load positioned too far off centre SWL 50 of NC OK load positioned as close as possible to the rear of the vehicle OK load positioned centrally be tween the lift columns e Be aware that the centre of grav
118. that point that is marked on the platform the maximum safe working load diminishes according to the load diagrams see also Point 6 e All column lift platforms must be protected from falling in case of accidental failure of the suspension system steel rope or chain sprocket pulley etc This protection can be 4 9 Double cable system cable rupture detection suspension system with 2 Steel lift cables plus 2 safety cables When one of steel lift cables breaks the platform is caught by the safety cable and a cable rupture detection activated From this mo ment onwards the platform can only be lowered to offload any goods on the platform An emergency button allows to LIFT and CLOSE the platform in order to stow it into it s travel position and drive to a professional service agent see Chapter 4 10 Load safety device LSD suspension system with 1 steel cable or chain and a mechincal spring activated safety device mounted to each of the lift runners In the unlikely event of a steel rope or chain breaking the LSD will jam the lift runner and the platform in the lift column preventing the platform to drop more than 100mm from its position at the time of the failure see Chapter B DHOLLANDIA e Fig 4 11 Safety rails safety rails should be fitted and used in applications where significant risk exists that the operator could be injured when falling off the platform UK Work at Heights Reg
119. tted according to the Fitting Instructions of DHO and the Body and Equipment Building Instructions of the manufacturer of the CV e A weight test and commissioning certificate with positive result e copy of the last inspection certificate relating the yearly inspection TUV inspec tion special inspection or repeated inspection e Acopy of the last maintenance and repair report as mentioned in the User s Manual 8 3 7 The final decision if a warranty claim is accepted and reimbursed by lies with DHO alone 8 3 8 The right of DHO to have specific warranty works carried out in specific workshops ap pointed by it doesn t entitle the user of the HTL in case of repetition or with another HTL under warranty to have works carried out in 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 ha
120. ulation 2005 and are compulsory above 2m lifting height Safety rails are available in a wide range of executions to suit the particular needs of the opera tor see examples Fig 4 11 DHOLLANDIA safety rails are available with integrated LIFT LOWER controls see Fig 4 12 e Fig 4 13 4 button foot controls mounted to the platform option 782 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 5 5 e Fig 4 14 Protection of toes feet amp limbs safety solutions are adopted to Prevent that the operator standing on the front edge of the platform would crush or sheer his toes feet amp limbs between the lifting platform and the underside of one of the vehicle floors Prevent that the operator standing on the rear edge of one of the loading floors would crush or sheer his toes feet amp limbs between the lowering platform and the top side of this vehicle floor One of the methods shown under 4 14 is adopted in most cases 4 14 Toe guard flap with detection when the operator puts his weight on this flap at the front edge of the platform the LIFT function is stopped 4 14 0 double toe guard flaps on platform and vehicle floor when
121. uld not be altered while the bar is under torsion 1 0j Br A l l l l l AN M lt 2 In case of doubt on any of the subjects this chapter stop immediately and ask Y advice from DHOLLANDIA prior to continuing DHOLLANDIA B3 81 2 Hydraulic components e n 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 Fig 1 9 Tilt cylinder with internal sprin e Dismounting of hydraulic cylinders general release the oil pressure in the hydraulic circuit by pushing the control switches for LOWER for revision of the lift cylinders or OPEN for revision of the tilt cylinders for approx 20 sec Only when the oil pressure is open close released is it allowed to remove the corresponding articulation pins Dismounting of hydraulic TILT cylinders take into account that the some tilt cylinders are equipped with strong internal springs see Fig 1 9 generating a strong pull force on the articulation pins when the platform stands in its closed position Consult the spare parts list to check the cylinder construction e n o
122. ulgaria Sofia 359 2 870 42 76 Saudi Arabia Alaa Industrial Equipment Damman 966 1448 4482 Czech Republic Dhollandia Czech Republic Troubsko 420 545 232 603 Slovakia Dhollandia CE Predmier 421 41 500 10 80 Dhollandia branch IKJ 45 45 70 0201 South Africa Grenco Capetown 27 21 555 90 00 E Dhollandia branch Helsinki 358 45 26 90077 Spain Dhollandia Spain Madrid 34 91 877 16 50 Dhollandia France 33 134 11 74 00 Reder System Barcelona 34 937 18 09 94 Free service 33 825 042 966 51 606 Dhollandia Sweden Alvesta 46 8 594 63 400 Germany Dhollandia Germany Hamburg 49 40 76 11 96 0 Switzerland Dhollandia Vertretung M llheim 41 52 762 77 00 Great Britain
123. us Repeat the same test on the other side of the platform on the other set of steel cables 6 ORDERING SPARE PARTS e The following information must be confirmed when ordering spare parts year of construction amp serial number of the tail lift Spare parts reference consult the spare parts lists The desired quantity of each item Your administrative data company name invoice address VAT number purchase order number delivery address and expected delivery time e The type year of construction amp serial number of the tail lift can be found on the identifica tion stickers see point 2 in Chapter DHOLLANDIA 7 FAULT FINDING amp REPAIR 7 1 Summary activation of electrical solenoids per tail lift function e Incase of a malfunction the operator can verify a number of points himself before calling Scheme MECH E HYDR MECH X an approved DHOLLANDIA service agent MECH SA Hydraulical mixed system Is the isolator switch for the tail lift called HTL hereafter in the vehicle cabin switched MECH Single Acting on Are the main power plugs between the tractor unit and the trailer properly con nected Is the battery switch in the exterior control box switched on 15 the main fuse for the HTL near the vehicle batteries still functional LOWER 0 Y 15 the connection of the HTL to the vehicle batteries ok Are the batteries auxiliary batteries too
124. used with auxiliary controls featuring the functions LOWER only 4 button foot controls 2 button wander leads 2 button fixed interior controls The use of 3 or 4 button auxiliary controls including TILT results in confusion and errors It might cause damage to the tail lift and injuries to the operator or third parties near by DHOLLANDIA ve 8 WARRANTY CONDITIONS 8 1 Abbreviations DHO DHOLLANDIA or her official national agent distributor HTL Hydraulic tail lift CV Commercial vehicle 8 2 Period 8 2 1 The warranty period lasts 12 months from the day that the HTL is taken into operation for the first time This point in time is determined by the date of the weight test and commis sioning of the HTL prescribed by and conform with the CE Machine Directive and the fitting instructions of DHO without exceeding however 3 months after the delivery date of the HTL concerned For this purpose the results of the weight test and commissioning must be duly reported and inscribed in the Fitting Declaration in the User s Manual issued with every HTL 8 2 2 The initial warranty period is not modified or influenced by occurring service repair or improvement works or by the replacement of failing parts 8 3 Conditions 8 3 1 In case of a warranty claim DHO has the right to examine the defect or failure or to have it examined For this purpose the supplied object if mounted to a wheeled
125. valves and where they are fitted Verify if the ring of the cartridge is damaged or the valve is stuck in open position by dirty or ice control valves in the power pack are single acting or double acting e The seal on the piston of the tilt cylinder s is are leaking e HTL with hydraulic tilt at ground level the seal of the hydraulic memory cylinder is leaking For most types of HTL multiple valve system there must be a combination of different defects if the platform falls open spontaneously safety valve leaking on one cylinder and the cylinder seal leaking on the other or the safety valves on both cylinders leaking and the control valve in the power pack leaking A single malfunction wouldn t be enough if the hydraulic circuit counts more than 1 safety valve Verify if the manual emergency operation on the electro valves is firmly closed Test and verify if the tilt cylinders and hydraulic memory are not leaking internally See RMT 6b Revise the cylinders if required Flush purge the cartridge of the safety valves on the tilt cylinders and if applicable the control valve in the power pack see RMT HB5 revise replace O rings or replace the part DHOLLANDIA m 8 EMERGENCY OPERATION 8 1 Introduction and safety instructions e 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
126. ve been returned and the warranty claim has been positively recognized the invoice is credited 0 3 12 Except in case of different contractual agreement the warranty is always limited to the free replacement of the failing parts Labour and mileage costs relating to a roadside repair are only reimbursed if the CV is physically blocked due to the nature of the tail lift failure and according to the agreed labour rates and standard or agreed repair times See document C GAR 02 EN In case of different contractual agreement whereby full warranty is guaranteed the labour cost is only taken into consideration at the standard repair times prescribed by DHO which represent an average time required to repair specific problems by trained tail lift technicians and at the standard hourly labour rates foreseen in the DHO network 56 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 servicea
127. vehicle must be presented at the DHO workshop or any other workshop appointed by DHO to this respect The same is also valid for the warranty repair works themselves 8 3 2 Warranty can only be attributed to HTL which are maintained in the original delivery condition and specification Modifications to the construction or safety devices of Dhollandia HTL are strictly forbidden except in case of explicit prior written approval by DHO 8 3 3 Defects failures deficiencies in general that restrict the utility of the HTL due to faulty design construction material deficiencies or failing manufacture are solved by rectifying works or by substitution replacement and this at the discretion of DHO _ DHOLLANDIA A42 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 fi
128. weak open BS 0S Has the mechanical platform lock been released EP 52 MTS LE this has been verified and an approved service agent intervenes to repair the HTL it is very important that the fault analysis is executed in a logical and systematic way Too often components are replaced at random until the malfunction disappears Such method All valves D S U H S DA S DA is very expensive however on labour hours and spare parts cost IS US SA B I U IS US SA H D U IS US SA Therefore it is very important to identify quickly and precisely if a malfunction has an SA single acting electrovalve electrical a hydraulic or a mechanical cause DA double acting electrovalve For instance when a HTL doesn t LOWER it can be that R starter solenoid of the electric motor The coil s of control valve in the power pack or one of the safety valves D on the H control valve LIFT in the power pack lift cylinders receive no current electrical fault D safety valve LOWER on the lift cylinders one of the cartridges of the safety valves D on the lift cylinders has been hit and bent 5 control valve CLOSE in the power pack by a projecting stone or that one of the braking valves on the cylinders is blocked sca u hydraulic fault 2 2 ECCE on the 2 leg one of the piston rods of the lift cylinders is bent by overload or accident 2 mechani redes
129. x 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 24 5 25 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 25 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 26 Never step or climb on a load Prior to putting load on the platform its angle should be inclined a few degrees upwards to compensate for the compression of the vehicle suspension and the minimal play in the articulations of the lift Doing so the platform will find itself in a perfect horizontal position after placing the load onto it Never adjust the angle of the platform when it is loaded Do so only when the platform is empty see Fig 5 27 For lifts with conical platform always use the automatic tilt at ground level See 7 11 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 125 of the nominal capacity of the tail lift see Fig 5 28 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 tha
130. y that all articulation points get a grease collar on both sides of the bearing or articulation protect ing it against ingress of water salt sand or dirt e Ensure all grease nipples function correctly and replace any defective nipples For articu lations that cannot be greased even after replacing the grease nipple the articulation pin must be dismounted and polished and its grease channel must be cleaned As ultimate solution the articulation pin must be renewed e Always use acid free grease The use of graphite grease is not allowed e Verify if the platform lock and or platform retaining catch operate smoothly and lubricate with oil if necessary e he various types of HTL should be greased according to the grease plans in Fig 3 1 and following In case of special tail lifts deviating from these images contact DHOLLANDIA to obtain further instructions DHOLLANDIA Fig 3 2 DH VB VO VX VO5 double cable system Fig 3 3 Lifts with chains Fig 3 4 Lifts with single cable sol M fO IO morirme oa OF OF i d Ine a S e SSS tos ose i TL hOU IC FE IRE 9 e H P RS E M M OQ 1L DHOLLANDIA 4 TESTING THE CABLE CHAIN RUPTURE DEVICE Fig 4 1 chains Fig 4 2 steel cables e The column li

multi-deck column lifts user`s manual maintenance

Contents

Download Pdf Manuals

Related Search

Related Contents