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Summary of Contents for DEL DL500G MK5
- Page 1 INSTALLATION MANUAL COLUMN TAILIFTS...
- Page 2 Email: sales@del-uk.com Website : del-uk.com EC Declaration of conformity for machinery We hereby declare that: DEL Column Tailift Models: DL, DO, FC, S, TL are in conformity with the provisions of the Machinery Directive (2006/42/EC) and the EMC Directive (2014/30/EU) and furthermore declare that parts of the following European harmonised standards ...
- Page 3 Invalidate the warranty Lead to equipment failure Create a hazard that is not immediately obvious at the time of installation. If you are unsure about any aspect of the installation procedure please contact DEL service. IMPORTANT This manual forms part of the Inspection record for the tailift, and should be passed on to the end user, together with the operators manual.
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Page 4: Table Of Contents
Hiab UK Ltd Installation Manual - Column Tail lifts CONTENTS Installation procedure.……………………………….…….….……….… 5 Location of control positions.………………………….….…….…...14 In-line fuses and the earth cable.…………………….….…….………….16 Tail lift mounting and bracing…...……………………….……………..… 18 Load Safety Device ( LSD )………………………….……...…………… 22 Power pack relief valve……………………………….……….…….……. 23 Chain adjustment…………………………………….……….…….……... -
Page 5: Installation Procedure
Hiab UK Ltd Installation Manual - Column Tail lifts 1. INSTALLATION PROCEDURE The following procedure covers a standard bolt-on installation, if the lift is to be welded to the vehicle body, please refer to the welding notes ( Page 9 ) Special precautions When fitting the tail lift, a minimum horizontal gap of 78mm is required between the mov- ing parts of the platform and the fixed parts of the vehicle, except at those points where... - Page 6 Hiab UK Ltd Installation Manual - Column Tail lifts COLUMN LIFT INSTALLATION PROCEDURE 1. Disconnect Battery ( Check it is fully charged ) and ensure the mounting area of the body is free of fixing heads and other protruding objects before fitting the lift. 2.
- Page 7 Hiab UK Ltd Installation Manual - Column Tail lifts Drill suitable clearance holes into the vehicle frame to correspond with the countersunk holes which are pre-drilled in the lift columns. Using the countersunk bolts provided, bolt the lift to the vehicle frame ensuring that the nut is tightened to the torque specified in the technical section ( Page 11, M8 ).
- Page 8 (see section 8). Also fit the supplied caps to the top of each column. 25. Complete the final inspection checklist. 26. Complete the test certificate and forward a copy to DEL. 27. Ensure that the installation and operators handbooks are passed on to the end user of the lift.
- Page 9 Hiab UK Ltd Installation Manual - Column Tail lifts WELD-ON LIFTS IMPORTANT When welding ensure: - The vehicle’s battery is fully charged and disconnected before work commences. A good earth is achieved by clamping the earth cable onto the lift columns, but NEV- ...
- Page 10 Hiab UK Ltd Installation Manual - Column Tail lifts FULL CLOSURE LIFT INSTALLATION PROCEDURE Safety chain angles for lifting and installation NOTE For correct lifting and installation of the FC500 lift, use both eyebolts and do not exceed a maximum chain angle of 30 deg. Remove eyebolts after completing the installation of the lift.
- Page 11 Hiab UK Ltd Installation Manual - Column Tail lifts 1. Disconnect Battery ( Check it is fully charged ) and ensure the mounting area of the body is free of fixing heads and other protruding objects before fitting the lift. 2.
- Page 12 Hiab UK Ltd Installation Manual - Column Tail lifts Use the ’’V shape’’ line to position the holes (20 mm from the edge). A minimum of 7 holes (per side) equally distributed should be drilled to attach the lift to the vehicle frame.
- Page 13 18. Check and adjust if needed the fully raised position of the platform. The DEL design of tailift differs from all other lifts in operation and the floor level adjustment is critical to the safe working and life of the lift.
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Page 14: Location Of Control Positions
Hiab UK Ltd Installation Manual - Column Tail lifts 2. LOCATION OF CONTROL POSITIONS Please refer to the instructions for electrical installation regarding ancillary equipment from your supplier. Install control units at suitable places, but the position of the controls unit should ensure that the operator has a good view of the load, the working area and the loading area, whilst maintaining a safe distance from the risk zone between the platform, the body and passing traffic. - Page 15 Hiab UK Ltd Installation Manual - Column Tail lifts 12T BOX/CURTAIN SIDE BODY Position the 3 button hand control inside the vehicle with the cable exiting downwards and using the supplied Cover. Attach the 2 button cover outside and mount the control again with the cable facing downward.
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Page 16: In-Line Fuses And The Earth Cable
Hiab UK Ltd Installation Manual - Column Tail lifts 3. INSTALLATION OF IN-LINE FUSE & EARTH The following instructions cover lifts fitted with an insulated earth cable, which cover all of the 24v systems supplied and some of the 12v systems. For 12v systems not fitted with an insulated earth cable i.e. - Page 17 In line Fuse Direct connection to batteries can be made on most vehicles. If in doubt please contact Del. CCP connected vehicles will need a 3-way power lead adapter. Supplied with CCP spec lifts. Route main battery cable from tailift to the battery along the chassis avoiding the exhaust, fuel pipes and sharp edges.
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Page 18: Tail Lift Mounting And Bracing
Both upper and lower bracing is required when mounting a lift to a dropside body vehicle. The body should be built with a box section rear frame, braced above and below bed as shown below. Specialized bracing kits are also available for certain body manufacturers, See Del Sales. Hiab.com/en-gb/our-brands/del & N... - Page 19 Hiab UK Ltd Installation Manual - Column Tail lifts Determine the best hole pattern of 2 Rows x 3 holes to suit the chassis. IMPORTANT - Ensure that that the required hole pattern conforms to the tailifts R58-03 Approval by either sending the ‘x’, ‘y’...
- Page 20 Hiab UK Ltd Installation Manual - Column Tail lifts BOX BODY (1500kg LIFTS) DROPSIDE BODY In addition to the mid-bracing, upper bracing is also required when mounting a lift to a dropside body vehicle. The body should be built with a box section rear frame, braced above bed as shown below.
- Page 21 IMPORTANT Please refer to page 9 for precautions to take when welding. HYDRAULIC BODY LOCK If a tipper lift is supplied with a Hydraulic Body Lock, please contact DEL Sales for installation instructions (ref. Part No. 61317) Issue S...
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Page 22: Load Safety Device ( Lsd )
Installation Manual - Column Tail lifts 5. LOAD SAFETY DEVICE ( LSD ) DEL Tailifts are fitted with a chain failure LSD. During transit and installation of the lift, the LSD is disengaged to prevent accidental operation. TO ACTIVATE THE LSD Lower the platform to within 300mm of the ground. -
Page 23: Power Pack Relief Valve
Hiab UK Ltd Installation Manual - Column Tail lifts 6. POWER PACK RELIEF VALVE & GAUGE PORT Identify gauge port on power pack and connect pressure test gauge suitable for pressure range. If gauge port is not present one can be created using a tee adaptor. Turn the relief valve CLOCKWISE to INCREASE the load. -
Page 24: Chain Adjustment
Hiab UK Ltd Installation Manual - Column Tail lifts 7. CHAIN ADJUSTMENT 1. With the platform in the stowed position, Remove the main housing cover ( Toe Using mole-grips, clamp Guard ). adjuster to stop twisting 2. Using the hand control, lower the plat- form to a suitable position and Open the during adjustment, platform. -
Page 25: Location Of Warning Decals
Hiab UK Ltd Installation Manual - Column Tail lifts 8. LOCATION OF WARNING DECALS A) TAILIFT OPERATION B) CAUTION C) WARNING D) MAX LOAD E) MAINTENANCE F) TAILIFT ISOLATION FULL SURROUND GUARD OPERATION SELF ERECT GUARD OPERATION (WHERE APPLICABLE) Issue S... - Page 26 Hiab UK Ltd Installation Manual - Column Tail lifts G) STOW INDICATOR (ON H) ISOLATION J - FLAGS DASHBOARD) IF FITTED (ON DASHBOARD) TEL. 01993 708811 Pt No 54215 M) WARNING - KE EP K) ISOLATE POWER SUPPLY L) KEEP FEET CLEAR HANDS CLEAR LIFT OPERATION DECAL POSITIONS, DUMPOVER LIFTS Affix the ‘TAILIFT OPERATION, and ‘HOLD HERE TO OPEN &...
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Page 27: Tests After Installation
Do not leave a loaded platform unattended IMPORTANT – CE REGULATIONS REQUIRE THE TEST CERTIFICATE TO BE COMPLETED AND RETURNED TO DEL ( Hiab UK Ltd ) The Zinc Building, Ventura Park, Carterton, OX18 1AD. The lift shown for illustration purposes is the DL500. The same tests apply to all other column lift models. - Page 28 1750mm. This value translates to the vertical dotted line indicating a maximum difference between A’ and B’ of 61mm. If the difference between the measurements is greater than that shown by the graph, contact DEL After Sales for advice. Issue S...
- Page 29 Hiab UK Ltd Installation Manual - Column Tail lifts ALLOWABLE DIFFERENCE BETWEEN MEASUREMENTS 2750 2500 2250 2000 1750 1500 1250 1000 DIFFERENCE BETWEEN MEASUREMENTS (MM) Initial Measure- After 15 minutes Difference between ment Measurements A’ A’ & B’ B’ A’ & C’ C’...
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Page 30: Test Checklist
Hiab UK Ltd Installation Manual - Column Tail lifts 4) SAFETY FUNCTION TESTS A) Platform Raise and Lower Speed With the SAFE WORKING LOAD ONLY on the platform measure the time taken for the platform to lower from bed height to the ground. With No Load on the platform, measure the time taken for the platform to raise ... -
Page 31: Technical Information
Hiab UK Ltd Installation Manual - Column Tail lifts 11. TECHNICAL INFORMATION TORQUE SETTINGS – TIGHTENING TORQUES (N/M) GRADE 8.8 GRADE 10.9 G 1/4 G 3/8 HYDRAULIC FLUID Automatic Transmission Fluid – Viscosity - 39 Centi-strokes at 40°C 7.5 Centi-strokes at 100°C Type ‘A’... - Page 32 Hiab UK Ltd Installation Manual - Column Tail lifts Installed weights. Approx Installed Weight Lift Type Model of Lift (Standard Spec) Column DL500G MK5 135KG DL500FG 140KG DL500GP 150KG DL500GRP 135KG FC500 195KG* TL750 260KG TL1000G 260KG S1000G 295KG S1500G MK5...
- Page 33 Hiab UK Ltd Installation Manual - Column Tail lifts CENTRE OF GRAVITY – The centre of gravity of a column tailift lies at approximately 0.2 times the distance from the back of the lift columns to the front edge of the platform and halfway between the lift columns.
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Page 34: Final Inspection Checklist
CAUTION: Do not use the tailift if any of the items be- low are not checked and verified. If you have any ques- tions contact DEL sales. Failure to verify the following could result in severe damage to the tailift or personal injury. -
Page 35: Lift Test Certificate
Hiab UK Ltd Installation Manual - Column Tail lifts Hiab UK Ltd Cargotec Industrial Park, Lift Test Certificate Ellesmere SY12 9JW Tel. 01691 623100 DATE: ……………………….. EMAIL: sales@del-uk.com CUSTOMER NAME:……………………….… INSTALLER/TESTER NAME:……………………... ADDRESS…………………………………… ADDRESS: ………………………………………….. ……………………………………………… ………………………………………………………… ……………………………………………… ………………………………………………………… ………………………………………………... -
Page 36: Wiring And Hydraulic Diagrams
Hiab UK Ltd Installation Manual - Column Tail lifts Issue S... - Page 37 Hiab UK Ltd Installation Manual - Column Tail lifts Issue S...
- Page 38 Hiab UK Ltd Installation Manual - Column Tail lifts Issue S...
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Page 39: Electrical Cable Installation Notes
Hiab UK Ltd Installation Manual - Column Tail lifts 15. ELECTRICAL CABLE INSTALLATION NOTES Power Cable Bend radius A smaller bend radius than provided by the wire supplier will put extra stress on the installation as well as over time damage the internal copper strands. This will increase the electrical resistance and by that accelerate the turn of events that can lead up to that the wire breaks. - Page 40 Contact Us: Hiab UK Ltd Cargotec Industrial Park Ellesmere SY12 9JW Tel. 01691 623100 EMAIL: sales@del-uk.com Hiab.com...
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Questions and answers
My DL5000 is jamming. The whole lift goes up and down as it should but I cannot fold down or fold up the platform. An you suggest what the problem might be?
Hi, I **** looking for our operatives to complete a basic inspection of the tail lifter (Del 550kg) before use. Is there a competent persons checklist available?