DL -48

Operation/Maintenance
Edition 7/2010
Translation of the original operating instructions

DAUTEL GMBH
Lifting technology - Vehicle technology - Communal technology
Dieselstrasse 33 · D-74211 Leingarten · Telephone +49 (0)7131 407-0
Fax +49 (0)7131 407-107 Sales/Tech. · 407-104 Purch./Admin. · 407-333 Customer service
Internet: www.dautel.de · E-mail: [email protected]
 Table of
1. General Contents
information
DL -48 Operating Instructions

Page
1. General information 7
1.1 Introduction 7
1.2 Guarantee and liability 8
1.3 Copyright 9
1.4 Special instructions 9

2. Description 11
2.1 Specifications 11
2.2 Type plate / Technical data 13
2.3 Overview 14
2.4 Accessories and special equipment 14

3. Safety 15
3.1 Safety equipment 15
3.2 Accident prevention 15

4. Operation 21
4.1 Intended use 21
4.2 Operating personnel 21
4.3 Operating the tail-gate lift 21
4.3.1 Putting into operation 22
4.4 Load-bearing capacity and load distances 24
4.4.1 DL -48S load-bearing capacity diagram 24
4.4.2 DL -48L load-bearing capacity diagram 26
4.4.3 Two-handed operation of the external control unit 28
4.4.4 Two-footed operation on the platform 30
4.4.5 One-footed operation on the platform 31
4.4.6 Remote operation - general 32
4.4.7 Cable remote control 34
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 1. General
Table information
of Contents
DL -48 Operating Instructions

Page
4.4.8 Wireless remote control 34
4.5 Flatbed trailer or trailer with tail-gate lift 36
4.6 Other information to be observed during operation 36
4.7 Working with accessories 37
4.7.1 Supports - general 37
4.7.2 Single-acting drop-down protector, type A, F, V 38
4.7.3 Side drive-over plate 39
4.7.4 Hitch with ball head or jaw coupling 39
4.7.5 Rain-Lock with secondary control 40

5. Maintenance 41
5.1 General information - safety 41
5.2 Daily maintenance 42
5.2.1 Safety and warning equipment 42
5.3 Weekly maintenance 42
5.3.1 Cleaning 42
5.3.2 Lubricating bolt bearing points 43
5.3.3 Lubrication diagram 44
5.3.4 Battery check 45
5.3.5 Trailer charge cable and main current cable 45
5.3.6 Threaded suspension and bolt bearing points 45
5.3.7 Hitches 45
5.4 Monthly maintenance 45
5.4.1 Hydraulic system 45
5.4.2 Drive unit 47
5.4.3 Control unit 47
5.4.4 Locking, tightness of the cargo door closure,
tilt cylinder setting 47
5.4.5 Markings for operator standing area (only for remote operation) 47
5.5 Semi-annual maintenance 47
5.5.1 Operating speeds for CE variants 47
5.5.2 Electric motor 47
5.5.3 Platform connecting heads 47
5.6 Annual maintenance 48

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 Table of
1. General Contents
information
DL -48 Operating Instructions

Page
5.6.1 Annual inspection 48
5.6.2 Suspension (once a year) 48
5.6.3 Oil change in hydraulic tank 48
5.6.4 Bleeding the cylinders 49
5.6.5 Inspecting the bearing points 49
5.7 Before the cold season 49
5.8 At least once every 6 years 49

6. Fault clearance 50
6.1 Checks by the driver before calling on
the workshop 50
6.2 Emergency operation in the case of failure
of the tail-gate lift control unit 50
6.3 Control unit functional method 52
6.4 Notes for the workshop 52
6.5 Fault clearance 54

7. Disassembly and disposal 60

8. Service centres 60

9. Circuit diagrams 60

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 1. General information
DL -48 Operating Instructions

1. General information
1.1 Introduction The observance of the current safety
regulations and an awareness of
This manual is designed to enable
safety concerns must therefore also
you to thoroughly familiarise yourself
be a basic condition for operators
with the operation of the DAUTEL
entrusted with its operation.
tail-gate lift.
Modifications to the tail-gate lift sup-
So please read the manual carefully
plied by us are generally not permitted.
before commissioning the tail-gate
In exceptional cases modifications
lift.
may be authorised by us in writing
and tested by TÜV.
This manual describes the DAUTEL
Furthermore, we refer you to the "Accident
LIFTER -48 series.
prevention" and "Safety instructions" chap-
ters and the sections of the text identified
ATTENTION! by .
The specifications contained in It is important for the operator to know
these operating and maintenance how the tail-gate lift is correctly oper-
instructions are applicable to tail- ated and handled.
gate lift variants which comply with
the CE standard (for EU countries) A fault can often be traced back to
and tail-gate lift variants for the ex- incorrect maintenance or improper
port market (non-EU countries). operation.
Specifications and information Therefore, the manual should be kept
which only apply to export variants in the vehicle for quick access.
are identified as follows:
For replacement parts orders
- the type of tail-gate lift
= Does not comply
- the production/serial number
with the CE standard
- and the year of manufacture
must be indicated.

In the event that the tail-gate lift is This information is found on the type
operated by untrained personnel, plate on the control unit.
great danger can arise for both the The information can also be gathered
operator and nearby persons. from the master data list in the test-log
book.

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 1. General information
DL -48 Operating Instructions

Note the name of the replacement - Improper use of the tail-gate lift
parts according to the replacement - Overloading
parts manual. The replacement
parts manual can be obtained from - Failure to comply with the
us separately. specified max. weights and load
Repairs may only be made with distances
original replacement parts!
Please understand that we reserve - Improper assembly, commis-
the right to undertake changes to sioning, operation or mainte-
the scope of supply in terms of nance of the tail-gate lift
form, equipment and technology,
as well to correct errors, at any - Operating the tail-gate lift with
time. defective safety equipment or
incorrectly attached or non-
No claims may be derived from the functioning safety and protec-
information, drawings and descrip- tive equipment
tions given in these instructions.
- Failure to observe information
The data given in these instruc- in the operating instructions
tions are based on the technical pertaining to transport, stor-
status of 2010. age, assembly, commissioning,
operation and maintenance of
the tail-gate lift
1.2 Guarantee and
liability - Unauthorised modifications to
the structure of the tail-gate lift
Our "General terms and conditions
of sale and supply" and "War- - Inadequate monitoring of ma-
ranty conditions" are generally chine parts which are subject
applicable. to wear
Both can be found on our web-
site. - Improperly performed repairs
Guarantee claims and claims of
liability for damage to persons and - Failure to use safety-critical
property are excluded where the original replacement parts
cause can be traced back to one
or more of the following:

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 1. General information
DL -48 Operating Instructions

1.3 Copyright 1.4 Special instructions

Dautel retains the copyright for these Two types of instructions are used
operating instructions. in this manual to highlight important
information.
These operating instructions are only
intended for the operator and their CAUTION!
personnel. Contains information which must be
observed in order to protect people
They contain regulations and instruc- from injury.
tions which may not, either in full or
in part, be ATTENTION!
- copied Contains information that must be
- distributed or observed in order to prevent damage
- communicated in any other to the tail-gate lift or to the lorry.
manner.
The terms "driving position" and
Violations may result in prosecution. "transport position" are also used in
reference to the tail-gate lift.

Driving position
Position which the tail-gate lift must
be placed in while the vehicle is in
motion.

Operating position
Position of the tail-gate lift intended for
raising and lowering loads. Platform
is open and ready for use.

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 2. Description
1. General information
DL -48 Operating Instructions

2. Description
2.1 Specifications
The hoist gear's light yet robust Depending on the available space,
construction is executed from high- the complete drive unit including the
tensile materials. The large bearings control box is permanently installed on
are designed as low-wear permanent the support pipe as a side-mounted
bearings. unit or the drive unit can be housed
separately in another place.
The platform is constructed from steel
or aluminium, making it warp resistant The lift cylinders are single-acting
and slip-proof. hydraulic cylinders, and the tilt cylin-
ders double-acting. The piston rods
Platform movement options: are protected against rust and, de-
- Open/Close pending on the version, also against
- Raise/lower stone chips.
- Tilts down to the ground fully auto-
matically after the lowering proc- Electrically unlockable non-return
ess valves and a flow control valve to
- Automatic return to horizontal posi- act as a hose-rupture safety device
tion when raising are located in the bottom of the lift
- Tilts up or down to compensate for cylinders.
the incline when working on gradi- The lowering speed is maintained at a
ents and loading or unloading on practically constant level, regardless
ramps. of the load.

If the vehicle is being loaded on a ramp Electrically unlockable non-return

and the edge of the platform is resting valves and flow restrictors are located
on the ramp, the lift system automati- in the bottom of the tilt cylinders.
cally adapts to the spring deflection of
the vehicle (float position up). The tail-gate lift is controlled via the
side-mounted control unit, using two
If the vehicle is unloaded on the ramp, foot pedals on the platform, or with
readjustment is required to ensure a remote control.
that the platform remains in constant
contact with the ramp. The device is driven electro-hydrau-
lically by a 12 or 24 V operating
voltage.

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 1. Description
2. General information
DL -48 Operating Instructions

Recommended generators and

batteries

A generator with at least 14 V / 45 anticipated, especially during winter

A or 28 V / 35 A is customary for the operation (note that this will void the
operation of tail-gate lifts. guarantee!).
A generator with approximately 14 V The tail-gate lift is connected to the
/ 80 A or 28 V / 80 A is recommended existing vehicle battery.
for operation exclusively in towns In normal cases, the following battery
and cities. sizes should be present:

If a sufficient battery charge cannot Load Battery

be guaranteed, e.g. when driving very capacity capacity
short distances, it must be recharged 1000 12V: 1x143 Ah
by a separate charging station. 1500 24V: 2x88 Ah
For tractors with trailers or flatbed 2000
24V: 2x143 Ah
trailers, two battery sets must be 3000
charged. Therefore, it is advisable to If the lighting for the cargo area is con-
use a generator with approximately nected via the Dautel control board,
28 V/100 A. It must be ensured that it will switch off automatically after
both battery sets are continuously approx. 15 minutes of non-use. When
supplied with sufficient charge cur- the foot pedal is pressed, it turns back
rent using the appropriate equipment. on automatically.
If other strong power consumers
(heating or cooling units) are installed
on the vehicle in addition to the tail-
gate lift, their consumption must also
be taken into consideration. If neces-
sary, please consult with us before
proceeding.

If battery sizes, cable sections or

generator sizes are significantly
undercut, or permissible cable
lengths are exceeded, operational
faults and consequential damage
as well as malfunction of the power
relay or the electric motor should be
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 2. Description
1. General information
DL -48 Operating Instructions

2.2 Type plate / Technical data

2000-48L/
D-24-09-150-220
141587-001
2010
2,000 kg

Max. 1,200 mm Max. 2,000 kg

With 1,000 kg Up to 750 mm

End of curve* Start of curve*

Associated load Nominal load distance

Max. load distance Max. load

* See load diagram

The technical data of the tail-gate lift can be gathered from the type plate
on the control unit.
Weights and load distances must be observed without fail!

4-cylinder Generation
Rated load capacity Type code

2000 - 4 8 L /
D - 24 - 09 - 150 - 220
Country ID Arm length Operating pressure

Operating voltage Parallelogram

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 1. Description
2. General information
DL -48 Operating Instructions

2.3 Overview
1 Platform

2 Linkage

9 3 Lift cylinder

4 Tilt cylinder
4
5 Drive unit with
type plate
1
6 6 Operating unit with
type plate

8 7 Underrun guard
3
8 Support pipe

7 9 Foot control on
2 5 the platform

2.4 Accessories and special equipment

- Mechanical support - Soft close function
- Hydraulic support - Charge cable for trailer/flatbed
- Automatic supports trailer battery
- Drop-down protectors (generally - Hitch
recommended for carted goods) - Remote controls (wireless, cable)
- Drive-over plate - Sliding mechanism (Lifterflex)
- Platform with slip-resistant alu- - Locking systems for securing the
minium oxide or plastic coating load
- Lubricatable bearing points - Coding switch
- Central lubrication system - Biodegradable hydraulic oil
- VEHH interface - Seal systems
- Quickmatic - Folding underrun guard
- Rain-Lock with secondary control - Folding horizontal/vertical platform

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 3. Safety
1. General information
DL -48 Operating Instructions

3. Safety Requirements on the operating

personnel
3.1 Safety equipment Persons will only be entrusted to oper-
Dautel tail-gate lifts are equipped with ate tail-gate lifts without supervision if
the following safety equipment: they are over 18 years of age, have
been trained to operate a tail-gate lift,
- Electrically unlockable non-return and have proven themselves capable
valves to the operator.
- Line rupture valves
- Flow control valves Supervisor
- Pressure-limiting valves If multiple persons are working on
- Two-handed/footed operation tail-gate lifts together, a supervisor
- Locking control positions must be appointed.
- Warning markings, stipulated mark-
ings for operator's standing area Operation
- Warning signs
Special variants may deviate from Secure vehicle against unintentional
this list. movement (handbrake, gearbox,
chocks).

3.2 Accident prevention The working area of the tail-gate lift

Tail-gate lifts operated in the European must be well-lighted. We recommend
Union (EU) are subject to the EC Ma- the use of flood lamps.
chinery Directive, and particularly
EN 1756-1. In Germany BGG 945 Tail-gate lifts must be operated in such
must also be observed. a way that no crushing or shearing
The technical design and testing are zones occur between the tail-gate
regulated in these regulations. lift and the surrounding parts, and so
For tail-gate lifts that are operated that tasks which must performed on
outside of the EU, Chapter 3.1 is load-carrying equipment or the load
not binding, however the applicable during operation as intended can be
national regulations must also be carried out unimpeded.
observed here.
The proper positioning of supports on
When operating the tail-gate lift, the fol- appropriate surfaces must be ensured
lowing instructions must be followed. before operating the tail-gate lift. Pow-
er-driven supports must be observed
during extension and retraction.

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 1. Safety
3. General information
DL -48 Operating Instructions

Tail-gate lifts that are operated in or Tail-gate lifts may not be loaded be-
extend into the vicinity of public traf- yond the permissible load-bearing
fic must be secured against traffic capacity. The load-bearing capac-
hazards in an appropriate manner in ity diagram or type plate must be
accordance with national road safety observed.
regulations (blinking warning lights,
warning flags, ...). The centre of gravity must be placed
as close to the vehicle as possible.
The range of movement of the tail-gate Loading on one side should generally
lift must be kept clear of persons and be avoided, in order to prevent twisting
objects. The unnecessary presence of in the hoist gear and to stop the lifting
persons on or in the range of movement arm from colliding or projecting out on
of tail-gate lifts is not permitted. one side.

Open compartment doors on the Attention!

vehicle must be secured. One-sided loading using only half of
the distance between support arms
Handling and conduct during op- reduces loading capacity by 50%!
eration One-sided loading outside of the
area between support arms is strictly
The operating personnel must ensure prohibited - operating personnel are
that no persons are endangered during an exception.
all movements of the tail-gate lift. Example: DL 1000 with a 600mm
one-sided load on the right-hand
The tail-gate lift must be constantly side of the vehicle at a load distance
observed during extension and re- of 1,000mm, less the weight of the
traction, opening and closing as well operator, max. load-bearing capacity
as raising and lowering. Particular is approx. 200kg!
attention must be paid to the crush-
ing and shearing zone between the Loads must be placed on the plat-
platform and superstructure, between form so that unintended changes
the platform and road surface and in position are prevented. Secure
between the under-run guard and loads against sliding and rolling off!
road surface. Tail-gate lifts without a drop-down
Tail-gate lifts may only be controlled protector installed may not be used
from the intended control positions. for the transport of rolling containers
without brakes.

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 3. Safety
1. General information
DL -48 Operating Instructions

When fitting the tail-gate lift with the pacity and permissible load distance
one-foot operation or by remote control, of the tail-gate lift.
the feet of the operator may under no The raising and lowering of loads
circumstances extend beyond the edge may only take place with the platform
of the platform facing the vehicle. positioned horizontally. Loading may
Risk of crushing! not lower the platform's incline. The
Remaining in the standing areas pro- automatic incline must be used on the
vided for the operator is mandatory ground (raise or lower command). When
(painted footprints)! unloading on inclined surfaces rollable
loads can push or pull with great force.
Only the operator is permitted to ride
along on the platform. The standing area The following are strictly prohibited:
provided for the operator (400 mm x 600
mm) must be kept clear for this purpose. 1. Any improper use
When riding along, grips for stability 2. Standing under the platform and
must be utilised. Climbing onto the load under the load
and platform are not permitted. 3. Use of the tail-gate lift as an
lifting work platform
Moving the platform with ground con- 4. Intentionally causing vibrations
veyors is only permitted if the weight in the tail-gate lift
does not exceed the load-bearing ca- 5. Throwing objects from or onto
the platform
Possible loading examples
6. Driving onto the platform with
1. Raising or lowering the load impermissibly high axle loads,
For max. loading capacity e.g. fork lift truck
and load distance, see load-
bearing capacity diagram 7. Loading in excess of the max.
loading capacity

These behaviours may result in:

- Crushing and shearing
- Falling
2. Rolling over with a pallet truck and - Rolling away
load on the ramp
Max. total load = Max.
The notice "Warnings on misuse" on
loading capacity of the
tail-gate lift the operating station must be heeded
without fail!

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 1. Safety
3. General information
DL -48 Operating Instructions

Warnings on misuse

min. 150 mm

≤ x max
kg max

min. 200 mm

Verband der in Europa tätigen

Hubladebühnen-Hersteller e.V.
Association of European
Tail-Lift Manufacturers

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 3. Safety
1. General information
DL -48 Operating Instructions

Decommissioning Faults and repairs

Closed tail-gate lifts must be able to With faults that cannot be rectified in
twist slightly with the vehicle. accordance with Chapter 6 of these
instructions, the tail-gate lift must be
Tail-gate lifts must be secured against decommissioned and secured against
unauthorised use after shut-down. unauthorised use. Customer service
For this purpose, the main switch must must be informed.
be secured by lock or with a code.

The tail-gate lift is only out of operation CAUTION!

and in driving position if the indicator
light in the cab has gone out. If the tail-gate lift is raised and the
platform closed with outside help
The vehicle may not be driven if the in the case of fault, there is an acute
tail-gate lift is not in driving position! danger to life in the swivel range of
The only exception is when driving up the tail-gate lift! Since the lift has
to a loading ramp with the platform been moved with outside help, the
open on company grounds. cylinders are not filled with oil. This
means that all safety equipment is
without braking effect.

When opening the tail-gate lift, it may

suddenly fall back into its original
position. Therefore it is mandatory to
make sure that the closed tail-gate lift
is secured with sturdy lashings and
the like. The notice sticker enclosed
as the final page in this manual must
be applied so that it is clearly visible
(reorder!).

Travel may only take place at slow

speeds and to the nearest work-
shop.
Opening may only take place using
outside help such as a crane or fork
lift.

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 1. Safety
3. General information
DL -48 Operating Instructions

If possible, it is better to only operate Pressure hoses must be replaced as

the tail-gate lift after successful repair needed, but at least every 6 years.
work and pressure feed of the lift cyl- The replacement of pressure hoses
inders and possibly tilt cylinders. must be noted in the test-log.

It is the duty of the operator to perform

daily inspections for the presence and
effectiveness of all safety and warning
equipment, as well as safety signs and
notices, and to have any deficiency
rectified immediately.

Before starting maintenance or repair

work under raised parts of the tail-gate
lift, they must be secured to prevent
unintended movement.

Should a load-bearing component

break, the supporting structure and
motor, including all equipment, must
be inspected. Damages parts must
be replaced by original replacement
parts.

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 4. information
1. General Operation
DL -48 Operating Instructions

4. Operation 4.3 Operating the tail-gate

lift
4.1 Intended use
(Special variants may deviate from
The serially manufactured tail-gate
the operating procedure described
lift is designed for raising and lower-
here!)
ing cargo.
Normally the tail-gate lift is connected
Any use other than intended is pro-
to the vehicle battery through a main
hibited.
current fuse connection.
When carrying out repair work or in
4.2 Operating personnel case of emergency the current sup-
Upon delivery of the vehicle, the ply to the tail-gate lift is interrupted by
operator will be instructed by the disconnecting the positive terminal on
manufacturer in the operation and the battery.
maintenance of the Dautel tail-gate
lift.
Main current cable
Only persons who have been instruct-
ed by the operator may be assigned
with operating the tail-gate lift.
The operating instructions are to be
read carefully beforehand.

The details relating to accident pre-

vention regulations for operating per-
sonnel are also to be observed!

Knurled nut
Main current fuse

The main current fuse is connected to

the positive terminal of the battery.

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4. General information
DL -48 Operating Instructions

4.3.1 Putting into operation Switching on from the control unit

With trailers or flatbed trailers, switch-
Switching on from the cab
ing on takes place directly on the
Press the button in the cab. The con-
control unit by means of a proximity
trol lamp indicates the switched-on
switch/coding switch.
position.
The control lamp is also illuminated
when switched off if the platform is
not closed or if hydraulic supports with
feedback signal (optional) are fitted
but not fully retracted.

Proximity switch/Coding switch

Press to switch on

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 4. information
1. General Operation
DL -48 Operating Instructions

An indicator light that monitors plat-

form position of the trailer or flatbed CAUTION!
trailer is located in the cab.
Under no circumstances should
If available, extend the supports (see the platform be moved downward
Supports). Open the platform locking when under load!
mechanism (if available).

If movement is sluggish, briefly press As soon as the tail-gate lift has been
raise and lower before opening the operated using the foot remote control,
locking mechanism. the control unit will no longer work with
two-handed operation.
When the platform is open, please
note that placing a load on the plat-
form will compress the vehicle's rear
suspension and cause the platform to
slope down to the rear. The platform
should be tilted upwards an appropri-
ate amount to compensate.

If necessary, this upward tilt can also

be corrected with the load in place
with DL -48 models.

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DL -48 Operating Instructions

4.4 Load-bearing capacity and load distances

4.4.1 DL -48S load-bearing capacity diagram

"b"

CAUTION!
If the load distance "b" is increased, the load-bearing capacity "G" of
the tail-gate lift is reduced.

Information only for load positioned in the middle. With one-sided loading of
the platform the load-bearing capacity is reduced by up to 50%. Please note
Chapter 3.2!

The weight of the operating personnel must be taken into account.

Load-bearing capacity information on the type plate in the control unit and the
centre of gravity marking on the platform must be observed without fail!
The diagrams shown here are only a general overview.
Only the load-bearing capacity information on the type plate on the
control unit is valid!

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1. General Operation
DL -48 Operating Instructions

DL-48S

*Start of curve

*End of curve

* See also explanation on load data and load distance data in Chapter 2.2

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4. General information
DL -48 Operating Instructions

4.4.2 DL -48L load-bearing capacity diagram

"b"

CAUTION!
If the load distance "b" is increased, the load-bearing capacity "G" of
the tail-gate lift is reduced.

Information only for load positioned in the middle. With one-sided loading of
the platform the load-bearing capacity is reduced by up to 50%. Please note
Chapter 3.2!

The weight of the operating personnel must be taken into account.

Load-bearing capacity information on the type plate in the control unit and the
centre of gravity marking on the platform must be observed without fail!
The diagrams shown here are only a general overview.
Only the load-bearing capacity information on the type plate on the
control unit is valid!

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 4. information
1. General Operation
DL -48 Operating Instructions

DL-48L

*Start of curve

*End of curve

* See also explanation on load data and load distance data in Chapter 2.2

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 1. Operation
4. General information
DL -48 Operating Instructions

4.4.3 Two-handed operation of the external control unit

Opening
Operate the two switches accordingly. Move the left-hand switch down and
the right-hand switch up.

Open the platform until it is practically horizontal. Remember to tilt it upwards

so that the platform is in a horizontal position in its loaded state.

If the lorry is not on an even surface (i.e. it is facing uphill or downhill), the plat-
form must be positioned horizontally - see figures. (The position you select will
be assumed by the platform automatically for each subsequent lift process).

Tilting down
Operate the two switches accordingly. Move the left-hand switch down and
the right-hand switch up.

Downhill

Tilting up
Operate the two switches accordingly. Move the left-hand switch up and the
right-hand switch down.

Uphill
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 4. information
1. General Operation
DL -48 Operating Instructions

Lowering
Move both switches down.

Lower the platform until it rests on the road surface. Hold the operating levers
in the “Lower” position until the platform has been lowered all the way down
to the ground.

Raising
Move both switches up.

Only actuate the “Raise” function. The edge of the platform raises up first,
travelling to the horizontal preset position from above, then the platform lifts
off the ground. Move it up to the top edge of the vehicle floor. Remember to tilt
it upwards so that the platform is in a horizontal position in its loaded state.

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DL -48 Operating Instructions

Closing
Operate the two switches accordingly. Move the left-hand
switch up and right-hand switch down.

Actuate the “Close” function until the platform is positioned against the lorry
superstructure.
If the tail-gate lift is equipped with a “soft close” function, the
final part of the closing process occurs at a reduced speed.

4.4.4 Two-footed operation on the

platform
The pedal switch can be operated with
the heel or ball of the foot.
Only raising/lowering and automatic
tilting up/down are possible.

Double inching function

Raising and automatic upward tilting

Press and hold the H pedal switch
twice within 0.5 seconds.
Then press the S pedal switch.
The inching function is then active on
the S pedal switch. Lower Raise

Lowering and automatic downward

tilting
Press and hold the S pedal switch
twice within 0.5 seconds.
Then press the H pedal switch.
The inching function is then active on
the H pedal switch.

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1. General Operation
DL -48 Operating Instructions

4.4.5 One-footed operation on the

platform

CAUTION! Risk of crushing!

Observe the pinch point between
platform and superstructure with-
out fail!
Feet may under no circumstances
extend over the platform edge.

Lower Raise

Raising and automatic upward tilting

Press and hold the H pedal switch

The pedal switch can be operated with once. The raising process is ex-
the heel or ball of the foot. ecuted.

Only raising/lowering and automatic

tilting up/down are possible. Lowering and automatic downward
tilting

Press and hold the S pedal switch

twice within 0.5 seconds. The lower-
ing process is executed.

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DL -48 Operating Instructions

4.4.6 Remote operation - general In combination with the "Safety point"

attached on the outside of the su-
The operator must be instructed
perstructure, "Tilt up/Close" and "Tilt
by the vehicle manufacturer before
down/Open" can also be initiated with
commissioning.
the wireless remote control.

When operating the tail-gate lift from

the road surface, the operator must
CAUTION! Risk of crushing!
maintain a minimum distance of one
Observe the pinch point between meter to all edges of the platform in
platform and superstructure with- order to avoid the risk of crushing.
out fail! When operating the tail-gate lift from
inside the superstructure, the operator
Feet may under no circumstances
must maintain a minimum distance of
extend over the platform edge.
250 mm to the sill in order to avoid
the risk of crushing.
The tail-gate lift may not be operated
by remote control unless the minimum
clearances are observed.

Operating personnel must stand

strictly in the area of the platform
marked with footprints.

The platform is opened and lowered

using the control unit. "Raise" and
"Lower" can then be initiated by re-
mote control.

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DL -48 Operating Instructions

The danger area (250 mm to the The tail-gate lift may not be operated
sill) must be clearly identified by the with the remote control without having
vehicle manufacturer (e.g. white/red a clear view of the work area.
stripes), if necessary the operator may
be assigned a predefined standing The stickers must applied on the
position by applying markings (e.g. superstructure (outside/inside) in the
two footprints). line of sight of the operator.

While operating the tail-gate lift with If markings or warning notices are
the remote control, the operator must damaged, they must be replaced.
be able to clearly see the work area in
order to avoid endangering persons
in the vicinity of the platform.

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4. General information
DL -48 Operating Instructions

4.4.7 Cable remote control 4.4.8 Wireless remote control

Raising and automatic upward tilting

Press button

Lowering and automatic downward

tilting

Press button
Hand transmitter

This wireless remote control can be

used to initiate the Raise, Lower, Tilt
up and Tilt down functions.

Depending on the type of tail-gate

lift, the receiver for the wireless re-
mote control is fitted in the handheld
transmitter, in the unit cover, or on the
support pipe.

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DL -48 Operating Instructions

Lower (one-handed)

For protection against unintended Tilt up/Close (two-handed)

triggering of the Tilt up and Tilt down
functions, they can only be actuated
if the end of the handheld transmitter
is held right up to the safety point and
the "START" button on the transmitter
is pressed simultaneously. Tilt down/Open (two-handed)

All functions can only be actuated by

remote control with the tail-gate lift
switched on.

START button/two-handed operation STOP button

This button switches off the entire

remote control.
The remote control must be switched
on with this button. It is also used for To stop a function from being triggered
the "two-handed operation" function unintentionally and so that the remote
control is not switched on permanently,
Now the required functions can be the handheld transmitter has a limited
triggered with the respective button. activation period.
If no function is triggered or the START
button is not pressed within a period
of 2 minutes, the remote control au-
Raise (one-handed) tomatically switches off.
In order to continue working with the
remote control, the START button
must be pressed again.

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4. General information
DL -48 Operating Instructions

4.5 Flatbed trailer or trailer 4.6 Other information to be

with tail-gate lift observed during operation
In this case, the tail-gate lift is switched The time to complete a lift is highly
on via the proximity switch on the ex- dependent on the load and the
ternal control unit, however the display charge of the batteries.
of the platform position occurs in the
cab of the vehicle.
Avoid unnecessary lift movements.
The charge cable for the trailer bat-
teries also carries the feedback signal
Use the platform properly to capacity,
for the platform position.
do not move it up and down without
interruption.

During the lifting process, if the battery

charge drops significantly, or if the
platform controller does not respond,
discontinue operation of the tail-gate
lift. Risk of motor overheating.
Recharge the battery using the vehicle
engine.

The energy taken from the battery

Proximity switch/Coding switch
must not be greater than the amount
When connecting and disconnecting added during driving.
the charge cable, it must be ensured
that the connector on the trailer is Remedy:
live. Contact with metal parts can Install a stronger generator.
destroy the fuses of the charge cable.
The batteries will then no longer be Depending on the version, the electric
charged. motor comes with electrical overheat
Therefore, the charging plug is not protection, which is triggered in the
inserted into a metal holder, but is event of overheating. After a cooling
attached to the housing, or kept in period of approx. 5 minutes (depend-
a parking socket with the opening ing on ambient temperature) it is
pointing downwards. switched back on.

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1. General Operation
DL -48 Operating Instructions

4.7 Working with accessories For unloading, set the supports so

they are in contact with the ground.
4.7.1 Supports - general
If supports are not adjusted upward Before driving, release the supports
during loading, the chassis subframe, using the unlocking rod (see Fig.) and
the supporting frame or the supports bring them into their driving position.
can be overloaded. When in the driving position, the sup-
ports must always be secured with
If supports are not adjusted downward the retaining chains.
during unloading, an impermissible tilting
to the rear can occur with vehicles with Hydraulic supports
short wheelbase.

The ground must be capable of bear- Actuate the toggle switch on the
ing the load of the supports. external control unit and observe the
moving process.
Before driving, check that the supports
are in the driving position (retracted and
secured). Extend
Mechanical supports

Release the clamping device with an

unlocking rod as shown in the figure
and, for loading, extend the supports Retract
up to approx. 30 - 50 mm above the
road surface.

Max. direct supporting force = 2t / sup-

CAUTION! port ø40
Please note that the lorry is subject Max. direct supporting force = 4t / sup-
to spring compression when the port ø55
supports are released! The monitor of the support position
with proximity switches (optional)
Max. direct supporting issues a warning to the driver in
force = 1t / support the cab if the supports are not fully
retracted.

If an engine immobiliser is fitted on

the lorry, it is also impossible to start
the engine.
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DL -48 Operating Instructions

4.7.2 Single-acting drop-down Unloading

protector, type A, F, V Operate the switch head or catch, put
up the folding wings.

Move rolling container against the fold-

ing wing and lower platform completely
to the ground.

Pull container away from the folding

wing so that it can be closed again.
Type A drop-down protector - roller
diameters up to 200mm Loading with type A, V
Slide rolling container over closed
folding wing onto the platform. Put up
the folding wing and slowly roll the con-
tainer up against the folding wing.

Loading with type F

Put up the folding wings by operating
the catch.
Type F, V drop-down protector - roller
Slide rolling container over the
diameters up to 120mm
raised folding wing onto the platform.
The folding wings automatically jump
Only prevents rolling containers back to locked position after being
from rolling off in the direction of the traversed and secure the container
platform tip. without additional actuation.

Raise platform completely and slide

ATTENTION! container into the superstructure.
The horizontal position of the plat-
Operate the switch head and bring the
form is particularly important here.
folding wings back into their original
If the platform is tilted upward too
position.
far, the containers will roll back into
the superstructure. If the platform
is tilted downward too far, rolling
containers are no longer held and
roll over the folding wing.

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DL -48 Operating Instructions

4.7.3 Side drive-over plate If any damage or deformation is

caused in an accident or by resting
This is used for unloading rolling con-
on or collision with a fixed object, the
tainers and is attached into the side
entire mechanical scope of delivery
Fixorand end profile on the platform
including all mounting parts must be
using specially shaped fastening
replaced.
brackets.
The hitch must be fitted using the
Depending on the variant, the side
installation instructions and provided
drive-over plates can either be at-
with an approval certificate from an
tached on the left or right.
authorised certification body (e.g.
a TÜV German technical inspection
Pay attention to the max. load-bearing
association).
capacity of the drive-over plate!
We would also like to draw attention
to the fact that the installation and free
4.7.4 Hitch with ball head or jaw
space dimensions from EEC Directive
coupling
94/20 must be observed.
Hitches are tried-and-tested com-
ponents. You can find the approved The hitch may only be used to pull
weight data on the type plate. trailers which have a suitable tow
The max. trailer load is entered in the coupling.
vehicle documentation. If the towing eye has to be removed
Hitches are components which are during installation of the hitch, the
subject to special requirements when coupling on the hitch is an appropriate
it comes to safety. For this reason, you alternative, provided that the permitted
are not permitted to make retroactive trailer load is not exceeded and that
changes, either to the hitch itself or you are towing on roads suitable for
to the mounting parts. ordinary traffic.
This includes, in particular, bending,
welding or machining which deviates
from the authorised assembly work
listed in the approval certificate or in
the operating instructions.

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 1. Operation
4. General information
DL -48 Operating Instructions

4.7.5 Rain-Lock with secondary control

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 5. Maintenance
1. General information
DL -48 Operating Instructions

5. Maintenance
Before beginning maintenance work the tail-gate lift must be secured against
unintentional movement (e.g. support with trestles, attach to crane, etc.).

5.1 General information -

safety switching off safety devices, are ex-
pressly prohibited.
ATTENTION!
Carefully attach and secure larger
If, when performing repairs, the tail- assemblies to lifting gear when re-
gate lift is held closed in the locking placing.
mechanism and the cylinders are
not completely filled with oil, the Before working on the hydraulic sys-
“Raise” and “Close” functions must
tem, ensure that it has been depres-
first be actuated until the lift and tilt
cylinders are tensioned and able surised.
to hold the weight of the platform. Only tighten nuts and bolts when the
Only then can the locking mecha- hydraulic system has been depres-
nism be disengaged. Otherwise surised.
there is the risk of the platform Only perform maintenance and repair
suddenly falling down when the work on the hydraulic system once it
lock is released. has cooled down.
The pre-set hydraulic pressure may
The following maintenance work must not be changed.
be carried out punctually.
When working on components which
Maintenance work may only be store energy, e.g. shocks or gas
undertaken by qualified specialist springs, they must always be unloaded
personnel. before commencing work.
Ensure that the vehicle and the tail- Before carrying out welding work, be
gate lift are secured against uninten- sure to read the lorry manufacturer's
tional start-up, before commencing instructions relating to electrical
with maintenance work. Also, the modules (ABS, EPS, EDC, etc.).
tail-gate lift must be secured against Remove the control module of the
unintentional movement (e.g. support tail-gate lift.
with trestles, attach to crane, etc.).
Upon completion of maintenance
Improvised solutions in order to at- work, be sure to check screwed con-
tempt to restore functionality, e.g. nections for tightness.
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 1. Maintenance
5. General information
DL -48 Operating Instructions

Upon completion of maintenance Visual and wear inspection

tasks, test safety devices for func-
tionality. - Warning signs and notices
- Warning flags
Replace defective components im- - Markings for standing area on
mediately. the platform

Only use original replacement and Function check

wear parts. It cannot be guaranteed
that third-party parts are designed - Toggle switch on the control unit
and manufactured for load and safety- for automatic resetting and
relevant requirements. proper functioning
- Two-handed operation
Significant repairs to the supporting - Remote control for function and
frame or platform must be entered in damage
the test-log book! - Flashing warning lights on the
platform for proper functioning
- Pedal switch for automatic
5.2 Daily maintenance resetting and damage
- Pedal switch operation (control)
5.2.1 Safety and warning for proper/incorrect function
equipment (proper functioning, see Chap. 4)
Check that all safety and warning - Drop-down protectors for proper
equipment is present and working functioning
effectively. - If fitted, proximity switches for
Check that all safety signs and notices proper functioning
are present and legible / check for
damage. 5.3 Weekly maintenance
Any defects discovered must be recti-
5.3.1 Cleaning
fied immediately. The tail-gate lift may
only be operated again after these The tail-gate lift may not be cleaned
defects have been rectified. with a high-pressure cleaner for the
first 6 weeks after painting. After this
time the jet nozzle must be held at
least 50 cm away. In doing so, make
sure that the attached type plates
(underrun guard, tow bar, control box)
are not damaged.

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1. General information
DL -48 Operating Instructions

Cleaning fluids must be pH neutral 5.3.2 Lubricating bolt bearing

with mild effects. They may not be points
aggressive and may not have altering DL -48 series tail-gate lifts are gener-
effects on rubber and plastic parts ally only equipped with maintenance-
(expanding, shrinking, embrittling). free bolt bearing points.
This also applies for the especially Regular lubrication is not necessary.
slip-resistant platform surface. Spray-
ing with cold cleaning solvent or oil is Spraying the lateral thrust faces of
not permitted. the bearings and bolt protrusions
with lubricant or applying a few drops
No cleaning agents that chemically of lubricating oil is recommended.
attack the oxide coating may be used This also prevents the possible occur-
on components made of aluminium, rence of noise and protects against
such as guide profiles, valve blocks, corrosion.
etc. The cleaning agents must lie in
the chemically neutral range of pH 5-8. The DL -48 may be fitted
The cleaning agent "Concit Citrus- with manually lubricated bearing
reiniger" from Cowa, for example, points as special equipment. All lubri-
fulfils this requirement. No materials cating points must then be greased
such as steel wool, emery paper, etc., in accordance with the Lubrication
which strip anodised coatings, may diagram. A single-nipple central lubri-
be used either. cation system can be fitted as another
accessory. In this case, lubrication is
If other agents are used, e.g. fat- performed via a central lubricating
dissolving agents (when transporting nipple.
grease, etc.), our authorisation must The various parts of the tail-gate lift,
be obtained. such as the locking mechanisms,
When cleaning, make sure that no control box cover, drop-down protec-
moisture gets into the control unit tors, mechanical supports or other
or drive unit. For this reason, these auxiliary equipment must be checked
areas should only be wiped clean for ease of movement and oiled as
with a dry cloth. necessary.
Dirt deposits should be removed from
the drop-down protector by rinsing.

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DL -48 Operating Instructions

5.3.3 Lubrication diagram

5 4

3 2 1

1 Lift cylinder / Linkage Single-nipple central lubrication

system
2 Platform / Linkage

3 Tilt cylinder / Platform

4 Lift cylinder / Support pipe

5 Support pipe / Linkage

6 Tilt cylinder / Support pipe

12 lubricating points in all

Recommended grease:
Optimol Optipit Microflux Trans or an equivalent grease, but not graphite
grease.

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DL -48 Operating Instructions

5.3.4 Battery check 5.3.6 Threaded suspension

and bolt bearing points
The battery check is very important.
Batteries discharge automatically. Visual inspection of the mounting bolts.
Therefore recharging while the vehicle Immediately tighten threaded connec-
is not in use (e.g. in the case of truck tions which have become loose.
rental companies or with trailers) is Always replace damaged bolts im-
beneficial, particularly in the winter. mediately with new bolts.

Measure acid density of all cells with Given that these are special bolts,
a battery syringe: only original replacement parts
Density 1.28 kg/dm³ = Battery may be installed!
charged
Density 1.23 kg/dm³ = Battery dis- 5.3.7 Hitches
charged
Check tow coupling, tow bar, etc.,
for fastening, wear, and crack for-
The acid density may not fall below
mation.
1.23 kg/dm3 in any cell!
If this is frequently the case, a stronger
generator should be installed. 5.4 Monthly maintenance
The fluid level in the battery must 5.4.1 Hydraulic system
be above the plates; refill as neces- Check hydraulic lines for tightness.
sary.
Check hydraulic hoses for chafe and
When replacements are necessary, kink points. Immediately replace dam-
HD batteries should be used or aged hoses with original hoses.
deep-cycle batteries when used for
extremely short hauls. Check the oil level in the hydraulic
oil reservoir.
5.3.5 Trailer charge cable and In order to do this, the vehicle must
main current cable be practically level, both lengthwise
Clean plug contacts of the charge ca- and crosswise.
ble between the vehicle and the trailer Open the platform, lower it to the
and spray with contact spray. ground and automatically tilt down.
Check charge cable fuse for corrosion;
clean as necessary. Do not extend the hydraulic supports.
Check main current fuse for corrosion;
clean as necessary.
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 1. Maintenance
5. General information
DL -48 Operating Instructions

Measure the oil level with a dipstick, see table.

If it needs to be topped up, the cause of the oil loss must be found.
After topping up, carry out a cycle with the tail-gate lift.

The stipulated fill levels are minimums for a platform tilted down to the
road surface and for retracted support cylinders!

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DL -48 Operating Instructions

5.4.2 Drive unit 5.5 Semi-annual maintenance

Check cable entry points on the drive 5.5.1 Operating speeds for CE
unit for tightness. variants
Immediately replace damaged hous-
Check the opening, closing and low-
ing or rubber grommets.
ering speed.
5.4.3 Control unit
Max. opening and closing speed = 10°/
Check cable connections for tight- sec. = 9 sec. for 90°
ness and firm seating. Tighten as
necessary. The max. raising and lowering speed is
0.15 m/s. For a lifting height of 900mm,
raising or lowering time is 6 sec.
5.4.4 Locking, tightness of the Lifting height = Top edge of platform
cargo door closure, tilt to top edge of vehicle floor.
cylinder setting
Check the locking mechanism for
proper functioning and wear. 5.5.2 Electric motor
Check how the platform fits against Since worn carbon brushes lead
the cargo door closure. to heating of the motor, the carbon
If it is no longer possible to properly brushes must be checked for wear
close the locking mechanism or if the and ease of movement.
platform no longer fits correctly with In doing so, the accumulated carbon
the cargo door closure, the tilt cylinder dust must be blown off with com-
setting must be inspected. Please pressed air.
seek the assistance of a specialist Replace the carbon brushes as
workshop to do this. needed. The collector should then
Check the retaining bolts of the tilt- also be overturned and the insulation
cylinder rod heads for firm seating, milled out.
and if necessary retighten.

5.5.3 Platform connecting heads

5.4.5 Markings for operator standing
Inspect the feed rollers on the platform
area (only for remote operation)
for wear. Replace the rollers before
Check condition of the footprints the metal parts wear the connecting
painted on the platform/superstructure heads on the road surface.
as markings for the operator's stand-
ing area. Repaint as necessary.
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DL -48 Operating Instructions

5.6 Annual maintenance Recommended types of oil

5.6.1 Annual inspection
DAUTEL LBW special hydraulic oil
The tail-gate lift should be inspected AVIA Fluid RSL 10
by a technical expert and noted in the FUCHS Renolin B15 HLP 10
test-log (only CE variants).
Biodegradable hydraulic oils

5.6.2 Suspension FUCHS Plantohyd 15 S

(once a year) KLEENOIL (Panolin) HLP Synth 15
Retighten the mounting bolts for the
lifting frame to the specified tighten- For normal oil changes, the tank fill
ing torque. level must be measured; after repairs
to the cylinders the tank and cylinder
fill levels must be taken.
5.6.3 Oil change in hydraulic
tank
Oil change
Condensation causes faults in the
system! Open the platform, lower it to the
ground and automatically tilt down.
Dispose of waste oil properly!
Remove the oil drain screw on the
The disposal of waste oil is subject bottom of the tank and allow the oil
to strict guidelines established in the to drain.
German Waste Management Law/
Waste Oil Ordinance. If you have Inspect the oil filter; if necessary clean
any questions, please contact a local or fit a new filter.
waste disposal company.
Fill with new oil and run through the
The same oil may be used in both whole cycle once.
summer and winter for fault-free
operation. Bleed the tilt cylinders and check the
The following types of oil are permit- oil level again.
ted. The order of display does not
represent any evaluation, and the list
makes no claim to completeness.

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DL -48 Operating Instructions

5.6.4 Bleeding the cylinders 5.7 Before the cold season

Protect the rubber seal on the lorry
Tilt cylinders should always be bled superstructure against freezing.
after an oil change.
Only allow trained personnel to per-
form this task.
5.8 At least once every 6 years
5.6.5 Inspecting the bearing points Replace all hydraulic hoses and note
in the test-log.
Inspect play on the bearings using
a feeler gauge.

Wear limits/Bolt bearing play

Bearing point A (Bolt/Sleeve-bearing

bushing)

New condition
Smallest play = 0.1 mm
Greatest play = 0.3 mm
Wear limit = max. 1 mm

Bearing point B (Bolt/Steel fixed-

bearing hole)

New condition
Smallest play = 0.2mm
Greatest play = 0.6mm
Wear limit = max. 1.5mm

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 1. Fault
6. General information
clearance
DL -48 Operating Instructions

6. Fault clearance Before the fuse is replaced, the exist-

ing fault must be rectified.
6.1 Checks by the driver before
calling on the workshop Control current fuse defective?
Is the lift switched on in the cab or Fuse max. 10 A
proximity keyswitch on the control
unit?

Is the battery charged? 6.2 Emergency operation in

Check each cell with a battery sy- the case of failure of the
ringe. tail-gate lift control unit
Min. acid density = 1.23 kg/dm³
If the cab activation system or manual
Max. acid density = 1.28 kg/dm³
operation fail, all basic functions of
the tail-gate lift can be operated by
If the voltage drops below min. 9 V
an so-called emergency bridge on
for a 12 V system or 19 V for a 24 V
the control circuit board.
system under load, the control unit
To do this, fold up the unit cover, then
is no longer guaranteed to function
pull the blade receptacles for manual
properly.
operation off the control board.
Remove one of the two blade recep-
Main current fuse defective or main
tacles from the terminal block EO
current switched off at the circuit
(Emergency Operation) on the control
breaker (see figure)
board and connect to the respective
contact on the control board (control
Main current cable panel).

2 = Raise
3 = Lower
4 = Close
5 = Open

On the advanced control-board vari-

ant, another cable bridge must also
be plugged into the ET (Emergency
Tilting) socket, as automatic ground
Knurled nut tilting will not work.
Main current fuse

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6. Fault
information
clearance
DL -48 Operating Instructions

If the emergency bridge does not work,

check the 10A control fuse.
The emergency bridge serves exclu-
sively for bringing the vehicle back
into the driving position.
After successfully performing the CAUTION!
emergency bridge, a Dautel customer
The lift responds immediately
service workshop must be immediate-
when the contact is touched.
ly located and the fault remedied.

Hold bridge on desired function, do

not attach.

1 2 3 4 5 EO + BK BN BU GN/YE

Emergency Operation "OFF" Emergency Operation "ON"

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DL -48 Operating Instructions

6.3 Control unit functional 6.4 Notes for the workshop

method
All the necessary switches, valves, Before performing repairs to the elec-
etc. for the control of the tail-gate trical system, the main current must
lift are consolidated centrally on the be switched off without fail.
control board in the unit housing.
In principle, fault clearance for electri-
Two 10A automotive fuses must be cal faults takes place on the control
plugged into the control board, which board in the unit housing.
safeguards the control circuit and
lighting circuit for the cargo area.

A so-called control module is plugged

into the control board.
The control module handles all func-
tions for controlling the platform (pedal
switch, flashing lights, feedback signal
of the proximity switch to the cab) and
the cargo-area lighting.
On the advanced control-board vari-
ant, the control module handles ad-
ditional functions, such as Quickmatic,
soft close, automatic retraction of the
hydraulic supports, Sure-Loc, etc.

All basic functions of the tail-gate lift

(raising, lowering, closing, opening)
can also be operated without the
control module.
The test lamps to be used may have
a maximum 2 W / 0.2 A.

All inputs or outputs of the control unit

can be checked using the legend in
the circuit diagram.

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6. Fault
information
clearance
DL -48 Operating Instructions

Faults can also be caused by the posi- Pressing the “Raise” function runs the
tive cable being sound, but without the platform against the tail edging profile
presence of the earth connection of the of the superstructure. Now the pres-
consumer load (e.g. solenoid). sure set in the hydraulic system can
be read. After repairs to the hydraulics
A coil defect can be determined by (e.g. cylinder, hose or valve replace-
checking the coil resistance with an ment) we recommend also replacing
ohmmeter. the hydraulic oil.
Like coils are interchangeable and
can be switched.
If, for the purpose of fault clearance,
a coil is switched to the pole tube of
the valve, it must likewise be switched
on the control board (in order to avoid
malfunctions).
When switching the coils, make abso-
lutely sure that the coils with O-rings
are sealed on both ends.

The valve "VS1" in the drive unit is

designed as a slide valve.
The "V1" and "V2" valves in the drive
unit are designed as double sealed Test connection
seat check valves.
The valves on the lift and tilt cylinders
are single sealed seat check valves.
CAUTION!
In order to check the pressure setting, After carrying out repairs on the
a pressure gauge must be connected hydraulics with the platform closed,
to the A-line of the hose kit, behind the “Raise” and “Close” functions
the unit. must first be actuated in order to
fill the cylinders again with oil.
They must be able to bear the net
weight of the platform before the
locks are opened.

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6. General information
clearance
DL -48 Operating Instructions

6.5 Fault clearance

The customary test lamps should be used for electrical tests! (max. 2
W/0.2 A)
Fault Cause Remedy
Tail-gate lift does not Insufficient oil in the tank, Top up oil.
raise or only slowly; pump sucks in air.
pump motor running
normally. Electromagnetic control Check whether there is
valves VS1 and/or V2 a voltage on the control
have not been actuated. board when actuating the
valves (Raise function) or
check the solenoids with
a magnetic tester.

Pump defective. Replace pump.

Pressure-limiting valve Check pressure.

set too low.

Tail-gate lift does not Low battery charge. Recharge battery. Check
raise or only slowly; the individual cells. Check
pump motor running the charge cable. As a
audibly slower. stopgap, leave vehicle
engine running.

Battery discharged, gen- Install a stronger gen-

erator too weak. erator.

Main current fuse oxi- Replace.

dised on the battery
terminal.

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 1. General
6. Fault
information
clearance
DL -48 Operating Instructions

Fault Cause Remedy

Tail-gate lift does not Main current cable oxidised Clean off contact points.
raise or only slowly. at the contact point.

Insufficient earth return Install additional earth

line. return line.

Charge-cable plug con- Clean, replace.

nectors corroded.

Fuse of the charge cable Replace.

defective.

Carbon brushes worn. Maintain the motor.

Discontinue use of the
unit, otherwise electric
motor will be damaged.

Pump motor does not Activation in the cab or Switch on, replace.
run. coding switch not actu-
ated or defective.

Main current fuse burned Replace.

out.

Control fuse burned Replace (10A).

out.

Toggle switch or pedal Replace.

switch defective.

Control cable for control Replace, install.

unit or platform cable
broken.

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 1. Fault
6. General information
clearance
DL -48 Operating Instructions

Fault Cause Remedy

Pump motor does not Power relay defective. Replace.
run.
Carbon brushes worn. Replace.

Thermal overload switch After a 5-minute cool-

has tripped. down period, the motor
is ready to use again.
Remove the unit cover
during operation.

Control fuse repeatedly Short circuit or too many Rectify the short circuit,
burns out. consumers. switch off consumers.

Pump motor does not Power relay stuck. Disconnect the main cur-
cut off. rent from the fuse unit. If
necessary, replace the
power relay.

Tail-gate lift cannot be Tilt cylinder valves and/or Check solenoids, cables,
opened, or only slowly; V1 not actuating. signal output on the
pump motor running. control board and valve
bodies.

Flow restrictors (DBV2) in Clean.

the tilt cylinder dirty.

Platform frozen on the Thaw, treat the seal to

vehicle superstructure. prevent item freezing
to it.

Remove platform bolts,

56 2009793.00 - Edition 7/2010
 1. General
6. Fault
information
clearance
DL -48 Operating Instructions

Fault Cause Remedy

Tail-gate lift cannot be Platform bearing points clean, inspect bearing
opened, or only slowly; stiff. points, re-install with
pump motor running. grease.

Platform rubs against the Briefly press Lower, then

superstructure. Open.

Platform lowers too Flow control valve SRV1 Clean or replace.

quickly or too slowly in the unit is dirty or de-
(permissible speed 15 fective.
cm/sec.).

Platform lowers un- Flow control valve SRV2 Clean or replace.

evenly. in the right-hand lift cylin-
der is dirty or defective.

Platform clearly lowers Lift cylinder valves and R e p l a c e or clean

evenly and of its own V2 leaking. valves.
accord (e.g. 20-30mm
in 5 mins).

Platform does not low- Cables or valves on the R e p l a c e c a b l e s o r

er. lift cylinders or valve V2 valves.
defective.

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 1. Fault
6. General information
clearance
DL -48 Operating Instructions

Fault Cause Remedy

Platform cannot be Cable break, pedal switch Replace.
raised or lowered with defective.
the pedal switches.
Cable break; platform Replace.
cable

All cables OK, but no sig- Replace tilt switch.

nal received from the tilt
switch when the platform
is level

Platform clearly tilts Valves in the tilt cylinders Replace valves or leak-
the tip down of its own and V1 leaking. ing.
accord (e.g. 30-50 mm
in 5 mins). Defective seal in tilt cyl- Replace tilt cylinder.
inder.

Platform opens too Flow restrictor DB1 in the Clean.

quickly. unit clogged.

Platform cannot be fully Tilt-cylinder rod heads Adjust.

closed. incorrectly adjusted.

Support pipe warped due Replace support pipe.

to overloading.

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 1. General
6. Fault
information
clearance
DL -48 Operating Instructions

Fault Cause Remedy

Tail-gate lift does not Load too heavy or centre Check load. Note the load
raise the full load. of gravity exceeded. diagram.

Suction filter clogged Clean

Pump defective Repair

DBV on the unit set incor- Adjust

rectly

Platform tip does not tilt Tilt switch HG2 does not Check tilt switch or ca-
down to the ground. switch off the tilt cylinder ble and, if necessaru,
valves. replace.

Platform stops while Platform cable broken Replace

raising or lowering with
the pedal switches.

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 1. Disassembly
7. General information
and disposal
DL -48 Operating Instructions

7. Disassembly and
disposal
The oil is to be carefully removed from
all parts of the hydraulic system such
as tank, pump, valves, cylinders, lines
and hoses.
Grease and residual oil is to be re-
moved by means of a high-pressure
cleaner.
Hydraulic oil is to be disposed of via
a specialist dealer.
Remove cable and electronic com-
ponents.
Remove plastic components.
All components are to be disposed
of separately.

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 7. Disassembly
1. General
8. Service
and
information
disposal
centres
DL -48 Operating Instructions

You can find an up-to-date directory of our service centres on our website at:
www.dautel.de/Service/Servicestützpunkte.

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