tt755m owners manual - manufacturer of tieman tail lifts

1F Industry Circuit, Kilsyth South, VIC, 3137

TT755M TAIL LIFT

OWNERS MANUAL

Authorized by: GL UNCONTROLLED IF PRINTED Issue date: 04/2017

TT755ML OWNERS APR-17 of 33 Copyright Tuffman Pty Ltd 2017

T ABLE OF CONTENTS

• Section 1 OWNERS RESPONSIBILITY 3 • Maintaining your Tail Lift 4

• Section 2 WARRANTY • Tail Lift Identification 5 • Tail Lift Warranty 6

• Section 3 SAFETY INFORMATION • Important Safety Reminders 8 • Installation risks 10 • Potential Shear / Crush Injury Zones 12 • Risk Assessment 14 • Risk Matrix 16

• Section 4 TAIL LIFT SPECIFICATIONS • Standard Specifications 17 • Parts identification 18 • Dimensions and Specifications 19

• Section 5 TAIL LIFT OPERATIONS • Safe Loading 21 • Safety Information 22 • Important Notice and Operating Decals 23 • Operating Instructions 24 • Remote Control Unit 25 • Power Pack Information 26

• Section 6 TAIL LIFTS MAINTENANCE • Maintenance schedule 27 • Lubrication 28

• Section 7 SCHEMATICS • Hydraulic Schematic 29 • Electrical Schematic 30

• Section 8 TROUBLE SHOOTING 31

• Section 9 CONTACT DETAILS 33 ALTHOUGH EVERY EFFORT IS MADE TO ENSURE ACCURACY, CURRENCY AND COMPLETENESS OF THE INFORMATION CONTAINED IN THIS MANUAL, TUFFMAN PTY LTD DOES NOT GUARANTEE, WARRANT, REPRESENT OR UNDERTAKE THAT THE INFORMATION IS CORRECT, ACCURATE OR CURRENT. TUFFMAN PTY LTD IS NOT LIABLE FOR ANY LOSS, CLAIM, COST OR EXPENSE OF ANY KIND ARISING IN ANY WAY WHATSOEVER FROM THE INFORMATION CONTAINED IN THIS MANUAL.



SECTION 1: OWNERS RESPOSIBILITY

To ensure both your safety and the safety of others and the continued effective operation of your tail lift your responsibilities are as follows: ➢ Read and understand the information contained in the OWNERS MANUAL before using the tail lift

loader. ➢ Ensure any person who will be operating the tail lift has read and understood the Safety Information

and Operating Instructions contained in the owner’s manual as well as all relevant safety notices affixed to the vehicle.

➢ Ensure all decals, as shown in section 9 are in place and legible. Contact Tuffman immediately to

order replacement decals if any are missing or damaged.

➢ If you do not understand any part of the manual, contact Tuffman or your installer for clarification before using your tail lift.

➢ Check that your tail lift loader is fitted with a serial plate and that the plate has been engraved with a

serial number, capacity, installation month and Model number. ➢ Absence of an engraved serial plate will invalidate your warranty. If the serial number plate was not

fitted when the tail lift loader was installed, or any sections have been left blank, immediately contact the installer or Tuffman for rectification.

If any person other than the manufacturer (TUFFMAN PTY LTD) installed your tail lift loader you need to contact the installer for any repairs that you consider to be covered by warranty. For installations completed by third parties other than Tuffman, product warranty will be affected if installation is not in accordance with Tuffman installation guidelines.



MAINTAINING YOUR TAIL LIFT

Tuffman offers a Maintenance Service Agreement to ensure the trouble free and safe operation of your Tail Lift. Please contact the Tuffman service department on 1300 606 406 to discuss the service interval requirements for the conditions under which you use your Tieman Tail Lift. Regular Tail Lift Service includes but is not limited to the following: Please refer to Section 6 – Maintenance for our recommended Maintenance Inspection and Service Schedule. • Inspection of safety devices and critical components • External remote control base connection sealing (replace spring if required) • Control units & power pack seals in working order (replace as necessary) • Remote cable and unit (Replace/Repair as necessary) • Visual inspection and assessment for structural damage • Testing and cleaning of battery terminal and leads • Testing of battery cells • Testing all pins and bushes • Inspection of bolt tightness • Weld crack inspections • Inspection of hydraulic system for oil leaks • Inspection and cleaning/adjustment for oil leaks • Hydraulic oil level check and top up • Pressure test of hydraulic system • Pressure test of power pack • Pressure test of cylinders • Lubrication of all grease parts

• Full operation cycle test



SECTION 2: WARRANTY

( N ew Pr o du c ts )

TAIL LIFT IDENTIFICATION

The information required on this form may be required by Tuffman to assist in tracking owners’ service records.

This Owner’s Manual should be considered a permanent part of the vehicle and should remain within the vehicle at time of resale if Tail lift is to be sold with vehicle. OWNER: ________________________________________________________________ ADDRESS: ______________________________________________________________ __________________________ STATE: _______________ POSTCODE: ___________ TAIL LIFT SERIAL NUMBER: ______________________________________________ (Located on metal label attached to Tail lift, or on power pack.) MODEL: ________________________________________________________________ DELIVERY DATE: (DATE SOLD TO ORIGINAL PURCHASER): ___/___/___ PURCHASED FROM: _____________________________________________________ DEALER ADDRESS: ______________________________________________________ __________________________ STATE: _______________ POSTCODE: ___________



TAIL LIFT WARRANTY (Cont.)

Policy Tieman Tail Lifts are designed, manufactured and tested to conform to the relevant Australian Standards. They are manufactured in accordance with Tuffman’s strict manufacturing process based on a philosophy of continuous improvement.

Warranty This Tieman Product is free of defects in workmanship and materials for the period specified and subject to the conditions below.

This warranty represents the entire agreement between Tuffman and the owner pertaining to Tuffman’s warranties.

This Warranty is in addition to any statutory rights applicable in your State or Territory.

Warranty Period

Component

Warranty Period (months)

Parts Labour

Installation Service

Labour Parts Labour

Structure 24 12 12 3 3

Power pack 24 12 12 3 3

Cylinder 24 12 12 3 3

Electrical system 12 12 12 3 3

This Warranty applies from: 1. The installation date of the Product where it was delivered and installed by Tuffman Pty Ltd. 2. The shipping date to the purchaser of the Product (or his or her agent) where it was installed by other person(s).

Conditions This Warranty remains valid provided the Product is or was:

• Installed and commissioned in accordance with the Manufacturer’s installation manual.

• Used as intended in the Manufacturer’s literature.

• Maintained at regular intervals in accordance with Manufacturer recommendations.

• Free of any modifications or alterations (which include tampering with security seals).

• Not operated once a defect was known.

• Made available for repair during Tuffman’s normal Business Hours.

This warranty does NOT cover:

• Damage resulting from misuse or abuse.

• Damage resulting from poor or incorrect installation by other person(s).

• Damage to other equipment.

• Normal wear & tear.

• Claims where the Product has been incorrectly maintained or repaired.

• Transportation costs to and from the Manufacturer.

• Any costs associated with the Product being out of order. Limitation of Liability 1. Tuffman’s liability is limited to the repair of the Product and/or payment of the cost of replacing the Product with an

equivalent one at the discretion of Tuffman Pty Ltd. In the case of maintenance services, Tuffman’s liability is limited to providing the services again.

2. Tuffman makes no other express warranty or condition whether written or oral.



TAIL LIFT WARRANTY (Cont.) ( R e c on di t i o n ed Pr od u ct s )

Policy Tieman Re-conditioned Tail Lifts are designed, manufactured and tested to conform to the relevant Australian Standards. They are manufactured in accordance with Tuffman’s strict manufacturing process based on a philosophy of continuous improvement. Warranty This Tieman Re-Conditioned Product is free of defects in workmanship and materials for the period specified and subject to the conditions below. This warranty represents the entire agreement between Tuffman and the owner pertaining to Tuffman’s warranties. This Warranty is in addition to any statutory rights applicable in your State or Territory. Warranty Period

Component

Warranty Period (months)

Parts Labour

Installation Service

Labour Parts Labour

Structure 3 3 3 3 3

Power pack 3 3 3 3 3

Cylinder 3 3 3 3 3

Electrical system 3 3 3 3 3

This Warranty applies from:

1. The installation date of the Product where it was delivered and installed by Tuffman Pty Ltd.

2. The shipping date to the purchaser of the Product (or his or her agent) where it was installed by other person(s). Conditions This Warranty remains valid provided the Product is or was:

• Installed and commissioned in accordance with the Manufacturer’s installation manual.

• Used as intended in the Manufacturer’s literature.

• Maintained at regular intervals in accordance with Manufacturer recommendations.

• Free of any modification or alteration (which includes tampering with security seals).

• Not operated once a defect is or was known.

• Made available for repair during Tuffman’s normal Business Hours. This warranty does NOT cover:

• Damage resulting from misuse or abuse.

• Damage resulting from poor or incorrect installation by other person(s).

• Damage to other equipment.

• Normal wear & tear.

• Claims where the Product has been incorrectly maintained or repaired.

• Transportation costs to and from the Manufacturer.

• Any costs associated with the Product being out of order. Limitation of Liability 1. Tuffman’s liability is limited to the repair of the Product and/or payment of the cost of replacing the Product with an

equivalent one at the discretion of Tuffman Pty Ltd. In the case of maintenance services, Tuffman’s liability is limited to providing the services again.

2. Tuffman makes no other express warranty or condition whether written or oral.



SECTION 3: SAFETY INFORMATION

IMPORTANT SAFETY REMINDERS

NOTE: Improper operation of this Tail lift may result in serious personal injury. Do not operate unless you have been properly instructed and have read, and understand the installation instructions.

1. Ensure vehicle engine is turned off prior to using Tail Lift. 2. Do not ride the Tail lift during test loading procedures. 3. Ensure vehicle is parked on level ground prior to using Tail Lift. 4. Be certain the vehicle is properly and securely braked before operating Tail Lift. 5. Do not overload. See load rating and load position of this Tieman Tail Lift. Remember that this limit applies to both raising and lowering operations.

6. Test load should be placed in a stable position as near as possible to the center of the platform.

TUFFMAN PTY LTD have provided the following important Safety Reminders for installers and users.

Following these two pages under the heading of Safety Update Information is further specific information compiled through our ongoing commitment to improving the management of safe operating procedures which are also applicable for the installers of Tieman tail lifts.



IMPORTANT SAFETY REMINDERS (cont.)

7. Never stand in or move through, or allow anyone else to stand in or move through, the area in which the Tail Lift may operate or into which an unstable load may fall. 8. During service or repair turn off isolating switch and remove until work is completed, or disconnect battery (It is recommended you do both to prevent any possibility of an accident). 9. The Tail Lift should operate smoothly and the only noise during operation should be from the pump unit during the raise operation. If there are any oil leaks or damage to the Tail Lift, or if there is any scraping, grating or audible suggestions of rough running this should be investigated. The cause should be pinpointed and eliminated before further deterioration of performance occurs.



INSTALLATION RISKS

1. ALL 12/24V D.C. REMOTE CONTROL UNITS AND POWER PACKS.

Whilst is very unlikely that anyone would be subjected to an electrocution or burn risk whilst operating these units, it is necessary to advise of some potential risks associated with any reduction in the integrity of these units by mistreatment, improper maintenance or by any other means. 2. LOW RISKS – SHOCKS & BURNS

(A) There is a potential for any person to suffer from an electric shock from one of these units. If wearing "a PACEMAKER or similar type of vital lifesaving/preserving equipment" you may be adversely impacted by an electric shock or any current invasion to your body.

Installers should note that if any of their staff have these devices fitted they are fully aware of these low risks.

(B) The REMOTE CONTROL UNIT is currently rated at IP65 this means that the unit is "totally protected

against DUST and protected against LOW PRESSURE JETS of water from all directions & limited ingress (Penetration) permitted"

NOTE: - Exposure to high-pressure water spray directed onto or in the vicinity of the remote

control unit may cause water to penetrate the unit resulting in its malfunction. To prevent the remote possibility of this occurring, clients should ensure:

(a) The removal of the Remote Control Unit before using a high pressure jet/spray (b) Place the Remote Control Unit in a sealed protective bag strong enough to withstand the

pressures being applied to it. (c) Instruct ALL OPERATORS in the care and use of the Remote Control Unit against water

penetration. (C) There exists a low risk that BURNS could also be caused by a (D.C.) Direct Current discharge.

• Installers should in the interest of their employee's safety ensure adequate protection and operator training is conducted to minimise these very low risks.

3. TUFFMAN IS HAPPY TO PROVIDE THIS INFORMATION IN THE BEST INTERESTS OF ITS

CUSTOMERS’ COMMITMENT TO THE MAINTENANCE OF SAFER WORKPLACES. NOTE: - These risks do not only apply to equipment supplied and maintained by Tuffman, but

are risks inherent in the operation of ANY electrical equipment.

If you require any further assistance or have any queries please contact Tuffman.



INSTALLATION RISKS (cont.)

4. ALL MANUAL HANDLING INFORMATION

• In all states, there exists OCCUPATIONAL HEALTH & SAFETY Legislation including (Manual Handling) Regulations which require that an employer must ensure that manual handling likely to be a risk to health and safety is examined and assessed.

• "Manual Handling” generally means any activity requiring the use of force exerted by a person to lift, push, pull, carry or otherwise move or restrain any animate or inanimate object.

• Installers may find that they need to incorporate training in methods of Manual Handling appropriate for that manual handling task. An employer must make sure that an employee required to carry out any manual handling is provided with appropriate training.

• If any installers need to control any assessed risk by redesign of any of our products Tuffman are only too happy to assist.

• Under current National Plant Regulations any modification made will bring the designer litigation into force on the designer.

• This information is provided to assist any installers in meeting their vital Health and Safety objectives.

• If you have any queries or need any further assistance please contact Tuffman. 5. SAFETY INFORMATION – STANDING ON TAIL LIFT DURING OPERATIONS

• Tuffman do not recommend that any person stand on a tail lift during any operation of a tail lift. If it is necessary for any person to stand on the tail lift as a necessary work function a safe work procedure must be developed by the employer based on the Risk Assessments provided and an assessment of the actual working environment

• There is a risk of injury to any operator due to falling off the tail lift, potential shear/crush injuries, and injury due to sudden movement or collapse of the load either on the tail lift, inside vehicle or whilst loading a vehicle.

• Some installers have conducted their own Hazard Identification, Risk Assessment, and adopted Risk Control measures to allow their employees and/or others to stand on the tail lift during its operation.

• This practice is solely at the discretion of the installers and totally their responsibility, and therefore should ensure that the operator understands the risks and adheres to the installers procedures or Risk Control measures.

• Handrails/Guardrails in accordance with AS1657 should be used wherever possible to mitigate injury risks associated with persons riding on a tail lift platform.

DISCLAIMER: NOTE: Tuffman therefore does NOT accept any responsibility for any injuries sustained

for any person riding on the tail lift during its operation or standing on it at any time.



POTENTIAL SHEAR / CRUSH INJURY ZONES

1. INTRODUCTION

• When a tail lift is being operated through any phase of its Functional Capabilities, there is potential for INJURY to occur through CRUSHING or SHEARING to many areas of the body.

• If correct adherence to the recommended SAFE INSTALLATION PROCEDURES contained within this Manual is observed, then such injuries will not occur or will be prevented to as low as is reasonably possible.

• The vigilance, care, concentration and competency of anyone operating a tail lift at any time must be of the highest level.

• Injuries can occur not only to the installer, but other work-mates, associates and to members of the public. Therefore, tail lifts should ONLY BE OPERATED by FULLY TRAINED and COMPETENT operators.

2. UNAUTHORISED ADJUSTMENTS OF FLOW CONTROL VALVE

• No unauthorised adjustments are to be made to any part of the hydraulic system to increase the descent rate of any tail lifts as this increases the risk of injury, and any resulting injury occurring due to this action would most likely result in a more severe injury.

3. INJURY ZONES

• These zones or areas are usually the areas where;

(a) The tail lift closes up on any part of the vehicle’s body. (b) Any part of the tail lift or mechanisms that close up on any part, or housed in any part of the

tail lift. (c) The surface area at ground level equal to the dimensions of the actual tail lift plus any travel

distance due to its mechanical action. i.e. if a tail lift is 2.4m x 2.4m and during its raising/lowering action it moves away 400mm from the vehicle body, the potential impact area becomes 2.4m x 2.8m from its installed position. NOTE: The same principles apply to all tail lifts regardless of where they are fitted. 4. BATTERY ISOLATION SWITCH

• Installer to ensure all potential operators of the unit are aware of a potential LOW RISK of injury when ISOLATING the battery switch IF the tail lift is operated unexpectedly by any persons.

• This could occur because a person may place an arm between the tail lift and vehicle in some models to reach the battery isolation switch allowing the possibility of a shear/crush injury to occur.

NOTE: This practice is NOT the recommended action to operate the battery isolation switch. Installers should ensure owners are aware of this hazard and safe guard against it

accordingly during training sessions and/or competency validation testing. 5. MAINTENANCE/REPAIR OF TAIL LIFT - Potential Injuries

• Inadvertent operation during ANY maintenance or repair activity on a tail lift could cause injury.

• To prevent this from occurring, the person performing any maintenance/repair activity is to REMOVE the Battery Isolation Switch Key and keep it securely in their possession until the activity is completed.



POTENTIAL SHEAR / CRUSH INJURY ZONES (cont.)

6. TAIL LIFT OPERATION - Pre-operation Check

• To prevent the possibility of any injury occurring during any phase of operation of installation on the tail lift - the Operator is to ensure BEFORE any operation commences that no person has any part of their body within any potential injury zone and to maintain extreme vigilance during tail lift operations to ensure no person places any part of their body in these zones.

7. SAFETY INFORMATION - TROLLEY STOPS/GUARDS

• Tieman Tail lifts can be fitted with a range of trolley stops/guards designed to meet the individual requirements of its customers as required.

• In using equipment on tail lifts fitted with trolley stops/guards customers should be aware of the danger of trips and falls that could arise from them being used, particularly when they are in the raised position.

• It should be noted that if trolleys or other wheeled equipment with inappropriate sized wheels are being used on tail lifts with trolley stops/guards fitted, then this equipment could over run the trolley stops/guards and fail to be stopped by them.

• If trolleys or similar devices are uncontrolled and hit the trolley stops/guards, there is a potential risk of the LOAD being displaced.

• Installers should ensure that all operators are made aware of these dangers.

• For further assistance or information please contact Tuffman. 8. SAFETY INFORMATION - POWER PACKS

• Customers should be aware of the dangers of Power Packs fitted to the "roadside" position of any vehicle.

• It is the recommendation of TUFFMAN PTY LTD that power packs be fitted to the "kerb side" of a vehicle.

• However, there are situations when the Tail Lift design or the customer requires having either a single power pack fitted to the "roadside" position or have "dual side controls".

• In this event owners should ensure that all operators are instructed of the risks of "roadside" operation, i.e. the potential for being struck by other passing vehicles. Operators should be aware of the "recommended" safe positions in which to operate the tail lift when using either the "remote control unit" or the “Fixed Controls”.



RISK ASSESSMENT

IDENTIFICATION MECHANICAL HAZARDS (MH) PROBABILITY CONSEQUENCE TAIL LIFTS (GENERIC):

MH 1. HAZARD: 12/24V Electrocution/Shorting out hazard due Unlikely Major To steam or water high pressure cleaning. MH 2. Short out Hazard if cable wires damaged due to Unlikely Moderate excessive pull on cable. MH 3. Water penetration from any source. Unlikely Moderate MH 4. Remote Control Cable being crushed or Rare Major caught, resulting in severing, bare wires or fusion of wire, which may cause shock/burns due to an earth fault and resulting in possible unexpected operation of tail lift. MH 5. Shear & Crush injuries if person places any Unlikely Major part of body within the operating zones of the tail lift while operating, opening/closing tail lift to the appropriate level. MH 6. Shear or Crush injuries due to confusing or Rare Moderate obsolete operating instructions. MH 7. Slip, trip or fall hazard on slippery platform Likely Major MH 8. Foot crush injuries at edges of platform when Unlikely Major lowered to ground. MH 9. Electrocution/short/burning due to operators Unlikely Catastrophic un-authorised modification of circuitry to by-pass battery isolation switch. MH10. Tail lift operated inadvertently during repair/ Rare Major maintenance. MH11. Inappropriate Operation of tail lift by persons Rare Major authorised/un-authorised. MH12. Crushing due to operator's modification of Unlikely Catastrophic lowering speed flow control. This imposes severe safety risk to any person within lowering area of platform as it exceeds designed rate of descent. MH13. Fire hazard due to electrical short, causing Unlikely Major continual running of motor & overheating of electrical wire. MH14. Shear/Crush injuries due to tail lift failure Rare Catastrophic if hydraulics fails. MH15. Structural damage to tail lift causing Likely Catastrophic instability & potential injury from forklift being used on tail lift. MH16. Roadside Accident and injury to operators Unlikely Catastrophic and service/maintenance persons due to

fitting of power pack on Roadside position.

MH17. Potential trip & fall hazard on platform if Possible Major Trolley stops/guards fitted. MH18 Failure of hydraulic cylinder on tail lift Rare Catastrophic



RISK ASSESSMENT (cont.)

MH19 Failure of eye-bolt supporting hydraulic Rare Catastrophic Cylinder. MH20 Failure of tail lift pivot mechanism parts Rare Catastrophic pivot pin etc.

IDENTIFICATION MECHANICAL HAZARDS (MH) PROBABILITY CONSEQUENCE TK505 (2 Piece folded platform)

MH 1. HAZARD: MANUAL HANDLING. Soft tissue injuries Possible Major (to arms, shoulder, back, legs etc) may occur when the platform is unfolded to the ground or when folding up prior to pulling back into storage position. MH 2. Shear /Crush injuries could occur at: Possible Major

1. Pivot point of tail lift (risk varies According to design of vehicle body)

2. Where platform closes up against Vehicle body.

3. At joint of 2 platform pieces (where platform folds up).

4. When lowering folded part of platform to Ground.

MH 3. Wrist injury could occur when lowering the Likely Moderate folded platform section to ground if wrong handgrip is used.



Probability (Likelihood)

Major

Moderate

Minor

Insignificant

Is expected to occur in most Circumstances.

H

H

S

S

Will probably occur in most Circumstances.

H

H

S

M

Might occur at some time.

H

S

M

L

Could occur at some time. H

S

L

L

May occur only in exceptional Circumstances.

S

S

L

L

Consequence (Outcome of event) RISK MATRIX

INSIGNIFICANT = No injuries, low financial loss. MINOR = 1st Aid treatment, on-site release immediately contained, medium financial loss. MODERATE = Medical treatment required, on-site release contained with outside assistance, high financial loss. MAJOR = Extensive injuries, loss of production capability, off-site release with no detrimental

effects, major financial loss. STROPHIC = Death, toxic release off-site with detrimental effect, huge financial loss.

H = HIGH RISK : Requires Detailed Research and Management Planning by Engineering/Senior Management. S = SIGNIFICANT : Senior Management attention needed, changes to Policy, Specifications, Work Practices, . etc, may be needed M = MODERATE : Review, Modification, Rectification may be needed by Specified Managers. L = LOW RISK : Manage by routine procedures and work practices.



SECTION 4: TAIL LIFT SPECIFICATIONS

STANDARD SPECIFICATIONS

Model TT755M

CAPACITY kg 750kg

NOMINAL PLATFORM SIZE mm 2010 Width x 1005 Length + Ramp

Nominal ramp length mm 215

Fitting requirements mm 1230 Maximum Height Unloaded 770 Minimum Height Unloaded (Depending on vehicle overhang & desired road clearance)

Adds to vehicle mm 155 when fit to tray body or van 225 when fit to vehicle with barn doors

Load centre mm 500

C of G of unit when stowed mm 127

OTHER SPECIFICATIONS

Model TT755M WEIGHT INSTALLED (Nominal) kg 270

PLATFORM

Surface Steel Mesh (Hot Dip Galvanised)

Ramp Angle 15o

LIFT ARMS

Construction 19mm Plate

Arm Depth mm 93

Re-Bushable Yes

Arm Centre mm 686

LIFT FRAME

Construction 19 mm Plate & Angle

Frame Depth mm 242

Re-Bushable Yes

Overall width mm 1053

MAIN FRAME

Construction 100mm RHS

Bracket Thickness mm 25

PINS

Material Ø25mm Dia. High Grade Bar, Zinc Plated

Greasable Yes

BUSHES Heavy duty, Low maintenance bearing

HYDRAULIC

Power Pack with thermal overload Hydro-Tek

Motor Size 2.2 kW

Cylinder Quantity 3 (1 Lift, 2 Tilt)

Cylinder Size (Dia x Stroke) mm Ø75 x 204 mm (Lift) / Ø60 x 100 mm (Tilt)

Hoses 6mm (1/4") Double Wire Braid

Oil Type ISO Grade 22 Hydraulic Oil

OPERATION

Operation Power up/Close -- Gravity down/Open

Speed Down Adjustable with Flow Control

Closing Operation Hydraulic (Tilt Cylinders)

Locking Device Chain & Hasp

MASTER CONTROL BOX

Battery Isolation Switch Yes

Removable Remote Push Button Four (4) Button c/w 2.75m lead

Heavy Duty 7-pin Safety Plug Yes

DUE TO OUR POLICY OF CONTINUAL IMPROVEMENT, TUFFMAN RESERVE THE RIGHT TO ALTER SPECIFICATIONS WITHOUT NOTICE.



PARTS IDENTIFICATION FOR TT755M



DIMENSIONS AND SPECIFICATIONS FOR TT755M



DIMENSIONS AND SPECIFICATIONS FOR TT755M cont.



SECTION 5: TAIL LIFT OPERATION

SAFE LOADING

• Owner must ensure the driver and or operator are well trained in the correct loading procedures before using the Tieman TT755M Tail Lift.

• Please be conscious to the total lifting capacity of the Tieman TT755M Tail Lift.

Note: If a person must stand on the Tail Lifts (not recommended by Tuffman), care must be taken to

also include the weight of the person/s on the Tail Lifts in total load mass.

• Never stand on the tip of the platform. Please check the label on your Tieman TT755M to ensure that the allowable loading combinations are not exceeded.

NOTE: Load centre for 750kg must be no greater than 500mm from inside edge and located in the centre of the platform when lifting the maximum permissible load



SAFETY INFORMATION

BEFORE OPERATING TAIL LIFT BE SURE YOU UNDERSTAND 1. Improper operation of the Tail lift can result in serious personal injury. Do not operate the Tail

lift unless you have been properly instructed, have read and fully understood the operating instructions contained herein.

2. Be certain the vehicle is secured and the vehicle park brake applied before using the tail lift. 3. Always inspect your Tail lift for any damage before using it. If there are signs of improper

maintenance, damage to vital parts, slippery platform surface, do not use tail lift. Do not attempt your own repairs, unless you are specifically trained and authorised.

4. Do not overload. Observe safe working load signs. Remember that loading limits apply to both

raising and lowering operations. 5. Each load should be placed in a stable position as near as possible to the centre of the platform

as shown in the loading diagram. 6. Never stand in or move through, or allow anyone else to stand in or move through, the

operating area (NOTE: This is a potential injury zone). 7. Tuffman do not recommend that any person ride on the platform due to potential safety hazards

as detailed in the risk assessment. If imperative to do so, you must use all caution. 8. This tail lift is fitted with a safety flow control valve to prevent rapid descent of platform in the

event of hydraulic failure. 9. During Maintenance/Repair, turn off isolating switch and remove it until the work is completed,

or disconnect battery (It is recommended you do both to prevent any possibility of an accident). 10. You must use only Tuffman supplied spare parts particularly those parts designed to support

the loaded platform. 11. Do not attempt to modify the circuit to by-pass battery isolation switch. 12. Do not alter the speed flow control settings as this may cause rapid descent of the tail lift. 13. Adjustment of relief valve and consequently system pressure must not be performed without

prior consultation with Tuffman. 14. Do not use forklift on the Tail lift 15. Take care not to position any part of your body between any part of the Tail lift and vehicle

body.



Important notice and operating Decals

• Owners should ensure that the important safety information and operating instructions of the Tail Lift are understood by all operators.

MASTER CONTROL BOX



OPERATING INSTRUCTIONS CAUTION: Before operating the tail lift the operator must firstly complete the following safety checks.

• Ensure that vehicle brakes have been applied.

• Check that the ground upon which the tail lift is to rest is level and tail lift will make contact the ground along its full width.

Tuffman advises owners and operators that this tail lift must not be operated by persons who have not read and understood the following instructions. Owners and operators must observe all safety warnings, load positioning on platform and above all, the restriction on the maximum capacity of this tail lift. Tuffman will not be accountable for any incidents resulting from miss use or overloading this appliance.

• Use the fixed controls located in the master control box or plug in removal remote control pendant.

• Remove safety wire cable or chain & hasp securing the tail lift.

• Turn isolating key located in control box to the “ON” position.

• Operate button marked OPEN and the tail lift will tilt outwards into the horizontal position. • The tail lift can now be operated by pushing and holding the raise or lower buttons.

Stowing the Tail lift (Closing the platform)

• Raise the platform to the horizontal position level with the truck floor. • Press and hold the CLOSE button until the platform is in the vertical position. • Attach the safety chain and turn the isolating switch to the “OFF” position and remove key

Warning! Do not attempt to press OPEN or CLOSE during raising or lowering operation.



REMOTE CONTROL UNIT (Hand Held Type)

All Tieman Remote control Units are manufactured to exacting standards, designed to provide the maximum in reliability, ease of operation and safety. The current Units being supplied have a minimum IP rating of 65. This ensures the units are “totally protected against dust, and protected against LOW Pressure jets of water from all directions –limited ingress permitted”. This safety rating is usually more than adequate for most operating environments. NOTE: If the operating environment is harsher than that defined above, contact Tuffman or your supplier

to confirm the suitability of this rating before use. We offer extensive consultative, maintenance and sales support networks to both existing and potential customers, to ensure that we can completely meet your requirements. WARNING Under no circumstances can the reliability & safety of these units be guaranteed if they are

tampered with by non-authorised persons (i.e. non Tuffman or un-approved personnel) or; Used in environments for which they are not designed or recommended for use in; or; Damaged in anyway and not repaired by Tuffman approved personnel.

A breach of any of these recommendations will void any warranty.



POWER PACK INFORMATION



SECTION 6: MAINTENANCE

Maintenance Inspection and Service Schedule The servicing schedule for your tail lift should be based on the operating conditions and average

number of lifts per day it is subjected to. The following is the manufacturer’s recommended service

schedule based on an average usage of less than 25 lifts per day. If your tail lift is used in a particularly

harsh environment or is performing a high number of lifts per day please contact Tuffman to discuss a

more suitable schedule to ensure a long and reliable life from your tail lift.

DAILY CHECK

o Check for leaks in the hydraulic system. o Check the platform lock for correct operation. o Check the hydraulic oil level, if leaks are apparent. o Check the control box and switches for proper operation. o Check for damage or loose screws on hand control, cable and plugs.

MONTHLY CHECK AND GREASE

o Complete the daily check, plus the following: o Pressure wash the entire unit. o Check if securing bolts are all firm. o Check all welds for cracks. o Grease all grease nipples use Shell Retinax EP2 or Tuffman approved equivalent. o Replace any worn or broken parts. o Check the lifting and lowering speed are to requirements. o Check the oil level, and add, if necessary. (Use ISO Grade 22 and do not overfill).

6 - MONTHLY SERVICE (Minimum of 6 months between services)

o Complete the daily check o Complete the monthly check, plus the following: o Check all electrical cables for chafing or breaking. o Check all hydraulic lines for leaks, cracks or chafing. o Clean hydraulic oil suction filter. o Drain the hydraulic reservoir and re-fill with new, clean ISO Grade 22 oil (Every 12 months) o Check all bolts and washers for tightness. o Check max system pressure. o Check the lifting capacity. (See label for correct capacity). o Check all safety devices for proper operation. o Check the wear plates and replace, if necessary. o Check all electrical connections for tightness. o Check control wiring to remote control for damage.



LUBRICATION



SECTION 7: SCHEMATICS

HYDRAULIC SCHEMATIC



ELECTRICAL SCHEMATIC

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SECTION 8: TROUBLE SHOOTING

PROBLEM CAUSE CORRECTION

01 Motor not running a) Main switch is OFF - Turn switch ON b) Main switch is defective - Repair or replace switch c) Blown fuse in power pack - Replace fuse 12 Volt = 25 Amp, 24 Volt = 16 Amp d) Low battery - Charge or replace battery e) No current on buttons - Short in cable-repair or replace f) Ground strap is loose - Repair or replace ground strap g) Starter solenoid is defective - Repair or replace solenoid h) 2-button remote control is - Repair or replace control defective 02 Motor runs slowly a) Low Voltage - Check & clean all battery connections b) Poor earth connection - Contact at power pack loose - Second Cable from motor to chassis or to batteries. - Charge batteries c) Brushes are dirty or worn out - Replace brushes or motor 03 Empty platform will a) Low hydraulic oil - Check oil level and add new not raise filtered oil - Check hydraulic system for any leaks b) Suction Filter is plugged - Clean or replace Suction Filter 04 Motor runs - Platform a) No current on lift valve in - Check for current at lift valve will not raise power pack solenoid. Replace if necessary b) Lift valve defective - Clean or replace lift valve c) Flow control valve is closed - Adjust or replace flow control valve 05 Platform will not lower a) Main Switch is OFF - Turn switch “ON” b) No current on lift valve in - Check for current at lift valve power pack solenoid by energizing the “LOWER” button. c) Lift valve defective - Clean or replace solenoid lift valve d) Flow control valve is closed - Adjust or replace flow control valve



PROBLEM CAUSE CORRECTION

06 Platform lowers slowly a) In winter, it is normal - Use lower viscosity oil 46cst b) Flow control valve is - Adjust or replace flow control adjusted wrong valve c) Lubricate all grease fittings 07 Platform raises slowly a) Lift valve, inside power pack - Remove lift valve and blow out is leaking inside valve with air, in open & closed positions, reinstall and check again, if still not working, replace valve b) Low current to motor - Check & clean battery. - Charge batteries 08 Platform raises slowly a) Pump defective - Check pressure setting and repair or motor running normally replace pump. 09 Loaded platform a) Relief valve is set too low - Reset relief valve in Power pack stops when lifting, but to 195 Bar (2827 PSI).(Use a the motor is still calibrated pressure gauge is running to properly adjust the relief valve) b) Load is too heavy or placed - Check load capacity and position on in the wrong position platform c) Low hydraulic oil - Check reservoir and add oil if necessary

tt755m owners manual - manufacturer of tieman tail lifts

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