Dahl VARIODOCK User manual

UK
DAHL VARIODOCK™
Maintenance Manual
Installation and User Guide
503749 · 01.2021

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Maintenance manual, installation and user guide UK Dahl VarioDock™
IMPORTANT:
Please read these instructions in full before commencing
installation. Users must also read the instructions in full
before using the product. These instructions must be
submitted to the user on delivery of the VarioDock and
should be kept at an easily accessible location in the
vehicle.
Dahl Engineering’s VarioDock System has been tested in
accordance with, and satisfies the requirements of, ISO
10542-1:2012 and 7176-19:2008.
The docking system has been crash tested in frontal col-
lisions at 48 km/h, 20g, in connection with a wheelchair
weight of 200 kg + test dummies with a mass of 76.4kg
and 102kg where the lap belt was anchored to the floor
of the vehicle, (276.4 kg and 302 kg total weight).
For wheelchair and user facing forward in the vehicle
Table of contents
Warnings 3
Product overview 4-5
Documentation at handover 6
Maintenance interval 7-12
User guide 13-15
Installation of Dahl VarioDock 16-19
Tightening torque 20-21
Electrical connection 22-24
Accessories 25-26
Using VarioDock to anchor car seats 27
Safety belts 28-33
Spare parts 34-35
The securing system for the wheelchair and safety belts for
the user may be designated with the abbreviation WTORS
(Wheelchair Tiedown & Occupant Restraint Systems) in
these instructions.
Warnings
1. In the event that the instructions and warnings in this guide are not followed,
there is a risk of death or serious injury to the wheelchair user and the other
passengers in the vehicle.
2. Installation must be carried out by an experienced technician/fitter.
3. The docking station must be serviced and parts replaced with original Dahl
parts according to the instructions of the service manual. Failure to comply
with the instructions of the service manual may render the product partially
or completely inoperative or cause damage to the product, which can result
in serious or lethal injury to the user and/or other passengers of the vehicle in
the event of fatal injury.
4. Never begin driving the vehicle whilst a wheelchair is being docked in the
docking station or if the user’s safety belt is not secured.
5. Never begin driving the vehicle if the warning tone sounds and/or the red
warning lamp (LED) in the control panel flashes or lights up.
6. WTORS may only be used for forward-facing wheelchairs.
7. Contact Dahl Engineering or your dealer immediately if there is any doubt con-
cerning the use of the product or if the product has faults or non-conformities.
8. Users in wheelchairs should never be transported in the vehicle if certified
WTORS are not used.
9. The user should not be a passenger or driver of the vehicle if both lap belts
and shoulder belts are not used. This is to reduce the risk of the user’s head or
chest hitting interior vehicle elements and other passengers.
10. The docking system, seat belts and components shall be subjected to a check
and maintenance inspection at least once a year in accordance with mainte-
nance interval and documentation.
11. The user should never try to repair, adjust or modify the WTORS components.
Alterations or modifications to the system are strongly discouraged. Any alter-
ations carried out without prior agreement with Dahl Engineering are entirely
the responsibility of the fitter and/or the user.
12. It is forbidden to combine Dahl WTORS components with those of other manu-
facturers. Some belt fittings/components will be very obviously incompatible,
while others may appear to engage correctly, but might not withstand crash
loadings or perform satisfactorily.
13. Do not attach components to weak/non-solid components or materials.
14. The fitter is responsible for ensuring that the installed unit satisfies all statuto-
ry requirements. Contact local/national authorities if there is any doubt in this
regard.
15. Incorrect installation of safety belts and the docking station can cause mal-
functions which can result in death or serious injury to the user.
16. Belt webbing must be protected against contact with sharp edges and corners,
contact with solvents, polishing agents, oil and caustic/corrosive fluids or ma-
terials (in particular battery acid). Damaged, worn, torn or contaminated belt
webbing and components must be replaced. This should be checked daily.
17. An airbag should be deactivated if the user is situated less than 300 mm from
the airbag, or as recommended by the vehicle manufacturer. An airbag should
also be deactivated if retrofitted parts block or have an eect on its inflation/
expansion. If it is necessary to deactivate or remove the airbag, it is impera-
tive, before fitting the docking system, to check if the vehicle manufacturer
can oer a safety belt which is approved to be fitted without an airbag.
18. A docking station which has been involved in a collision from which the vehi-
cle has had to be towed away or where the airbag has been deployed, must be
sent to DAHL Engineering for inspection and possible repair. Safety belts and
components must be replaced without separating the components, because
they may have suered damage that is not visible to the naked eye.
19. Be sure to check national regulations with regard to minimum clear space
requirements and access to emergency exists for seats and wheelchairs for the
vehicle concerned.
20. It is essential, that wheelchair manufacturers’ instructions, references and
warnings are followed when installing and using Dahl Docking Systems. The
EU medical device directive states that a CE-marked medical device which has
been customized outside the manufacturer’s specifications thereby becomes
a customized medical device and that the CE-marking must be removed. Any-
one who customizes a CE-marked medical device outside the manufacturer's
specifications is responsible for quality, safety and performance of the device
and becomes the responsible manufacturer of the customized device.
Complying with the wheelchair manufacturer's user and installation guide
when installing the Dahl Docking System will ensure that the wheelchair
manufacturer's CE-marking will remain intact. Manufacturer manuals for all
CE-marked wheelchairs can be downloaded from our website.

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Maintenance manual, installation and user guide UK Dahl VarioDock™
Product overview
Inspection of the components delivered:
Start by checking if all of the components have been delivered correctly. Please contact
us immediately if any parts are missing.
The contents of a standard kit with Dahl VarioDock, art. no. 503600, are shown on the
next page. Safety belts for securing the user are not included in a standard kit and must
be ordered separately!
Dahl Engineering’s objective is to provide products for wheel-
chair users which satisfy the strict EU M1 safety requirements
for cars, when it is possible and to the extent it is possible, with
due consideration of the design and function of the aid and
appliance concerned. We are therefore continuing our eorts to
develop a range of tried and tested installation kits for dierent
vehicles. These installation kits are tested according to EU regu-
lation 2018/858, ECE R14 & R17, concerning seats and safety belt
anchorages in vehicles.
Dahl VarioDock System and wheelchairs are tested according
to the following:
• ISO 10542-1 SWM and ISO 7176-19, as well as EU Regulation
2018/858, ECE R14 & R17 in many dierent vehicles.
• ECE R10 (Electromagnetic compatibility in vehicles).
• A seat base which fits VarioDock has also been tested to meet
ECE R14 and ECE R17
• See our current range of tested installation kits in our product
catalogue which can be downloaded from our website: http://
wtors.com
Please do not hesitate to enquire whether an installation kit
that has been tested in accordance with the above directives is
available for the vehicle concerned. In this case, separate instal-
lation instructions are available, which must be followed when
installing the docking station.
Position Name Art. no. Quantity
1 Dahl VarioDockTM 503441 1
2 Installation kit 503699 1
3 Complete control box with wires 503700 1
4 Control panel 503553 1
5 Emergency release tool 503161 1
6 Installation tool 503610 1
7 Sticker 503653 1
Art.no. 503600
Dahl Engineering

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Maintenance manual, installation and user guide UK Dahl VarioDock™
Maintenance interval and documentation
Date: ___________ Km: ________________
Once a year or as required you must:
Carefully remove the top section of the docking station (remove the two bolts on each side). See instructions on page 21.
Clean the docking station.
Clean the locking cylinder and locking pin and lubricate with light oil.
Remove the locking pin if there are any signs of corrosion or damage (art. no. 503535).
Adjust the steel wire to the locking pin, art. no. 502400, if necessary.
All steel wires must be examined for signs of wear or evidence of breaks. Replace if necessary.
When the maintenance light is activated, VarioDock must undergo maintenance within 200 uses. Order service kit with art. no. 503636 (see also pages 34-35).
Test whether the manual emergency release functions properly and if the emergency release tool is in the vehicle.
Check whether the wires are loose in the terminals and whether they are intact and insulated. Replace if necessary.
Test whether the electromagnet/solenoid functions correctly.
Test whether the micro switch, art. no. 503640, functions correctly.
Test whether the warning tone (high-pitched howl) is activated and functions correctly.
Test whether the light diodes in the control panel function correctly along with the warning tone.
Check whether any nuts, bolts or screws are loose or damaged. Tighten/replace if necessary. This also applies to the lock plate and its fitting under the wheelchair.
VEHICLES 1ST OWNER
Name:
Street:
City:
Telephone:
Stamp of maintenance partner
Telephone:
VEHICLES 3RD OWNER
Name:
Street:
City:
Telephone:
Stamp of maintenance partner
Telephone:
VEHICLES 2ND OWNER
Name:
Street:
City:
Telephone:
Stamp of maintenance partner
Telephone:
VEHICLES 4TH OWNER
Name:
Street:
City:
Telephone:
Stamp of maintenance partner
Telephone:
Documentation at handover
to customer
Vehicle specifications:
Make & Model:
Vehicle Identification Number:
Year:
Information about the docking station:
Article Number:
Serial Number:
Production Date:
Next maintenance:
Date : ___________
Maintenance carried out:
Stamp
Replaced parts:

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Maintenance manual, installation and user guide UK Dahl VarioDock™
Maintenance interval and documentation
Date: ___________ Km: ________________
Once a year or as required you must:
Carefully remove the top section of the docking station (remove the two bolts on each side). See instructions on page 21.
Clean the docking station.
Clean the locking cylinder and locking pin and lubricate with light oil.
Remove the locking pin if there are any signs of corrosion or damage (art. no. 503535).
Adjust the steel wire to the locking pin, art. no. 502400, if necessary.
All steel wires must be examined for signs of wear or evidence of breaks. Replace if necessary.
When the maintenance light is activated, VarioDock must undergo maintenance within 200 uses. Order service kit with art. no. 503636 (see also pages 34-35).
Test whether the manual emergency release functions properly and if the emergency release tool is in the vehicle.
Check whether the wires are loose in the terminals and whether they are intact and insulated. Replace if necessary.
Test whether the electromagnet/solenoid functions correctly.
Test whether the micro switch, art. no. 503640, functions correctly.
Test whether the warning tone (high-pitched howl) is activated and functions correctly.
Test whether the light diodes in the control panel function correctly along with the warning tone.
Check whether any nuts, bolts or screws are loose or damaged. Tighten/replace if necessary. This also applies to the lock plate and its fitting under the wheelchair.
Maintenance interval and documentation
Date: ___________ Km: ________________
Once a year or as required you must:
Carefully remove the top section of the docking station (remove the two bolts on each side). See instructions on page 21.
Clean the docking station.
Clean the locking cylinder and locking pin and lubricate with light oil.
Remove the locking pin if there are any signs of corrosion or damage (art. no. 503535).
Adjust the steel wire to the locking pin, art. no. 502400, if necessary.
All steel wires must be examined for signs of wear or evidence of breaks. Replace if necessary.
When the maintenance light is activated, VarioDock must undergo maintenance within 200 uses. Order service kit with art. no. 503636 (see also pages 34-35).
Test whether the manual emergency release functions properly and if the emergency release tool is in the vehicle.
Check whether the wires are loose in the terminals and whether they are intact and insulated. Replace if necessary.
Test whether the electromagnet/solenoid functions correctly.
Test whether the micro switch, art. no. 503640, functions correctly.
Test whether the warning tone (high-pitched howl) is activated and functions correctly.
Test whether the light diodes in the control panel function correctly along with the warning tone.
Check whether any nuts, bolts or screws are loose or damaged. Tighten/replace if necessary. This also applies to the lock plate and its fitting under the wheelchair.
Next maintenance:
Date: ___________
Next maintenance:
Date: ___________
Maintenance carried out: Maintenance carried out:
Stamp Stamp
Replaced parts: Replaced parts:

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Maintenance manual, installation and user guide UK Dahl VarioDock™
Maintenance interval and documentation
Date: ___________ Km: ________________
Once a year or as required you must:
Carefully remove the top section of the docking station (remove the two bolts on each side). See instructions on page 21.
Clean the docking station.
Clean the locking cylinder and locking pin and lubricate with light oil.
Remove the locking pin if there are any signs of corrosion or damage (art. no. 503535).
Adjust the steel wire to the locking pin, art. no. 502400, if necessary.
All steel wires must be examined for signs of wear or evidence of breaks. Replace if necessary.
When the maintenance light is activated, VarioDock must undergo maintenance within 200 uses. Order service kit with art. no. 503636 (see also pages 34-35).
Test whether the manual emergency release functions properly and if the emergency release tool is in the vehicle.
Check whether the wires are loose in the terminals and whether they are intact and insulated. Replace if necessary.
Test whether the electromagnet/solenoid functions correctly.
Test whether the micro switch, art. no. 503640, functions correctly.
Test whether the warning tone (high-pitched howl) is activated and functions correctly.
Test whether the light diodes in the control panel function correctly along with the warning tone.
Check whether any nuts, bolts or screws are loose or damaged. Tighten/replace if necessary. This also applies to the lock plate and its fitting under the wheelchair.
Maintenance interval and documentation
Date: ___________ Km: ________________
Once a year or as required you must:
Carefully remove the top section of the docking station (remove the two bolts on each side). See instructions on page 21.
Clean the docking station.
Clean the locking cylinder and locking pin and lubricate with light oil.
Remove the locking pin if there are any signs of corrosion or damage (art. no. 503535).
Adjust the steel wire to the locking pin, art. no. 502400, if necessary.
All steel wires must be examined for signs of wear or evidence of breaks. Replace if necessary.
When the maintenance light is activated, VarioDock must undergo maintenance within 200 uses. Order service kit with art. no. 503636 (see also pages 34-35).
Test whether the manual emergency release functions properly and if the emergency release tool is in the vehicle.
Check whether the wires are loose in the terminals and whether they are intact and insulated. Replace if necessary.
Test whether the electromagnet/solenoid functions correctly.
Test whether the micro switch, art. no. 503640, functions correctly.
Test whether the warning tone (high-pitched howl) is activated and functions correctly.
Test whether the light diodes in the control panel function correctly along with the warning tone.
Check whether any nuts, bolts or screws are loose or damaged. Tighten/replace if necessary. This also applies to the lock plate and its fitting under the wheelchair.
Next maintenance:
Date: ___________
Next maintenance:
Date: ___________
Maintenance carried out: Maintenance carried out:
Stamp Stamp
Replaced parts: Replaced parts:

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Maintenance manual, installation and user guide UK Dahl VarioDock™
Securing the wheelchair in the VarioDock
TM
1. The user must be driven forward, but not into the
docking station. Now the height of the wheelchair
must be adjusted on the control panel (it is the vehi-
cle adapter/workshop that must specify the height
of the lock plate and write on the supplied sticker).
2. The VarioDock
TM
is equipped with a control switch
which indicates whether the lock plate is properly
engaged in the docking station. As soon as the
locking plate touches the locking pin, a warning tone
is heard and the red LED (LED) in the control panel
lights up until the locking plate is fully in place or the
wheelchair is driven away from the docking station.
3. As an indication that the wheelchair is properly
secured, the warning tone will cease, the red diode
in the control panel will go out and the green diode
lamp (LED) will light up.
4. By pressing the blue button on the control panel,
the docking station can be pulled down/tightened
so that unwanted slack is reduced while driving.
DO NOT press the green button to pull the docking
downwards, as the force which tightens the docking
station is not regulated, which may cause damage to
the wheelchair.
5. When the wheelchair is correctly secured, the safety
belt should be fitted and adjusted so that it fits the
user.
Do not drive the vehicle whilst a wheelchair is
being manoeuvred into position in the docking
station. In general, do not use the vehicle if the
wheelchair is not correctly secured, the warning
tone sounds and/or the red warning lamp (LED)
in the control panel flashes or is lit! Therefore,
always check if the lock plate is properly engaged
in the docking station by trying to back the wheel-
chair out of the docking station before moving the
vehicle. (It must not be possible to back out of the
docking station without pressing the red button in
the control panel).
Release from the VarioDock
TM
1. When the vehicle has been brought to a halt, remove
the safety belt.
2. Press the release button on the control panel
(see page 15, F), and the docking station will then
automatically drive upwards to the original height.
The locking pin is released for either 5 or 8 seconds
(optional). The red LED lights up and a warning
tone is heard. The locking pin is then automatically
locked / activated again. Do not try to back out of
the docking station until the red LED in the control
panel, indicating the release position, is lit.
WARNING!
Attempting to reverse the wheelchair before the
red LED has been illuminated will result in blocking
the docking station's lock mechanism which makes
it impossible to reverse. If this happens repeat the
above unlocking procedure.
3. Move the wheelchair away from the docking station
within the 5 or 8 second period.
If the locking pin is not released when you press the
red button in the control panel
1. In the event of electrical failure, a manual emergen-
cy release is located at the front edge of the docking
station. Push the red release arm to one side and
hold it there while the wheelchair moves away.
2. An emergency release tool in red is delivered with
each VarioDock. This has to be pushed between the
lock plate of the wheelchair and the docking station
to release the wheelchair.
VarioDock
TM
, seat belts and components should be
inspected at least once a year in accordance with the
maintenance interval and documentation.
Safety belts (Accessory for VarioDock
TM
)
Safety belts must be inspected and cleaned regularly.
Replace belts or straps that have faded in the sun, are
worn at the edges, have tears or show clear signs of
wear. Components that are damaged or worn must
also be replaced. Avoid soiling the belts with chemi-
cals, polishing agents, oil or, in particular, battery acid.
Cleaning the belts:
Wash by hand with hot water and mild soap. Rinse
thoroughly with water and allow to dry in the shade.
Do not expose the belts to direct sunlight and never
use powerful cleaning agents.
Only moving metal parts that are not in contact with
belt webbing should be lubricated with light oil when
necessary, and, if so, very carefully. Never lubricate
inertia reels or other components that are part of
the safety belt. Never let the belt webbing come into
contact with oil or grease.
Maintenance interval and documentation
Date: ___________ Km: ________________
Once a year or as required you must:
Carefully remove the top section of the docking station (remove the two bolts on each side). See instructions on page 21.
Clean the docking station.
Clean the locking cylinder and locking pin and lubricate with light oil.
Remove the locking pin if there are any signs of corrosion or damage (art. no. 503535).
Adjust the steel wire to the locking pin, art. no. 502400, if necessary.
All steel wires must be examined for signs of wear or evidence of breaks. Replace if necessary.
When the maintenance light is activated, VarioDock must undergo maintenance within 200 uses. Order service kit with art. no. 503636 (see also pages 34-35).
Test whether the manual emergency release functions properly and if the emergency release tool is in the vehicle.
Check whether the wires are loose in the terminals and whether they are intact and insulated. Replace if necessary.
Test whether the electromagnet/solenoid functions correctly.
Test whether the micro switch, art. no. 503640, functions correctly.
Test whether the warning tone (high-pitched howl) is activated and functions correctly.
Test whether the light diodes in the control panel function correctly along with the warning tone.
Check whether any nuts, bolts or screws are loose or damaged. Tighten/replace if necessary. This also applies to the lock plate and its fitting under the wheelchair.
Next maintenance:
Date: ___________
Maintenance carried out:
Stamp
Replaced parts:
User Guide – Operation of the VarioDockTM
Please refer to the description of VarioDockTM on page 14. The user must read these instructions in full prior to using the equipment.

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A B C
D
EF
G
H
Maintenance manual, installation and user guide UK Dahl VarioDock™
I
A B C
D
EF
G
H
Control panel
A Red diode lights up:
Wheelchair is not secured and can be
released from the VarioDockTM
B Green diode lights up:
Wheelchair is secured.
CLamp illuminates when maintenance
is due.
D Yellow button: Adjusts upwards. Keep
button pressed, to increase step length,
allowing quicker adjustment. Press but-
ton once to adjust in steps of 1mm.
E Green button: Adjusts downwards. Keep
button pressed, to increase step length,
allowing quicker adjustment. Press but-
ton once to adjust in steps of 1mm.
F Red button: Unlocks the VarioDockTM
G Blue button: Pulls docking station
down to reduce unwanted slack.
HSymbol for wheelchair's ground
clearance.
IDisplay shows the ground clearance of
VarioDockTM (wheelchair's ground clear-
ance must be measured, see instructions
on page 16).
To reduce standby power consumption, display can be set to standby mode (see more information under “electrical connection”)!
Functional description
The Dahl VarioDockTM (1) is designed to retain manual and
electric wheelchairs, as well as Dahl’s seat bases in the vehi-
cle’s floor. A control module (6) controls and monitors Dahl
VarioDockTM's features, distributes power to the various com-
ponents, as well as receiving and sending signals to and from
the control panel. Wires are included. Do not carry out any
modifications to the supplied wiring or other components. A
lock plate and an 8mm spacer (2) must be fitted under the
wheelchair. When the wheelchair is manoeuvred towards the
VarioDock, the wheelchair is guided into place by means of
the lock plate.
When the lock plate is fully engaged in the VarioDock, a
spring-loaded lock pin (3) automatically secures the lock
plate. VarioDock is equipped with a built-in control switch that
indicates whether the lock plate is correctly secured in the
VarioDock. As soon as the lock plate comes into contact with
the locking pin, a warning tone will sound (a high-pitched
howl), and the red diode/lamp - LED (A) in the control panel
will light up until the lock plate is either fully engaged or
else the wheelchair is removed from the VarioDock. With the
wheelchair correctly secured, the warning tone stops and
the green diode/lamp - LED (B) in the control panel will light
up to indicate that the wheelchair is properly secured. The
control panel (5) (see descriptions of control panel’s functions
on page 15) is connected to an electromagnet which triggers/
releases the lock pin for approx. 5 or 8 seconds, aer which it
is automatically locked once more.
In case of an electrical fault, there is a manual emergency
release (4) on the front edge of the VarioDock. The release
arm should be pushed sideways and held in order to release
the wheelchair. You can also use the emergency release tool,
which is delivered with the VarioDock. Fixing parts in the form
of bolts, nuts, washers, etc., are included.
Lock plate and spacer
Wheelchair, max. weight 200 kg
Control module

16 17
Varenr. DIV99L - Labels, matsølv
Format:85 x 20 mm, udstanset
Farver: Sort tryk
Reklamationer på grund af mindre afvigelser i trykfarver såvel standard som specialfarver imødekommes ikke. Der ydes ingen garanti for farvens mulighed for afsmitning eller lysægthed. For fejl som ikke er rettet i godkendt korrektur, hæfter køber alene.
Ved reklametryk eller lignende er evt. overtrædelse af copyright og varemærkerettigheder over for 3. part, alene for købers risiko og ansvar
. Korrekturer som IKKE er godkendt inden 1 mdr. efter modtagelse betragtes som annulleret.
Artikel:
Materiale:
Pladeformat:
1 el. 2-Sidet:
Graker____________________________
Oplag/Pladeantal _________________________
Bemærkninger:
Intern:
PDF:
Printer:
Skæring:
Laminat:
Stans:
DIV99L - Label 85 x 20 mm udst.
Matsølv folie
-
-
221019 + 181019 - EL
35990
-
Stans
-
-
-
1 4
7
2
5
3
6
Maintenance manual, installation and user guide UK Dahl VarioDock™
Varenr. DIV99L - Labels, matsølv
Format:85 x 20 mm, udstanset
Farver: Sort tryk
Reklamationer på grund af mindre afvigelser i trykfarver såvel standard som specialfarver imødekommes ikke. Der ydes ingen garanti for farvens mulighed for afsmitning eller lysægthed. For fejl som ikke er rettet i godkendt korrektur, hæfter køber alene.
Ved reklametryk eller lignende er evt. overtrædelse af copyright og varemærkerettigheder over for 3. part, alene for købers risiko og ansvar
. Korrekturer som IKKE er godkendt inden 1 mdr. efter modtagelse betragtes som annulleret.
Artikel:
Materiale:
Pladeformat:
1 el. 2-Sidet:
Graker____________________________
Oplag/Pladeantal _________________________
Bemærkninger:
Intern:
PDF:
Printer:
Skæring:
Laminat:
Stans:
DIV99L - Label 85 x 20 mm udst.
Matsølv folie
-
-
221019 + 181019 - EL
35990
-
Stans
-
-
-
Installation of Dahl VarioDock™
Installation must be carried out by a qualified and
experienced technician/fitter.
In the area where the wheelchair is to be locked into
the docking system, the floor must be flat along the
full length and width of the wheelchair. The length
of the flat floor must be such that it is possible to
manoeuvre the wheelchair into the docking system
without problems. It is essential that there is no dif-
ference in the height of the floor from one side to the
other at the location where the docking station is to
be installed. It is also important that the lock plate is
fitted straight/horizontally under the wheelchair. If the
above is not carried out carefully, there is a risk that
the wheelchair may not be manoeuvred properly into
place in the docking station.
1. Delivery of VarioDockTM
A. VarioDockTM is installed on a plate for transport
when delivered to avoid damage during transport.
Remove this plate and the 6 bolts before installing.
See also instructions 5 and 6 on page 17.
2. Installing the lock plate
A. Install the lock plate and 8 mm spacer under the
wheelchair in accordance with the wheelchair man-
ufacturer’s instructions, which can be downloaded
from our website, as well as instructions on the
drawings on pages 5 and 14. Before the lock plate
and spacer are installed, carry out the following:
B. The installer must make sure that the wheelchair
has a solid construction at the place where the
lock plate shall be installed which can withstand
the load during a collision. On our website http://
wtors.com you can see the list with all approved
adaptation kits for wheelchairs and download
manufacturers’ instructions for use and assembly,
which must be followed when installing the lock
plate and spacer.
C. Be aware that bolts with art.no. # 502800 for secur-
ing the lock plate are custom made bolts, which
are only available in one length. It is very important
that the installer carefully adjusts the bolts to the
correct length, which fits the individual wheel-
chair’s approved adaptation kit with spacers, if
applicable. If the bolts are too short to fully engage
into the entire thread depth, they will not be strong
enough to withstand the load during a collision. If
the bolts are too long, the batteries or other wheel-
chair components may be damaged. Therefore be
careful when shortening the bolts.
Warning! Never use bolts other than original Dahl
bolts # 502800 for fixing the lock plate. Standard bolts
are not strong enough to withstand a collision.
3. Measuring ground clearance
A. For correct determination of the wheelchair’s
ground clearance, it must be measured with the
user seated in the wheelchair (pay attention to
correct tyre pressure). Carefully drive the wheel-
chair into the VarioDockTM and set the height of
VarioDockTM so that there is 2 mm space between
the underside of the lock plate and docking station.
B. Read the ground clearance o the display and write
it on the supplied sticker (see the design of the
sticker on the right).
4. Location of VarioDock™
A. Place the wheelchair, with the user sitting in it,
facing forward in the vehicle at the desired installa-
tion location. If the user is the driver of the vehicle,
make sure that the user can reach and operate all
necessary instruments and driving functions in a
proper and safe manner from this position.
B. Place the docking station under the wheelchair.
C. Mark the docking station’s position on the floor
and the lock plate’s position (in width and length)
under the wheelchair.
5. Beginning installation work
Ask the wheelchair user to leave the vehicle, so that
installation work can begin.
A. Drive the VarioDockTM to the lowest position
(61mm) before you begin installation work.
B. Loosen the 4 bolts on the side of the VarioDockTM
(important: note instructions on page 21!) and
carefully remove the top section of the docking sta-
tion. See pictures 3 and 4 on page 17. (Please note
that electronic components are installed in the top
section!). Mark the location of the bolts on the floor
of the vehicle, and drill holes through the floor
at these locations. Be careful when marking and
drilling through the vehicle floor to avoid damage
to brake pipes, wires, fuel tank and the like. Never
drill any holes until you are certain that the holes
match the location of the installation components.
C. Secure the docking station with the supplied bolts,
nuts, etc. See illustrations pages 18 and 19.
Installation of Dahl VarioDockTM
Drill holes in
the anchorage
plate for running
through cables, if
necessary.
Removal of top section
Pictures 1-6
1. Loosen bolts, see instructions 3 on page 21
2. Bolts are loosened
3. Carefully remove the top section
4. Place top section as shown on picture
5. Plate and 6 bolts used for transportation
of the VarioDockTM, shown on picture 6,
must be dismantled and discarded!
6. The transportation plate and bolts are
now removed
Fitting the top section
Picture 7
When assembling the slide and bottom
frames, the pin of the potentiometer must
be carefully placed in the hole of the bottom
frame, otherwise there is a risk of damaging
the potentiometer. If the docking station is
tightened when the pin is not inserted in the
hole, the potentiometer will be destroyed/
damaged.
!

18 19
Maintenance manual, installation and user guide UK Dahl VarioDock™
Floor pockets
Reinforcing brackets
12 mm plywood
6 mm plywood
Plywood spacers
See further details in separate
installation instructions for
the vehicle in question.
#503684 / #503688 / #503689
Anchorage plate
Nut
#503660
Nut
#503660
Nut
#503660
Nut
#503660
Plywood
spacers
Plywood spacers
Anchorage plate Anchorage plate
Plywood
spacers
Plywood
spacers
Use a hammer to make a dent for the nut
if placed on top of floor pan
Fitting examples Fitting examples

20 21
4
3
1
2
!
Maintenance manual, installation and user guide UK Dahl VarioDock™
!
Art. nr. 503610
WARNING!
In countries where legislation demands meeting EU-Regulation
2018/858, Annex II, Part III, Appendix 3 relating to vehicles fitted
for wheelchairs, a fitting kit MUST be used, which has been
tested in the position and the specific vehicle the wheelchair
will be used in, for fitting the docking system and safety belts
for the wheelchair user.
Please enquire with regard to the current range of vehicle spe-
cific fitting kits with corresponding fitting instructions.
If a vehicle specific fitting instruction exists, it must be request-
ed from Dahl Engineering and followed when fitting safety
belts, floor pockets, floor rails and docking station.
The following fitting examples for fitting the Dahl VarioDock
can only be used in countries where no legal requirements for
tests of docking systems in the specific vehicle and mounting
position are to be found.
We always recommend using a fitting kit which has been
tested in the specific vehicle and which meets EU-regulation
2018/858.
BE CAREFUL:
When tightening nuts and bolts, they must not be tightened
so hard that the floor profiles are compressed or deformed.
Carefully tighten the bolts until the profiles in the floor of the
vehicle begin to give, though never more than the specified
maximum tightening torque for the bolt concerned.
Corrosion protection
All holes and installation elements under the floor of the
vehicle should be treated with an anti-corrosion agent.
Please also be aware of the vehicle manufacturer’s guide-
lines, if available, for corrosion protection. To avoid water
penetrating the holes in the floor of the vehicle, sealant must
be applied to the holes.
3. Art.no. 502839
– bolts on the side of the VarioDockTM
Loosen and tighten bolts in order 1-4. Before tighten-
ing, make sure all the bolts are engaged in the thread.
Otherwise, there is a risk that the latches inside the
docking station may fall out of position.
Bolts on the side of the docking station must be tight-
ened to 0.3mm slack between bolt and bushing so
that the bushing can rotate. Test if the lock coating on
the bolts works so the bolts cannot loosen during use.
➜ The lock coating on the bolts # 502839 can be
installed / removed max. 5 times. Thereaer, the
bolts must be replaced with new ones.
2. Art.no. 502685 and 502735,
bolts inside the VarioDockTM
All 6 bolts inside the VarioDockTM must be tightened
with 40 Nm. It is important to tighten these bolts
correctly. If the vehicle floor is not level, it will lead to
unnecessary wear and malfunction, and in the worst
case result in malfunction of the height adjusting
function of VarioDockTM.
When tightening the bolts, please use fitting tool with
art.no. #503610 to prevent washers turning out of
position. Please remove the fitting tool aer use.
Tightening torques
1. Art.no. 503125 – Dahl lock plate and 8mm spacer,
with Dahl Special Bolts #502800
These bolts must be tightened with 16-18 Nm and
secured with Loctite 222 or equivalent.
!
If bolts are tightened with more than
40 Nm, the docking station will not
function properly and there will be
permanent damage to the bottom
frame.
!
WARNING!
Risk of death or serious injury
If bolts are not properly secured and
they come loose, the docking station
cannot secure the wheelchair, thereby
causing risk of death or serious injury
for the wheelchair user and the vehi-
cle’s other passengers.

22 23
2
1
Maintenance manual, installation and user guide UK Dahl VarioDock™
Potentiometer Motor (+)
Solenoid /
Electromagnet (+)
Solenoid /
Electromagnet (-)
+12V battery
-battery
Reset-button
Motor (-) Microswitch
Parking
brake
Display
DIP switch
DIP switch
Electrical connection
Settings on DIP switches
DIP 1 og DIP 2:
Setting the tightening rate by pressing the blue button on the control panel
If VarioDock is to be used for multiple wheelchairs, we recommend choosing a low
tightening rate to avoid any damage to the wheelchairs due to excessive pulling.
! NOTE: Please enquire from the wheelchair manufacturer whether the wheelchair
may be pulled down, in order to avoid damage to the wheelchair.
DIP 1 DIP 2 Tightening rate
OFF OFF 15 kg +/- 10
OFF ON 30 kg +/- 10
ON OFF 40 kg +/- 10
ON ON 50 kg +/- 10
DIP 3: Holding time of the lock pin
DIP 3 Holding time of the lock pin
OFF 5 seconds
ON 8 seconds
DIP 4: Activation of parking brake
DIP 4 Parking brake contact function: NO or NC
OFF If a signal is connected when the parking brake is being activated, so that
12V can be measured on the control unit’s parking brake terminals 1 and
2 (polarity is irrelevant), switch 4 on DIP switch must be set to OFF (NO
function).
ON If a signal is cut o when the parking brake is activated, so that 12 V
CANNOT be measured on the control module’s parking brake terminals 1
and 2 (polarity is irrelevant), switch 4 on DIP switch must be set to ON (NC
function).
1. Disconnect the cable on the battery’s negative terminal.
2. Find a suitable installation site for the control panel.
If the docking station is used by a person driving the vehicle himself
– At an easily accessible and visible location when the wheelchair is
secured in the docking station and the driver is looking forward from
the driving position.
If the docking station is for a passenger – At a location which is visible
when the driver of the vehicle is sitting in the driver’s seat and looking
forward.
3. Wiring must be installed so that it is not exposed to mechanical loads
such as wear, vibrations, kinks and sharp edges which can cause breaks
and result in malfunctions or, in the worst case, a short circuit.
To ensure suicient power supply to the docking station, the supply
cable must be installed directly to the vehicle’s battery, otherwise there
is a risk of malfunction and overload of the vehicle’s original wiring.
The power supply must be fused with a 30 amp fuse (not included.) See
the wiring diagram on page 24 for correct connection.
4. Electrical connection
- To reset the maintenance counter, press the reset button down on the
circuit board for approx. 15 seconds. The yellow LED on the control
panel flashes when the reset is done.
- Parking brake (1) and (2): Polarity is not important.
- The soware reset is performed by pressing the up and down buttons
of the control panel simultaneously for 3 seconds.
- Function when lock pin is blocked: To protect the electrical system
from overload, the power supply for the locking mechanism will
pulsate if blocking the lock pin. This can be can be heard as pulsating/
clicking sound from inside the docking station.
DIP 5: Display which shows ground clearance (see Fig. I on page 15) can be set
to be permanently active or switch o aer 30 seconds.
DIP 5 Display state
OFF Display will switch o aer 30 seconds
ON Display is permanently active
DIP 6: No function
DIP 7 og DIP 8: Calibration of the height
Prior to calibration, it must be ensured that VarioDock can be adjusted with-
in the full range of travel (61-91mm)! Settings MUST be made in the order
shown.
DIP 7 DIP 8 Function
OFF OFF 1. Adjust VarioDock™ to approx. middle of the full range
of travel
ON OFF 2. Adjust the VarioDock™ to the top position – wait until
it stops by itself, before releasing the button
ON OFF 3. Adjust the VarioDock™ to the bottom position - wait
until it stops by itself, before releasing the button
ON ON 4. Set the display to lowest position in millimetres
(61mm) with the up / down buttons
ON OFF 5. Adjust the VarioDock™ to the top position - wait until
it stops by itself, before releasing the button
ON ON 6. Set the display to highest position in millimetres
(91mm) with the up / down buttons
OFF OFF 7. The settings are complete
5. Carefully fit the docking station’s top. It is important that the potentiometer
pin be placed in the hole in the bottom frame when assembling slides and
bottom frames. Otherwise there is a risk of damaging the potentiometer. If the
docking station's top is fitted and the potentionmeter is not sitting properly in
the hole, it will be damaged. See instructions on page 17. Please be careful to
place wires and cables so that they do not touch the moving parts.
6. Fit the cable onto the battery’s negative terminal.

24 25
EMERGENCY RELEASE TOOL
FOR DAHL DOCKING STATION
INSERT THIS PLATE IN THE GAP
UNDER THE DOCKING LOCK PLATE
WITH THIS SURFACE DOWNWARDS
PUSH FORWARD
UNTIL THE LOCK PIN RELEASES
AND BACK OUT THE WHEELCHAIR
#503642
#503646
Micro-interrupteur
#503690
#503645
#503641 #502350
Note 1
Note 2
Note 2
Note 2
#503648
#503644
#503649
#502457
#503640
#503647
#503554
#503643
Maintenance manual, installation and user guide UK Dahl VarioDock™
Solenoid/ Electromagnet
Art. no. 503161
12 Volt DC
Adjustment and final
check
1. Check the function, operation and location of
the docking station, control panel and safety
belt with the user sitting in the wheelchair.
2. Check if all nuts and bolts are properly tight-
ened.
3. Check if all wires and cables are free of the
moving parts of the docking station and
wheelchair.
4. Check if the manual emergency release mecha-
nism functions correctly.
5. Instruct the user in the correct use of the manu-
al release mechanism as well as the emergency
release tool.
6. Instruct the user in the correct use of the
docking station and go through all warnings
contained in these instructions.
7. Inform the user of maintenance and inspec-
tion as stated in the maintenance interval and
documentation.
You can find videos and more information about
maintenance and installation of DAHL Vario-
DockTM on our website: http://wtors.com
Wiring diagram Emergency release tool
Parking Brake Switch
Display with house
Potentiometer with Housing
Vertical Power
Motor Complete
Controller PCB with housing
Note 1: Terminal Block
Note 2: Electrical Plug
Microswitch

26 27
!
Maintenance manual, installation and user guide UK Dahl VarioDock™
!!
Dahl VarioDock™ has also been tested and approved for anchoring Dahl COMFORT
Seat with integrated 3-point seat belt, placed on seat row 2 or behind, in a number of
vehicle models.
Using VarioDock™ for anchoring the Dahl COMFORT Seat with an integrated 3-point
seat belt requires a particularly strong reinforcement kit for the vehicle floor which is
designed, tested and approved for the specific vehicle and installation position.
In the event of a collision, the vehicle’s floor will be subjected to a much higher
torque / load when using a seat with integrated seat anchorage points, than when
using a wheelchair, where all seat anchorage points are rooted in the vehicle body
and floor.
Please see the current delivery programme of approved and vehicle-specific anchor-
ing kits in our product catalogue, which can be downloaded from our website
http://wtors.com
WARNING! Risk of death or serious injury
Anchorage of Dahl COMFORT Seat
with integrated 3-point seat belt
Do not use VarioDock™ to anchor Dahl COMFORT Seats or other seats with integrated seat belt anchor points, if the vehicle has not been fitted with an
approved reinforcement kit for VarioDock™.
If a reinforcement kit that has been approved for this use has not been fitted, there is a risk that the user and other passengers in the vehicle may
suer serious or fatal injuries during a collision as a result of the vehicle floor being deformed severely or the anchoring points of the docking station
being torn loose.
Therefore, ask your dealer if a VarioDock™ reinforcement kit approved for anchorage of Dahl COMFORT Seat has been
fitted to the vehicle and mounting position prior to commissioning.
Seat bases for
original driver’s seats
In addition to being approved for wheelchair tie-down, Dahl
VarioDockTM has also been tested and approved for anchoring
a number of original car manufacturers’ seats.
We oer seat bases with pre-drilled holes that fit a number
of car manufacturers’ original driver’s seats and their original
seat heights. These seat bases can be anchored in theDahl
VarioDockTM and placed in the vehicle’s 1st seat row, allowing
the driver and passenger to swap places.
Our seat bases are tested in accordance with ECE Regulations
14 and 17.
Do not use the VarioDockTM for anchoring a car
seat which has not been tested and approved.
Always make sure that the vehicle floor is
approved for use of seats with integrated
3-point seat belt.
WARNING!
Risk of death or serious injury!
Please see current delivery programme with approved kits in
our product catalogue, which can be downloaded from our
website http://wtors.com

28 29
=
=
30°
45°
75°
300
15°
15°
10-60 mm 10-60 mm
75°
45°
30°
HHT
650mm
450mm
220 220
HHT
650mm
450mm
220 220
=
=
30°
45°
75°
300
15°
15°
=
=
*
500
100
400
200
45°
=
=
500
100
400
200
45°
*
=
=
500
100
400
200
45°
*
10-60 mm 10-60 mm
75°
45°
30°
Maintenance manual, installation and user guide UK Dahl VarioDock™
Recommendations for Clear Zones
Clear zones are recommended areas in which hard or sharp installation components or objects
should not be placed. The clear zone recommendations in ISO 10542 are based on the way in
which an occupant moves during a crash/collision. To reduce the risk of injuries to the head
and chest, hard vehicle components and parts for WTORS which lie within the clear zones
should be covered with padding that meets the requirements with regard to the hardness of
materials as specified in FMVSS 201, ECE regulation no. 21 or EU directive 74/60.
The wheelchair and user must be placed facing forward in the vehicle.
FCZ = Frontal Clear Zone
650 mm. when both lap belts and diagonal belts are used.
950 mm. when only lap belts are used.
The use of both lap belts and diagonal belts is recommended to reduce the risk of head and
chest impact. The majority of countries require the use of both lap belts and diagonal belts. It
may be impossible to comply with the recommendation for FCZ if the wheelchair is used by a
person driving the vehicle themselves.
HHT= Seated head height
Approx. 1200 mm for a small adult female. Approx. 1550 mm for a tall adult male.
Safety belts
Only use Dahl WTORS or e-(ECE), E-(EU) or ISO 10542 certified safety
belts for securing occupants of the vehicle. Please refer to Dahl
Engineering’s product catalogue containing WTORS and certified
safety belts.
Preferred and optional angles for location of the lap belt:
▲ = Preferred Zone / ■= Optional Zone
Recommended location of
shoulder belt’s top anchoring point:
▲ = Preferred Zone
■= Optional Zone
The lap belt should make full contact with the
front of the body in the area where the pelvis
and thighbone meet.
*= Installation height from the floor
and up to the shoulder and the
shoulder belt’s top anchoring
point depends on the height of
both the user and the wheelchair.
The shoulder belt’s anchoring
point must be located in such a
manner, that the belt runs over the
midpoint of the shoulder.
Safety belts must not be held
away from the body by wheelchair
components or parts such
as armrests or wheels.
When using wheelchair with
Dahl Docking system, the
floor anchorage points for
occupant restraitn should
be located 10-60mm outside
wheels, on each side.

30 31
A B C
81
Ø46
Ø46
( )
▲
(
▲
)
( )
Maintenance manual, installation and user guide UK Dahl VarioDock™
Driving direction
Driving direction
Driving direction
Art. no. 501897
Art. no. 501898
Installation of universal fitting in floor pocket and floor rail with airline hole pattern
Make sure that the floor pocket or floor rail is free of small stones or other dirt. If
necessary, clean prior to installation of the universal fitting. If the floor pocket or
the floor rail is not free of dirt, there is a risk that the fitting cannot be installed or
that it will not be fitted correctly.
1. Place the universal fitting over the holes.
2. Press downwards on the universal fitting so that the spring-action locking bolt
moves upwards. Whilst the fitting is being pressed downwards, push the fitting
backwards or forwards until the spring-action locking bolt slides down into one
of the holes.
3. A click should be heard when the locking bolt hits the bottom of the hole.
▲ = Preferred way of mounting
■= Optional way of mounting
Driving direction
Driving direction
Min 10 mm plywood
Installation examples of floor pocket
In countries where legislation demands meeting EU-Regulation 2018/858, Annex II,
Part III, Appendix 3 relating to vehicles fitted for wheelchairs, a fitting kit MUST be
used, which has been tested in the position and the specific vehicle the wheelchair
will be used in, for fitting the docking system and safety belts for the wheelchair
user.
Please enquire with regard to the current range of vehicle specific fitting kits with
corresponding fitting instructions.
If a vehicle specific fitting instruction exists, it must be requested from Dahl
Engineering, and followed when fitting safety belts, floor pockets, floor rails and
docking station.
The following fitting examples for fitting the Dahl VarioDock can only be used in
countries where no legal requirements to tests of docking system in the specific
vehicle and mounting position are to be found.
We always recommend using a fitting kit which has been tested in the specific
vehicle and which meets EU regulation 2018/858.
Warning

32 33
90°
90°
#500984
!
Maintenance manual, installation and user guide UK Dahl VarioDock™
!
Examples of installation of retractor and bracket
(D-loop) for anchoring of shoulder belt
Please see separate installation guide for mounting of anchoring kit
for shoulder belt for each vehicle.
Example with the retractor installed on the wall.
Example with the retractor installed in
the vehicle floor.
Example with 178 mm height adjustment
Art. no. 500945.
Here, examples are shown of the
proper orientation (90°/90) of the
D-loop and retractor for both floor
and wall mounted retractors.
It must be possible to rotate the
D-loop for the shoulder belt when
the bolt is tightened.
Installation of safety belts
Please also refer to separate installation instructions for
the safety belt concerned. We have safety belt anchor-
age kits available that have been tested in accordance
with ECE regulation 14.
Please enquire about our current range of kits.
Seat belts must, as a starting point, ALWAYS be anchored in the vehicle floor, not on the
wheelchair.
WARNING! Risk of death or serious injury
The docking station and vehicle-specific anchorage kits are designed and tested on condi-
tion that the seat belt is anchored to the vehicle body and floor, not on the wheelchair.
In the event of a collision, a wheelchair with an integrated safety belt will expose the dock-
ing station and vehicle floor to a much higher torque / load than a wheelchair where the seat
belt is anchored to the vehicle’s body and floor.
Thus, there is a risk that the wheelchair user and other passengers in the vehicle can suer
severe or fatal injuries during a collision, as a result of the vehicle floor being deformed
severely or the anchoring points of the docking station being torn loose. Therefore never
use the docking station for anchoring a wheelchair with integrated seat belt anchor points,
whether this is a 3-point belt, an H- or lap belt.
500984
Seat belt
501768
Removable safety belt
buckle with fitting
501762
Safety belt buckle for
permanent mount
#500984
Safety belt buckle can be orde-
red in dierent lengths. Please
ask about the current range.
Examples of seat belt
components

34 35
2
11
9
10
13
1
12
3
7
4
8
5
6
14
15
Maintenance manual, installation and user guide UK Dahl VarioDock™
Spare parts list for VarioDockTM
#503600
No Quantity Art. no. Description
1 1 503502C Top plate
2 1 503125 Lock plate, complete
3 1 503555 Lock pin, complete
4 1 502358 Top cover, complete
5 1 502357 Motor, complete
6 1 503554 Potentiometer, complete
7 1 503519C Cable for quick release
8 1 502350C Solenoid/Electromagnet
9 1 503553C Control panel
10 1 503161 Emergency Release Tool
11 1 503636 Service kit
12 1 503641 Solenoid cable, internal
13 1 503640 Microswitch with wiring, external
14 1 503700 Control Box with wiring harness and PCB, complete
15 1 503630 Circuit Board (PCB), only

Development and crash-test centre
Where safety starts
WHERE SAFETY STARTS
Dahl Engineering ApS |Løvevej 3 |DK-7700 Thisted |Danmark |Telefon: [phone]
e: [email protected] |w: wtors.com