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Dhollandia DH-RM.25, Installation Manual, Page: 35 / 79

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Dhollandia DH-RM.25 Installation Manual Download Page 35

34 

 

DHOLLANDIA 

11.2

 

CONNECTION BLOCK TERMINOLOGY 

 

 

The connection block distributes voltage signals to the corresponding pins for each desired function. [Figure 11.6] 

Figure 11.6

 

 

Horizontal pins are ground connections 

+ - Positive connection for extra controls 

R - Starter solenoid on motor 

H – Control valve (lift) in the power pack 

D – Electrical self-locking valves (Lower) on the lift cylinders 

S – Control valve (Close/Tilt up) in the power pack 

O – Electrical self-locking valves (Open/Tilt/Down) on the tilt cylinders 

I – Control valve (Slide In) in the power pack 

U – Control valve (Slide In) in the power pack  

 

 

Summary of Contents for DH-RM.25

Page 1: ...32 0 9 349 06 92 Fax 32 0 9 349 09 77 e mail info dhollandia be website www dhollandia com DH RM 25 INSTALLATION MANUAL Read the manual in its entirety before operating the tail lift Keep this manual...

Page 2: ...2 Connection block terminology 34 11 3 Gravity down wiring for the control switch 35 11 4 Power down wiring for the control switch 37 12 CONNECTION TO THE BATTERIES 39 13 PUTTING THE TAIL LIFT INTO SE...

Page 3: ...ch if not avoided will result in death or serious injury white letters on red background WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injur...

Page 4: ...ions in terms of periodic testing and certification DHOLLANDIA tail lifts are regularly being adapted to new vehicle and chassis developments and specialized customer requirements Therefore DHOLLANDIA...

Page 5: ...that results from operating a tail lift that has been modified from the original design without explicit written approval from the manufacturer DHOLLANDIA disclaims liability for any personal injury d...

Page 6: ...uctions are supplied as a separate manual with your tail lift You can also contact the national DHOLLANDIA distributor for the latest edition of this manual See page 4 for contact info Or download the...

Page 7: ...hinery and tools used for the installation Don t wear rings bracelets necklaces watches etc ALWAYS use the proper tool for the job Repair or replace worn or damaged tools before use Pay special attent...

Page 8: ...2 for prescribed torque values Welding should be done by qualified personnel only and only to the extent allowed by the vehicle manufacturer Ensure that the positive and ground cables are disconnected...

Page 9: ...rting the platform while it travels up and down 9 Lift Arm Weldment support brace between the parallel lift arms 10 Lifting Cylinder hydraulic cylinders used to LIFT LOWER the lift arms the platform a...

Page 10: ...the platform mostly mounted in fixed position at the side of the vehicle body or on the rear post of the body 20 Lift frame box beam connecting all main lifting components 21 Centre point of maximum l...

Page 11: ...g height of lift frame under the vehicle measured from the top of vehicle floor to the top of the lift frame main tube Mounting height Floor to Tube of frame MTG Mounting height of lift frame above th...

Page 12: ...11 DHOLLANDIA Figure 6 2...

Page 13: ...3 for parts corresponding to numbers in this table LAC Width of the lift arms Lift Arm Centre CHW Vehicle chassis width CHassis Width BWO MIN Min body width with pump unit in premounted position Body...

Page 14: ...he tail lift are present Compare the voltage of the vehicle batteries with the voltage of the hydraulic pump unit of the tail lift Compare the installation dimensions and maximum installation paramete...

Page 15: ...lation and while testing verify that the tail lift and its moving parts don t interfere with or cause damage to the vehicle systems e g to suspension braking system hydraulic and electrical circuits e...

Page 16: ...MPG 3 The max vehicle floor height VFH MAX and corresponding ground clearance MPG Before starting the installation verify if the actual floor height VFH of the vehicle falls within the given min and...

Page 17: ...the mounting height MFT of the tail lift ensure to stay within the applicable ranges for the installation parameters VFH MFT and MTG Consult the national DHOLLANDIA distributor for confirmation of max...

Page 18: ...hat would prevent the deck extension from being mounted flush against the rear door sill Follow the chassis cut out dimensions Figure 7 2 Trim the chassis beams long sills rear sill to the indicated d...

Page 19: ...addition to bolting if desired There are 2 models see drawing in appendix 1 Floor extension 2430mm wide incl side steps for 2145mm platform width 2 Floor extension 2590mm wide incl side steps for 2300...

Page 20: ...supplied with the tail lift Figure 8 3 1 Mount all bolts and locking nuts and fasten them hand tight 2 Ensure the extension plate is level with the vehicle floor Figure 8 2 and flush with the top sur...

Page 21: ...ith 7 welds of 5mm 102mm long on the top and bottom 3 DO NOT weld in the areas left and right where the steps and dock bumpers will be bolted on Figure 8 4 CAUTION Before welding note that welding on...

Page 22: ...2 platform sections Then unfold the flip over point Figure 9 1 Ensure the platform pitch adjustment bolts are zeroed out during the installation These can be used later to level the platform Figure 9...

Page 23: ...me by means of Figure 9 2 1 4 bolts M16 1 passing through spring washers M16 2 and intermediate plate 3 finally bolting into threaded plate 4 2 2 bolt M14 5 passing through 2 washers M14 6 and bolting...

Page 24: ...temporarily to the rear sill and floor of the vehicle Figure 9 3 Affix hoists at the inboard platform edge left and right Place C clamps on each side of the platform to prevent the hoist chain from s...

Page 25: ...vehicle and that it is flush and parallel with the extension plate Secure the correct platform position by clamping the platform main section to the 76mm mounting tubes Figure 9 5 Figure 9 5 WARNING...

Page 26: ...plates are designed as a bolt on system both where they mount to the lift frame and where they mount to the vehicle chassis If you intend to weld beware of precautions below NOTICE WARNING The tail li...

Page 27: ...f the mounting plates Slide the mounting plates sideways until they are perfectly aligned with the chassis rails Figure 10 1 Straighten the mounting plates and make sure they stand perpendicular to th...

Page 28: ...sis the bolts and nuts tightened with the required torque according to the instructions below and to the right Pay special attention to the type minimum quantity minimum size and strength position and...

Page 29: ...n damage the tail lift and or vehicle chassis and can cause serious bodily injury or death to the operator and any bystanders Therefore it is essential that the mounting plates are installed following...

Page 30: ...late Figure 10 5 If there is no overlap add a connection plate to extend the height of the mounting plate overlap the long sills and make min 2 pcs 10mm welds min 102mm long at the top of the mounting...

Page 31: ...6 To avoid movement of the lift frame by impact during use e g at the loading dock and firmly secure the positino of the lift frame on the chassis min one of the M14 bolts should be mounted in a roun...

Page 32: ...and protect it in such a way that it cannot be damaged by the moving parts of the tail lift or other vehicle components Figure 11 1 Feed the electrical cable through the rubber grommet at the rear of...

Page 33: ...ring logic for the DH RM 25 with power down function ref OAH025 01 is called DAD4 Figure 11 4 and uses the following abbreviations R starter solenoid for the DC motor S4 3 4 valve on the rear side of...

Page 34: ...33 DHOLLANDIA Figure 11 5 Figure 11 4...

Page 35: ...e ground connections Positive connection for extra controls R Starter solenoid on motor H Control valve lift in the power pack D Electrical self locking valves Lower on the lift cylinders S Control va...

Page 36: ...TY DOWN WIRING FOR THE CONTROL SWITCH The control switch and relay MUST be correctly wired to the connection block for proper operation Figure 11 7 Figure 11 7 To positive post on motor solenoid To gr...

Page 37: ...36 DHOLLANDIA For option OAE510 15 see Figure 11 8 below Figure 11 8 To positive post on motor solenoid To ground post on pump motor...

Page 38: ...R DOWN WIRING FOR THE CONTROL SWITCH The control switch and relay MUST be correctly wired to the connection block for proper operation Figure 11 9 Figure 11 9 To positive post on motor solenoid To gro...

Page 39: ...38 DHOLLANDIA For option OAE510 15 see Figure 11 10 below Figure 11 10 To positive post on motor solenoid To ground post on pump motor...

Page 40: ...39 DHOLLANDIA 12 CONNECTION TO THE BATTERIES A general schematic of how to correctly connect the batteries to the tail lift is provided in Figure 12 1 Figure 12 1...

Page 41: ...from the DOWNLOAD section on our website http www dhollandia com Please confirm you have reviewed the most up to date version of this manual prior to continuing If you want to operate the tail lift b...

Page 42: ...eakage correct the problem prior to continuing WARNING Improper use of the tail lift will put the operator at great risk of serious bodily injury and death If in doubt of how to use tail lift correctl...

Page 43: ...Bleed all air from the hydraulic circuits Preferably raise the rear end of the vehicle off the ground or raise the vehicle air suspension to its allowed maximum LIFT the platform to vehicle floor leve...

Page 44: ...m this position Figure 13 4 If platform opener is mounted too far out the platform could fall over when it is lowered to the ground and could hit the limbs of the operator or any bystanders Figure 13...

Page 45: ...cause the tail lift will decline slightly when loaded adjust the platform pitch so that the tip is 25 4mm to 50 8mm higher than the extension plate Figure 14 2 4 Adjust the platform pitch using the 2...

Page 46: ...45 DHOLLANDIA Figure 14 1 Figure 14 2...

Page 47: ...or 2310mm platform width 2 Bolt the side steps to the floor extension as shown If a 2590mm extension kit is specified install the extension kit far right in Figure 15 1 before mounting the side steps...

Page 48: ...tween the side steps and support channels on the body Figure 15 4 Fasten all bolts and locking nuts to the required torque values 8 In order to avoid impact damage it is recommended to have a minimum...

Page 49: ...to first grind off the galvanizing in areas where welding is to be done NOTICE Where chassis beams longs sills the rear sill and other steel chassis or body components have been cut grinded drilled w...

Page 50: ...rotated Test mount the walk ramp carrier assembly to the extension plate at the height that gives the adequate clearance for the walk ramp to slide in and out LIFT the folded platform into the intende...

Page 51: ...d in the maintenance manual Use a grease gun to pump grease in the lube fittings until a grease collar is formed on both sides of the bearing or articulation protecting it against ingress of water sal...

Page 52: ...51 DHOLLANDIA...

Page 53: ...e of the flip over point 3 If applicable connect the flashing platform lights if not prewired and verify their function If the operator is allowed to travel up and down on the platform it is strongly...

Page 54: ...act your regional DHOLLANDIA distributor See page 4 for contact info 3 The operator should comply with all affixed safety and instructions decals Be aware that the decals merely summarize the main poi...

Page 55: ...54 DHOLLANDIA EF0583 RM EN EF0565 EN EF0618 EN EF0570 CAP serial nr EF0564 EN EF0563 EN EF0562 EN xxxx...

Page 56: ...DECALS USED AND AFFIXED IN AREAS OTHER THAN THE REAR OF THE VEHICLE A Cabin switch in driver s cabin to switch electrical power to liftgate on off if so equipped B For circuit breaker in liftgate batt...

Page 57: ...icular tail lift or when ordering replacement parts 2 In addition to the tail lift type and serial number the various serial number labels provide additional information such as the maximum rated lift...

Page 58: ...parts Crushing shearing hazard Keep hands away from moving parts Crushing shearing hazard Keep feet away from moving parts Slipping hazard Tripping hazard Hazard caused by tilting objects Hazard of f...

Page 59: ...ovision lever valve creating an emergency exit Unlock Disengage the mechanical locking system Lock Engage the mechanical locking system Switch ON the electrical power Switch ON the electrical power to...

Page 60: ...CE WARNING Incorrect too soft or too hard tightening of mounting bolts can lead to accidental fall of the tail lift off the vehicle chassis A fall of the tail lift off the chassis can damage the tail...

Page 61: ...1 7 5 lbs ft 10 5 lbs ft M8 x 1 25 17 5 lbs ft 24 5 lbs ft M10 x 1 5 34 5 lbs ft 48 lbs ft M12 x 1 75 60 5 lbs ft 85 lbs ft M14 x 2 95 lbs ft 136 5 lbs ft M16 x 2 143 lbs ft 195 lbs ft Fine M14 x 1 5...

Page 62: ...and secured All articulation pins are equipped with lube fittings and are lubricated Areas of drilling cutting grinding welding etc are adequately protected against corrosion 3 Inspection of the elec...

Page 63: ...ly visible for the surrounding traffic platform lights flags reflective tape traffic cones At vehicle floor level the platform aligns flush with the extension plate A hand grip for the operator to hol...

Page 64: ...ntation for the operator The OPERATION MANUAL and MAINTENANCE MANUAL are available in the vehicle NOTICE WARNING The PDI check list completes the final quality inspection of the installation Once comp...

Page 65: ...LLANDIA recommends that the installer mounts a handgrip to the rear frame of the vehicle body Such handgrip will enable the operator to ALWAYS maintain 3 points of contact while lifting or lowering on...

Page 66: ...Make sure the cable 6 is protected against physical damage Run the cable inside the rear post of the vehicle body or mount a steel protection plate over it If the tail lift is equipped with a main ex...

Page 67: ...66 DHOLLANDIA Figure 20 4 Figure 20 5...

Page 68: ...67 DHOLLANDIA A general wiring schematic for gravity down with the two button handheld control is shown in Figure 20 6 Figure 20 6 To positive post on motor solenoid To ground post on pump motor...

Page 69: ...68 DHOLLANDIA For option OAE510 15 see Figure 20 7 below Figure 20 7 To positive post on motor solenoid To ground post on pump motor...

Page 70: ...69 DHOLLANDIA A general wiring schematic for power down with the two button handheld control is shown in Figure 20 8 Figure 20 8 To positive post on motor solenoid To ground post on pump motor...

Page 71: ...70 DHOLLANDIA For option OAE510 15 see Figure 20 9 below Figure 20 9 To positive post on motor solenoid To ground post on pump motor...

Page 72: ...71 DHOLLANDIA 20 6 CIRCUIT BREAKER A resettable circuit breaker option is also available for the connection to the batteries Figure 20 10 Figure 20 10...

Page 73: ...e in Figure 20 11 to properly connect the E0667 illuminated cab switch Figure 20 11 Figure 20 12 For orders that shipped with option OAE510 15 refer to Figure 20 13 to properly connect the cab switch...

Page 74: ...s are recommended battery cables and ground cables Recommended MIN cable sections for battery cables and ground cables Size electric motor Cable section 500 W 16 mm 5 AWG 1200 2200 W up to max 1500kg...

Page 75: ...This includes all countries excluding the Nordic countries suffering very cold winter climate Refer to the product specifications of Q8 Haydn ISO VG 22 attached for further technical details 2 Option...

Page 76: ...ready for installation behind the tail lift 6 Lift the new bumper assembly up and bring it in position on the mounting brackets of the lift frame 7 Mount the pins with spring support M2902 R M2902 L r...

Page 77: ...1720 092 ref 31 in exploded view through the holes in the bumper section 14 Turn the pins M1720 092 ref 31 in exploded view on the M12x70 mm eye bolts BO12 070 D ref 39 in exploded view and tighten by...

Page 78: ...mance with instructions Always wear safety gloves and a face screen when handling springs 19 Grease the lube fittings on the articulation pins at left and right side 18 Lower and lift the platform min...

Page 79: ...DHOLLANDIA service agents Only authorized OEM DHOLLANDIA replacement parts should be used for all repairs Consult the separate MAINTENANCE AND REPAIR MANUAL for safety instructions maintenance guideli...

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