Dhollandia DH-RP.10 Installation Manual Download

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Doc: FIT_RP.10_CE_EN_2020_rev0 Rev: 0 Date: JANUARY 1, 2020

Manufacturer:

DHOLLANDIA N.V. Zoomstraat 9 9160 LOKEREN (Belgium)

Tel : +32 (0)9 349 06 92 Fax : +32 (0)9 349 09 77

e-mail : [email protected]

website : www.dhollandia.com

DH-RP.10

INSTALLATION MANUAL

Read the manual in its entirety before operating the tail lift

Keep this manual in the vehicle cab, as reference for the driver and tail lift operator

900-1000kg

** Pictured: RP.10 tail lift

edition

Summary of Contents for DH-RP.10

Page 1: ...Tel 32 0 9 349 06 92 Fax 32 0 9 349 09 77 e mail info dhollandia be website www dhollandia com DH RP 10 INSTALLATION MANUAL Read the manual in its entirety before operating the tail lift Keep this man...

Page 2: ...11 1 Mounting of the control switch 31 11 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 BA...

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: ...bligations 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 DHOL...

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: ...IFT LOWER the lift arms the platform and its load 9 Mounting Plates used to mount the lift frame to the vehicle chassis 10 Bed Extension Plate heavy duty steel extension mounted to the rear sill of th...

Page 10: ...he side of the vehicle body or on the rear post of the body 18 Centre point of maximum load point up to which the maximum rated capacity of the tail lift is valid Beyond that point the maximum safe wo...

Page 11: ...Actual height from underside of chassis to top of the vehicle floor MFT Mounting height of lift frame under the vehicle measured from the top of vehicle floor to the top of the lift frame main tube M...

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

Page 13: ...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 W...

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: ...the lift arms and lift frame pre setting the mounting height MFT 445mm Figure 6 4 Figure 6 4 shows 1 the required overhang LOF LOP 2 the min vehicle floor height VFH MIN and corresponding ground clea...

Page 16: ...8 G 521 H 140 MFT 445 CTH MAX 457 MTG 673 VFH MAX 42 platform 1120 VFH MIN 42 platform 970 VFH MAX 50 platform 1170 VFH MIN 50 platform 970 LARM 800 if bed height is below 960mm set lock bar at 567mm...

Page 17: ...TICE If you decide to remove the mounting bar and change the mounting height MFT of the tail lift ensure to stay within the applicable ranges for the installation parameters VFH MFT and MTG Consult th...

Page 18: ...usions that 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 ind...

Page 19: ...lowed to weld the extension to the rear sill in 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 Floo...

Page 20: ...aces between the extension plate and rear sill remove any obstructions or adjust as needed Bolt the extension plate to the rear sill using 11 bolts M14 and locking nuts supplied with the tail lift Fig...

Page 21: ...l Figure 8 4 Tack weld the extension plate working from the centre outward making leveling adjustments as you proceed Finish with 7 welds of 5mm 102mm long on the top and bottom DO NOT weld in the are...

Page 22: ...re to turn the platform tilt adjustment bolts all the way IN to the stops Figure 9 1 Figure 9 1 Manually unfold the foldable platform with its 2 platform sections Then unfold the flip over point Figur...

Page 23: ...em 3 Figure 9 3 See also Slide the mounting plates outward as much as possible to obtain max clearance when raising the lift frame over the vehicle chassis Clamp 2 lengths of tube or angle brackets mi...

Page 24: ...flip over point as this section doesn t provide a stable hold of the platform and lift frame and damage to the point might occur Figure 9 5 Hoist the platform and attached lift frame and place a hydra...

Page 25: ...6 If required tilt the lift frame relative to the vehicle chassis to ensure that the top surface of the lift frame is parallel to the vehicle floor A torpedo level is commonly used to ensure the align...

Page 26: ...n conformance with the mounting instructions and dimensions indicated in the installation drawing and manual before drilling or welding the mounting plates to the chassis It is not allowed to reduce t...

Page 27: ...injury to the welder and any bystanders To avoid risk of serious personal injury ALWAYS use adequate coverage e g by a leather welding blanket to shield the thermoplastic pipes whenever welding is don...

Page 28: ...hten the mounting plates and make sure they stand perpendicular to the lift frame Ensure the lift frame is correctly centred under the vehicle chassis and body Figure 10 1 The mounting plates MUST be...

Page 29: ...ift spread over the widest possible surface to maximize the strength of the bolted connection Fasten the 6 bolts M14 per side with the required torque Figure 10 3 Per side 2x M24x2 10 9 hand tightened...

Page 30: ...rlap 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 plates per plate Apply equivalent...

Page 31: ...d to the proper torque shown in these installation instructions If you use mounting bolts not supplied by DHOLLANDIA make sure the total strength is at least equivalent as per this manual Check and re...

Page 32: ...osition fasten 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 d Feed the electrical cable through the rubber gromme...

Page 33: ...ppendix The wiring logic for the DH RP 10 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 4 2 valve on the...

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

Page 35: ...nd connections Positive connection for extra controls R Starter solenoid on motor H Control valve lift at the back of the power pack D Electrical self locking valves Lower on the lift cylinders S Cont...

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: ...s leakage 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 how to use tail lift correctl...

Page 43: ...uld investigate and correct to avoid damage to the tail lift or potential hazards for the operators Bleed all air from the hydraulic circuits Preferably raise the rear end of the vehicle off the groun...

Page 44: ...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 adjust...

Page 45: ...de steps with intermediate mounting blocks 2 in Figure 15 1 bolted together in 2 subsequent steps by means of 2 2 bolts M16 1 3 in Figure 15 1 to obtain 2590mm overall width 2 Bolt the side steps to t...

Page 46: ...e you comply with the instructions of the OEM vehicle manufacturer 7 Bolt the diagonal braces between the side steps and support channels on the body Figure 15 4 Fasten all bolts and locking nuts to t...

Page 47: ...welding note that welding on galvanized parts releases hazardous fumes Provide adequate ventilation and wear an appropriate toxic fume rated welding respirator It is strongly recommended to first grin...

Page 48: ...ther steel chassis or body components have been cut grinded drilled welded etc the installer should apply adequate anti corrosive coating to protect the vehicle and body against corrosion Check and ma...

Page 49: ...of water salt sand and dirt Note that the grease nipple might be located in the pin itself or in the larger assembly that pivots around the pin In case a pin has 2 grease nipples grease both sides En...

Page 50: ...49 DHOLLANDIA...

Page 51: ...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 52: ...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 53: ...52 DHOLLANDIA EF0583 RM EN EF0565 EN EF0618 EN EF0570 CAP serial nr EF0564 EN EF0563 EN EF0562 EN xxxx...

Page 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...sufficiently 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 oper...

Page 62: ...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 63: ...rm DHOLLANDIA 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 lower...

Page 64: ...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 65: ...64 DHOLLANDIA Figure 19 4 Figure 19 5...

Page 66: ...65 DHOLLANDIA A general wiring schematic for gravity down with the two button handheld control is shown in Figure 19 6 Figure 19 6 To positive post on motor solenoid To ground post on pump motor...

Page 67: ...66 DHOLLANDIA For option OAE510 15 see Figure 19 7 below Figure 19 7 To positive post on motor solenoid To ground post on pump motor...

Page 68: ...67 DHOLLANDIA A general wiring schematic for power down with the two button handheld control is shown in Figure 19 8 Figure 19 8 To positive post on motor solenoid To ground post on pump motor...

Page 69: ...68 DHOLLANDIA For option OAE510 15 see Figure 19 9 below Figure 19 9 To positive post on motor solenoid To ground post on pump motor...

Page 70: ...69 DHOLLANDIA 19 6 CIRCUIT BREAKER A resettable circuit breaker option is also available for the connection to the batteries Figure 19 10 Figure 19 10...

Page 71: ...e in Figure 19 11 to properly connect the E0667 illuminated cab switch Figure 19 11 Figure 19 12 For orders that shipped with option OAE510 15 refer to Figure 19 13 to properly connect the cab switch...

Page 72: ...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 c...

Page 73: ...ly available hydraulic oil is used in the majority of DHOLLANDIA lifts sold for use in normal climate conditions This includes all countries excluding the Nordic countries suffering very cold winter c...

Page 74: ...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...

Page 75: ...74 DHOLLANDIA...

Page 76: ...75 DHOLLANDIA...

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