Dhollandia DH-RPH 33 Installation Manual Download Page 2

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DHOLLANDIA

TABLE OF CONTENTS

UNDERSTANDING SAFETY AND WARNING SIGNS ...................................................................................................................... 3

INTRODUCTION, CONTACT INFO AND DISCLAIMERS ................................................................................................................. 4

SAFETY PRECAUTIONS FOR OPERATION ................................................................................................................................... 6

SAFETY PRECAUTIONS FOR INSTALLATION ............................................................................................................................... 6

LIFTGATE TERMINOLOGY .............................................................................................................................................................. 8

5.1

DH-RPH liftgate terminology ..................................................................................................................................................... 8

5.2

Installation parameters terminology .......................................................................................................................................... 9

5.3

Getting started ......................................................................................................................................................................... 11

INSTALLATION DIMENSIONS AND GUIDELINES ........................................................................................................................ 12

6.1

Installation dimensions ............................................................................................................................................................ 12

6.2

Installation resources .............................................................................................................................................................. 13

BED EXTENSION AND CHASSIS CUT .......................................................................................................................................... 14

7.1

Rear sill cut ............................................................................................................................................................................. 15

MOUNTING OF THE BED EXTENSION ......................................................................................................................................... 16

MOUNTING OF THE LIFT FRAME (PREMOUNTED PLATFORM) ................................................................................................ 18

FIXATION OF THE MOUNT PLATES ............................................................................................................................................. 22

10.1

Fixation of the mount plates OAM010 ..................................................................................................................................... 22

10.2

General remarks...................................................................................................................................................................... 25

INSTALLATION OF ELECTRICAL CONTROLS ............................................................................................................................. 26

11.1

Installation of the control switch (OAE015.PR

–

E0832.B) ...................................................................................................... 26

11.2

Installation of the cabin switch (OAE510.15

–

E0393.S.15) .................................................................................................... 28

11.3

Installation of extra controls

–

2 button remote control (OAE001

–

E0787.2.H) ...................................................................... 29

ELECTRICAL INSTALLATION ........................................................................................................................................................ 31

12.1

Installation of the (+) battery cable and (-) ground cable ......................................................................................................... 31

PUTTING THE LIFTGATE INTO SERVICE..................................................................................................................................... 34

PLATFORM ORIENTATION ............................................................................................................................................................ 37

MOUNTING OF THE SIDE STEPS ................................................................................................................................................. 38

15.1

Mounting the sides steps ......................................................................................................................................................... 38

15.2

Mounting of the optional widening blocks (OAM053) .............................................................................................................. 40

15.3

Mounting of the optional bumper light cluster kit (OAM060) .................................................................................................... 41

LUBRICATION INSTRUCTIONS ..................................................................................................................................................... 42

QUALITY CONTROL AND PDI ....................................................................................................................................................... 44

DECALS .......................................................................................................................................................................................... 46

18.1

Use of the ‘WARNING. LIFTGATE OUT OF SERVICE. DO NOT ATTEMPT TO OPERATE’ sign

........................................ 48

APPENDIX ....................................................................................................................................................................................... 49

19.1

Meaning of the safety and warning signs ................................................................................................................................ 49

19.2

Prescribed torque values for bolts and nuts ............................................................................................................................ 51

19.3

Electric and hydraulic requirements ........................................................................................................................................ 52

Summary of Contents for DH-RPH 33

Page 1: ...ON MANUAL Read the manual in its entirety before operating the liftgate Keep this manual in the vehicle cab as reference for the driver and liftgate operator Manufacturer DHOLLANDIA US L L C E mail us...

Page 2: ...OF ELECTRICAL CONTROLS 26 11 1 Installation of the control switch OAE015 PR E0832 B 26 11 2 Installation of the cabin switch OAE510 15 E0393 S 15 28 11 3 Installation of extra controls 2 button remot...

Page 3: ...2 DHOLLANDIA 19 4 Safe operator position on the platform 54 19 5 End note 55 19 6 Basic wiring diagrams 55 19 7 Checklist for preventative maintenance and repair 55...

Page 4: ...cates a potentially hazardous situation which if not avoided could result in minor or moderate injury black letters on yellow background NOTICE is used to address practices not related to physical inj...

Page 5: ...to use good common sense Contact your national DHOLLANDIA distributor if you have any questions regarding the installation operation repair and maintenance of DHOLLANDIA liftgates or to obtain replac...

Page 6: ...aims liability for any personal injury death or property damage that results from improper use of the liftgate or negligence to apply the precautions and instructions of the operation manual DHOLLANDI...

Page 7: ...tact the national DHOLLANDIA distributor for a copy of the latest set of instructions see contact info on page 4 or download the latest edition from the DHOLLANDIA website www dhollandia com Country l...

Page 8: ...gloves adequate ear protection a safety helmet when working under the vehicle chassis NEVER wear loose fitting clothes that may get trapped in the moving parts of the liftgate or in any machinery and...

Page 9: ...galvanization from the areas to weld Most liftgates are equipped with thermoplastic hoses that can be damaged by hot metal chips welding sparks and slag Damage to a hose can lead to sudden loss of hyd...

Page 10: ...o top of the vehicle floor applicable for the given arm length cth Chassis Total Height Actual height from underside of chassis to top of the vehicle floor mfc Mounting height Floor to Center of lift...

Page 11: ...ired overhang to the back side of the mount plates lop Lift Overhang to Power pack Required overhang to end of the premounted power pack lac Lift Arm Center Center width of the lift arm chw CHassis Wi...

Page 12: ...or technical documentation If the actual dimensions go outside of the maximum installation parameters DON T continue and contact your national DHOLLANDIA distributor for further advice Verify and mak...

Page 13: ...12 DHOLLANDIA 6 INSTALLATION DIMENSIONSAND GUIDELINES 6 1 INSTALLATION DIMENSIONS RPH 33 bed heights 41 49 RPH 33 bed heights 44 52...

Page 14: ...ieved or if the lift frame tube will not level out the installation guide bracket may be removed and the given dimensions can be sought manually with a floor jack The MAX vehicle floor height vfh is m...

Page 15: ...nd clearance mpg or at a lower ground clearance e g to fit within a shorter mounting space Ask DHOLLANDIA to confirm the required chassis cut dimensions as these might change in relation to the new gr...

Page 16: ...ar sill is subject to change depending on the depth of the rear sill on the vehicle Forsee a suitable depth and angle for this cut to allow the lift to stow properly in the closed position Where chass...

Page 17: ...nterline of the bed extension to the centerline of the rear sill Make sure it is level with vehicle floor If not level vary the mating surfaces between the bed extension and rear sill remove any obstr...

Page 18: ...16 5 mm 2 50 mm long on the top and bottom DO NOT weld in the areas left and right where the steps and dock bumpers will be bolted on CAUTION Before welding note that welding on galvanized parts relea...

Page 19: ...od 1 Use protection between the platform and the top of the posts to avoid causing damage to the liftgate 2 Lift the liftgate out of the inclined cradle of the skid Shift it forward and position it on...

Page 20: ...eplicated on both L R sides of the lift frame It is best to get these bolts hand tightened at this phase then torque them properly prior to welding bolting to the vehicle chassis Note a small bag cont...

Page 21: ...latform and lift frame and damage to the point might occur Hoist the platform and attached lift frame and place a hydraulic jack under the lift frame Alternatively the liftgate can be mounted using a...

Page 22: ...he installation guide bracket may be removed if the lift frame tube will not level If required tilt the lift frame relative to the vehicle chassis to ensure that the top surface of the lift frame is p...

Page 23: ...nt plates MUST be bolted to the lift frame according to the instructions in section 9 on page 19 Tighten the bolts and nuts with the prescribed torque See section 19 2 on page 51 The mount plates if b...

Page 24: ...s of the liftgate to the long sills on top of the chassis by means of 2 bolts M14 per side or equivalent Fasten these bolts with the prescribed torque Alternatively the chassis beam may be secured via...

Page 25: ...o join the plate to either the long sill or the vehicle cross members NOTICE It is essential that bolts and nuts used to mount the lift frame to the chassis are fastened with the required torque see v...

Page 26: ...rear sill and vehicle body require adequate anti corrosion protection Make sure you comply with the instructions of the vehicle manufacturer ALWAYS protect and cover thermoplastic hoses with a welding...

Page 27: ...rill the screw holes and the passage for the electrical cable Use 10 32 1 inch 4 3mm self tapping screws to mount the control switch Route the electrical cable to the pump unit Position fasten and pro...

Page 28: ...27 DHOLLANDIA...

Page 29: ...provided with the DH R series liftgates is a simple single pole single throw switch The switch interrupts power from the vehicle batteries to the connection block inside the power pack This cable wir...

Page 30: ...least amount of slack in the cable Measure the holes on the holster and receptacle units and use them to drill the screw holes Use 10 32 1inch 4 3mm self tapping screws to mount the control holster an...

Page 31: ...30 DHOLLANDIA...

Page 32: ...battery cable to the positive motor terminal and the negative ground cable to the negative motor terminal are fastened with the prescribed torque To ensure the reliability of the lift over many years...

Page 33: ...he cable must go to the negative terminal on the electric motor Use a second wrench so the ground terminal does not turn in its place Turning the terminal in place will damage the grounding inside the...

Page 34: ...ake sure they make a downward curve as they exit the control box or power pack so that water can drop off in a natural way This is an easy way to prevent water ingress through the grommets or cable gl...

Page 35: ...isolator switch or a combination of both Operate LIFT to raise platform up to vehicle floor Stop when you hear the hydraulic pump turn in overpressure WARNING Improper use of the liftgate can put the...

Page 36: ...rate smoothly and quietly and at a fairly constant pace Only the sound of the power pack should be audible In case of jerking movements or odd sounds discontinue investigate the issue at hand and corr...

Page 37: ...towards the leading edge of the platform and the top of the lift arms A small M8 bolt will be located on each side if applicable that holds the main platform pivot pin s in place Remove these bolt s...

Page 38: ...rm Check and adjust the orientation of the whole platform compared to the bed extension and vehicle floor Because the liftgate will decline slightly when loaded adjust the platform pitch so that the t...

Page 39: ...loor height of the vehicle in order to maintain an adequate departure angle from the rear axle Bolt the side steps to the bed extension as shown Note if 102 widening blocks OAM053 were included in the...

Page 40: ...for vehicles with more than 10 ft 3 m overhang to the center of the rear axle For cases with insufficient ground clearance side steps with a flexible bottom step are available option ref OAM057 LR Ref...

Page 41: ...of the liftgate order 102 body widening blocks for the bed extension may have been specified If so refer to the installation graphic below Maintain a 90 angle between the steps and the bed extension F...

Page 42: ...latforms and 2 for wider platforms Both sides vehicle will need to be configured in mirrored fashion for configurations 1 and 2 Fasten 3x M10 bolts and locking nuts per side to the prescribed torque s...

Page 43: ...rease plans select required plan Use a grease gun to inject grease until a grease collar is formed on both sides of the articulation that will protect it from ingress of water salt sand and dirt etc N...

Page 44: ...43 DHOLLANDIA...

Page 45: ...sides of the platform 2 Install the platform flags to the underside of the platform point 3 If applicable connect the flashing platform lights and verify their function If the operator is allowed to t...

Page 46: ...ly the safety decals to the liftgate and vehicle body before delivery to the customer conform with instructions under 18 on page 46 NOTICE WARNING The PDI check list completes the final quality inspec...

Page 47: ...with the instructions below Note the decals marked as EXAMPLE can vary in function of the maximum rated capacity of the liftgate or the chosen type of external control box NOTICE Remove any unwanted...

Page 48: ...EN EF0580 EN CAP EF0565 EN EF0616 US EF0618 EN Loading decal with SNR EF0562 EN EF0597 US LIFTGATE DECALS USED AND AFFIXED IN AREAS OTHER THAN THE REAR OF THE VEHICLE Serial tag for Owner s Manual EF0...

Page 49: ...any unsafe condition exists or unusual noises or movements are noticed DO NOT use the liftgate and affix the WARNING LIFTGATE OUT OF SERVICE DO NOT ATTEMPT TO OPERATE sign provided with the liftgate o...

Page 50: ...rail Protect yourself from falling off the platform or vehicle floor Crushing shearing hazard Keep feet away from moving parts Wear safety gloves Slipping hazard Wear safety toe shoes Tripping hazard...

Page 51: ...linder SLIDE OUT the platform Unlock Disengage the mechanical locking system SLIDE IN the platform Lock Engage the mechanical locking system Push the stabilizing LEGS DOWN Switch ON the electrical pow...

Page 52: ...in conformance with prescribed torque Retighten if required Use a calibrated torque wrench to tighten bolt and nut connections to the prescribed torque value NOTICE WARNING Incorrect too soft or too...

Page 53: ...bles Size electric motor Cable section 500 W 16 mm 5 AWG 12V 1200 2000 W 1100 3300 lbs capacity length 33 ft 1100 3300 lbs capacity length 33 60 ft Capacity 3300 lbs Length 60 ft 3 AWG 1 AWG 0 1 0 AWG...

Page 54: ...the liftgate but often overlooked in troubleshooting Make sure you take these into consideration when executing repairs or maintenance checks DHOLLANDIA mainly uses 3 types of oils in its hydraulic s...

Page 55: ...the vehicle body This handgrip will enable the operator to maintain 3 points of contact while travelling on the platform in accordance with the operation manual The handgrip is normally foreseen by t...

Page 56: ...from your national DHOLLANDIA distributor or downloaded from our website If in doubt where to find your national DHOLLANDIA distributor visit the official DHOLLANDIA website www dhollandia com Country...

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