Dhollandia DH-L 3300 lbs, Installation Manual

Page 1: ...LLATION 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 ma...

Page 2: ...f the seal kit 21 7 4 Method with horizontal platform 22 8 MOUNTING OF THE LIFT FRAME 23 8 1 Introduction 23 8 2 Positioning of the lift frame with OAM010 24 8 3 Fixation of the mounting plates OAM010...

Page 3: ...ERATE sign 60 16 APPENDIX 61 16 1 Meaning of the safety and warning signs 61 16 2 Prescribed torque values for bolts and nuts 63 16 3 Electric and hydraulic requirements 64 16 4 Grease plans 66 16 5 C...

Page 4: ...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 injury w...

Page 5: ...s regarding the installation operation repair and maintenance of DHOLLANDIA liftgates or to obtain replacement copies of manuals or decals DHOLLANDIA US LLC United States West 12968 Santa Ana Avenue F...

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: ...overalls protective 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...

Page 9: ...WAYS grind off the 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...

Page 10: ...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 arm Mounting height of lift frame under the vehicle...

Page 11: ...th power pack in premounted position bci Body Cut Inside Width of the mid panel between the lift arms bcw Body Cut Width Width of the cut outs for the lift arms and tilt cylinders blb Body Light Boxes...

Page 12: ...for further advice Verify and make sure that the vehicle chassis and body are strong enough to support the forces induced by the liftgate at its maximum rated capacity Refer to the instructions of the...

Page 13: ...N DRAWING sent upon the order confirmation will provide you with the critical installation dimensions that should be observed If no installation drawing is available use the DHOLLANDIA POCKET GUIDE pa...

Page 14: ...respect the maximum installation parameters vfh mfc mcg Study the image below explaining how mfc and mcg are correctly measured ALWAYS make sure you comply with applicable bumper bar regulations and...

Page 15: ...rs cross the rear cross member of the vehicle floor this rear cross member must be restricted in height to dimension lft This lft depends on the mounting height mfc and the position of the platform be...

Page 16: ...15 DHOLLANDIA 6 2 COMMON INSTALLATION DIMENSIONS Listed below are common models offered by DHOLLANDIA US and their associated fitting ranges LMM 33 LMH 33 44...

Page 17: ...16 DHOLLANDIA LMS 55 66...

Page 18: ...lift WARNING ALWAYS make sure that the lift frame and mounting plates are installed in accordance with the installation instructions of DHOLLANDIA Pay special attention to the type of bolts minimum qu...

Page 19: ...dard cantilever liftgates DH LM Container locks NOTICE To stow the platform correctly it must first be LIFTED to the vehicle floor until the hydraulic circuit goes in overpressure Then CLOSED again un...

Page 20: ...atforms with extended edge options OAP312 OAP313 OAP407 etc require method 3 7 1 METHOD WITH THE FITTING JIGS Measure the outside width across the lift arms This dimension corresponds with the inside...

Page 21: ...the INSTALLATION DRAWING and in the POCKET GUIDE Next raise the platform and position it onto the supports Slide a spacer D 5mm see above between the platform and the rear frame of the body Adjust an...

Page 22: ...latform With fitting jig With vertical platform INSTALLATION DRAWING without seal kit INSTALLATION DRAWING with seal kit If an INSTALLATION DRAWING is available the required spacer Q for original DHOL...

Page 23: ...loor Slide the required spacer between the rear cross member and the platform Secure the platform and prevent it from falling by means of an overhead crane hoists forklift with slings etc Centre the p...

Page 24: ...haped chassis beams Trailer chassis with I shaped chassis beams Universal mounting plates OAM010 Special execution with option ref OAU009 Mounting plates are not adjustable in longitudinal direction T...

Page 25: ...2 Dismount the pins for the lift arms from the platform hands Raise the lift arms 3 to the fitting jigs 4 or to the platform hands depending on the chosen installation method Slide the articulation pi...

Page 26: ...to the vehicle floor In case of bolt on mounting plates fit the mounting plates over the frame by means of the bolts and nuts supplied in the kit bag Do not tighten the bolts and nuts at this stage M...

Page 27: ...anyhow note that liftgate might be equipped with thermoplastic hoses Observe the important precautions in 4 on page 6 Ensure that the lift frame is correctly centered under the vehicle chassis and bo...

Page 28: ...27 DHOLLANDIA...

Page 29: ...nd the spread of the bolts over the full surface of the mounting plate Fasten the bolts and nuts with the required torque see values for shear Maximize the spread of the mounting bolts over the full s...

Page 30: ...tened in height but with respect for the instructions in this section NOTICE Various vehicles manufacturers offer pre punched chassis and don t allow you to drill additional holes through the chassis...

Page 31: ...subframe Drill the holes of the drill bit M value of the bolts 1 64 0 5mm Fit the mounting plates bolts and nuts to the vehicle chassis and subframe Fasten all bolts and nuts with the required torque...

Page 32: ...s overlapping the subframe must be additionally fastened 1 By adding 2 additional bolts per instructions below 2 By welding 2 seams connecting the mounting plates with the subframe per instructions be...

Page 33: ...le 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 blanket Inspect th...

Page 34: ...applicable legislation and refusal of the vehicle upon inspection It can put other parties in traffic at great risk and could result in sever injury or death 8 6 2 Towing hitch with OAM010 mounting pl...

Page 35: ...tion to the type of bolts minimum quantity per side minimum size and strength class and position Fasten the bolts and nuts with the required torque see values for shear If the towing hitch must be rep...

Page 36: ...a separate kit or if adjustments are required observe the installation instructions sent upon order confirmation or contact your national DHOLLANDIA distributor for a copy of the dedicated mounting i...

Page 37: ...OR INSTALLATION MAINTENANCE AND REPAIR manual In case of doubt contact the national DHOLLANDIA distributor for further assistance WARNING The platform and the lift frame are very heavy When falling on...

Page 38: ...an alternative push the piston rod in or pull it out manually as follows 1 Open the safety valves on the lift cylinders manually see below 2 Loosen up the hydraulic couplings of the hoses connected to...

Page 39: ...le in the tilt cylinders with the hole in the platform hands by means of the electrical controls or manually see procedure above Mount the pins of the tilt cylinders The rollers are mounted and the bo...

Page 40: ...stops at the rear cross member of the vehicle body Self fabricated end stops bolted welded to the chassis or subframe Self fabricated adjustable end stops mounted to the vehicle chassis or subframe N...

Page 41: ...thin 2 50 mm from the articulation point of the lift cylinder are not possible a hard stop against the rear cross member of the vehicle floor is required 10 2 PLATFORM STOW POSITION If applicable moun...

Page 42: ...detach both tilt cylinders from the platform unless it is hung up on a gantry crane with hoists a fork lift with slings etc The stroke of the tilt cylinders 1 is most easily adjusted while they are d...

Page 43: ...ign the wholes in the adjustable extensions 4 with the holes in the platform hands Mount the pins of the tilt cylinders 1 and the rollers in the same way as originally supplied See also 9 from page 36...

Page 44: ...or safe operation practices 3 methods are available to mount the stabilizing legs to the lift frame OAH014 01 stabilizing legs are mounted with fixed brackets on the lift frame OAH014 02 stabilizing l...

Page 45: ...so that you end up with a positive ground clearance d when the stabilizing legs are fully lowered down Follow the bolt instructions below to mount the stabilizing legs to the lift frame Preferably use...

Page 46: ...switch Dual toggle switch control box to be combined with a cabin switch Optional separate main external control box with main battery disconnect switch Premounted on the lift frame no extra work requ...

Page 47: ...quired torque Option OAM025 offers a quick fit bracket to mount the control box on the bumper tube 11 2 INSTALLATION OF THE BATTERY CABLE AND GROUND CABLE APPENDIX 16 3 on page 64 provides important i...

Page 48: ...and the ground cables 2 Make sure this conduit is suitable for automotive purposes and its class is adapted to possible sources of heat nearby In case of doubt contact your national DHOLLANDIA distrib...

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Page 50: ...lectrical cables ALWAYS make sure they make a downward curb 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...

Page 51: ...LANDIA contact the vehicle importer or DHOLLANDIA for further advice When installing cables make sure these cannot be cut squeezed chafed heated and melted or damaged otherwise by the equipment mounte...

Page 52: ...51 DHOLLANDIA 11 3 1 Installation of 3 Button Wander Lead OAE002 E0784 M S...

Page 53: ...52 DHOLLANDIA 11 3 2 Installation of cabin cutoff switch OAE510 15 E0393 S 15...

Page 54: ...ect the problem prior to continuing Air might be trapped in the hydraulic circuits as long as the liftgate has not been bled Air can cause the platform to make unexpected movements and can put the ins...

Page 55: ...ls as indicated in the MAINTENANCE AND REPAIR MANUAL Refer to appendix 16 4 from page 66 onwards for relevant grease plan of the liftgate or download any from the website www dhollandia com Country la...

Page 56: ...e platform closes correctly in stow position Make sure that the platform will be clearly visible in public traffic 1 Apply the RD WH reflective marking tape on both sides of the platform 2 Install the...

Page 57: ...SERV G 003 of the MAINTENANCE AND REPAIR MANUAL or contact your national DHOLLANDIA distributor for help See contact info on page 4 Apply the safety decals to the liftgate and vehicle body before deli...

Page 58: ...safety decals to the liftgate and vehicle body in accordance with the instructions below Note the decals marked as EXAMPLE can vary in function of the maximum rated capacity of the liftgate or the ch...

Page 59: ...58 DHOLLANDIA EF0583 LM EN EF0565 EN EF0620 EN EF0580 EN CAP...

Page 60: ...59 DHOLLANDIA EF0585 US Serial Number EF0581 EN EF0563 EN EF0616 EF0562 EN...

Page 61: ...y and that no maintenance or repair is required see 7 6 located in the OPERATION MANUAL If any unsafe condition exists or unusual noises or movements are noticed DO NOT use the liftgate and affix the...

Page 62: ...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 63: ...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 64: ...d in conformance with required 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 h...

Page 65: ...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 66: ...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 67: ...H LM 3300 6600 lbs 1500 3000 kg A copy of the grease plans can also be obtained from the national DHOLLANDIA distributor see contact info on page 4 or downloaded from the DHOLLANDIA website www dholla...

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Page 70: ...the back plate of the power pack by means of an Allen key nr 4 Unscrew the bolt and nut completely From the outside unbolt the 2 vertical Allen bolts that hold the 2 main elements of the entry seal t...

Page 71: ...ber grummets are repositioned correctly after passing the cables A If no main battery disconnect switch connect the battery cable to the incoming terminal of the starter solenoid see B below Connect t...

Page 72: ...ed in their assigned channel If the nut was dismounted or had become dislocated insert it back into its socket At the inside mount the Allen bolt back in its original position Tighten the bolt firmly...

Page 73: ...ter to drip off in a natural way Thus you can easily prevent water ingress in the connections of the battery cables NOTICE To ensure the reliability of the lift over many years it is extremely importa...

Page 74: ...of the main battery disconnect switch Fasten the M8 bolt connection torque 17 7 Ft Lbf 24 N m Slide the heat shrink hose over the connection bolt up to the incoming pole 3 of the main battery disconn...

Page 75: ...control box to allow water to drip off in a natural way Thus you can easily prevent water ingress in the connections of the battery cables 1 and 5 NOTICE To ensure the reliability of the lift over man...

Page 76: ...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 77: ...inside the control box or power pack Replacement copies can be obtained from your national DHOLLANDIA distributor or downloaded from our website If in doubt where to find your national DHOLLANDIA dis...

Page 78: ...Frequency OK Corrected Main external control box cover installation to vehicle body Condition fastening to the vehicle body undamaged 180 days 3500 cycles Main battery disconnect switch in control box...

Page 79: ...ections in pump unit electric connection board Condition all connections tight dry and corrosion free 180 days 3500 cycles Limit switches pressure switches tilt sensors optional Condition operation au...

Page 80: ...ation instructions fastened with required torque 180 days 3500 cycles 9 Platform Frequency OK Corrected Platform construction Condition undamaged no deformation cracks in material or welds no corrosio...

Page 81: ...m load Lift the platform Check if lift capacity is sufficient Check general operation and stability Check safe working speeds Lift lower max 6 sec Hydraulic open and close max 10 sec Auto tilt at grou...

Page 82: ...ions Partial works or inspections to follow Maintenance or inspection performed by Service center Name of technician Date of next maintenance inspection Safety first ALWAYS follow the instructions and...