Dhollandia DH-S Series Installation Manual
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Dhollandia DH-S Series Installation Manual

Dhollandia DH-S Series Installation Manual

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DH-S*
INSTALLATION MANUAL
900–6,600lbs (400-3000kg)
** Pictured: SM.20 liftgate
Manufacturer:
DHOLLANDIA US, L.L.C.
Tel : +1 704 629 5542 E-mail : us.info@dhollandia.com
132 W Virginia Ave
Bessemer City North Carolina, 28016
website : www.dhollandia.com
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
Doc: FIT_S_US_EN_2019_rev4
Rev: 4 Date: OCTOBER 14, 2019

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  • Page 1 900–6,600lbs (400-3000kg) ** Pictured: SM.20 liftgate Manufacturer: DHOLLANDIA US, L.L.C. Tel : +1 704 629 5542 E-mail : us.info@dhollandia.com 132 W Virginia Ave Bessemer City North Carolina, 28016 website : www.dhollandia.com Read the manual in its entirety before operating the liftgate...

  • Page 2: Table Of Contents

    LUBRICATION INSTRUCTIONS ..............................47 COMMISSIONING AND QUALITY CONTROL..........................50 DECALS ......................................51 15.1 Regular decals ..................................51 15.2 Use of the ‘WARNING: LIFTGATE OUT OF SERVICE. DO NOT ATTEMPT TO OPERATE’ sign ........54 15.3 Identification decals ................................. 55 APPENDIX ....................................... 56 DHOLLANDIA...
  • Page 3 Safe operator position on the platform ............................ 63 16.5 2-button portable control ................................. 64 16.6 Circuit breaker ..................................68 16.7 Cab cut-off switch ..................................69 16.8 Electric and hydraulic information ............................70 16.9 Mounting diagrams .................................. 79 16.10 End note ....................................81 DHOLLANDIA...

  • Page 4: Understanding Safety And Warning Signs

    Many safety signs and symbols used in this manual are based on international standards, others refer to specific situations or actions. • Consult Appendix 1 for an overview of signs and symbols used in DHOLLANDIA manuals, and their meaning. Make sure you understand these signs and symbols prior to starting the installation. Examples of standard ANSI...

  • Page 5: Introduction And Disclaimers

    It provides you with general instructions applicable to the common truck and trailer types. It might be possible that specific issues particular to your installation case are not adequately covered by this manual. If in doubt, please contact your local DHOLLANDIA distributor for further assistance.

  • Page 6: Contact Information

    NOTICE Please confirm you have reviewed the most up-to-date version of this manual prior to operation of the associated DHOLLANDIA liftgate. See below for instructions to download the latest version of the manual.

  • Page 7: Safety Precautions For Operation

    These instructions are supplied as a separate manual with your liftgate. • You can also contact your national DHOLLANDIA distributor for the latest edition of this manual. See page 5 for contact info. Or download the latest edition from the website: www.dhollandia.com...
  • Page 8 DHOLLANDIA liftgate. • In case of doubt, ALWAYS contact your national DHOLLANDIA distributor for further advice, prior to continuing. • ALWAYS wear appropriate Personal Protective Equipment. This includes but may not be limited to: ANSI rated glasses with side guards, or a wrap-around face shield;...
  • Page 9 Except for the support channels and bracing of the side steps, which are usually welded to the cross members of the auxiliary chassis, DHOLLANDIA liftgates are designed as a bolt-on system, and don’t require any welding. See Appendix 2 for prescribed torque values.

  • Page 10: Liftgate Terminology

    Control Box: contains control buttons used to operate the lift. Center point of maximum load: point up to which the maximum rated capacity of the liftgate is valid. Beyond that point, the maximum safe working load diminishes according to the applicable load charts. DHOLLANDIA...
  • Page 11 Figure 6.1 4, 5, 6 DHOLLANDIA...

  • Page 12: Installation Parameters Terminology

    Mounting height of lift frame above the ground: measured from the top of the lift frame main tube to the ground [= Mounting height Tube of lift frame to Ground] Ground clearance under liftgate [= Mounting clearance Plates to Ground] [= Platform Depth] Required mounting space to end of lift frame [= Lift Overhang to Frame] DHOLLANDIA...
  • Page 13 Figure 6.2 DHOLLANDIA...
  • Page 14 Thickness of the rear cross member or sill of the vehicle bed [= Body Floor Thickness] Max. thickness of the rear cross member or sill of the vehicle bed, in the maneuver zone BCW for the lift arms and tilt cylinders [= Lift Floor Thickness] Figure 6.3 BFT/LFT BWO MIN DHOLLANDIA...

  • Page 15: Getting Started

    / or body will not adversely affect the structural integrity of the chassis and / or body. • In the event instructions of vehicle manufacturer conflict with the installation instructions issued by DHOLLANDIA (e.g. on fuse ratings, etc.), contact your national DHOLLANDIA distributor for further assistance. •...

  • Page 16: Installation Dimensions

    Do not release the locking bolts of the auto-tilt brackets on the lift frame before the liftgate installation is fully finished [Figure 6.4]. Figure 6.4 INSTALLATION DIMENSIONS • If an INSTALLATION DRAWING is available (via order confirmation), this will provide you with the critical installation dimensions that should be observed. [see Figure 6.5] Figure 6.5 DHOLLANDIA...
  • Page 17 Verify that the actual vehicle dimensions comply with the max. vehicle bed height VFH max, and with the min. / max. mounting heights MFT. Figure 6.8 ≠ • Determine the applicable fitting height MFT either from the FITTING DRAWING supplied with the liftgate, or from the TECHNICAL SUMMARY. DHOLLANDIA...
  • Page 18 VFH, MFT, and MTG given for every lift arm. • Also make sure that the new fitting situation complies with the compulsory bumper bar regulations. See [Figure 6.9] for an example of the important fitting dimensions. Figure 6.9 Dimensions table inches 1960 71½ 1820 1300 ≥ ≥ DHOLLANDIA...
  • Page 19 Adjust the rear side of the body accordingly. BCW and CHW depend on the arm width LAC. LFT depends on the fitting height MTG. • The height of the rear cross member LFT varies also with the shape of the platform: standard platform hands or option (S245.S). [see Figure 6.13] Figure 6.2 Option S245.S 4” DHOLLANDIA...

  • Page 20: Types Of Chassis And Fitting Methods

    [Figure 7.4] 2. Pre-mounted or integrated slide plates, which cannot move side to side, but are configurable via their adjustable mounting brackets. [Figure 7.5] Figure 7.5 • Take this information into account when preparing the fitting work of the liftgate. DHOLLANDIA...

  • Page 21: Mounting Of The Lift Frame: 3 Ways To Get Started

    1. The distance between the 2 fitting jigs matches the outside width across the arms. 2. The distance from each fitting jig to the middle line is equal so they are perfectly centered in the rear body aperture. [Figure 8.3] Figure 8.2 Figure 8.1 Figure 8.3 DHOLLANDIA...

  • Page 22: Method With Horizontal Platform

    See also section 9.3 regarding arm stops. DHOLLANDIA...

  • Page 23: Using The Quick-Fit Transport Rack (Option S410)

    With option S410, the liftgate is delivered fully pre-mounted on a transport rack. [Figure 8.8 – 8.9] • In this case, the preparation is restricted to determining the start point (L1) for the sliding tubes under the chassis. [Figure 8.10] Figure 8.8 Figure 8.9 Figure 8.10 DHOLLANDIA...

  • Page 24: Mounting Of The Lift Frame And Sliding Tubes

    [see Figure 9.5 – 9.6]. Approximate values. • For aluminium sliding tubes, fasten the toothed racks [3 in Figure 9.6] just in front of the end stops at an equal distance from the edge of the sliding tubes (left and right). ⚠ DHOLLANDIA...
  • Page 25 Figure 9.8 shows a trailer chassis with a platform buffer mounted to it inside the sliding tube. See [Figure 9.7] for the length (L) at which the bumper should be mounted for this instance. Figure 9.7 Figure 9.8 Figure 9.9 ❶ ❶ ❷ L= ± 8” (200mm) ❷ DHOLLANDIA...
  • Page 26 WARNING Do not drill, weld, or cut any parts of the slide tubes or the vehicle chassis until the full mounting position of the liftgate has been validated and tested with a positive result. DHOLLANDIA...

  • Page 27: Position Of The Mounting Brackets On The Aluminium Sliding Tubes For Dh-Sm(R) 1500-2000 Kg

    For side-mounted sliding tubes, wider brackets are available to mount the liftgate alongside the spring hangers of a mechanical vehicle suspension. [Figure 9.] ❸ Figure 9.13 ❹ ❷ ❶ 3 / side MIN. MAX. " (200mm) " (350mm) 0” 4” (100mm) DHOLLANDIA...
  • Page 28 • 1 and 2 in [Figure 9.14] show the mounting bracket too far to the rear, and too far to the front, respectively (4” threshold): Figure 9.14 ❶ ❷ Figure 9.15 ⚠ ⚠ DHOLLANDIA...

  • Page 29: Differences For Dh-Ssu(R) 2000-3000 Kg And Dh-Sk(S) 1000-2000 Kg

    It is important to position the mounting brackets of the sliding tubes properly. Incorrect positioning can lead to overload situations and premature failure of the liftgate. [Figure 9.16] Figure 9.16 ❸ ❹ ❷ #4 / ❶ side MIN. MAX. " (500mm) " (600mm) 0” 4” (100mm) DHOLLANDIA...

  • Page 30: Steel Sliding Tubes

    2. Except for chamfered chassis, the parallelism of the sliding tubes to the chassis. [2 in Figure 9.19] 3. The parallelism between the 2 sliding tubes, one in comparison to the other. [3 in Figure 9.19] Figure 9.19 ❸ ❶ ❷ DHOLLANDIA...
  • Page 31 • Note: for semi-trailers or trailers with chamfered chassis, special slide plates with and angle compensation of 5° and 3° are available upon request. Consult your national DHOLLANDIA agent for further information. • Make sure that the left and right sliding tubes are mounted at an equal distance from the rear of the vehicle chassis.
  • Page 32 Before 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 grind off the galvanizing in areas where welding is to be done. ▪ DHOLLANDIA...

  • Page 33: Adjustment And Fastening Of The Slide Plates

    1. The front brackets sit flush with the front side of the lift frame 2. The upper and lower bolts are fastened gradually and the alternating order 3. The bolts are fastened with a torque wrench to the required Nm setting [see appendix] DHOLLANDIA...
  • Page 34 The torque fastenings of all bolts should be checked after completion of the compulsory static and dynamic weight tests at the end of the fitting process, and retightened if necessary. Figure 9.28 Figure 9.29 Figure 9.30 Figure 9.31 ❶ Per Side 2x M24 (8.8) 450 Nm 332 lbf-ft ❶ DHOLLANDIA...

  • Page 35: Mounting The Platform & Finalizing The Mechanical Work

    If the electric controls are being used to move the cylinders, proceed with care. The cylinders might contain air, and can therefore react with unforeseen characteristics. • Secure the pins of all articulation points firmly by means of locking bolts (supplied with the liftgate) and pressurize cylinders gently. DHOLLANDIA...

  • Page 36: Check The Position Of The Tooth Rack Of The Retraction System

    [Figure 10.6] • Push the 2 square bars [1 and 2 in Figure 10.7] firmly against their respective slide plate and fasten them together by means of a locking bolt M8. ❸ ❷ ❶ 1x M8 ❸ Figure 10.8 DHOLLANDIA...

  • Page 37: Mount The End Stops For The Work Position

    Fasten the locking bolt of the end stops to the required torque settings. • Slide the liftgate in and out several times to verify if the platform assumes the correct work position at the loading floor of the vehicle. Fine tune the position of the end stops if required. DHOLLANDIA...
  • Page 38 Figure 10.15 ❶ ❷ Per Side ❷ 1x M16 (8.8) 195 Nm 143 lbf-ft End stops for retraction ❶ movement Slide plates ❷ ❸ Slide tubes Figure 10.12 Figure 10.13 Figure 10.14 ❸ ❸ ❸ ❶ ❶ ❶ ❷ ❷ DHOLLANDIA...

  • Page 39: Finalize The Stow Position Of The Platform

    2. To make the stow position of the platform comply with the legal bumper requirements [see Figure 10.17] Figure 10.17 13¾” 21½” • This can be a fabricated set of platform rubbers, forseen by the body builder, or any of the standard options S255, S256, through S259. See appendixes for more information. DHOLLANDIA...
  • Page 40 Option S256.ST [Figure 10.20]: these buffers are designed for under-mounting sliding tubes on semi-trailer chassis. Figure 10.20 • They can be adjusted over a range (H3) [Figure 10.20]. They are normally bolted to the rear-most mounting bracket for the sliding tubes, but can also be welded or bolted to the vehicle chassis itself. DHOLLANDIA...
  • Page 41 For orders including option S417, fit the electric switch (providing the signal that the platform is or is not in stow position) [see 1 in Figure 10.21]. Prepare the wiring to the dashboard of the vehicle cabin according to the wiring diagrams in the appendices. Figure 10.21 ❷ ❶ DHOLLANDIA...

  • Page 42: Electrical Installation

    • If not supplied with the liftgate, these can be downloaded from the “DOWNLOAD” section on our website: www.dhollandia.com • Please confirm you have reviewed the most up-to-date version of this manual prior to continuing. •...

  • Page 43: Optional Mounting Brackets

    In a standard installation, the control box is supplied loose with the liftgate and is mounted to the body of the vehicle. • For orders including option S411.S, DHOLLANDIA supplies a quick-fit bracket to mount the control box to the sliding tubes adapted to the specific type of tube in the unit [see Figure 11.2] ❶...

  • Page 44: Routing Of The Electric Cables

    11.3 ROUTING OF THE ELECTRIC CABLES • A general schematic of how to correctly connect the batteries to the liftgate is provided in [Figure 11.4]. Figure 11.4 DHOLLANDIA...
  • Page 45 The mounting system for the conduit is adapted to the different types of sliding tubes [see Figure 11. – Figure 11.]. Figure 11. Aluminum sliding tubes, side-mounted Figure 11. Aluminum sliding tubes, under-mounted Figure 11. Steel sliding tubes, under-mounted DHOLLANDIA...
  • Page 46 Figure 11.6 Figure 11.7 Figure 11.8 DHOLLANDIA...

  • Page 47: Putting The Liftgate Into Service

    2. Tilt the platform back up to horizontal position, and lower the platform completely (further down below the normal ground level), until the lift cylinders are fully retracted, and continue to push the function “lower” for another 20 seconds [see Figure 12.2]. Figure 12.2 DHOLLANDIA...

  • Page 48: Lubrication Instructions

    • If so equipped, verify if the platform lock operates smoothly, and lubricate with oil if necessary. NOTICE To maximize the durability and operational reliability of the liftgate, it is important to lubricate the pivot points thoroughly after installation. DHOLLANDIA...
  • Page 49 DHOLLANDIA...
  • Page 50 DHOLLANDIA...

  • Page 51: Commissioning And Quality Control

    During weight test, verify if the hydraulic pump pressure suits the maximum rated lift capacity in this particular mounting situation. Adjust the pressure if too high or too low, seal the pressure relief valve after that using the provided tamper-evident cap. Figure 14.1 Figure 14.3 Figure 14.2 DHOLLANDIA...

  • Page 52: Decals

    2. NEVER remove or paint over any decal. Missing, worn or illegible warning decals MUST be immediately replaced. Get free replacement decals from DHOLLANDIA. Contact your regional DHOLLANDIA distributor. See page 5 for contact info. 3. The operator should comply with all affixed safety and instructions decals. Be aware that the decals merely summarize the main points, and that the operator MUST know, understand, and comply with the full contents of the operation manual.
  • Page 53 DO NOT attempt to repair liftgate yourself, unless you have been trained and authorized to do so. distance of minimum 10” from the inboard edge of the platform adjacent to the rear sill of the vehicle body. EXAMPLE ❸ ❻ DHOLLANDIA...
  • Page 54 Tail lift decals used and affixed in areas, other than the rear of the vehicle: ⓫ For circuit breaker in liftgate battery compartment Cabin switch in driver’s cabin to switch electrical power to tail lift on / off (if so equipped) For main fuse in liftgate battery compartment DHOLLANDIA...

  • Page 55: Use Of The 'Warning: Liftgate Out Of Service. Do Not Attempt To Operate' Sign

    ‘WARNING. LIFTGATE OUT OF SERVICE. DO NOT ATTEMPT TO OPERATE’ sign provided with the liftgate on a position clearly visible to other potential operators. See examples below. The liftgate MUST not be used again until it has been serviced or repaired by a qualified service technician. EF0586.US EXAMPLE DHOLLANDIA...

  • Page 56: Identification Decals

    15.3 IDENTIFICATION DECALS Every DHOLLANDIA liftgate is identified and labelled with a unique 8-digit serial number (with or without a space between the first and last 4 digits). This number is used for any inquiry on a particular liftgate, or when ordering replacement parts.

  • Page 57: Appendix

    16.1 DECALS WARNING signs MANDATORY ACTION signs Overview and keep visual control over the working Contact your regional DHOLLANDIA distributor. area of the liftgate at all times. Consult the DHOLLANDIA website. General warning sign used to alert the user to potential hazards.
  • Page 58 Switch OFF the electrical power to the liftgate via the main battery disconnect switch and / or cabin switch. This is an operation to be executed manually (as opposed to an electrical function controlled by means of one of the control units). DHOLLANDIA...

  • Page 59: Prescribed Torque Values For Bolts Supplied With Liftgate

    Type of thread Size Strength class 10.9 Standard M6 x 1 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2 M16 x 2 Fine M14 x 1.5 M16 x 1.5 M20 x 1.5 M24 x 2 DHOLLANDIA...
  • Page 60 265.5 lbs-ft lbs-ft M24 x 2 lbs-ft lbs-ft Banjo Bolt Torque Specifications BSPP Metric Pounds Newton Pounds Newton Banjo Banjo Force - Metre Force - Feet Metre Bolt Bolt Feet (lbsf- (Nm) (lbsf-ft) (Nm) Size Size 10.5 24.5 136.5 DHOLLANDIA...

  • Page 61: Pdi Checklist 1/2

    The requirement for mechanical or hydraulic stabilizing legs has been checked and been fulfilled (if applicable). The actual fitting dimensions don’t exceed the theoretical maximum fitting dimensions mentioned in the fitting drawings. The lift has been fitted to conform with the fitting instructions of DHOLLANDIA, and the Body Building Guidelines of the OEM vehicle manufacturer.
  • Page 62 A hand grip for the operator to hold when lifting / lowering with the platform, is mounted on the rear frame of the vehicle body. 7- General operation, practical tests Y / N Unfolding and folding test: ▢ The platform opener is mounted in adequate position. When LOWERED at the ground, the platform stands just inside from vertical position. DHOLLANDIA...
  • Page 63 Operating a liftgate that hasn’t successfully passed the PDI can put the operator and third parties at great risk and could result in serious personal injury or death. • It is therefore essential that the PDI check is completed with due diligence, and any shortcomings rectified prior to delivery of the vehicle to the operator. DHOLLANDIA...

  • Page 64: Safe Operator Position On The Platform

    • To reduce the risk that the operator crushes their feet between the raising floor and the end of the vehicle floor, DHOLLANDIA recommends that the installer paints a 16x16” (405mm x 405mm) safe operator position at a safe distance of min. 10” (254mm) away from the inboard platform edge.

  • Page 65: 2-Button Portable Control

    The handheld control [1] is also equipped with a magnet, so that it will stick to any metal surface. • Mark the safe operator position on the platform and mount a hand grip to the rear frame of the vehicle body in conformance with Appendix 4. DHOLLANDIA...
  • Page 66 Figure 16.4 DHOLLANDIA...
  • Page 67 • A general wiring schematic for gravity down with the two-button handheld control is shown in [Figure 16.5]. Figure 16.5 DHOLLANDIA...
  • Page 68 • For option OAE510.15, see Figure 16.6, below: Figure 16.6 DHOLLANDIA...

  • Page 69: Circuit Breaker

    16.6 CIRCUIT BREAKER • A resettable circuit breaker option is also available for the connection to the batteries. [Figure 16.9] Figure 16.9 DHOLLANDIA...

  • Page 70: Cab Cut-Off Switch

    Refer to the appropriate connection sequence in Figure 16.10 to properly connect the E0667 illuminated cab switch. Figure 16.10 Figure 16.11 • For orders that shipped with option OAE510.15, refer to Figure 16.12 to properly connect the cab switch. Figure 16.12 DHOLLANDIA...

  • Page 71: Electric And Hydraulic Information

    The correct diagram applicable for the liftgate supplied can be found on the inside of the control box. If correct diagram is not present inside control box, contact your national DHOLLANDIA distributor for further assistance, or download from the website.
  • Page 72 U I = 3/4 valve on the rear side of the pump unit H = lift circuit S = tilt circuit D = self-locking valve on the lift cylinders SA = single acting lock valve DA = double acting lock valve DHOLLANDIA...
  • Page 73 DHOLLANDIA...
  • Page 74 DHOLLANDIA...
  • Page 75 DHOLLANDIA...
  • Page 76 DHOLLANDIA...
  • Page 77 DHOLLANDIA...
  • Page 78 DHOLLANDIA...
  • Page 79 1. Standard oil: ISO VG 22. This common and widely 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 climate. Refer to the product specifications of Q8 - Haydn ISO VG 22 (*) attached for further technical details.

  • Page 80: Mounting Diagrams

    16.9 MOUNTING DIAGRAMS DHOLLANDIA...
  • Page 81 DHOLLANDIA...

  • Page 82: End Note

    16.10 END NOTE • DHOLLANDIA would like to thank you for using our products and leave you with this final notice and warning. • Additional information about this liftgate and many other DHOLLANDIA products is available at the following link: http://www.dhollandia.com...

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