Dhollandia DH-SM Installation Manual
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Dhollandia DH-SM Installation Manual

Dhollandia DH-SM Installation Manual

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DH-SM
INSTALLATION MANUAL
2200-6600lbs (1000-3000kg)
** Pictured: SMM liftgate
Manufacturer:
DHOLLANDIA US, L.L.C.
E-mail : us.info@dhollandia.com
270 Southridge Parkway
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
Ref: xxx Doc: FIT_US installation manual SM_US EN_2020 Rev: 0 Date: JULY 22, 2020

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  • Page 1 DH-SM INSTALLATION MANUAL 2200-6600lbs (1000-3000kg) ** Pictured: SMM liftgate Manufacturer: DHOLLANDIA US, L.L.C. E-mail : us.info@dhollandia.com 270 Southridge Parkway 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...

  • Page 2: Table Of Contents

    Getting started ................................... 11 INSTALLATION METHODS ................................12 INSTALLATION DIMENSIONS ................................13 INSTALLATION OF THE DH-SM MOUNTING BRACKETS ......................16 INSTALLATION OF THE SLIDE TUBES ............................19 Note for liftgates type DH-SMR* with bolt-on mounting plates ....................21 MOUNTING OF THE LIFT FRAME ..............................22 10.1...
  • Page 3 19.7 OAM041 Weld-on chassis extension for trailers ........................60 19.8 OAM.056.1 bolt-on kit for trailer bogie rails ..........................61 19.9 End note ....................................63 19.10 Basic wiring diagrams ................................63 19.11 Checklist for preventative maintenance and repair ....................... 63 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 19.1 on page 49 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. •...

  • Page 5: Introduction, Contact Info And Disclaimers

    It contains general instructions applicable to the most common types of trucks and trailers. Possibly, specific issues particular to your case are not adequately covered by this manual. If in doubt, contact your national DHOLLANDIA distributor for further assistance prior to continuing.
  • Page 6 • Take notice of the following important disclaimers: DISCLAIMERS • DHOLLANDIA disclaims liability for any personal injury, death, or property damage that results from operating a liftgate that has been modified from the original design, without written approval from the manufacturer. •...

  • Page 7: Safety Precautions For Operation

    • Safety instructions are a matter of progressive insight. The basics are listed in this manual, but contact 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 →...
  • Page 8 DHOLLANDIA liftgate. • In case of doubt, ALWAYS contact the national DHOLLANDIA distributor for further advice, prior to continuing. • ALWAYS wear appropriate Personal Protective Equipment. This includes but may not be limited to: safety glasses with side guards or a wrap-around face shield;...

  • Page 9: Liftgate Terminology

    • DHOLLANDIA liftgates are designed as a bolt-on system, and don’t require any welding. See appendix 19.2 on page 51 for prescribed torque values. • If for any reason, trouble-shooting and / or repair might be needed during the installation process, consult and follow the guidelines and safety instructions of the MAINTENANCE MANUAL.

  • Page 10: Installation Parameters Terminology

    Required overhang to the end of the lift frame Lift Overhang to end of Power pack Required overhang to the end of the Power pack Lift Overhang to end of slide Tubes Required overhang to the end of the slide tubes DHOLLANDIA...
  • Page 11 Lift Floor Thickness Max. thickness of the rear sill of the vehicle floor, in the maneuver zone the lift arms and tilt cylinders Width Over Tires Width over the tires, determines the max. width of the bumper bar or DHOLLANDIA...

  • Page 12: Getting Started

    Make sure planned modifications to the vehicle chassis and body will not adversely affect the strength and integrity of the vehicle. • If the 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 advice. See contact info on page 4.

  • Page 13: Installation Methods

    The lift frame is available in only one configuration for the North-American market: DH-SM* with fixed, premounted slide plates. The slide plates cannot move sideways. The lateral adjustment to the chassis width done via adjustable mounting brackets for the slide tubes.

  • Page 14: Installation Dimensions

    For liftgates with a dedicated factory order, an INSTALLATION DRAWING is available, summarizing the critical installation dimensions to be observed. [Figure 7.1]. • For liftgates ex warehouse stock, an INSTALLATION DRAWING can be obtained from the national DHOLLANDIA distributor. See page 4 for contact info. •...
  • Page 15 The mounting height is measured from the top of the vehicle bed to the center of the lift arm articulation pin. Look carefully [Figure 7.3] how to measure this dimension on the DH-SM range. • In absence of an installation drawings, following simplified methods are sometimes applied: 1.
  • Page 16 Ensure all mounting brackets are mounted at equal height under the vehicle body or above the bottom line of the chassis [1], so that the slide tubes end up hanging fully parallel [2] front to rear, with zero space [3] between mounting bracket and the top face of the slide tube. DHOLLANDIA...

  • Page 17: Installation Of The Dh-Sm Mounting Brackets

    8 INSTALLATION OF THE DH-SM MOUNTING BRACKETS • The height of the mounting brackets is determined as detailed in section 7. • Also the longitudinal position of these brackets, the installation parameters most, mob1...3 [see section 5] are determined by the INSTALLATION DRAWING.
  • Page 18 [1]. NOTICE • Most indications in this section refer to truck chassis. • Refer to Appendix 19.7 for trailer installations with weld-on chassis extension option OAM021. • Refer to Appendix 19.8 for trailer installations with bolt-on bogie-rail mount kit. DHOLLANDIA...
  • Page 19 The platform stop bumpers can be mounted at 3 different heights, corresponding with variable ground clearances under the platform in its travel position. [Figure 8.6] • Take the applicable legal underrun / crash bar legislation into consideration when adjusting the ground clearance of the stowed platform. Figure 8.6 DHOLLANDIA...

  • Page 20: Installation Of The Slide Tubes

    The platform is usually mounted flush with the rear end of the chassis or body. Without further consultation of DHOLLANDIA [see page 4 for contact info], do NOT hide the platform deeper than 2” under the chassis or body. [Figure 9.2] 2.
  • Page 21 Bolt the slide tubes to the mounting brackets on the chassis with 2 bolts / bracket as instructed. [Figure 9.5] • Fasten the bolts with the required torque value, and check again after completion of the installation and weight test. Figure 9.3 Figure 9.4 Figure 9.5 DHOLLANDIA...

  • Page 22: Note For Liftgates Type Dh-Smr* With Bolt-On Mounting Plates

    To move the slide plates sideways, first remove the M8 locking bolt [1 on Figure 9.7] that locks the left side and right side gear wheel tubes together. [Figure 9.7]. The bolt M8 must be repositioned after mounting of the lift frame [section 11] and alignment of the gear wheels on the toothed bars [section 12]. Figure 9.6 Figure 9.7 DHOLLANDIA...

  • Page 23: Mounting Of The Lift Frame

    Bring the lift frame in front of the slide tubes, so that the rollers on the slide plates align up with the openings in the slide tubes. • Manually push and guide the lift frame inside the slide tubes. Figure 10.2 DHOLLANDIA...
  • Page 24 If the slide plates are not correctly positioned, slightly loosen the mounting bolts of the slide tubes to the mounting brackets, then push or pull the slide tubes laterally to move them into correct position. Fasten the bolts again with the prescribed torque. See appendix 19.2 on page 51. DHOLLANDIA...

  • Page 25: Note For Liftgates Type Dh-Smr* With Bolt-On Mounting Plates

    A fall of the liftgate off the chassis can damage the liftgate and / or vehicle chassis, and can cause serious bodily injury or death to the operator and any bystanders. • Therefore, it is essential that the slide tubes, slide plates, bolts etc. are installed following the instructions of this manual. DHOLLANDIA...
  • Page 26 • The torque fastenings of all bolts should be checked after completion of the installation and weight test, and retightened if required. Figure 10.5 Figure 10.6 DHOLLANDIA...

  • Page 27: Mounting Of The Platform

    The hydraulic cylinders and circuits might contain air. The piston rods might slide out with shocks when the cylinders are filled with oil. • The installer must consult and follow the DHOLLANDIA safety instructions for maintenance and repair. Negligence can lead to serious personal injury. •...
  • Page 28 Align the brackets for the tilt cylinders on the platform [1] with the tilt cylinder extensions [2] themselves [Figure 12.3]. Insert the pivot pins L+R [2 on Figure 11.4]. Mount their locking bolts and the platform rollers [3 in Figure 11.4]. Fasten the locking bolts with the required torque. Figure 11.3 Figure 11.4 DHOLLANDIA...

  • Page 29: End Stops And Adjustment Of The Toothed Bars

    The end stops for the slide plates consists of a lock plate [1] to be inserted inside the slide tube, a toothed clamp [2]to go on the outside below the slide tube, and a bolt + nut M16 [3] to compress both together. [Figure 12.2 – 12.3] Figure 12.1 Figure 12.2 Figure 12.3 DHOLLANDIA...
  • Page 30 Make sure the teeth of the gear wheels are correctly centered and lined out between the teeth of the toothed bars. Adjust and center again if needed. Fasten the bolts of the toothed bars with the required torque. See appendix 19.2 on page 51. Figure 12.6 DHOLLANDIA...

  • Page 31: Note For Liftgates Type Dh-Smr* With Bolt-On Mounting Plates

    Failure to set and adjust the gear wheels and toothed bars correctly according to the figures 12.5 - 12.8 can lead to premature failure of the gear wheels and / or the toothed bars, and can disable the slide in / slide out functions. DHOLLANDIA...

  • Page 32: Additional End Stops For The Lift Arms Against The Chassis

    Example in Figure 14.1: end stop [1] is as close as possible to the lift cylinder anchor point and is OK. End stop [2] is too far away from the lift cylinder anchor point [3] and is not OK. • If in doubt, contact your local DHOLLANDIA distributor for further guidelines. See page 4 for contact info. Figure 13.1 •...

  • Page 33: Electrical Installation

    • Read and follow the instructions FIT-ELEC-GENERAL-… (latest update). If not supplied with the liftgate, these can be downloaded from the “DOWNLOAD” section on our website: www.dhollandia.com → Country & language selection → Downloads → Mounting instructions → General → … select required manual •...

  • Page 34: Installation Of The (+) Battery Cable And (-) Ground Cable

    Using the main battery disconnect switch [# 4a] for connection of the (+) battery cable [# 1] , and the bolt at the rear corner of the control box [# 4b] for connection of the (-) ground cable [# 2a – 2b]. Continued on next page… DHOLLANDIA...
  • Page 35 (-) ground cables cannon plugs option OAE506 • Foresee a flexible protective conduit over the full length of the (+) battery cable [# 1 above] and the (-) ground cables [# 2]. DHOLLANDIA...
  • Page 36 • 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 distributor. See page 4 for contact info. • Fasten all connections at both ends of the cables thoroughly. Loose connections can lead to bad contacts and overheating, followed by premature failing of the electrical circuit.

  • Page 37: Routing Of The Wire Loom

    Verify the routing of the conduit [4] and wire loom both at travel position and work position of the liftgate. Make sure the conduit [4] cannot be stretched, squeezed, caught or damaged otherwise while sliding the lift frame and pump unit in / out. • Readjust and fine-tune the position of the mounting bracket(s) [1-2] if required. DHOLLANDIA...

  • Page 38: Installation Of Extra Controls

    • Read and follow the instructions FIT-ELEC-OPTION-… (latest update). If not supplied with the liftgate, these can be downloaded from the “DOWNLOAD” section on our website: www.dhollandia.com → Country & language selection → Downloads → Mounting instructions → General → … select required manual •...

  • Page 39: Putting The Liftgate Into Service

    Push the LIFT button to raise the platform to the vehicle floor. Stop when you hear the hydraulic pump turn in overpressure. NOTICE Check for visible leaks of hydraulic oil as the system is being pressurized. If there is leakage, correct the problem prior to continuing. DHOLLANDIA...
  • Page 40 LIFT the platform back to vehicle floor level. OPEN the platform fully to its deepest inclined position, continue to press OPEN for 20 sec. CLOSE or TILT UP the platform again, and repeat until no air bubbles run back to the oil reservoir. DHOLLANDIA...

  • Page 41: Commissioning & Quality Control

    Loosen the counter nuts, then adjust the bolt length and retighten the adjuster nuts. [1 in Figure 16.2]. Make sure both sides are adjusted equally, so that all bolts will the support the platform and its load evenly. Figure 16.1 Figure 16.2 DHOLLANDIA...
  • Page 42 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 16.3 INBOARD platform edge DHOLLANDIA...

  • Page 43: Placement Of Decals

    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. Figure 17.1 ❶ ❽ ❹ ❺ ❶ ❽ ❼ ❷ ❸ ❾ ❻ DHOLLANDIA...
  • Page 44 ❶ ❷ ❸ ❹ ❺ ❻ DHOLLANDIA...
  • Page 45 ❼ ❽ ❾ DHOLLANDIA...

  • Page 46: Use Of The 'Warning. Liftgate Out Of Service. Do Not Attempt To Operate' Sign

    See examples below. • The liftgate must not be used again until it has been serviced or repaired by a qualified service technician. • Place this decal along with the User Manual in the glove box compartment of the vehicle. EF0586.US DHOLLANDIA...

  • Page 47: Identification Decals

    17.2 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 48: Platform Orientation

    Falling cargo will put the operator and any bystanders at serious risk of bodily injury and death. • Therefore, it is important that the pitch of the flip-over point and complete platform are adjusted correctly conform with instructions in this manual. DHOLLANDIA...
  • Page 49 Figure 18.1 Figure 18.2 DHOLLANDIA...

  • Page 50: Appendix

    19.1 MEANING OF THE SAFETY AND WARNING SIGNS WARNING signs MANDATORY ACTION signs Overview and keep visual control over the Contact your regional DHOLLANDIA distributor. working area of the hydraulic ramp at all times. General warning sign used to alert the user to Consult the DHOLLANDIA website.
  • Page 51 / or Switch between external and internal controls. 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 52: Prescribed Torque Values For Bolts And Nuts

    A fall of the liftgate off the chassis can damage the liftgate 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 the instructions of this manual. DHOLLANDIA...

  • Page 53: Electric And Hydraulic Requirements

    • The applicable wiring diagrams are saved at the inside of the main external control box, and can be found there for reference. • A copy of the wiring diagrams can also be obtained from the national DHOLLANDIA distributor [see contact info on page 4];...
  • Page 54 It is important to follow these guidelines with due care. A lot of oils or fluids used in automotive industry, such as transmission fluids and ATF oils, are not suitable for liftgate use. DHOLLANDIA has not tested the potential consequences of oils and fluids with deviating specifications and cannot be held responsible or legally liable for any damage to the liftgate caused by the replenishment with non- compatible oils or fluids;...

  • Page 55: Grease Plans

    • This annex includes grease plans for the most frequent DH-SM* liftgates. • 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.dhollandia.com →...
  • Page 56 DHOLLANDIA...
  • Page 57 DHOLLANDIA...

  • Page 58: Connections To The Main External Control Box

    PVC base of the control box to ensure proper sealing. Once this basis is solidly wrapped and sealed, move the gun further away from the basis, and swing it around the incoming pole (3) to obtain complete and even shrinking of the hose on all sides. DHOLLANDIA...
  • Page 59 Insufficient torqueing of the connection bolts can cause overheating and short circuits. Improper sealing can cause water ingress, and premature corrosion to the battery cable connection. • DHOLLANDIA disclaims liability for any personal injury or property damage that results from improper or negligent installation. DHOLLANDIA...

  • Page 60: Safe Operator Position On The Platform

    3 points of contact while travelling on the platform, in accordance with the operation manual.] • The handgrip is normally foreseen by the body builder as part of the design of the box. A DHOLLANDIA alternative can be ordered with spare part ref. M1406.

  • Page 61: Oam041 Weld-On Chassis Extension For Trailers

    19.7 OAM041 WELD-ON CHASSIS EXTENSION FOR TRAILERS • DH-SM slider liftgates can be mounted to North-American style trailer chassis by means of the kits presented in Appendix 19.7and 19.8. • OAM041 features a truck-chassis look-alike chassis extension [1] that is welded to the underside cross bearers [2] of the vehicle body.

  • Page 62: Oam.056.1 Bolt-On Kit For Trailer Bogie Rails

    [4a] in the bogey rails [4] with maximum ½” (1.5 mm) tolerance. • If the tolerance between the bush [5] and the orifices [4a] exceeds 1.5 mm for both sides of bush [5], contact the national DHOLLANDIA distributor. See contract info on page 4.
  • Page 63 DHOLLANDIA...

  • Page 64: End Note

    19.9 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/...
  • Page 65 Work order # Checklist for preventative maintenance and inspection Client PO # Client : Plate : Mileage : Address : Model + S/N : Contact phone : City : ST : Zip : Date : GENERAL When “NOT OK”, liftgate must be serviced or repaired prior to further use Before getting started…...
  • Page 66 Condition, battery maintenance, charging system output is sufficient, connections are secure. Apply dielectric grease to all exposed connections. Main fuse or circuit breaker in battery box 90 days 1750 cycles Terminals tight, corrosion free, no signs of overheating, verify operation if manual trip present (+) Battery and cables, plugs, terminal connections, protective looms 180 days Condition, undamaged, secured with clamps and/or cable ties, inspect full length and connection at...
  • Page 67 Condition, rod surface free of paint, dirt, scratches and pitting Cylinder lock valves 180 days 3500 cycles Condition, undamaged, clearance from mounting plates, bumper, other fixed parts Tilt cylinders Yearly Adjustment of extension rods, fastening of their lock nuts Hydraulic circuits of cylinders, valves and couplings 90 days 1750 cycles No visible oil leaks in operation and at rest...
  • Page 68 90 days 1750 cycles Apply grease along the full inside of the slide tubes After wash Attention : no greasing is required on single-fold liftgates with rollers (types DH-SM) ! Hydromotor, hydraulic circuits, valves and couplings 90 days 1750 cycles...
  • Page 69 bed. Hydraulic circuit general 90 days 1750 No visible oil leaks during operation and at rest cycles Test and inspection results Frequency OK ? Corrected □ □ □ Liftgate has been: serviced repaired inspected  The liftgate is safe and suitable for further use ...

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