Dhollandia DH-L Series Installation Manual
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Dhollandia DH-L Series Installation Manual

Dhollandia DH-L Series Installation Manual

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DH-L* 3300-6600 lbs
INSTALLATION MANUAL
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
Order ref : xxx Doc: FIT_US installation manual LM_US EN_2020 Rev: 2 Date: OCTOBER 21, 2021

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  • Page 1 DH-L* 3300-6600 lbs INSTALLATION MANUAL 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

    Physical installation of the external control box ........................45 11.2 Installation of the (+) battery cable and (-) ground cable ......................46 11.3 Installation of extra controls ..............................50 11.3.1 Installation of 3-Button Wander Lead - OAE002 (E0784.M.S) ..................51 DHOLLANDIA...
  • Page 3 Connections to the main external control box type 3 ....................... 73 16.7 Safe operator position on the platform ............................ 75 16.8 End note ....................................76 16.9 Basic wiring diagrams ................................76 16.10 Checklist for preventative maintenance and repair ......................... 76 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 16.1 on page 61 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

    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 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 ALWAYS confirm you have reviewed the most up-to-date version of these manuals prior to installation and operation of the associated 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 Welding should be done by skilled and qualified installers only. • The marking is normally foreseen by the body builder, or can be ordered from DHOLLANDIA with option ref. OAT140.L / OAT140.R. A metal paint mask can be ordered from DHOLLANDIA with spare parts ref. EF0100.

  • Page 10: Liftgate Terminology

    5 LIFTGATE TERMINOLOGY DH-LM* LIFTGATE TERMINOLOGY Refer to the OPERATION MANUAL for an overview of the most important terminology used in DHOLLANDIA manuals. INSTALLATION PARAMETERS TERMINOLOGY larm Lift ARM length Length of the lift arms vfh max Vehicle Floor Height max Max.
  • Page 11 Available mounting space for rear truck lights on outside of the tilt cylinders Body Floor Thickness Thickness of the rear cross member of the vehicle floor Lift Floor Thickness Max. thickness of the rear cross member of the vehicle floor, in the manoeuvre zone for the lift arms and tilt cylinders 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 Dimensions And Guidelines

    • The INSTALLATION 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 (paper or App) to learn the maximum and minimum installation parameters per type of liftgate.
  • Page 14 • Compare the maximum installation parameters indicated in these sources with the actual vehicle dimensions. If the actual dimensions go outside of the maximum installation parameters, DON’T continue and contact your national DHOLLANDIA distributor for further advice. • The applicable mounting height...
  • Page 15 → If platform is mounted directly against the rear frame, dimension is lower. → If platform is mounted with sealing rubbers or other spacer, dimension is higher. DHOLLANDIA...

  • Page 16: Common Installation Dimensions

    COMMON INSTALLATION DIMENSIONS • Listed below are common models offered by DHOLLANDIA US and their associated fitting ranges: LMM-33 LMH-33 / 44 DHOLLANDIA...
  • Page 17 LMS-55 / 66 DHOLLANDIA...

  • Page 18: Important Guidelines

    Incorrect or negligent installation can cause the liftgate to fall off the vehicle chassis once the platform is loaded, and can put the installers, the operators and bystanders at great risk of bodily injury or death. • In case of doubt, don’t continue, but contact your national DHOLLANDIA dealer for further advice. DHOLLANDIA...

  • Page 19: Rear Doors With Container Locks

    • Additional guidelines are available for cases where the rear doors sit behind the rear frame of the body and rear cross member of the vehicle floor, or where the locks sit on the outside face of the rear doors. • These guidelines can be obtained from your national DHOLLANDIA distributor, or can be downloaded from the DHOLLANDIA website: www.dhollandia.com →...

  • Page 20: Methods To Mount Liftframe

    • For half width platforms, position the fitting jigs in function of the arm width lac, and the foreseen position of the half platform in the rear body aperture. • Fasten the fitting jigs to the rear cross member of the vehicle floor by means of bolts, clamps or spot welding. DHOLLANDIA...

  • Page 21: Method With Vertical Platform

    • If the liftgate is mounted with a seal kit between the closed platform and vehicle body, the position of the platform must be adjusted to suit the thickness of the sealing rubbers. See 7.3 on page 21. DHOLLANDIA...

  • Page 22: Impact Of The Seal Kit

    • If an INSTALLATION DRAWING is available, the required spacer Q for original DHOLLANDIA seal kits is mentioned on it. • If no drawing is available, the following guidelines can be used. Top & side profile Floor profile 1”...

  • Page 23: Method With Horizontal Platform

    Make sure the platform is parallel and level with the vehicle floor. • The gap between the rear cross member of the vehicle floor and the inboard platform edge will need to be covered by a bridge plate or other techniques. See also 6.3.2 on page 18. DHOLLANDIA...

  • Page 24: Mounting Of The Lift Frame

    Mounting plates are not-adjustable in longitudinal direction. The clamping blocks enable adjustments in longitudinal and lateral direction. Mounting plates and lift frame are mounted together. Mounting plates can be mounted on the chassis first, lift frame can be attached to the plates later. DHOLLANDIA...

  • Page 25: Positioning Of The Lift Frame With Oam010

    Therefore, handle the lift frame with extreme care. Use an adequate wheeled mounting jack to move the lift frame safely, without a risk of collapse. • • Slide the articulation pins through the fitting jigs (or platform Raise the lift frame to the correct mounting height mfc. hands) and the lift arms. DHOLLANDIA...
  • Page 26 • Make sure the lift frame is positioned in accordance with the INSTALLATION DRAWING or indications in the POCKET GUIDE (paper or App), before drilling or welding the mounting plates to the chassis. • It is not allowed to reduce the width of the mounting plates without prior authorization from DHOLLANDIA. DHOLLANDIA...

  • Page 27: Fixation Of The Mounting Plates Oam010

    Straighten the mounting plates, and make sure they stand perpendicular to the lift frame. • The mounting plates should be bolted to the lift frame according to the instructions included in the bolt kit supplied with the liftgate (see below). DHOLLANDIA...
  • Page 28 DHOLLANDIA...
  • Page 29 Fasten the bolts and nuts with the required torque (see values for “shear”). • Maximize the spread of the mounting bolts over the full surface of the plates overlapping the chassis and subframe. DH-LMM / DH-LMH @ 3300 – 4400 lbs DHOLLANDIA...
  • Page 30 • If the spread of the holes on pre-punched chassis doesn’t comply with the instructions above, first check if you can change the mounting height to get a better match between the mounting plates and the pre-punched chassis holes. DHOLLANDIA...
  • Page 31 It is essential that bolts and nuts used to mount the lift frame to the chassis, are fastened with the required torque (see values for “shear”). • If you use mounting bolts not supplied by DHOLLANDIA, obtain confirmation of the required torque from your supplier and make sure they guarantee at least an equivalent strength. •...

  • Page 32: Additional Remarks For Heavy-Duty Lifts And Very Long Platforms

    DH-LM.30 > 5500 lbs and / or pd > 88 ½” Solution with 2 additional bolts: Solution with 2 welding seams on subframe: NOTICE • Before doing any welding, take note of the precautions for welding in 4 from page 6 onwards. DHOLLANDIA...

  • Page 33: General Remarks

    NOTICE WARNING • In case of doubt how to install the liftgate correctly, DO NOT go any further, but ask your local DHOLLANDIA distributor for professional advice. • Negligence can put the technical personnel, the operator, and third parties at great risk, and could result in severe injury or death.

  • Page 34: Mounting The Towing Hitch

    • Bumper bars and towing hitches must be installed according to DHOLLANDIA’s instructions, and all bolts fastened with the required torque [see values for “shear”]. It is not allowed to modify these constructions without prior written approval from DHOLLANDIA.
  • Page 35 • Pay special attention 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 repositioned in height and / or depth, the same number of bolts as originally supplied must be used. EXAMPLE DHOLLANDIA...
  • Page 36 • If the bumper bar is supplied as 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 instructions. See contact info on page 4.

  • Page 37: Mounting Of The Platform

    • ALWAYS observe the safety instructions and precautions contained in the GENERAL SAFETY INSTRUCTIONS FOR INSTALLATION, MAINTENANCE AND REPAIR manual. • In case of doubt, contact the national DHOLLANDIA distributor for further assistance. • Grease the bearings of the lift arms [# 1 – 3 below] and the adjustable extension of the tilt cylinders [# 2] before mounting the corresponding articulation pins.
  • Page 38 3. Push / pull the piston rod by hand. Open valve Close valve • Operate LIFT and pressurize the lift cylinders gently. Stop as soon as you hear the hydraulic system turn in overpressure. • If applicable, remove the fitting jigs. • Remove the wheeled mounting jack. DHOLLANDIA...
  • Page 39 To OPEN the platform, most tilt cylinders are powered in by powerful internal springs (*). The piston rods will react quickly and suddenly when releasing the hydraulic pressure. (*) Exception: in case of option OAH026, the tilt cylinders are powered in by means of hydraulic pressure (power open). DHOLLANDIA ...

  • Page 40: Other Mechanical Works

    • The end stops [# 2] must result in an adequate pressure of the platform on the sealing rubbers (if applicable). Adjust if required. • Fasten all bolted connections with the required torque. See appendix 16.2 on page 63. DHOLLANDIA...

  • Page 41: Platform Stow Position

    10.2 PLATFORM STOW POSITION • If applicable, mount the aluminium profiles and sealing rubbers (option OAT001 - …OAT005) to the rear frame of the body. See also 7.3 on page 21. Installation DHOLLANDIA...
  • Page 42 Use the function CLOSE to slide out the tilt cylinders [# 1] to groove on the threaded end [# 2]. If this is not possible, contact the maximum stroke S. your national DHOLLANDIA distributor for longer extensions [# 4]. DHOLLANDIA...
  • Page 43 If the platform is equipped with a platform lock, bolt or weld the fixed eye of the lock at the side of the vehicle body. • If the liftgate must comply with EN12642 on the Securing of Cargo, contact your national DHOLLANDIA distributor prior to ordering the liftgate, to determine the required interfaces. See contact info on page 4.

  • Page 44: Adjustment Of The Hydraulic Stabilizing Legs

    NOTICE • DHOLLANDIA strongly recommends the use of hydraulic stabilizing legs to load and unload heavy machinery. • The use of stabilizing legs is mandated by various vehicle manufacturers. Consult the instructions of the vehicle manufacturer.
  • Page 45 Follow the bolt instructions below to mount the stabilizing legs to the lift frame. Preferably use 4 bolts per stabilizing legs, a minimum of 3 is required. If this is not possible, contact your national DHOLLANDIA distributor for further help (probably stabilizing legs with a longer stroke).

  • Page 46: 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 47: Installation Of The (+) Battery Cable And (-) Ground Cable

    (+) battery cable from the main battery fuse to the main battery disconnect switch of the control box (if applicable), or to the incoming main terminal of the starter solenoid; 2. and a (-) ground cable, from the negative terminal of the batteries to the negative terminal of the electric motor. DHOLLANDIA...
  • Page 48 • 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 49 DHOLLANDIA...
  • Page 50 • When mounting electrical 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 the grommets or cable glands. DHOLLANDIA...

  • Page 51: 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 52: Installation Of 3-Button Wander Lead - Oae002 (E0784.M.s)

    11.3.1 Installation of 3-Button Wander Lead - OAE002 (E0784.M.S) DHOLLANDIA...

  • Page 53: Installation Of Cabin Cutoff Switch - Oae510.15 (E0393.S.15)

    11.3.2 Installation of cabin cutoff switch – OAE510.15 (E0393.S.15) DHOLLANDIA...

  • Page 54: Putting The Liftgate Into Service

    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 correct prior to continuing. DHOLLANDIA...

  • Page 55: Lubrication Instructions

    • 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 & language selection → Downloads → Maintenance & Repair → Grease plans → … select required plan •...

  • Page 56: Quality Control And Pdi Test

    • If the operator is allowed to travel up and down on the platform by other means than original foot controls, mark a safe operator position of 16” x 16” (400 mm) at a safe distance of 10” (250 mm) from the hazardous crushing area between the inboard platform edge and the rear cross member of the vehicle floor. DHOLLANDIA...
  • Page 57 • If in doubt how to adjust the pressure relief valve, refer to procedure I-SERV-G-003 of the MAINTENANCE AND REPAIR MANUAL, or contact your national DHOLLANDIA distributor for help. See contact info on page 4. •...

  • Page 58: Decals

    Affix the 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 chosen type of external control box. DHOLLANDIA...
  • Page 59 ❶ ❷ ❸ ❹ DHOLLANDIA...
  • Page 60 ❺ ❻ ❼ ❽ ❾ DHOLLANDIA...

  • Page 61: 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 62: Appendix

    16.1 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 63 / 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 64: 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 65: 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 66 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 67: Grease Plans

    This annex includes grease plans for the most frequent liftgates DH-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.dhollandia.com →...
  • Page 68 DHOLLANDIA...
  • Page 69 DHOLLANDIA...

  • Page 70: Connections To The Main External Control Box Type 1

    Reserve the wider for the ticker channels. supplied with the liftgate. battery & ground cables. Use the narrower Route the cable in such a way that it cannot for control units, cables of electro valves be damaged or pinched. etc. DHOLLANDIA...
  • Page 71 DC motor by means of a hexagonal key nr. assigned channels. Push them down into key nr. 13. the groove, make sure the cables don’t overlap the vertical divider lips between the various channels. DHOLLANDIA...
  • Page 72 Allen Key nr. 5. At the inside, route all cables so that they Use cable ties to bind the cables together, are protected against damage, pinching protect cables against vibration, and finish and chafing. off in a clean way. DHOLLANDIA...
  • Page 73 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 74: Connections To The Main External Control Box Type 3

    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 75 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 76: 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 77: End Note

    16.8 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 78 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 79 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 80 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 81 Extras for cantilever liftgates Frequency OK ? Corrected Rear closure platform, in travel position Yearly Pressure against the rear frame, sealing, adjustment of the tilt cylinder extensions Platform behind rear doors, in travel position Yearly Correct distancing from the rear doors, interference with the rear doors, adjustment of the tilt cylinder extensions Practical tests Frequency...
  • Page 82 Test and inspection results Frequency OK ? Corrected □ □ □ Liftgate has been: serviced repaired inspected  The liftgate is safe and suitable for further use  The liftgate required further testing The liftgate requires immediate maintenance or repair prior to further use ...

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