Dhollandia DH-RPM 25 Installation Manual
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Dhollandia DH-RPM 25 Installation Manual

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DH-RPM 25
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 RPM_US EN_2022 Rev: 1 Date: SEPTEMBER 1, 2023

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Summary of Contents for Dhollandia DH-RPM 25

  • Page 1 DH-RPM 25 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

    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 DHOLLANDIA...
  • Page 3 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 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

    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 • DHOLLANDIA disclaims any liability for damage arising from modifications to the vehicle in its entirety as a result from installation. All modifications to the vehicle must be done in accordance to instructions issued by the vehicle and body 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: Liftgate Terminology

    Make sure the main battery power is disconnected while installing the liftgate. Connect the battery power to the liftgate only when the installation is completed, or as required in the installation instructions. • 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. •...

  • Page 10: Installation Parameters Terminology

    Mounting height Floor to top of lift frame Mounting height of lift frame above the ground: measured from the floor of the Tube vehicle to the top of the lift frame tube Mounting clearance Plates to Ground Ground clearance under liftgate Platform Depth Overall platform depth DHOLLANDIA...
  • Page 11 Required overhang to end of the premounted power pack Lift Arm Center Center width of the lift arm CHassis Width Chassis width of the vehicle bwo min Body Width Outside min Min. body width with power pack in premounted position DHOLLANDIA...

  • Page 12: Getting Started

    • DHOLLANDIA disclaims any liability for damage arising from modifications to the vehicle in its entirety as a result from installation. All modifications to the vehicle must be done in accordance to instructions issued by the vehicle and body manufacturer.

  • Page 13: Installation Dimensions And Guidelines

    6 INSTALLATION DIMENSIONS AND GUIDELINES INSTALLATION DIMENSIONS RPM-25 – bed heights 39” – 45” RPM-25 – bed heights 43” – 51” DHOLLANDIA...

  • Page 14: Installation Resources

    FULLY LOADED vehicle. In case of a lower vfh, the risk exists that the platform will not fold / unfold under the bed extension. INSTALLATION RESOURCES • If in doubt on any installation parameters given, please reach out to your local DHOLLANDIA distributor. See contact info on page 4. DHOLLANDIA...

  • Page 15: Bed Extension And Chassis Cut

    It is possible to mount the lift at a higher ground 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 ground clearance mpg.

  • Page 16: Rear Sill Cut

    Where chassis beams, longs sills, the rear sill and other steel chassis or body components have been cut, grinded, drilled, etc…, the installer should apply adequate anti-corrosive coating to protect the vehicle and body against corrosion. Check, and make sure you comply with the instructions of the OEM vehicle manufacturer. DHOLLANDIA...

  • Page 17: Mounting Of The Bed Extension

    Ensure the bed extension is level with the vehicle floor, and flush with the top surface of the rear sill. • Then tighten the bolts to the prescribed torque. Work from the center outward. See 19.2 on page 51 for prescribed torques. DHOLLANDIA...
  • Page 18 Before welding, note that welding on galvanized parts releases hazardous fumes. Provide adequate ventilation, and war 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 19: Mounting Of The Lift Frame (Premounted Platform)

    • Run the bolts in a sufficient amount to allow the platform to rest in a level state. • Tighten the jam nuts against the platform to ensure the bolts will not back out. DHOLLANDIA...
  • Page 20 • • This configuration is typically desirable for cutaway chassis. The mount plates should be put in the wide configuration only if needed to accommodate the chassis width chw. Wide configuration DHOLLANDIA...
  • Page 21 Therefore, handle the platform and attached lift frame with great care. Use hoists and a gantry crane to raise the platform and attached lift frame in their correct mounting position. • Place C-clamps on each side of the platform to prevent the hoist chain from slipping off the platform. DHOLLANDIA...
  • Page 22 Ensure the platform and lift frame are positioned in conformance with the mounting instructions and dimensions indicated in the installation drawing and manual, before drilling or welding the mount plates to the chassis. • DO NOT reduce the height of the mount plates without prior written authorization from DHOLLANDIA. DHOLLANDIA...

  • Page 23: Fixation Of The Mount Plates

    Fasten the mounting bolts with the prescribed torque (see values for “shear”). • Disregard could lead to a fall of the liftgate and its load, and may put the operator and bystanders at risk of serious personal injury or death. DHOLLANDIA...
  • Page 24 NOTICE • Various vehicles manufacturers offer pre-punched chassis and don’t allow you to drill additional holes through the chassis beams. • Consult the Fitting and Body Building Instructions of the vehicle manufacturer, and make sure you comply. DHOLLANDIA...
  • Page 25 During installation, the bolts and nuts should be fastened to the proper torque, shown in these installation instructions. • If you use mounting bolts not supplied by DHOLLANDIA, make sure the total strength is at least equivalent as per this manual. •...

  • Page 26: 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 27: Installation Of Electrical Controls

    Prevent ingress of water into the pump unit and control boxes if applicable. • Route and secure cables downward, forming a “drip loop” as they exit the pump unit. • Connect the wires of the cable to the connection points in the pump unit as per wiring diagram below. DHOLLANDIA...
  • Page 28 DHOLLANDIA...

  • Page 29: Installation Of The Cabin Switch (Oae510.15 - E0393.S.15)

    • The switch interrupts power from the vehicle batteries to the connection block inside the power pack. • This cable wiring for the cabin switch must be a minimum of 16 AWG (1.5mm ) to avoid voltage drop issues. DHOLLANDIA...

  • Page 30: Installation Of Extra Controls - 2 Button Remote Control (Oae001 - E0787.2.H)

    Prevent ingress of water into the pump unit and control boxes if applicable. • Route and secure cables downward, forming a “drip loop” as they exit the pump unit. • Connect the wires of the cable to the connection points in the pump unit, as per wiring diagram below. DHOLLANDIA...
  • Page 31 DHOLLANDIA...

  • Page 32: Electrical Installation

    To ensure the reliability of the lift over many years after installation, check and make sure the cables pass through the back plate of the pump unit, are properly mounted, and will seal the inside of the pump. • DHOLLANDIA disclaims liability for any personal injury or property damage that results from improper or negligent installation. (+) battery cable Motor solenoid...
  • Page 33 Use a second wrench so the ground terminal instructions in section 11 on page 26. does not turn in its place. Turning the terminal in place will damage the grounding inside the motor and render it inoperable. DHOLLANDIA...
  • Page 34 • 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 35: Putting The Liftgate Into Service

    The installer MUST remain vigilant and stay out of the range of motion of the platform and the moving parts of the lift as long as the hydraulic circuits have not been bled and all functions duly tested. DHOLLANDIA...
  • Page 36 LIFT the platform again and repeat until no more air bubbles back to the oil reservoir. • If the platform opener assembly was dismounted during installation or moved, make sure all bolts are fastened with the prescribed torque. DHOLLANDIA...
  • Page 37 / servicing may result in serious injury of the operator or service personnel. • Therefore, the tension in the bar should only be adjusted by someone who has been specifically trained to do so. It is NOT a user serviceable part. DHOLLANDIA...

  • Page 38: 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 39: Mounting Of The Side Steps

    Maintain a 90° angle between the steps and the bed extension. • Fasten 2x M14 bolts and locking nuts per side to the prescribed torque settings For the proper torque specs, please refer to appendix 19.2 on page 51. DHOLLANDIA...
  • Page 40 Refer to section 19.4 on page 54 regarding the safe operator position on the platform and climbing up the side steps safety with the placement of hand grips on the vehicle body. NOTICE CAUTION • If you intend to weld, ALWAYS follow the NOTICE and CAUTION with regards to welding in section 4 on page 6. DHOLLANDIA...

  • Page 41: Mounting Of The Optional Widening Blocks (Oam053)

    At the time 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. • Fasten 4x M16 bolts and locking nuts per side to the prescribed torque settings. DHOLLANDIA...

  • Page 42: Mounting Of The Optional Bumper Light Cluster Kit (Oam060)

    Fasten 3x M10 bolts and locking nuts per side to the prescribed torque settings. NOTICE • DHOLLANDIA US offers a lamp kit to pair with option OAM060. • If specified during the order process, these lamps (with integrated backup lights) will be included along with wiring instructions to the vehicle.

  • Page 43: Lubrication Instructions

    Refer to appendix 19.7 from page 55 onwards for the relevant maintenance checklist for DH-R* style liftgates. Download any grease plans from the website at: www.dhollandia.com → Country & language selection → Downloads → Maintenance & Repair → Grease plans → … select required plan •...
  • Page 44 DHOLLANDIA...

  • Page 45: Quality Control And Pdi

    16 x 16” (400 mm) at a safe distance of 10” (250 mm) removed from the hazardous crushing area between the inboard edge of the platform and the rear sill of the vehicle body. • Work through the CHECKLIST FOR THE PRE-DELIVERY- INSPECTION (PDI) TEST. See Appendix 19.7 on page 55. • Complete the practical tests indicated therein. DHOLLANDIA...
  • Page 46 • Adjust the pressure if too high or too low, seal the pressure relief valve after that. • If in doubt how to adjust the pressure relief valve, contact your national DHOLLANDIA distributor for help. See contact info on page 4. •...

  • Page 47: 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. NOTICE • Remove any unwanted debris or residue from surfaces before installing any of the decals to ensure proper adhesion. DHOLLANDIA...
  • Page 48 EF0580.EN.CAP ❶ ❸ EF0565.EN ❺ EF0616.US EF0618.EN ❹ ❻ Loading decal (with SNR) ❽ EF0562.EN EF0597.US ❼ LIFTGATE DECALS USED AND AFFIXED IN AREAS OTHER THAN THE REAR OF THE VEHICLE: Serial tag for Owner’s Manual EF0814.EN.US EF0816.ENFR EF0817.ENFR DHOLLANDIA...

  • Page 49: 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 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 mount 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 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 56 19.5 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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