Actuall DoorLIFT DL-6 User manual

INSTALLATION GUIDE
Version 10-2020
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1. Index
DoorLIFT DL-6
Remote door system
Installaon guide
Index
1Index 3
2 Pre-installaon requirements 4
2.1 General review 4
2.2 Ensure adequate clearance above door 5
2.3 Change the top roller brackets 5
2.4 Body specic requirements 6
3Electrical planning 7
4Track installaon 8
4.1 Posioning the rail on the roof 8
4.2 Fastening the rail to the roof 9
5Installing the door connector plate 10
6Installing turnbuckle connecng rod 11
6.1 Installing the turnbuckle connecng rod 11
6.2 Checking the turnbuckle connecng rod 13
7Installing the emergency release cable system 14
7.1 Drilling the holes 14
7.2 Installing the lock 14
7.3 Installing the release cable 15
8Installing the control box 18
8.1 Mounng the control box 18
8.2 Feeding the cable through the box 18
8.3 Connect the cable to the control box 19
8.4 Connect the cable to the track 19
8.5 Oponal funcons 20
8.6 Connect to the baery 21
9Adjusng the sensors 22
9.1 Adjusng the door closed sensor 22
9.2 Adjusng the door open sensor 24
10 Programming remote controls 25
11 First operaon of the system 26
12 Overview of electronic indicators 28
13 Appendix A - Push buons (DL-8000810) 30

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DoorLIFT DL-6
Remote door system
2. Pre-installaon requirements
The DoorLIFT is intened as an auxiliary system for a manually operated shuer door. The DoorLIFT is a heavy duty
cycle drive system which requires consistent, reliable power. To secure a good working operaon, please follow
the below quesons before starng the installaon.
As well as ensuring the body and vehicle can accept the DoorLIFT, it’s important that the door is compable. Use
the following checklist to ensure the door is in good working condion.
1. Has the correct balancer been installed on your Roll-Up door?
2. Is the radius of the track suitable for DoorLIFT operaon? The DoorLIFT might have diculty with ght radius
tracks during the closing cycle.
3. Is the Roll-Up door balanced properly? Does it work easily, UP or DOWN by hand?
4. Is the door in good working condion? Make sure there are no broken panels, hinges or rollers etc.
5. Is the top panel of the door strong enough, or will it require reinforcement to prevent it from “exing” during
the closing cycle?
6. Is the power supply adequate? The system requires a 12 or 24 volt, 65 amp source. Has the baery and charging
system been well maintained? Baeries that are poorly maintained or highly discharged may not be able to
operate the system. The “Low voltage” indicator will shut system down when the power supply in not sucient.
7. Will a proper power supply always be available? In a trailer applicaon a secondary power supply may be
required when the tractor is absent.
8. The DoorLIFT is oponally supplied with two remote transmiers. Will that be adequate or will alternave
acvaon devices be required? Addional remote transmier, remote switches, etc. These items might be
useful for dock workers or others who may need access to the cargo area of the truck or trailer.
If any of the above answers are "no", do not connue with the DoorLIFT installaon and contact your
dealer for installaon support.
2.1 General review
Installaon guide

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DoorLIFT DL-6
Remote door system
2.2 Ensure adequate clearance above door
Check to ensure you have enough clearance above the open door to
allow the top edge of the door to go through the radius. Make sure
there is a minimum of 45mm between the door and the ceiling.
Check if you are using the right type of top closure arm for you door
(see secon 2.3 below).
If there isn’t enough clearance contact your shuer door supplier to
enquire whether the track can be modied to allow installaon of
the DoorLIFT.
2.3 Checking the top roller brackets
Make sure that the right type of top closure arm is installed on your
door to be sure that the door closes in the right way. You will need
an adjustable type with two rollers to give the best result.
This also will give you a beer clearance between the door and the
ceiling.
If you have any doubts, please contact your shuer door supplier
for assistance.
Installaon guide

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DoorLIFT DL-6
Remote door system
1. In case the track will be mounted to
roof bows a reinforcement (A) at the
header (above the roller shuer) could
be necessary, as forces applied upwards
can go up to 1000N. In worse case, it
can li the roof.
2. Never glue the complete track against
the roof. In case of installaon errors or
future repairs, it should be possible to
disconnect the track from the roof.
3. Keep a minimum clearance of 700 mm
behind the track! This because for a
proper service to the system the motor
unit needs to be removed from the
track. This only can be done by
removing the rear cover and slide the
700 mm long motor unit out of the
track.
Note: If the length of the aluminium
track needs to be reduced, the cut must
be made at rear of the track (furthest
from the door opening). The shortest
length of track required, to operate
properly is: door height + 92 cm.
4. Shuer door reinforcement is needed in
case of a plasc type door or a thin
wooden door. Consult with your doorli
supplier if this is needed on your roll-up
door.
2.4 Body specic requirements
As every vehicles body is dierent, your Doorli supplier can not be responsible for the body specic mechanical
connecons to roof and shuer door. Although we strongly suggest:
A
700 mm
Installaon guide

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DoorLIFT DL-6
Remote door system
3. Electrical planning
The rst decision to make is where to install the control module. Ideally this is to be installed as close to the baery
as possible keeping in mind the supplied baery cable is 2,5m long (or longer on request). Depending on which side
of the vehicle the baeries are on will determine the route of the DoorLIFT prole cable. Baery cable has a
diameter of 9mm while the prole cable has a diameter of 8,5mm. These will be relave if these cables are routed
into conduits.
The diagram below depicts suggested posions of the control module for trucks.
In small truck applicaons you could install the control module in the cab. This is only recommended if there is an
alternave entry into the cargo area, side door or cab pass-through. If the door does not open for any reason, you
will have no access to the control box without these alternave entry points.
Insulated trucks or trailers will require some addional support in the ceiling before installing the DoorLIFT rail. Do
not aempt to install the DoorLIFT track to an unsupported substrate. Track mounng measures for insulated retro
ts should of been accounted for already in the preliminary phase.
If installing auxiliary items such as switches, lights, etc, plan locaons and wiring routes. Note: these auxiliary items
are not included with the DoorLIFT and are supplied by the er or end-user.
Mounng details of the housing:
Doorli Control box
Baery (power supply)
Connecon ignion, buzzer and oponal controls
Doorli system
Prole cable
Installaon guide

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DoorLIFT DL-6
Remote door system
4. Track installaon
4.1 Posioning the rail on the roof
Mark the center line on the roof and measure
100mm sideways, as in the picture.
BE AWARE: Check pre-installaon requirements (page 4) for any reinforcements needed.
NOTE: Depending on the roof/body structure the installer is required to decide on the type of fasteners and
amount of connecons.
NOTE: Keep a space of 20-30 mm between the front of the
track and the balancer
20-30 mm
Place the le side (facing the door) of the
track allong the line. Keep a clearance
between balancer and track.
BE AWARE: when the distance between track and balancer is too
much, it will hurt the operaon of the system.
Installaon guide

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DoorLIFT DL-6
Remote door system
4.2 Fastening the rail to the roof
Use the groves in the track to DRILL the
required holes. The number of holes depends
on the roof structure. Minimum
requirements: front, back and middle of the
track. In case of dry freight applicaons,
always connect to every roof bow.
Insulated ceilings require furring strips or
some type of mounng brackets to secure the
track to the ceiling liner and roof. These
measures should of been accounted for in the
Pre Install Inquiry. DO NOT SECURE TRACK TO
THE CEILING LINER ONLY WITH NO SUPPORT.
Never glue the track to the ceiling
TIP: Moving the motor unit back and forth in the track in this step and the next
makes liing the track assembly easier. Move the lever, shown at the right, to
the manual posion. The motor unit can now be moved by hand. Moving the
lever towards the baery icon will put the motor unit back in automac mode.
Use large diameter head screws or rivets
where the screw heads or rivet heads do not
protrude more than 1.8mm from their seated
posion. The motor unit will hit the
protruding screw or rivet heads during its
travel if the heads protrude more than
1.8mm into its path of moon.
Secure the track to the roof. The number of
rivets is to be decided by the installer, as
every body is dierent. The aluminium prole
weighs approximately 14Kg and the motor
unit 7Kg.
* Important: Please drill and
install the fasteners using the
V-shaped guides on the track.
This will have motor clearance
implicaons if not followed.
Installaon guide

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DoorLIFT DL-6
Remote door system
5. Installing the door connector plate
IMPORTANT: Page 6 indicated that top panel reinforcements may be required.
NOTE: Depending on the shuer structure the installer has to decide on the type of fasteners.
With the door in the closed posion and the motor
as close to the door as possible, raise the door
slightly to ensure the tab on the connector plate is
aligned with the tab on the motor unit. Once you
are sased with the posion of the connector
plate, secure it to the top panel.
Dry-freight door connecon plate
Insulated-freight door connecon plate
or
Place the door connecon plate in te
center of the door.
Center line Center line
9x
IMPORTANT: Conrm alignment with the motor unit
before drilling holes
Installaon guide

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DoorLIFT DL-6
Remote door system
6. Installing turnbuckle connecng rod
50mm
Make sure the roll-up door is in the fully
closed posion.
Slide the DoorLIFT motor unit towards the
door, as far as it will go, then slide it back
from the stop screw approximately 50mm.
See marker on the track. Lock the motor at
this posion.
NOTE: This is very important! The motor
unit should never touch the screw.
Measure A
Dry freight
Meassure A
Insulated freight
Select the right holes and measure the distance in between
6.1 Installing the turnbuckle connecng rod
Installaon guide

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DoorLIFT DL-6
Remote door system
NOTE: The operaon of the system will be interfered when the rod does protrude into the fork.
The length of the threaded rod is:
Measurement A - 70 mm
Cut the threaded rod to length
Install the connecon bar in the previous selected
holes and secure the nut.
13 mm
Installaon guide

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DoorLIFT DL-6
Remote door system
30-45 degrees
25mm
Aer installaon the connecon bar should be in a 30-45 degree angle, when the door is in
closed posion.
The motor-unit should always be 25mm away from the end screw.
6.2 Checking the turnbuckle connecng rod
Installaon guide

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DoorLIFT DL-6
Remote door system
7. Installing the emergency release cable system
7.1 Drilling the holes
Apply the drill template decal and align the le edge
of the template with the centerline of the connector
plate.
Drill the holes completely through as per drill
template.
7.2 Installing the lock
1. Locate the lock assembly, turn the key
90 degrees and remove the core of the
lock from the lock housing plate. Insert
the housing plate into the holes on the
face of the door. Use masking tape if
necessary to hold the housing to the
face of the door.
2. Select the appropriate length screw
from the kit and secure the interior
mounng plate to the housing.
Installaon guide

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DoorLIFT DL-6
Remote door system
7.3 Installing the release cable
1. Insert the end of the cable with the stop into the
guide tube at door-end of the motor unit, push
the cable through unl you can see it in the
opening where the lever is. Insert the
stop through the release lever and
engage the lever (lock the DoorLIFT).
With the lever engaged, push the cable
50mm further into the motor. You can
temporarily hold the cable 50mm past
the lever with masking tape to keep it
from moving.
2. Slide the cable sleeve over the cable and 50mm
into the guide tube in the motor housing.
3. Mark the sleeve 25mm below the door
connector plate. Remove the sleeve and cut it
on the mark. DO NOT CUT THE CABLE. Slide the
sleeve back over the cable and into the motor
housing tube.
50 mm
Installaon guide

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DoorLIFT DL-6
Remote door system
4. Ensure the cable is sll 50mm past the release
lever in the motor housing and the lever is sll
engaged. Using good quality cuers cut the
cable 25mm below the lock mounng plate. Not
using a proper tool to cut the stainless cable can
cause the end of the cable to fray and become
dicult to insert into the lock cylinder.
5. Slide the red tube, the 60mm piece of cable
sleeve and the plasc cover base over the cable.
Push the cable through the door and lock
housing so it protrudes through the face
6. Insert the cut end of the cable into the hole on
the back of the lock core. Secure the cable by
ghtening the set screw on the side of the core
with a 2mm Allen key. Be sure it is as ght as
possible. Insert the core into the housing, turn
90 degrees, and remove the key.
Installaon guide

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DoorLIFT DL-6
Remote door system
7. Use the two screws provided to secure the
exterior cover over the lock assembly.
8. Locate and secure the rear cable cover on the
mounng plate using the two 4,8x32 screws pro-
vided. This cover also acts as a clamp for the
60mm secon of cable sleeve. Make sure the
cable sleeve ends in the middle of the lock. See
picture
9. Slide the cable sleeve up so there is a clearance
of 30mm to the red sleeve. Use the two 4,8x19
screws and plasc clamp to secure the cable
sleeve and clamp to the holes on the door con-
nector plate.
10. Make sure that the sleeve is only 50mm into the
guide tube and not protruding in the slot of the
motor-unit. This will prevent the lever from mo-
ving and the door cannot be disengaged anymo-
re.
Outside door
Installaon guide
30mm

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DoorLIFT DL-6
Remote door system
8. Installing the control box
8.1 Mounng the control box
Mount the control box as determined earlier in the manual. Double check the points
below to ensure the ideal locaon.
Reminder: the standard baery cable is 2,5m long so the distance from
the box to the baery can’t be more than that. (longer cable on request).
Be aware: of the environmental condions of your chosen locaon when
the truck is in use. For example, placing the box behind the wheels could
result in high pressure water and road debris against the box.
Cable direcons
Make sure the cable connectors
are down to prevent moisture
entering the box
WARNING: The size of the supplied cable(s) is determined by the DoorLIFT power requirements. DO NOT splice
wires for extra length, this can cause voltage drop, resulng in poor/intermient operaon or damage.
Longer cable (ll 5m) is available on request.
DO NOT CONNECT THE BOX TO THE BATTERY YET
8.2 Feeding the cable through the box
Run the prole cable from the track to the control box. This cable comes in two pieces and will have to be spliced
with the solder/bu connector kit given in package. Match the color scheme below between the two cut cables.
Note: If the cable is too long, it can be cut accordingly.
WARNING: Be sure to protect all cables from sharp edges by using loom and or grommets whileroung cables
through conduits and bulkheads.
Installaon guide

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8.3 Connect the cable to the control box
8.4 Connect the cable to the track
Plug the other end of the prole cable to the track plug. While connecng, push unl you
hear a "click".
DoorLIFT DL-6
Remote door system
Push in unl you hear it “click”
Plug the one end of the prole cable to the box. While connecng, push unl you hear a "click".
Push in unl you hear it “click”
Installaon guide

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DoorLIFT DL-6
Remote door system
8.5 Oponal funcons
8-lead wire harness
Wire Item
1Up/down input
2Up input
3Down input
4Signal block (ignion lockout)
5+ 12V output (max 250 mA)
6Door ajar output (ground)
7Cargo light output (ground)
Yellow/green Ground (max 250 mA)
Connect auxiliary devices to the DoorLIFT control box through the 8
-lead auxiliary harness using the wire chart below as a guide. The
pig-tailed end of the harness has numbers.
The 8-pin male receptacle on the box comes equipped with a plug
to protect the connector from water and dirt if the harness is not
used. This plug is removed if the harness is ulized.
WARNING: Protect unused harness leads against water, debris, dust and possible short-circuits
Push in unl you hear it “click”
Installaon guide