Dhollandia DH-RPL 22 User manual

Order ref: xxx Doc: FIT_US installation manual RPL_US EN_2022 Rev: 750 Date: SEPTEMBER 1, 2023
DH-RPL 22
INSTALLATION MANUAL
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
Manufacturer:
DHOLLANDIA US, L.L.C.
E-mail : [email protected]
270 Southridge Parkway
Bessemer City North Carolina, 28016
website : www.dhollandia.com

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DHOLLANDIA
TABLE OF CONTENTS
1UNDERSTANDING SAFETY AND WARNING SIGNS...................................................................................................................... 3
2INTRODUCTION, CONTACT INFO AND DISCLAIMERS................................................................................................................. 4
3SAFETY PRECAUTIONS FOR OPERATION ................................................................................................................................... 6
4SAFETY PRECAUTIONS FOR INSTALLATION............................................................................................................................... 6
5LIFTGATE TERMINOLOGY .............................................................................................................................................................. 8
5.1 DH-RPL liftgate terminology...................................................................................................................................................... 8
5.2 Installation parameters terminology .......................................................................................................................................... 9
5.3 Getting started......................................................................................................................................................................... 11
6INSTALLATION DIMENSIONS AND GUIDELINES ........................................................................................................................ 12
6.1 Installation dimensions............................................................................................................................................................ 12
6.2 Installation resources .............................................................................................................................................................. 12
7BED EXTENSION AND CHASSIS CUT .......................................................................................................................................... 13
7.1 Rear sill cut ............................................................................................................................................................................. 14
8MOUNTING OF THE BED EXTENSION ......................................................................................................................................... 15
9MOUNTING OF THE LIFT FRAME (PREMOUNTED PLATFORM)................................................................................................ 17
10 FIXATION OF THE MOUNT PLATES ............................................................................................................................................. 21
10.1 Fixation of the mount plates OAM010..................................................................................................................................... 21
10.2 General remarks...................................................................................................................................................................... 24
11 INSTALLATION OF ELECTRICAL CONTROLS ............................................................................................................................. 25
11.1 Installation of the control switch (OAE015.PR –E0832.B)...................................................................................................... 25
11.2 Installation of the cabin switch (OAE510.15 –E0393.S.15) .................................................................................................... 27
11.3 Installation of extra controls –2 button remote control (OAE001 –E0787.2.H)...................................................................... 28
12 ELECTRICAL INSTALLATION ........................................................................................................................................................ 30
12.1 Installation of the (+) battery cable and (-) ground cable......................................................................................................... 30
13 PUTTING THE LIFTGATE INTO SERVICE..................................................................................................................................... 33
14 PLATFORM ORIENTATION............................................................................................................................................................ 36
15 MOUNTING OF THE SIDE STEPS................................................................................................................................................. 37
15.1 Mounting the sides steps......................................................................................................................................................... 37
15.2 Mounting of the optional widening blocks (OAM053) .............................................................................................................. 39
15.3 Mounting of the optional bumper light cluster kit (OAM060).................................................................................................... 40
16 LUBRICATION INSTRUCTIONS..................................................................................................................................................... 41
17 QUALITY CONTROL AND PDI ....................................................................................................................................................... 43
18 DECALS .......................................................................................................................................................................................... 45
18.1 Use of the ‘WARNING. LIFTGATE OUT OF SERVICE. DO NOT ATTEMPT TO OPERATE’ sign ........................................ 47
19 APPENDIX....................................................................................................................................................................................... 48
19.1 Meaning of the safety and warning signs................................................................................................................................ 48
19.2 Prescribed torque values for bolts and nuts ............................................................................................................................ 50
19.3 Electric and hydraulic requirements ........................................................................................................................................ 51

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19.4 Safe operator position on the platform .................................................................................................................................... 53
19.5 End note.................................................................................................................................................................................. 54
19.6 Basic wiring diagrams ............................................................................................................................................................. 54
19.7 Checklist for preventative maintenance and repair ................................................................................................................. 54

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DHOLLANDIA
1UNDERSTANDING SAFETYAND 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 48 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.
•Please take special notice of the following signs used in the manual. They indicate the likelihood and severity of a potential injury if
a person fails to follow the instructions presented on the safety sign.
DANGER: indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. [white letters on red background]
WARNING: indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury. [black letters on orange background]
CAUTION: indicates a potentially hazardous situation which, if not avoided, could result in minor or
moderate injury. [black letters on yellow background]
NOTICE: is used to address practices not related to physical injury. [white letters on blue background]
SAFETY INSTRUCTIONS: indicate general instructions relative to safe work practices, reminders of
proper safety procedures, or the location of safety equipment. [white letters on green background]
SAFETY ALERT SYMBOL: is used to alert the user to potential hazards. All safety messages that
accompany this sign shall be obeyed to avoid harm. [free-standing, or on back-ground colors red,
orange, yellow or black]
WARNING
•Failure to understand and to follow the instructions in this manual can put the operator and any bystanders at great risk of serious
bodily injury and death.
•Prior to operating the liftgate, make sure you understand the safety and warning signs used, and read them in conjunction with
the instructions in this manual.
•If in doubt, DO NOT operate the liftgate. Contact your national DHOLLANDIA distributor. See page 4 for contact info.
NOTICE
SAFETY
INSTRUCTIONS

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DHOLLANDIA
2INTRODUCTION, CONTACT INFO AND DISCLAIMERS
•This manual provides you with the information necessary for the installation of the 2200 lbs capacity DH-R* fold away lifts.
•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.
•DHOLLANDIA liftgates are regularly adapted to new vehicle and chassis developments and specialized customer requirements.
Therefore, DHOLLANDIA reserves the right to alter product specifications without prior notice. Such modifications might not have
been included at the time this manual was printed.
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.
•It is the sole responsibility of the installer(s) to follow best workshop practices for safety and craftsmanship and to use good
common sense.
•Contact your national DHOLLANDIA distributor if you have any questions regarding the installation, operation, repair and
maintenance of DHOLLANDIA liftgates, or to obtain replacement copies of manuals or decals:
DHOLLANDIA US, LLC
DHOLLANDIA CANADA, Inc.
DHOLLANDIA MEXICO
270 Southridge Parkway
Bessemer City NC 28016
2105 Boulevard des Enterprises
Terrebonne Quebec J6Y1W9
Fracc. Industrial Dinamo Norte
Calle Tierra 103-105
Salinas Victoria CP 65500
Monterrey Nuevo Leon, Mexico
980-443-4446
(company line)
514-360-6125 ext.3
(parts and service)
[e-mail]
[e-mail]
[e-mail]
[e-mail]
[e-mail]
[e-mail]
[phone]
[e-mail]
The latest version of all manuals can also be downloaded from the DHOLLANDIA website:
www.dhollandia.com → Country & language selection → Downloads → … select required manual
WARNING
•Improper installation can cause damage to the liftgate, can reduce its durability and reliability, and can put the operator and
bystanders at great risk of serious bodily injury and death in many ways.
•It is therefore essential that the liftgates are installed with proper care, in compliance with the installation instructions of this manual
and the fitting and body building instructions of the vehicle manufacturer.
•In case of doubt, ALWAYS contact your national DHOLLANDIA distributor for further advice, prior to continuing.

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DHOLLANDIA
•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.
•DHOLLANDIA disclaims liability for any personal injury, death, or property damage that results from improper use of the liftgate
or negligence to apply the precautions and instructions of the operation manual.
•DHOLLANDIA disclaims liability for any personal injury, death, or property damage that results from incorrect of negligent
installation.
•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.
•There are no warranties, express or implied, including the warranty of merchantability or a warranty of fitness for a particular
purpose extending beyond that set forth in this manual.

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3SAFETY PRECAUTIONS FOR OPERATION
•It is essential that the installers understand and apply the safety instructions and precautions contained in the
OPERATION MANUAL issued with the liftgate.
•Therefore, make sure you consult the OPERATION MANUAL prior to installing or operating the liftgate.
4SAFETY PRECAUTIONS FOR INSTALLATION
•It is essential that the personnel involved in installing, servicing and repairing hydraulic liftgates knows, understands
and applies the safety instructions and precautions contained in the GENERAL SAFETY INSTRUCTIONS FOR
INSTALLATION, MAINTENANCE AND REPAIR manual.
•Make sure you consult these instructions prior to installing the hydraulic liftgate.
•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 → Country & language selection → Downloads → Operation manuals →
General information →… select required manual
WARNING
•Improper use of the liftgate will put the operator and other parties at great risk of serious bodily injury and death.
•To reduce the risk of serious bodily injury to the operator and any bystanders, the use of the liftgate is restricted to skilled operators,
who have been properly trained, and who know and understand the full content of the operation manual.
•To reduce the risk of serious bodily injury or death, the operator must ALWAYS comply with all safety instructions and warning
labels in the operation manual before and while operating the liftgate.
•Please confirm you have reviewed the most up-to-date version of this manual prior to installation and operation of the associated
liftgate.

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DHOLLANDIA
WARNING
•The installers are exposed to various dangers. Improper use of the liftgate, ignorance and neglect during installation, will put them
at great risk of bodily injury and death.
•Once the liftgate is in service, improper installation can cause damage to the liftgate, can reduce its durability and reliability.
Further, it can also put the operator and bystanders at great risk of serious bodily injury and death.
•Therefore installation works MUST carried out by skilled technicians, who have been professionally trained, and have mastered
the contents of all manuals:
1. OPERATION MANUAL
2. INSTALLATION MANUAL
3. GENERAL SAFETY INSTRUCTIONS FOR INSTALLATION, MAINTENANCE AND REPAIR
•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; steel toe safety shoes; fire-resistant overalls; protective gloves; adequate ear protection; a
safety helmet when working under the vehicle chassis.
•NEVER wear loose-fitting clothes that may get trapped in the moving parts of the liftgate, or in any machinery and tools used for
the installation. Don’t wear rings, bracelets, necklaces, watches etc…
•ALWAYS use the proper tool for the job. Replace worn or damaged tools before use.
•Pay special attention to the lifting devices (forklifts with slings, overhead cranes, hoists, etc.) used to handle the liftgates, and for
the clamping tools used to clamp the liftgate, its platform, mount plates and various other components to the vehicle chassis and
/ or body. Ensure these tools are appropriate for the job, and in good working order.
•Place the vehicle on a flat even ground and chock the wheels so that it cannot move during the installation. In case of a motor
vehicle, make sure the engine is off and the parking brake is engaged.
•Do not work underneath the liftgate or within reach of the platform and the moving parts, without properly securing and supporting
the platform and the lift frame against an accidental fall. Use an overhead crane and hoists, a forklift with slings or equivalent
means to secure the heavy components.
•NEVER modify DHOLLANDIA liftgates or their mount plates, NEVER deviate from the described installation procedures without
prior written consent by the manufacturer.

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DHOLLANDIA
NOTICE
•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 50
for prescribed torque values.
•If for any reason, troubleshooting and / or repair might be needed during the installation process, consult and follow
the guidelines and safety instructions of the MAINTENANCE MANUAL.
•If for any reason, welding would be required, please take note of the following precautions:
5LIFTGATE TERMINOLOGY
5.1 DH-RPL LIFTGATE TERMINOLOGY
•Refer to the OPERATION MANUAL for an overview of the most important terminology used in DHOLLANDIA manuals.
CAUTION
Welding on galvanized parts can produce hazardous fumes. To avoid intoxication:
•ALWAYS wear a suitable respirator.
•ALWAYS provide good ventilation.
•ALWAYS grind off the galvanization from the areas to weld.
•Most liftgates are equipped with thermoplastic hoses that can be damaged by hot metal chips, welding sparks and
slag. Damage to a hose can lead to sudden loss of hydraulic pressure and an accidental drop of the platform.
•The penetration of welding sparks and slag can also cause a flash fire.
•Both types of incidents can put the welder or installer and any bystanders at great risk of personal injury or death.
To avoid these risks:
→ALWAYS protect and cover thermoplastic hoses with a welding blanket, prior to grinding, drilling and welding.
→ALWAYS inspect the hydraulic hoses at the end of the installation process. Make sure all hoses are
undamaged, replace them if required.
Welding can cause severe damage to the electronic components of the vehicle and liftgate. To prevent damage:
•ALWAYS follow the instructions and precautions of the vehicle manufacturer.
•DO NOT weld if this is not authorized by the vehicle manufacturer.
•ALWAYS disconnect the positive and negative battery terminals.
•ALWAYS connect the ground directly to the component being welded, as close to the weld as possible.
Welding should be done by skilled and qualified installers only.

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DHOLLANDIA
5.2 INSTALLATION PARAMETERS TERMINOLOGY
larm
Lift ARM length
Length of the lift arms
vfh max
Vehicle Floor Height max
Max. vehicle floor height (UNLOADED), applicable for the given arm length
vfh
Vehicle Floor Height
Actual vehicle floor height (UNLOADED)
vfh min
Vehicle Floor Height min
Min. vehicle floor height (FULLY LOADED)
cth max
Chassis Total Height max
Max. height from underside of chassis to top of the vehicle floor, applicable for
the given arm length
cth
Chassis Total Height
Actual height from underside of chassis to top of the vehicle floor
mfc
Mounting height Floor to Center of lift
arm
Mounting height of lift frame under the vehicle: measured from the top of vehicle
floor to the center of the lift arm
mft
Mounting height Floor to top of lift frame
Tube
Mounting height of lift frame above the ground: measured from the floor of the
vehicle to the top of the lift frame tube
mpg
Mounting clearance Plates to Ground
Ground clearance under liftgate
pd
Platform Depth
Overall platform depth