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Dhollandia DH-RPM 25 User Manual

Dhollandia DH-RPM 25
56 pages
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Order ref: xxx Doc: FIT_US installation manual RPM_US EN_2022 Rev: 1 Date: SEPTEMBER 1, 2023
DH-RPM 25
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 : us.info@dhollandia.com
270 Southridge Parkway
Bessemer City North Carolina, 28016
website : www.dhollandia.com
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Dhollandia DH-RPM 25 Specifications

General IconGeneral
BrandDhollandia
ModelDH-RPM 25
CategoryFarm Equipment
LanguageEnglish

Summary

UNDERSTANDING SAFETY AND WARNING SIGNS

Safety Alert Symbol and Definitions

Explains general warning signs, danger, caution, notice, and safety instructions used in the manual.

Critical Safety Warning

Emphasizes risks of serious injury or death from improper use and failure to follow instructions.

INTRODUCTION, CONTACT INFO AND DISCLAIMERS

Installation Warning

Highlights severe risks of injury or death due to improper installation.

Manual Version Notice

Advises confirming the most up-to-date manual version before operation.

INTRODUCTION, CONTACT INFO AND DISCLAIMERS

Important Disclaimers

Outlines manufacturer's disclaimer for modifications, improper use, and installation.

SAFETY PRECAUTIONS FOR OPERATION

Operation Hazard Warning

Warns that improper use risks serious bodily injury or death to operators and bystanders.

Manual Review for Operation

Stresses reviewing the most up-to-date manual for safe operation.

SAFETY PRECAUTIONS FOR INSTALLATION

Installation Hazard Warning

Highlights dangers to installers from ignorance or neglect during installation.

SAFETY PRECAUTIONS FOR INSTALLATION

Electrical Installation Precautions

Advises disconnecting power and following specific cautions for electrical work.

LIFTGATE TERMINOLOGY

INSTALLATION PARAMETERS TERMINOLOGY

Defines key terms related to liftgate dimensions and installation parameters.

LIFTGATE TERMINOLOGY

GETTING STARTED

Provides initial steps and crucial checks before starting the liftgate installation process.

INSTALLATION DIMENSIONS AND GUIDELINES

INSTALLATION DIMENSIONS

Presents diagrams and measurements for two different bed height ranges.

INSTALLATION DIMENSIONS AND GUIDELINES

INSTALLATION RESOURCES

Advises contacting the DHOLLANDIA distributor for any doubts on installation parameters.

BED EXTENSION AND CHASSIS CUT

Chassis Cut Recommendations

Provides guidance on chassis cut dimensions for different bed heights.

Chassis Cut Notice

Notes regarding recommended dimensions, deviations, and anti-corrosive coating.

BED EXTENSION AND CHASSIS CUT

REAR SILL CUT

Illustrates rear sill cut requirements for different bed heights and mentions anti-corrosive coating.

MOUNTING OF THE BED EXTENSION

Bed Extension Mounting Procedure

Details steps for aligning, drilling, and bolting the bed extension to the rear sill.

Bed Extension Warning

Warns about the heavy weight of the bed extension and the need for lifting aids.

MOUNTING OF THE BED EXTENSION

Bed Extension Welding

Shows how to weld the bed extension and specifies areas to avoid welding.

MOUNTING OF THE LIFT FRAME (PREMOUNTED PLATFORM)

Lift Frame Handling Warning

Warns about the heavy weight of the lift frame and the need for lifting aids.

Lift Frame Leveling

Explains how to adjust the platform to ensure it is level.

MOUNTING OF THE LIFT FRAME (PREMOUNTED PLATFORM)

Lift Frame Mounting Procedure

Details steps for attaching the lift frame using hoists or forklifts.

FIXATION OF THE MOUNT PLATES

Standard Mount Plate Configuration

Shows how to fit and align mount plates for standard chassis widths.

Wide Mount Plate Configuration

Illustrates mount plate configuration for wider or cutaway chassis.

FIXATION OF THE MOUNT PLATES

Alignment Tube Installation

Describes using alignment tubes and counterweights for positioning the lift frame.

Forklift Mounting Method

Details how to mount the liftgate using a forklift with appropriate precautions.

FIXATION OF THE MOUNT PLATES

Lift Frame Leveling and Securing

Explains how to hoist, jack, and secure the lift frame for proper alignment.

FIXATION OF THE MOUNT PLATES

Mount Plate Bolting Procedure

Details bolting mount plates to the chassis, including torque and quantity.

FIXATION OF THE MOUNT PLATES

Bolt Positioning and Chassis Compliance

Guides on bolt placement and adhering to vehicle manufacturer's chassis instructions.

FIXATION OF THE MOUNT PLATES

Weld Recommendations

Provides minimum weld counts and lengths for securing mount plates.

GENERAL REMARKS

Subframe Connection Strength

Stresses the importance of subframe/long rail connection strength if not bolted.

Installation Doubt Protocol

Advises contacting distributor for doubts and warns of risks from negligence.

INSTALLATION OF ELECTRICAL CONTROLS

INSTALLATION OF THE CONTROL SWITCH

Details mounting the toggle switch and routing its electrical cable to the pump unit.

INSTALLATION OF ELECTRICAL CONTROLS

Toggle Switch Wiring Diagram

Shows the wiring diagram for the toggle switch (primary control).

INSTALLATION OF ELECTRICAL CONTROLS

INSTALLATION OF THE CABIN SWITCH

Explains the cabin switch function and wiring requirements, minimum 16 AWG.

INSTALLATION OF ELECTRICAL CONTROLS

INSTALLATION OF EXTRA CONTROLS – 2 BUTTON REMOTE CONTROL

Details mounting the 2-button remote control and routing its cable.

INSTALLATION OF ELECTRICAL CONTROLS

2 Button Remote Wiring Diagram

Presents the wiring diagram for the 2-button remote control.

ELECTRICAL INSTALLATION

INSTALLATION OF THE (+) BATTERY CABLE AND (-) GROUND CABLE

Covers connecting battery cables, fuse, and ground cable to motor terminals.

ELECTRICAL INSTALLATION

Battery Cable Routing and Connections

Illustrates routing and connecting positive and negative battery cables to the motor.

ELECTRICAL INSTALLATION

Battery Cable and Ground Circuit Best Practices

Recommends dual cables, protective conduits, dielectric grease, and proper routing.

PUTTING THE LIFTGATE INTO SERVICE

Final Checks Before Service

Ensures correct installation, torque, and electrical connections before powering up.

Initial Liftgate Operation

Guides on initial lift/lower operations and checking for leaks and air in circuits.

PUTTING THE LIFTGATE INTO SERVICE

Hydraulic System Bleeding

Details the process for bleeding air from the hydraulic circuits.

PLATFORM ORIENTATION

Platform Opener Adjustment

Explains how to adjust the platform opener for proper leaning and unfolding.

Torsion Spring Adjustment Caution

Warns that torsion springs are dangerous and adjustment requires trained personnel.

PLATFORM ORIENTATION

Platform Leveling and Pitch Adjustment

Guides on ensuring the platform is level and adjusting its pitch for optimal loading.

MOUNTING OF THE SIDE STEPS

MOUNTING THE SIDES STEPS

Details mounting side steps to the bed extension, considering step size and angle.

MOUNTING OF THE SIDE STEPS

Side Step Support Channel Welding

Describes welding support channels and applying anti-corrosive coating.

Side Step Ground Clearance Caution

Warns about impacts of increased ground clearance and suggests flexible steps.

MOUNTING OF THE SIDE STEPS

MOUNTING OF THE OPTIONAL WIDENING BLOCKS

Provides instructions for mounting optional 102" body widening blocks.

MOUNTING OF THE SIDE STEPS

MOUNTING OF THE OPTIONAL BUMPER LIGHT CLUSTER KIT

Details mounting an optional bumper light cluster kit for rear lamps.

LUBRICATION INSTRUCTIONS

Lubrication Points and Procedure

Guides on lubricating articulation points with acid-free grease after installation and in service.

LUBRICATION INSTRUCTIONS

Greasing Plan Diagram

Illustrates specific grease points (GP1-GP12) on the liftgate assembly.

QUALITY CONTROL AND PDI

Final Liftgate Functions Verification

Details checks for platform alignment, folding, and visibility in traffic.

Safe Operator Zone Marking

Advises marking a safe operator zone to prevent crushing hazards.

QUALITY CONTROL AND PDI

Weight Test and Pressure Adjustment

Covers adjusting hydraulic blow-off pressure during weight testing and sealing the relief valve.

PDI Success Warning

Warns that operating a liftgate without a successful PDI can cause damage or injury.

DECALS

Decal Placement Guide

Shows placement of various safety and information decals on the liftgate and vehicle.

DECALS

Specific Decal Information

Details specific decals related to safety instructions, capacity, and wiring.

USE OF THE ‘WARNING. LIFTGATE OUT OF SERVICE. DO NOT ATTEMPT TO OPERATE' SIGN

Out of Service Sign Procedure

Instructs on using the "Out of Service" sign when maintenance or repair is needed.

APPENDIX

MEANING OF THE SAFETY AND WARNING SIGNS

Explains various warning, mandatory action, and prohibition signs used in the manual.

APPENDIX

Electric / Hydraulic Function Signs

Details signs for electric/hydraulic functions like open, lower, lift, close, slide, and stabilizing legs.

APPENDIX

PRESCRIBED TORQUE VALUES FOR BOLTS AND NUTS

Provides a table of metric and imperial torque values for various bolt sizes and stress types.

APPENDIX

ELECTRIC AND HYDRAULIC REQUIREMENTS

Lists recommended cable sizes and minimum battery/generator requirements for different systems.

APPENDIX

Hydraulic Oil Types and Suitability

Lists recommended hydraulic oil types and warns against using unsuitable fluids.

APPENDIX

SAFE OPERATOR POSITION ON THE PLATFORM

Details risks for operators on the platform and how to maintain safe positions.

APPENDIX

END NOTE AND MAINTENANCE

Concludes the manual, emphasizing maintenance and authorized service.

BASIC WIRING DIAGRAMS

Explains where to find basic wiring diagrams and how to obtain copies.

CHECKLIST FOR PREVENTATIVE MAINTENANCE AND REPAIR

Refers to subsequent pages for a preventative maintenance and care checklist.

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