Holland TG Series User manual

Installation Manual
TG Series Liftgates
2500/3000/3500 Lb. Capacity
XL-TG10149IM-en-US Rev A
TG SERIES DOUBLE CYLINDER
TG SERIES SINGLE CYLINDER

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XL-TG10149IM-en-US Rev A 12-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.
Introduction......................................................................2
Warranty...........................................................................2
Notes, Cautions, and Warnings..........................................2
Section 1 – Safety Precautions..........................................3
Section 2 – Model and Serial Number Location..................6
Section 3 – Liftgate Terminology………………….……………...7
Section 4—Frame Preparation……………………………………..8
Section 5—Deck Extension Installation………………………..10
Section 6—Liftgate Installation…………………………………. 11
Section 7– Pump Assembly Installation……………………… 14
Section 8– Hydraulic Hose Installation…………………...…..16
Section 9– Toggle Installation……………….. …………………17
Section 10– Electrical Installation…………………….……....18
Section 11– Auxiliary Battery Electrical Installation……..…..20
Section 12– Initial Platform Lowering…………..………………..22
Section 13– Return Spring Installation...………………………..23
Section 14– Latch Pin Installation……………………….………..23
Section 15– Step Installation……………..………………………..24
Section 16– Roller Opener Installation……………...…………..25
Section 17– Decal Installation……………...……………………..26
Introduction
This manual provides you with the information necessary
for the installation of the SAF-HOLLAND TG Series Liftgate.
Warranty
Refer to the complete warranty for the country in which the
product will be used. A copy of the warranty certificate is
included with the product as well as on the SAF-HOLLAND
Web Site (www.safholland.us and www.safholland.ca).
Notes, Cautions and Warnings
You must read and understand all of the safety procedures
presented in this manual before starting any work on the
liftgate.
NOTE:
For liftgate components replacement, contact
SAF-HOLLAND Customer Service at:
U.S. 1-888-396-6501
Canada 1-800-503-9847.
NOTE:
In the United States, work shop safety
requirements are defined by federal and/or
state Occupational Safety and Health Act.
Equivalent laws may exist in other countries.
This manual is written based on the
assumption that OSHA or other applicable
employee safety regulations are followed by
the location where work is performed.
Used without the safety alert symbol,
indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
Indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation
which, if not avoided, could result in death
or serious injury.
IMPORTANT:
Includes additional information that if
not followed could lead to hindered
product performance.
NOTE :
Includes additional information to enable
accurate and easy performance of
procedures.
Throughout this manual, you will notice the terms “NOTE,”
“IMPORTANT,” “CAUTION,” and “WARNING,” followed by
important product information. So that you may better
understand the manual, these terms are as follows:
Contents

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XL-TG10149IM-en-US Rev A 12-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.
IMPORTANT:
Read this manual before using this
product. Keep this manual in a safe
location for future reference.
Failure to follow the instructions and
safety precautions in this manual can
result in death or serious injury.
1. Safety Precautions
General Safety Precautions
1. To reduce the risks and ensure safety at all times, this
section of the manual details a number of safety rules
which should always be adhered to.
2. Study all the safety messages in this manual and on
the equipment carefully.
3. You must be fully trained on the capabilities and the
limitations of this equipment to operate the
equipment properly.
4. Always use the proper tool for the job. Repair or
replace worn or damaged tools before starting any
repairs.
Operating Safety Precautions
1. Never operate the liftgate unless the area is clear of
obstacles and other personnel.
2. When operating the liftgate from ground level, always
stand to one side of the platform. Ensure fingers, arms,
hands, legs and feet are clear of the moving liftgate.
3. Do not exceed the maximum rated capacity of the
liftgate.
4. In an emergency situation, release the control switch to
stop the liftgate.
5. Ensure liftgate is in stowed position when not in use.
6. Never step off moving equipment, only step off the plat-
form when it is in contact with the ground or at deck
height when entering the vehicle.
7. Check for slippery surfaces before stepping off the lift-
gate platform.
8. Never jump off the liftgate.
Safety Precautions
NOTE :
Proper tools must be used to perform the
installation procedures in this manual. Many of
these procedures require special tools.

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XL-TG10149IM-en-US Rev A 12-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.
Installation Safety Precautions
1. Do not work underneath the liftgate without properly
supporting the raised platform and liftframe in accor-
dance with workplace safety requirements.
2. Never strike any part of the liftgate with a steel
hammer.
3. Safety protection should always be worn as protection
from pressurized fluid spray, flying debris, and other
airborne matter when working with tools, power tools,
4. While servicing or repairing equipment, always
disconnect the electrical power to the pump motor and
ensure that the platform and liftframe is supported on
the ground or secured in the travel lugs.
5. When welding is required, ensure that the battery
ground cable is disconnected and that all electrical
equipment is completely electrically isolated before
welding is initiated
(Figure 1).
6. Before starting any welding, ensure that the area to be
repaired is cleaned of debris and combustible
material. Have a charged fire extinguisher available
and know how to use it.
7. When searching for an oil leak, wear work gloves and
use a piece of cardboard or wood as a detector. Wear a
safety face shield or goggles for eye protection. Never
use your bare hands to check for fluid leaks
(Figure 2)
.
Figure 1
Figure 2
Safety Precautions
Failure to turn off vehicle motor before
commencing work could allow vehicle to
move which, if not avoided, could result
in death or serious injury.
NOTE :
Never operate the liftgate with the vehicle
running unless instructed to by this manual for
specific service items.
Failure to properly protect yourself when
searching for hydraulic leaks could result
in fluid injection into the skin which, if
not avoided, may result in death or seri-
ous injury.

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XL-TG10149IM-en-US Rev A 12-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.
Failure to depressurize the hydraulic sys-
tem could result in fluid injection into the
skin which, if not avoided, may result in
death or serious injury.
8. Pressure can remain in a hydraulic system after the
power source and pump have been shut down. Ensure
that there is no pressure in any of the hydraulic
cylinders or hoses before performing work on
components, or disconnecting any hoses
(Figure 3)
.
Figure 3
Safety Precautions
9. Inspect the equipment daily for potential fire hazards
and make any necessary repairs immediately .
10. Inspect electrical wiring and connections, and
hydraulic hose runs to ensure they are secure and not
rubbing against other components.
12. Clean up any excess grease, oil accumulation and
spillage immediately. Use only non-flammable
products for cleaning the liftgate or components.
13. A cylinder lock strap has been factory installed be-
tween the cylinder mounting pins. This strap keeps the
liftgate in the proper position for installation. This cyl-
inder lock strap must remain in position until the lift-
gate has been welded to the vehicle, the motor wiring
has been connected to the battery, and the hydraulic
system has been activated to fill the hoses and cylin-
der under pressure. Care must be taken during instal-
lation to ensure that this strap is not bent, as this
would affect the proper function of the liftgate when
installed. Contact SAF-Holland customer service for
replacement cylinder lock straps
(Figure 4)
.
NOTE :
Batteries contain acid that can burn you and
they produce gas that can explode, follow bat-
tery manufacturers’ safety instructions that
come with it when working on your battery.
Failure to follow manufacturers’ safety
instructions when handling batteries may
result in explosion which, if not avoided,
may result in minor to moderate injury.
Figure 4
CYLINDER LOCK STRAP

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2. Liftgate Model &
Serial Number Location
Each SAF-HOLLAND liftagte has a stamped metal tag
that identifies the liftgate model number and the serial
number. This tag is clearly visible as it is attached to the
front roadside of the maintube
(Figure 5).
In order to
properly identify your SAF-HOLLAND liftagte and it’s
components when communicating with SAF-HOLLAND or
your dealer, please record the model and serial numbers
below and refer to them when ordering replacement
parts LIFTGATE MODEL AND SERIAL
NUMBER TAG ATTACHED TO THE
FRONT ROADSIDE OF THE MAIN
TUBE
Figure 5
Model and Serial Number
I
Information
Model Number
TG 35 48
36” long
42” long
45” long
47” long
48” long
52” long
61” long
Platform Size
Capacity
2,500 lb.
3,000 lb.
3,500 lb.
Model
Serial Number before Nov. 1, 2008
E 01 000123 N
Facility Code
Sequence Number
Year Code
Month Code
After Nov. 1, 2008
98 02 312 0123
Sequence Number
Day of Year
Year Code
Facility Code
Equipment Model No.:_________________________
Serial No.:_________________________________
Purchase Date:______________________________
Dealer:____________________________________

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XL-TG10149IM-en-US Rev A 12-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.
TG Liftgate Terminology
7
4
2
3
6
5
8
11
12
13
14
15
16
17
1
10
9
ITEM DESCRIPTION
1 CONTROL STATION
2 INNER PLATFORM
3 OUTER PLATFORM
4 ADJUSTING BOLTS
5 TORSION SPRING
6 COMPRESSION MEMBER
7 ROLLER OPENER
8 PARALLEL ARMS
9 LIFT FRAME
ITEM DESCRIPTION
10 LIFT CYLINDER
11 SIDE STEPS
12 PUMP BOX MOUNT
13 PUMP BOX
14 TRAVEL LATCH
15 MAIN TUBE
16 ATTACHING PLATES
17 DECK EXTENSION
3. Liftgate Terminology

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XL-TG10149IM-en-US Rev A 12-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.
4. Frame Preparation
NOTE:
Prior to installation verify the vehicle rear
doorsill will support required loads.
Frame Preparation
NOTE:
Standard Mount: Additional frame
modifications may be necessary, depending
on the application
(Figures 6 or 7)
.
Figure 6
Standard Mount
Truck Install
REAR SILL
POST
Failure to properly engage the vehicle
parking brake prior to installing the lift-
gate may allow vehicle movement which,
if not avoided, could result in death or
serious injury.
1. Remove bumper, step, or any protrusions that would
prevent your deck extension from being mounted flush
against the rear doorsill.
2. Follow the frame cutout requirements as shown for
your preferred installation
(Figures 6, or 7).
12”
5.38
9”
15” (for 36” Platforms)
21” (for 42”, 45”,47”,
48” 52” & 61”
Platforms)
Figure 7
Standard Mount
Trailer Install
9” 5.38
12”
REAR SILL
POST
15” for 36” Platforms
21” for 42”, 45”,47”,
48” 52” & 61”
Platforms
24” for TG3561 ONLY
STANDARD MOUNT

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Frame Preparation
Figure 8
Flush Mount
Truck Install
Figure 9
Flush Mount
Trailer Install
27” for 36” Platforms
33” for 42”, 45”,47”, 48”
52” & 61” Platforms
12”
9” 5.38”
POST
36” for TG3552 & TG3561 ONLY
27” for 36” Platforms
33” for 42”, 45”,47”, 48”
52” & 61” Platforms
9” 5.38
12”
POST
36” for TG3552 & TG3561 ONLY
NOTE:
Flush Mount: Deck extension replaces the
rear sill and is mounted flush with the rear
frame posts
(Figures 8 or 9)
.
Failure to properly engage the vehicle
parking brake prior to installing the lift-
gate may allow vehicle movement which,
if not avoided, could result in death or
serious injury.
NOTE:
Prior to installation verify the vehicle rear
doorsill will support required loads.
1. Remove bumper, step, or any protrusions that would
prevent your deck extension from being mounted flush
against the rear doorsill.
2. Follow the frame cutout requirements as shown for
your flush mount installation
(Figures 8 or 9).
FLUSH MOUNT

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Deck Extension Installation
Position of Deck Extension (Standard Mount Only)
1. Position and support the deck extension flush with the
rear doorsill of the vehicle. Ensure the deck extension
is flat and flush with the deck of the vehicle.
NOTE:
Some vehicles may be higher at the back
than the front or could be on unlevel ground;
therefore, the deck of the truck may be
sloped from the rear down to the front.
Ensure that the deck extension is parallel to
the truck deck.
Figure 10
Failure to isolate electrical equipment
from ground prior to welding could re-
sult in overload which, if not avoided,
may result in property damage.
1/4” 2”-6”
1/4” TYP
Figure 11
RIB
1/4” 2”-6” 1/4
TYP
2. The deck extension must be centered with respect to
the vehicle chassis. This ensures that the liftgate is
mounted on the centerline of the vehicle.
3. Tack weld into position.
4. Weld per
Figures 10 and 11
.
5. Deck Extension Installation
TOP VIEW
BOTTOM VIEW
NOTE:
When welding is required, ensure that the
battery ground cable is disconnected and
that all electrical equipment is completely
electrically isolated before welding is
initiated.