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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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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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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XL-TG10149IM-en-US Rev A 12-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.
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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XL-TG10149IM-en-US Rev A 12-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.
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.

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Liftgate Installation
1. Unfold the platform and flip over (
Figure 12).
2. Attach two temporary 2”x2”x3/16”x38” angle brack-
ets to the deck extension with 18” of overhang. These
brackets will help maintain alignment (
Figure 13).
3. Wrap a chain around the platform and attach the chain
to a hoist with adequate capacity. Attach a “C”-clamp
on both the road side and curb side of the platform to
ensure a chain does not slide out from under the plat-
form
(Figure 14).
Position of Deck Extension
Figure 12
6. Liftgate Installation
NOTE:
Do not work underneath the liftgate without
properly supporting the raised platform and
liftframe in accordance with workplace safety
requirements.
Failure to properly support the raised
platform and liftframe may result in the
liftgate collapsing which, if not avoided,
could result in death or serious injury.
Figure 13
Failure to wrap the chain around the plat-
form may result in dropping the liftgate
which, if not avoided, could result in
death or serious injury.
HOIST
CHAIN
“C”-CLAMP
2 PLACES
POSITION CHAIN
AROUND PLATFORM
PLATFORM
FLIP OVER
Figure 14
18” BOTH ANGLES
38” BOTH ANGLES

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XL-TG10149IM-en-US Rev A 12-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.
Liftgate Installation
4. Lift the platform with the hoist and place a floor jack
under the maintube
(Figure 15).
5. Centre the platform on the vehicle and maintaining a
1/4” gap with a spacer between the deck extension
and the platform. Continue to support the platform.
6. The platform must be flush and parallel with the
deck extension maintaining a 1/4” gap between the
deck extension and the platform
(Figure 16).
7. Ensure the liftagte is positioned correctly from the top
of the deck extension to the top of the main tube
across the full length.
(Figure 17).
24”±½” for all models except where noted below
22”±½” for all TG35 models
21”±½” for all TG2536 low mounts
8. Use floor jacks to reposition the main tube parallel to
the vehicle deck both front to rear and left to right.
Figure 16
Figure 17
24”±½” all models except
where noted below
22”±½” for all TG35
21”±½” for TG2536 low mount
ATTACHING PLATE
DECK EXTENSION
MAIN TUBE
1/4” GAP
PLATFORM DECK EXTENSION
Figure 15
HOIST
FLOOR JACK
ANGLE BRACKET

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XL-TG10149IM-en-US Rev A 12-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.
Figure 19
Liftgate Installation
1/4”
1/4”
MAIN TUBE
ATTACHING PLATES
BOTH
ATTACHING
PLATES
BOTH
ATTACHING
PLATES
VEHICLE FRAME
ADJUSTING BOLTS
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.
Failure to isolate electrical equipment
from ground prior to welding could
result in overload which, if not avoided,
may result in property damage.
Figure 18
9. Use the platform adjusting bolts to lock the main tube
in position
(Figure 18).
10. Once satisfied with the main tube positioning, weld the
liftgate attaching plates to the main tube and to the
vehicle frame per
Figure 19.

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1/4” TYP
Pump Assembly Installation
Main tube Mount (Standard Option)
Truck & Trailer Installation
1. Using the supplied fasteners, fasten the pump
assembly to the end of the main tube
(Figure 20).
2. Torque nuts to 30-40 Ft-Lbs.
Figure 22
Side Mount Box
1. Locate the pump box behind the curbside mud flap
under the vehicle no more than 4’ from the back of the
vehicle and 6” in from the curbside of the vehicle body
(Figure 21).
2. Position the pump assembly brackets against the truck
cross members and weld per
Figure 22.
Figure 20
Figure 21
MAIN TUBE BRACKET
SUPPLIED
FASTENERS
7. Pump Assembly Installation
4’

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XL-TG10149IM-en-US Rev A 12-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.
Side Mount & Battery Box
1. Locate the pump box assembly on the curbside under
the vehicle on front of the sliding suspension but no
more than 20’ from the back of the vehicle and 6” from
the curbside of the vehicle body
(Figure 23).
2. Position the pump assembly brackets against the
trailer cross members and weld per
Figure 24.
Pump Assembly Installation
20’
Figure 23
IMPORTANT:
Ensure the lid can be removed.
1/4”
TYP
FULL
LENGTH
CROSSMEMBER
PUMP BOX
MOUNTING
BRACKET
1/4”
TYP
FULL LENGTH
Figure 24

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A
B
Hydraulic Hose Installation
A
B
NOTE:
Packaged with your liftgate, you will find two
hoses of equal length.
1. Connect a hose to the ‘A’ fitting on the main tube, feed
through the hole in the attaching plate, then connect
the other end to the ‘A’ fitting on the back of the pump
box
(Figure 25, 26 & 27).
2. Connect a hose to the ‘B’ fitting on the main tube, feed
through the hole in the attaching plate, then connect
the other end to the ‘B’ fitting on the back of the pump
box
(Figure 25, 26 & 27).
3. Install the supplied abrasion sleeve over both hydrau-
lic hoses and through the hole in the attaching plate
.
Figure 25
Figure 26
Figure 27
8. Hydraulic Hose Installation
IMPORTANT:
Hydraulic hoses and hydraulic fittings
are shipped with end caps installed
which must be removed before
installation.
ATTACHING
PLATE HOLE

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Toggle Installation
STRAIN RELIEF
Figure 28
Figure 29
1. Position the toggle in a location that is accessible from
the ground and deck level.
2. Run and secure the control station cable under the
vehicle chassis to the pump box.
3. Feed the control station cable through the strain relief
on the back of the pump box
(Figure 28).
4. Connect the green wire from the control station cable
to the power side terminal of the pump solenoid
(Figure 29).
5. Connect the white wire from the control station cable
to the coil with white wire from the diode harness
(Figure 29).
6. Connect the black wire from the control station cable
to the coil with black wire from the diode harness
(Figure 29).
7. Coil the excess control station cable inside the pump
box.
9. Toggle Installation
NOTE:
Verify the vehicle power supply is disconnected
prior to installing the toggle.
DIODE HARNESS
WHITE WIRE (UP)
WHITE WIRE
FROM CONTROL
STATION (UP}
BLACK WIRE
FROM CONTROL
STATION (DOWN}
GREEN WIRE FROM
CONTROL STATION
(POWER SIDE)
DIODE HARNESS
BLACK WIRE (DOWN)

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Electrical Installation
1. Identify the power source from either the truck or the
connector at the front of the trailer on which your lift-
gate is to be installed.
2. Feed one end of the power cable through the strain
relief in the pump box
(Figure 30).
3. Strip the protective rubber coating from the end of the
cable that’s inside the pump box.
4. Install the cable end on the bare end of the cable and
crimp securely into place.
STRAIN RELIEF
Figure 30
Figure 31
CONNECT POWER
CABLE
Figure 32
10. Electrical Installation
Failure to properly secure the cable and
may result in electrical overload which, if
not avoided, may result in electrical com-
ponent damage.
5. Connect the load end of the power cable as follows:
5a. For a pump box without batteries connect the
cable end to the power side of the motor start
solenoid
(Figure 31).
5b. For a pump box with batteries connect the cable
end to the power side of the 150A circuit breaker
in the pump box
(Figure 32).
6. Route the power cable along the underside of the
vehicle to the front and secure to cross members.
6a. For truck installations the cable needs to be long
enough to reach the vehicle battery.
6b. For trailer installations the cable needs to be long
enough to reach the connector
.
CIRCUIT BREAKER
POWER CABLE

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SINGLE POLE
CONNECTOR
TO PUMP
MOTOR
SOLENOID
MOTOR
GROUNDED
MOTOR GROUNDED
Electrical Installation
CIRCUIT BREAKER
OR IN-LINE FUSE
PUMP BOX
MASTER DISCONNECT
SWITCH
BATTERY GROUNDED
BATTERY
Figure 33
NOTE:
Ensure the master disconnect switch is in the
off position prior to connecting the battery.
Figure 34
7. Connect the line end of the cable as follows:
7a. For truck installation
(Figure 33).
7a.1. Mount the circuit breaker as close to the
truck battery as possible.
7a.2. Mount the master disconnect switch in the
cab where the driver can reach it.
7a.3. Cut the cable at the master disconnect
switch and circuit breaker positions and
prepare the cable ends per steps 3 & 4.
7a.4. Connect the cable to the master disconnect
switch, circuit breaker, and battery.
7b. For trailer installation
(Figure 34).
7b.1. Mount the connector to the front of the
trailer adjacent to the airline connections.
7b.2. Cut the cable at the connector position and
prepare the cable end per steps 3 & 4.
7a.3. Attach the cable to the connector.
IMPORTANT:
Verify that the tractors electrical system
is properly designed to protect the lift-
gate and tractor from overload.

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+
_
+
_
1. Position the auxiliary batteries so the positive
terminals are towards the outside of the edge of the
trailer.
2. Install the supplied battery tie down strap. Tighten the
nuts on the threaded bars to ensure the batteries are
securely seated.
3. Connect the red (positive) 12”battery cable to the
positive terminals of the battery
(Figure 35).
4. Connect the black (negative) 12”battery cable to the
negative terminals of the battery
(Figure 35).
11. Auxiliary Battery & Cable Installation
Auxiliary Battery & Cable Installation
Figure 35
Figure 36
+
_
+
_
BLACK 12” CABLE
RED 12” CABLE BATTERY
TIE DOWN STRAP
RED 18” CABLE
MASTER DISCONNECT
SWITCH
CIRCUIT BREAKER
RED 12” CABLE
IMPORTANT:
SAF-HOLLAND recommends the use of
12V Group 31 Top Stud Post AGM or Heavy
Duty dual purpose type batteries with a
minimum reserve capacity of
170 AMP hours/1000 CCA.
5. Connect the red (positive) 18”battery cable that is al-
ready installed on the master disconnect switch to the
positive terminal of the battery
(Figure 36).
6. Connect the red (positive) 12” cable that is already
installed on the circuit breaker to the positive terminal
on the battery.
(Figure 36).
IMPORTANT:
Verify the master disconnect switch is off
before connecting it to the battery.
Failure to turn the master disconnect
switch off prior to connecting power may
result in unintended pump operation
which, if not avoided, may result in prop-
erty damage.