SAF-HOLLAND TG 25 User manual

XL-TG20004BM-en-US · 2014-01-14 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,
and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
TG 25 Main Tube Cylinder Bushing Kit
Insallation Instructions
TG Series Liftgate
Introduction
These instructions provide the information necessary for the
installation of the TG 25 main tube cylinder bushing kit.
When replacement parts are required, SAF-HOLLAND highly
recommends the use of only SAF-HOLLAND Original Parts. A
list of technical support locations that supply SAF-HOLLAND
Original Parts and an Aftermarket Parts Catalog are available
on the internet at www.safholland.us or contact Customer
Service at 888-396-6501 USA or 800-503-9847 Canada.
Notes, Cautions, and Warnings
Before starting any work on the unit, read and understand all
the safety procedures presented in this manual. This manual
contains the terms “NOTE”, “IMPORTANT”, “CAUTION”, and
“WARNING” followed by important product information. These
terms are defined as follows:
NOTE: Includes additional information to enable accurate
and easy performance of procedures.
IMPORTANT: Includes additional information that
if not followed could lead to hindered
product performance.
Used without the safety alert symbol, indicates
a potentially hazardous situation which, if
not avoided, could result in property damage.
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury.
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
1. General Safety Precautions
DO NOT work underneath the liftgate without properly
supporting the raised platform and lift frame in accordance
with workplace safety requirements.
NEVER strike any part of the liftgate with a steel hammer.
DO NOT hit steel parts with a steel
hammer as parts could break, sending
flying steel fragments in any direction
creating a hazard which, if not avoided,
could result in minor or moderate injury.
Safety protection should always be worn as protection from
pressurized fluid spray, flying debris, and other airborne
matter when working with tools, power tools, welding
equipment, and dangerous chemicals.
NOTE: NEVER operate the liftgate with the vehicle running
unless instructed to by these procedures.
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.
While servicing or repairing equipment, ALWAYS disconnect
the electrical power to the pump motor and ensure that
the platform and lift frame is supported on the ground or
secured in the travel lugs.
Clean up any excess grease, oil accumulation and spillage
immediately. Use only non-flammable products for cleaning
the liftgate or components.
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.
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.
Failure to depressurize the hydraulic
system could result in fluid injection into
the skin which, if not avoided, could
result in death or serious injury.
Additional safety and operational precautions can be found
in the TL and TG Series Operation and Maintenance Manual
XL-TG10150UD-en-US.
Avoid contact with electrical connections inside the pump
box which are not isolated.
Failure to avoid contact with electrical
connections will result in shock which,
if not avoided, could result in death or
serious injury.

2XL-TG20004BM-en-US · 2014-01-14 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,
and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Welding Standards
2. Welding Standards
2.1 Scope
This specification applies to all components supplied by
SAF-HOLLAND®, and its products. The customer assumes
all responsibility for weld integrity if weld material and
procedure differ from that listed below.
2.2 Material
Frame attachment components made from low carbon or
high-strength alloy steel are to be welded with AWS filler
metal specification AWS A5.18, filler metal classification
ER-70S-3, ER-70S-6 or equivalent unless specified on the
installation drawing.
NOTE: Any substitution for filler material from the above
standard MUST comply, as a minimum, with the
following mechanical properties:
Tensile Strength - 72k psi (496 MPa)
Yield Strength - 60k psi (414 MPa)
$IBSQZ7OPUDIGUMCT/tNBUo F (-17.7o C)
% Elongation - 22%
The recommended welding gas for gas metal arc welding
(GMAW) is 90% Argon / 10% CO2. If a different gas is used,
welds MUST comply with penetration requirements shown
(Figure 1). Where the installation drawing specifies different
than above, the drawing shall prevail.
2.3 Procedures
Tack welds used for positioning components are to be
located in the center of the final weld, where practical. Tack
weld should be completely fused to the finish weld. DO NOT
break arc at the end of the weld. Back up all finish welds
at least 1/2" (12.7 mm) or a sufficient amount to prevent
craters at the end of the weld. Where weld is shown to go
around corners, it is assumed the corner represents a stress
concentration area. DO NOT start or stop weld within 1" (25.4 mm)
of the corner. Particular care should be taken to prevent
undercutting in this area.
2.4 Workmanship
It is the responsibility of the customer to provide good workmanship
when attaching components to the frame structure.
2.5 Weld Size
If weld size is not specified, the effective throat of the weld
MUST be no smaller than the thinnest material being welded
(Figure 1).
Figure 1
LACK OF FUSION OF
ANY KIND IN THIS AREA
IS NOT ACCEPTABLE AT
ANY TIME
PENETRATION AS MEASURED
THROUGH SEAM
TARGET PENETRATION TO BE
10% OF THINNEST MATERIAL
FROM INTERSECTION OF FILLET
AS SHOWN
TARGET PENETRATION

3
XL-TG20004BM-en-US · 2014-01-14 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,
and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Figure 2
Kit Contents and Bushing Installation
3. Kits Contents (Figure 2)
ITEM DESCRIPTION PART NUMBER QTY.
1 Lift Frame Boss 2112100004580 2
2 Sleeve, 1-5/16" O.D. x 1" Long XA-50194 1
3
Hydraulic Cylinder Mounting Pin,
1" Diameter x 8-1/2" Long XA-50020 1
4 Pin, Spring 1/4" x 1-1/2", Plated XB-21-S-250-1500P 1
4. Bushing Installation
1. Open and lower the liftgate to the ground in accordance
with the TL and TG Series Operation and Maintenance
Manual XL-TG10150UD-en-US. Avoid contact with electrical
connections inside the pump box which are not isolated.
Failure to avoid contact with electrical
connections will result in shock which,
if not avoided, could result in death or
serious injury.
2. Disconnect the power to the motor.
3. With a punch, remove the spring pin from the hydraulic
cylinder mounting pin (Figure 3).
4. Remove the pin and rotate the hydraulic cylinder clevis
out of the mounts (Figure 3).
5. With a grinder, remove the sleeve from the cylinder
mount (Figure 3).
6. Align the new parts. Insert the new pin through one lift
frame boss, both cylinder mount plates and then through
the second lift frame boss (Figure 4).
7. Prep the cylinder mount surfaces where the lift frame
bosses will be welded. With a grinder, remove any paint
or galvanizing within 1" to 4" (25-101 mm) of the weld
surface. Position the lift frame bosses and align the top
and leading edge of the lift frame bosses flush with the
top and leading edge of the cylinder mounts (Figure 4).
Bushing Kit Part Number: 2074300000090
1
1
2
43
Figure 4
Figure 3
CYLINDER MOUNTS
CYLINDER MOUNTS
TOP AND LEADING
EDGE FLUSH
HYDRAULIC
CYLINDER
CLEVIS
LIFT
FRAME
BOSS
SPRING PIN
HYDRAULIC CYLINDER
MOUNTING PIN
HYDRAULIC CYLINDER
MOUNTING PIN
SLEEVE

SAF-HOLLAND USA, Inc. · 888.396.6501 · Fax [phone]
SAF-HOLLAND Canada Limited · 519.537.3494 · Fax [phone]
Western Canada · 604.574.7491 · Fax [phone]
SAF-HOLLAND Mexico · 52.55.5362.8743 · Fax [phone]
www.safholland.us
XL-TG20004BM-en-US · 2014-01-14 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF, and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Bushing Installation
Figure 5
Figure 6
8. Weld the lift frame boss as illustrated (Figure 5).
NOTE: When welding is required, ensure that the battery
ground cable is disconnected and all electrical
equipment is completely electrically isolated
before welding is initiated.
Failure to follow manufacturers’ safety
instructions when handling batteries may
result in explosion which, if not avoided,
could result in minor to moderate injury.
9. Align the hole of the new sleeve so it will line up
with the hole of the new pin, and weld as illustrated
(Figure 5 and 6).
10. Touch up paint as required. For galvanized liftgates,
touch up in accordance with the most recent release
of ASTM a 780: standard practice for repair of damaged
and uncoated areas of hot dip galvanized coatings,
which specifies the use of zinc-rich paints.
11. Remove the previously installed new pin.
12. Rotate the hydraulic cylinder clevis back into position
between the cylinder mounts. Re-install the new pin,
ensuring the pin hole aligns with the newly installed
sleeve hole (Figure 6).
13. Install the newly supplied spring pin into the newly
installed sleeve hole.
ALIGN HOLES
SLEEVE
LIFT FRAME BOSS
ALL FOUR
SIDES, BOTH
BLOCKS
1/8"
HYDRAULIC
CYLINDER
MOUNTING PIN
1/4"