SAF XL-TG10150UD User Manual

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Operation and Maintenance Manual

TL and TG Series Liftgates

• 2500 / 3000 / 3500 / 4000 / 5000 Lb. Capacity

TL SERIES DUAL CYLINDER

TG SERIES SINGLE CYLINDER

TG SERIES DUAL CYLINDER

XL-TG10150UD-en-US Rev B

Contents

Contents Page

Introduction ......................................................................... 3

Warranty .............................................................................. 3

Notes, Cautions, and Warnings ............................................. 3

Section 1 – General Safety Precautions ................................ 4

Section 2 – Model and Serial Number .................................. 6

Section 3 – Decal Part Numbers ........................................... 7

TL Series Terminology ........................................................... 8

TG Series Terminology .......................................................... 9

Section 4 – Pre-Operation Information ............................... 10

Section 5 – Control Switch Operation ................................. 10

Section 6 – Raising or Lowering the Platform ..................... 11

Introduction

This manual provides you with the information necessary for the care, maintenance, inspection, and safe operation of the SAF-HOLLAND TL and TG Series Liftgate.

NOTE: For liftgate components replacement, contact

SAF-HOLLAND Customer Service at: U.S. 888-396-6501 Canada 800-503-9847

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 website (www.safholland.us and www.safholland.ca). It may also be ordered directly from SAF-HOLLAND; the address is shown on the back cover.

Notes, Cautions, and Warnings

Contents Page

Section 7 – Unfolding the Platform .................................... 12

Section 8 – Foot Pedal Opener Operation ........................... 14

Section 9 – Platform Loading ............................................. 15

Section 10 – Stowing the Platform ..................................... 18

Section 11 – Filling the Hydraulic Reservoir ........................ 20

Section 12 – Routine Service and Inspection....................... 21

Section 13 – Troubleshooting ............................................. 22

Section 14 – Pump Hydraulic and Electrical Diagrams ......... 24

Section 15 – Pump Hydraulic and Electrical Schematic........ 25

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.

Throughout this manual, you will notice the terms “NOTE,” “IMPORTANT,” “CAUTION,” and “WARNING” followed by useful product information. So that you may better understand the manual, those terms are 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.

You must read and understand all of the safety procedures presented in this manual before operating or starting any work on the liftgate.

NOTE: In the United States, workshop 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.

Proper tools must be used to perform the maintenance and repair procedures described in this manual. Many of these procedures may require special tools.

XL-TG10150UD-en-US Rev B · 2013-05-23 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

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.

General Safety Precautions

1. General Safety Precautions

Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or both.

Please observe the following safety instructions in order to maintain the operational and road safety of your SAF-HOLLAND Liftgate:

1. You must be fully trained on the capabilities and the limitations of this equipment to operate the equipment properly.

2. When operating the liftgate, always stand to one side of the platform. Make sure that the area is clear of obstacles, other personnel, fingers, arms, hands, legs, and/or feet.

Failure to keep area near your liftgate clear could create a crush and/or pinch hazard which, if not avoided, could result in death or serious injury.

IMPORTANT: DO NOT exceed liftgate capacity when

raising or lowering platform.

Failure to avoid overloading the liftgate may result in platform failure which, if not avoided, could result in death or serious injury.

3. Make sure liftgate is in stowed position when not in use.

4. NEVER step off moving equipment. Only step off the platform when it is in contact with the ground or at deck height when entering the vehicle.

Failure to lower the platform to ground level before stepping on or off platform could result in mild to moderate injury.

We highly recommend the use of only SAF-HOLLAND Original Parts.

A list of SAF-HOLLAND Technical Support locations to supply SAF-HOLLAND Original Parts can be found at www.safholland.us or by contacting SAF-HOLLAND Customer Service at U.S. 1-888-396-6501 or Canada 1-800-503-9847.

Servicing Safety Precautions

1. DO NOT work underneath the liftgate without properly supporting the raised platform and liftframe in accordance 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, welding equipment, and dangerous chemicals.

NOTE: Never operate the liftgate with the vehicle running

unless instructed to by this manual for specific service items.

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.

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. Check for slippery surfaces before stepping off the liftgate platform.

6. NEVER jump off the liftgate.

7. In an emergency situation, release the control switch to stop the liftgate operation.

8. SAF-HOLLAND Liftgates require routine service, inspection, and maintenance in order to maintain optimum performance, proper operation, and to identify normal wear.

Failure to properly engage the vehicle parking brake prior to operating or maintaining liftgate may allow vehicle movement which, if not avoided, could result in death or serious injury.

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General Safety Precautions

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).

Failure to properly protect yourself when searching for hydraulic leaks could result in fluid injection into the skin which, if not avoided, could 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).

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.

Figure 1

Figure 2

NOTE: Batteries contain acid that can burn and they

also produce gas that can explode, follow battery manufacturers’ provided safety instructions when working on your battery.

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. 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.

11. Clean up any excess grease, oil accumulation and spillage

immediately. Use only non-ﬂammable products for cleaning the liftgate or components.

Figure 3

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Model and Serial Number Information

2. Liftgate Model and Serial Number Location

Each SAF-HOLLAND liftgate has a stamped metal tag that identifies the liftgate model and serial number (Figure 4). This tag is attached to the front roadside of the main tube (Figure 5). In order to properly identify your HOLLAND liftgate and its components when communicating with SAF-HOLLAND or your dealer, please record the model and serial numbers and refer to them when ordering replacement parts (Figure 6).

Model Number

TL / TG 35 48

Platform Size

36" long 42" long 44" long 45" long

Capacity 2,500 lbs. 3,000 lbs. 3,500 lbs.

47" long 48" long 52" long 61" long

4,000 lbs. 5,000 lbs.

Figure 4

Figure 5

MODEL NUMBER

XXXXXXXXXX-XXXX

SERIAL NUMBER

XXXXX

Model

TL TG

Serial Number before November 1, 2008

E 01 000123 N

Facility Code

Sequence Number

Year Code

Month Code

Serial Number after November 1, 2008

98 02 312 0123

Sequence Number

Day of Year

Year Code

Facility Code

Equipment Model No.: _______________________________

LIFTGATE MODEL AND SERIAL NUMBER TAG LOCATION

Serial No.: _________________________________________

Purchase Date: _____________________________________

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Decal Requirements

3. Decal Part Numbers

IMPORTANT: All decals must be installed, maintained,

and kept visible and legible.

Prior to placing the vehicle into service, inspect all decals listed below. Ensure the decals are in the correct location and are legible (Figures 6 and 7). Replace any damaged and/or missing decals.

It is the responsibility of the end user to periodically inspect all decals and ensure that they are clean and completely legible. If any decals are missing, loose, damaged, or difficult to read, contact SAF-HOLLAND Customer Service to order replacements immediately.

DECAL QTY. ENGLISH FRENCH DESCRIPTION

A 2 XB-50341 XB-50348 Max. Capacity 2500

2 XB-50340 XB-50347 Max. Capacity 3000

2 XB-57537 XB-50347 Max. Capacity 3500

2 XB-51913 XB-51914 Max. Capacity 4000

2 XA-58882 XA-58883 Max. Capacity 5000

B 2 XB-51170 XB-57067 Pinch Point

C 1 XB-54995 XB-64388 High Pressure Fluid

D 2 XB-50528 XA-62611 Safety Latches

E 1 XB-50346 XB-50353 WARNING

F 1 XB-50345 XB-50352 Instructional

G 1 XB-50344 XB-50349 CAUTION - Always Stand Clear

H 1 XB-62815 XB-62878 WARNING - Riding Platform

Figure 6

CURBSIDE

Figure 7

ROADSIDE

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TL Liftgate Terminology

ITEM DESCRIPTION

1 Cart Stops

2 Inner Platform

3 Outer Platform

4 Adjusting Bolts

5 Torsion Spring

6 Compression Member

7 Roller Opener

8 Lift Frame

9 Lift Cylinder

ITEM DESCRIPTION

10 Side Steps

11 Pump Box Mount

12 Pump Box

13 Travel Latch

14 Main Tube

15 Attaching Plates

16 Deck Extension

17 Control Station

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TG Liftgate Terminology

ITEM DESCRIPTION

1 Control Station

2 Inner Platform

3 Outer Platform

4 Adjusting Bolts

5 Torsion Spring

6 Roller Opener

7 Parallel ARms

8 Lift Frame

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ITEM DESCRIPTION

9 Lift Cylinder

10 Side Steps

11 Pump Box Mount

12 Pump Box

13 Travel Latch

14 Main Tube

15 Attaching Plates

16 Deck Extension

Liftgate Operation Instructions

4. Pre-Operation Information

1. Ensure the platform is clear of obstacles and other personnel.

2. Inspect liftgate for any damage, bruised paint or bent components.

3. Inspect electrical cables and hydraulic hoses, repair or secure as necessary.

Failure to repair and/or replace worn or damaged components before use could result in liftgate failure which, if not avoided, could result in death or serious injury.

4. Read and understand the decals referenced in Section 3.

5. Vehicle must be on ﬂat, level ground before operating liftgate.

6. Ensure that the vehicle parking brake is securely engaged.

5. Control Station Switch Operation

To operate the liftgate, use the toggle switch on the control station located at the rear of the vehicle (Figure 8).

This toggle switch enables the operator to raise and lower the liftgate platform (Figure 9).

Figure 8

REAR OF VEHICLE

CONTROL STATION

Figure 9

Failure to keep clear of the moving liftgate could create a crush and/or pinch hazard which, if not avoided, could result in death or serious injury.

NOTE: If the Operator is required to ride the liftgate,

observe and familiarize yourself with the liftgate operation, decals and manuals. Ensure stable footing at all times. The switch only allows the operator to raise or lower the platform.

XL-TG10150UD-en-US Rev B · 2013-05-23 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

Liftgate Operation Instructions

6. Raising or Lowering the Platform

Failure to secure load prior to operating platform could allow load to shift and strike operator which, if not avoided, could result in moderate injury.

IMPORTANT: This unit is intended for loading and

unloading cargo only. If personnel are required to ride the liftgate, familiarize yourself with this liftgate manual.

Failure to ensure stable footing while riding the liftgate could allow the operator to fall which, if not avoided, could result in death or serious injury.

6.1 Raising the Platform

1. Stand to the side of the vehicle and clear of the platform,

push the control station toggle switch in the UP direction (Figure 10).

NOTE: The toggle switch must remain engaged for the

platform to continue moving upward.

2. To stop the platform from moving upward, release the

toggle switch.

Figure 10

CONTROL STATION

TOGGLE SWITCH

Figure 11

CONTROL STATION

6.2 Lowering the Platform

1. Stand to the side of the vehicle and clear of the platform,

push the control station toggle in the DOWN direction (Figure 11).

NOTE: The toggle switch must remain engaged for the

platform to continue moving downward.

2. To stop the platform from moving downward, release the

toggle switch.

DOWN

TOGGLE SWITCH

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Liftgate Operation Instructions

7. Unfolding the Platform

IMPORTANT: There are two different travel latch

options: The HOOK option or the CHAIN option. Determine which option you have before proceeding.

7.1 Travel Hook Option

1. Stand clear of the liftgate, and using the control station, raise the stowed platform until the latch pins disengage from the hooks (Figure 12).

2. Rotate the lock handle to allow the latch pins to clear the travel latch hooks, and while holding the handle, lower the platform until clear of the travel latch hooks (Figure 13).

3. Continue lowering the unit until the liftgate firmly contacts the ground.

NOTE: Some TL liftgates have an optional foot pedal

opener installed as shown in Figure 18. If the liftgate you are operating has the foot pedal option, skip to Section 8 Foot Pedal Opener Operation.

Figure 12

CONTROL STATION

TOGGLE SWITCH

Figure 13

LOCK HANDLE

Failure to ensure stable footing while engaging the foot pedal could result in slipping which, if not avoided, could result in minor or moderate injury.

4. Grasp the platform to rotate it down. As the platform starts to rotate, step back to allow the platform to fall into a horizontal position (Figure 14).

Failure to keep feet clear of platform during operation could create a crush and/or pinch hazard which, if not avoided, could result in death or serious injury.

5. While standing clear and to the side, grasp the flip over section and rotate it allowing it to fall into a horizontal position.

TRAVEL LATCH HOOK

Figure 14

FLIP OVER SECTION

PLATFORM

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Liftgate Operation Instructions

7.2 Travel Chain Option

1. Stand clear of the liftgate, and using the control station,

raise the stowed platform to relieve any tension on the travel chain (Figure 15).

2. Disengage the travel latch chain hook from the platform.

(Figure 16).

3. With the travel chain clear, lower the unit until the

liftgate firmly contacts the ground.

NOTE: Some TL liftgates have an optional foot pedal opener

installed as shown in Figure 19. If the liftgate you are operating has the foot pedal option, skip to Section 8 Foot Pedal Opener Operation.

Failure to ensure stable footing while engaging the foot pedal could result in slipping which, if not avoided, could result in minor or moderate injury.

4. Grasp the platform to rotate it down. As the platform

starts to rotate, step back to allow the platform to fall into a horizontal position (Figure 17).

Failure to keep feet clear of platform during operation could create a crush and/or pinch hazard which, if not avoided, could result in death or serious injury.

Figure 15

CONTROL STATION

TOGGLE SWITCH

Figure 16

TRAVEL LATCH CHAIN HOOK

PLATFORM

5. While standing clear and to the side grasp the flip

over section and rotate it allowing it to fall into a horizontal position.

Figure 17

FLIP OVER SECTION

PLATFORM

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Liftgate Operation Instructions

8. Foot Pedal Opener Operation

(TL Option Only)

1. Grasp the platform and insert one foot into the foot pedal (Figure 18).

2. While applying weight to the foot pedal, slowly rotate the platform out from under the vehicle (Figure 19).

Failure to ensure stable footing while engaging the foot pedal could result in slipping which, if not avoided, could result in minor or moderate injury.

3. As the platform starts to rotate, remove your foot from the foot pedal and step aside to allow the platform to fall to a horizontal position (Figure 20).

Failure to keep feet clear of platform during operation could create a crush and/or pinch hazard which, if not avoided, could result in death or serious injury.

4. While standing clear and to the side, grasp the flip over section rotating it open to the horizontal position.

Figure 18

PLATFORM

FOOT PEDAL

Figure 19

PLATFORM

FOOT PEDAL

Figure 20

PLATFORM IN THE HORIZONTAL POSITION

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Liftgate Operation Instructions

9. Platform Loading

Failure to keep load within platform edge could create a crush hazard which, if not avoided, may result in damage to the load.

Failure to keep loads stable and within design capacity could result in falling objects or component failure which, if not avoided, could result in death or serious injury.

When riding the platform, failure to keep feet within front edge of platform could create a crush hazard which, if not avoided, could result in death or serious injury.

9.1. Cart Stop Operation (TL Only)

NOTE: The TL cart stops are divided into curbside and

roadside halves of the platform. To raise all the cart stops, both triggers must be rotated.

1. To raise the cart stops, fully rotate both the curbside and

roadside triggers (Figure 21).

2. To lower the cart stops, fully rotate both curbside and

roadside triggers until the cart stops are flush with the platform (Figure 22).

Failure to keep load within platform edge could create a crush hazard which, if not avoided, may result in damage to the load.

Figure 21

ROADSIDE TRIGGER

CART STOPS

TRIGGER

CURBSIDE TRIGGER

Figure 22

ROADSIDE TRIGGER

CART STOPS

TRIGGER

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CURBSIDE TRIGGER

Liftgate Operation Instructions

9.2 Loading from the Ground

1. Using the control station, open the platform from the stowed position and lower it to the ground (Refer to Sections 6 and 7).

IMPORTANT: Never operate a fork lift truck on or over

the platform.

Failure to remove fork lift trucks from the liftgate platform area could cause component failure which, if not avoided, could result in death or serious injury.

2. Load the platform by placing the load center as close to the center of the platform as possible and placing the heaviest part of the load to the front of the platform (Figure 23).

For TL Models

Engage the cart stops to the up position (Figure 21).

3. Using the control station toggle switch at the rear of the vehicle, raise the platform to deck height and unload (Figure 24). If required, repeat procedures to continue with additional loads.

4. When the liftgate has been unloaded, lower and stow the platform (Refer to Sections 6 and 10).

Figure 23

PLACE LOAD ON CENTER OF PLATFORM

FRONT OF PLATFORM

Figure 24

DECK HEIGHT

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Liftgate Operation Instructions

9.3 Loading from the Vehicle

1. Using the control station, open and raise the platform to

deck height (Refer to Sections 6 and 7).

For TL Models

Engage the cart stops to the Up position (Figure 21).

2. Load the platform by placing the load center as close to

the center of the platform as possible and placing the heaviest part of the load to the front of the platform (Figure 25).

IMPORTANT: Never operate a fork lift truck on or over

the platform.

Failure to remove fork lift trucks from the liftgate platform area could cause component failure which, if not avoided, could result in death or serious injury.

3. Using the control station toggle switch on the rear of the

vehicle, lower the platform to the ground.

For TL models

Lower the cart stops and unload (Figure 26). If required, repeat procedures to continue with additional loads.

4. When the liftgate has been unloaded, stow the platform

(Refer to Section 10).

Figure 25

PLACE LOAD ON CENTER OF PLATFORM

FRONT OF PLATFORM

Figure 26

CART STOPS DOWN

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Liftgate Operation Instructions

10. Stowing the Platform

IMPORTANT: There are two different travel latch options:

The HOOK option or the CHAIN option. Determine which option you have before proceeding.

Travel Hook Option

1. Lower the platform to below waist level, lift the end of the flipover section, rotating it about the pivot bolts and allow the flipover to fall onto the platform (Figure 27).

Failure to keep feet clear of platform during operation could create a crush and/or pinch hazard which, if not avoided, could result in death or serious injury.

2. Lower the platform to the ground and rotate the inner platform allowing it to rest against the platform roller openers (Figure 28).

3. Stand clear and using the control station, raise the platform until the lock pins are above the travel latch.

NOTE: When the liftgate is fully retracted to the stored

position, release the control switch.

Figure 27

FLIP OVER SECTION

PIVOT BOLTS

Figure 28

ROLLER OPENERS

4. Visually check to ensure that both lock pins are properly engaged in the travel latch hooks (Figure 29).

Figure 29

TRAVEL LATCH HOOK

LATCH PIN

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Liftgate Operation Instructions

Travel Chain Option

1. Lower the platform to below waist level, lift the end of

the flipover section, rotating it about the pivot bolts and allow the flipover to fall onto the platform (Figure 30).

Failure to keep feet clear of platform during operation could create a crush and/or pinch hazard which, if not avoided, could result in death or serious injury.

2. Lower the platform to the ground and rotate the inner

platform allowing it to rest against the platform roller openers (Figure 31).

3. Stand clear and using the control station, raise the

platform until the platform is in fully raised position.

NOTE: When the liftgate is fully retracted to the stored

position, release the control switch.

4. Position the travel latch chain hook into the latch hook

hole in the side of the platform (Figure 32).

Figure 30

FLIP OVER SECTION

PIVOT BOLTS

Figure 31

ROLLER OPENERS

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Figure 32

HOLE IN PLATFORM

TRAVEL LATCH HOOK

Filling the Hydraulic Reservoir

11. Filling the Hydraulic Reservoir

IMPORTANT: Keep dirt, water, and other contaminants

from entering the hydraulic system; clean the area to prevent contamination of the hydraulic ﬂuid and use a clean funnel with a fine screen mesh.

1. Set the vehicle parking brake.

2. TG Models Using the control station, put the platform in the up and open position (Figure 33).

TL Models

Using the control station, put the platform in the down and open position (Figure 34).

3. Remove the filler cap and add recommended hydraulic fluid to pump reservoir. Check that the hydraulic fluid is at the proper fill level (Figure 35).

IMPORTANT: Always use the correct grade of hydraulic

fluid. Refer to the chart below for recommended hydraulic fluid or contact your SAF-HOLLAND representative.

Figure 33

TG MODEL IN UP AND OPEN POSITION

Figure 34

TEMPERATURE RECOMMENDED FLUIDS

RANGE MANUFACTURER TYPE

Above 0° C (32° F)

-25 to 65° C (-15 to 150 ° F)

-35 to 50 ° C (-30 to 120° F)

-45 to 40° C (-50 to 100° F)

Any

Any ESSO, EXXON MOBIL, SHELL

EXXON, ESSO, SHELL, PETRO-CAN

Any ESSO, EXXON, SHELL

AW-32 ISO 32

HYDRAUL 50 DTE 11 DONAX TD Low Viscosity

UNIVIS N15 TELLUS T15 MV ARCTIC 15

MIL-H-5606 UNIVIS J-13 UNIVIS HV1 13 FLUID #4

TL MODEL IN DOWN AND OPEN POSITION

Figure 35

FILLER CAP

12. Routine Service and Inspection

12.1 Daily Inspection

1. Daily or before each trip, inspect the liftgate for damage

to mounting assemblies, mechanical parts, and hydraulic components and hoses. Any noticeable defects must be repaired prior to operation to avoid damage and possible injury. Inspect and verify the condition of the following key components:

• Torsion springs – are not broken or rusted

• Stowage lock mechanism – is in working order

• Attaching plates – no bends and/or cracked welds are present

• Deck extension – no cracked welds are present

• Pivot points – no pin movement caused by excessive wear

• Pivot points – all pins and bushings are present and in good working order

• Shackles – are in proper orientation and proper platform presentation

• Platform – no bends are present

• Platform – no weld cracks are present

• Flip over – no bends are present

• Flip over – no weld cracks are present

• Control switch – is in properly operational

• Control switch – no damage is present

• Control switch – have no noticeable corrosion

• Hydraulic hoses – have no leaks

• Hydraulic hoses – are secured properly

• Hydraulic hoses – no rub or abrasion marks are present

• Cylinders – have no leaks

• Cylinders – no damage is present

2. Inspect and replace any decals that have been removed or have become illegible.

12.2 Monthly Inspection

1. Every 1000 cycles or 30 days, whichever occurs ﬁrst, lubricate all pivot points using EP2 chassis grease. In severe winter conditions, it may be necessary to lubricate more frequently.

2. Lubricate linkage pivot points with light spray lubricant.

3. Check oil level in reservoir (1/2" [13 mm] from top of tank with cylinders retracted).

4. Verify electrical connections, coat with dielectric grease or equivalent.

12.3 Yearly Inspection

1. Change the oil and oil ﬁlter. When ﬁlling pump reservoir, use a funnel with a fine mesh screen. Use only recommended hydraulic fluid (refer to Section 15).

Routine Service and Inspection

2. Lubricate linkage pivot points with light spray lubricant.

3. Inspect all decals. Replace any decals that are not clearly visible or legible.

12.4 Alternate Year Inspection

1. Every 24,000 cycles or two (2) years, whichever occurs first, inspect all pivot points for wear. Replace any pins or parts that show signs of wear.

2. Replace any worn hydraulic hoses, leaking fittings or leaking cylinders.

3. Undercoat all crossmembers by removing plugs in crossmembers; spray undercoat inside and replace plugs.

NOTE: Some models may be equipped with greaseless

bushings at all or most pivot points.

IMPORTANT: Review General Safety Precautions before

working on hydraulic or electrical components.

12.5 Monthly Hydraulic and Electrical Inspection

1. Inspect and remove the coil from the valve and look for signs of corrosion. If corrosion is present, clean and repair as necessary.

2. Inspect to ensure all hydraulic hoses are tight and not leaking. If hoses are showing signs of wear, replace as necessary. After torquing the hydraulic hoses, SAF-HOLLAND recommends putting a line across the fittings for a future visual reference that will indicate loose fittings.

3. Inspect the filler cap for signs of damage. The foam baffle on the inside of the cap should be ﬂat and in place. Inspect all wire connections on toggles, push buttons or any other controls attached to the liftgate. Clean and apply dielectric grease to all electrical components to help reduce corrosion.

4. Inspect all wiring and wiring connections to ensure they are tight and free of corrosion. If the pump has foreign debris, clean the entire pump and wire connections. Once you are satisfied that all components are clean, apply non-aerosol dielectric grease to all connections. If any wires show signs of deterioration, replace as required.

5. SAF-HOLLAND recommends that you flush and replace the hydraulic oil every year to ensure contaminates are flushed from the system. Remove the pump tank and wipe free with a lint free cloth. If present, clean reservoir magnet of contaminants. Remove the strainer and flush. Replace the strainer. Remove any contaminates.

NOTE: To reduce downtime, bring in your liftgate every

two to three (2-3) months for quick and simple inspections. Daily inspections while doing the circle check on your vehicle will spot any concerns before they become serious failures.

Troubleshooting

13. Troubleshooting

PROBLEM POSSIBLE CAUSE RESOLUTION

Platform lowers slowly or does not lower. Flow control incorrectly installed. Check location and direction of arrow on valve.

Electrical connections loose, disconnected or corroded. Check connections and wire condition.

Battery does not have enough voltage to activate solenoid properly.

Restriction/blockage of hydraulic hose. Check hoses for external damage or pinching.

Flow control valve blocked. Clean or replace valve.

Mechanical components seized or damaged. Lubricate all pivot points and replace all

Incorrect or contaminated oil in system. Oil should be clean and for the appropriate

Unit will not lift capacity load. Hydraulic system not plumbed properly. Check to see that the hose connected to the ‘A’

Hydraulic cylinder leaking internally. Replace seals or complete cylinder.

Relief valve setting too low. Adjust relief valve setting.

Hydraulic pump worn. Change worn parts or pump.

Oil expels from reservoir while loading. Too much oil in reservoir. Ensure level of oil allows displacement of rods.

Wrong ﬂow control ﬁtting. Check that the number stamped on ﬂow control

Motor is not running when lowering platform. Check faulty ‘down button’ on push-button

Pump will not operate. Master disconnect switch is turned off Verify the main power is turned on.

Battery does not have enough voltage/current. Verify voltage and recharge or replace battery.

Electrical wiring to pump is loose, disconnected or corroded

Remote control switch broken or shorted. Check wiring to switch.

Solenoid switch on pump faulty. Check solenoid switch.

Electrical coupling to trailer not complete (Tractor/Trailer vehicles only).

Verify voltage and recharge or replace battery. Ensure that cables are in good condition with secure connections.

Check for blockages in hoses.

damaged items.

geographical climate.

port is plumbed to the rod end of the cylinder.

valve is correct as per the appropriate schematic.

control box.

Ensure that cables are in good condition with secure connections.

Check wiring to pump.

Connect coupling.

Troubleshooting

PROBLEM POSSIBLE CAUSE RESOLUTION

Platform will not raise. Battery does not have enough voltage/current. Verify voltage and recharge or replace battery.

Ensure that cables are in good condition with secure connections.

Insufﬁcient oil in reservoir. With platform on ground, ﬁll tank within 2" of top

with Dextron III Automatic Transmission Fluid.

Defective actuating coil on valve. Replace actuating coil.

Liftgate is overloaded. Reduce the load on the platform.

Hose or ﬁtting leak. Check and re-torque ﬁttings.

Leaking check valve or relief valve. Clean, adjust or replace valve.

Worn piston seals. Replace seals.

Worn or scored piston. Replace cylinders.

Pivot points seized. Lubricate.

Pump is worn out. Replace pump.

Broken pump shaft or coupler. Replace shaft or coupling as necessary.

Platform will not raise smoothly. Insufﬁcient oil in reservoir. Fill reservoir.

Air lock in hydraulic system. Operate ‘Raise Control’ for a few seconds at

top of stroke. Repeat two (2) times, pausing between operations.

Undue mechanical wear or lack of lubrication. Lubricate pivots, replace worn parts.

Platform creeps down when stationary. Cylinder seal leak. Replace seals or cylinder if scored.

Worn or dirty check valve. Clean or replace valve.

Hose or ﬁtting leak Replace hose or tighten ﬁtting

Platform raises slowly. Battery does not have enough voltage/current. Verify voltage and recharge or replace battery.

Ensure that cables are in good condition with secure connections.

Liftgate is overloaded. Reduce load on platform.

Faulty cable connections: Electrical connections corroded or disconnected.

Pump motor not grounded adequately. Check grounding to truck frame.

Hose leaking. Tighten or replace hoses.

Cylinder internal leak. Replace seals or replace cylinder.

Lack of lubrication or undue mechanical wear. Lubricate all pivot points and replace worn parts.

Incorrect relief valve setting. Check relief valve setting.

Worn pump. Replace pump.

Check connections.

Pump Hydraulic and Electrical Diagram

14. Pump Hydraulic and Electrical Diagrams

Figure 36

A PORT (C1) (UP)

(TOP VIEW)

BLACK WIRE FROM CONTROL (2W2P) (DOWN)

B PORT (C2) (DOWN)

(SIDE VIEW)

WHITE WIRE FROM TOGGLE (4W2P) (UP)

POWER FROM BATTERY

(END VIEW)

POWER TO CONTROL (GREEN)

15. Pump Hydraulic and Electrical Schematic

Figure 37 (Hydraulic Schematic)

B (DOWN) A (UP)

34 BAR 500 PSI

193 BAR 2800 PSI

Pump Hydraulic Schematic

BLACK WIRE (2W2P)

WHITE WIRE (4W2P)

Figure 38 (Electrical Schematic)

1.98 CC/REV

0.121 IN3/REV

2W2P VALVE COIL FLOW PORT C2

BLACK (DOWN) FLOW PORT C2

MOTOR START SOLENOID

GREEN (POWER)

WHITE (UP) FLOW PORT C1

+ 12V DC BATTERY(+VE)

4W2P VALVE COIL FLOW PORT C2

Notes

From fifth wheel rebuild kits to suspension bushing repair kits,

SAF-HOLLAND Original Parts are the same quality components used

in the original component assembly.

SAF-HOLLAND Original Parts are tested and designed to provide

maximum performance and durability. Will-fits, look-alikes or, worse

yet, counterfeit parts will only limit the performance potential and

could possibly void SAF-HOLLAND’s warranty. Always be sure to spec

SAF-HOLLAND Original Parts when servicing your

SAF-HOLLAND product.

SAF-HOLLAND USA

www.safholland.us

SAF-HOLLAND CANADA

WESTERN CANADA

www.safholland.ca

SAF-HOLLAND MEXICO

www.safholland.com.mx

info@safholland.com

SAF-HOLLAND USA, INC. 1950 Industrial Blvd., Muskegon, MI 49442 www.safholland.com

888.396.6501

519.537.3494

604.574.7491

52.55.5362.8743

Fax 800.356.3929

Fax 800.565.7753

Fax 604.574.0244

Fax 52.55.5362.8743

SAF XL-TG10150UD User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual