SAF XL-TG10156UD User Manual

Operation, Maintenance, and Parts Manual

TLV Series Liftgate

• 2750 Lb. Capacity

XL-TG10156UD-en-US Rev A

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

TLV Liftgate Terminology ...................................................... 8

Section 4 – Pre-Operation Information ................................. 9

Section 5 – Control Switch Operation ................................... 9

Section 6 – Raising or Lowering the Platform ..................... 10

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 .................................... 11

Section 8 – Platform Loading ............................................. 12

Section 9 – Stowing the Platform ....................................... 13

Section 10 – Filling the Hydraulic Reservoir ........................ 14

Section 11 – Routine Service and Inspection....................... 15

Section 12 – Troubleshooting ............................................. 16

Section 13 – Pump Hydraulic and Electrical Diagrams ......... 18

Section 14 – Pump Hydraulic and Electrical Schematic........ 20

Section 15 – Liftgate Components ...................................... 22

Section 16 – Hydraulic Components ................................... 24

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-TG10156UD-en-US Rev A · 2013-04-18 · 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.

XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

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

XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

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, serial numbers, dealer, and purcahse date and refer to them when ordering replacement parts.

Model Number

TLV 27 48

Platform Size

48" long

Capacity 2,750 lbs.

Figure 4

Figure 5

MODEL NUMBER

XXXXXXXXXX-XXXX

SERIAL NUMBER

XXXXX

Model

Serial Number after November 1, 2008

98 02 312 0123

Sequence Number

Day of Year

Year Code

Facility Code

Equipment Model No.: _______________________________

Serial No.: _________________________________________

Purchase Date: _____________________________________

Dealer: ____________________________________________

LIFTGATE MODEL AND SERIAL NUMBER TAG LOCATION

XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

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-59726 XB-59727 Maximum Capacity 2,750

B 2 XB-51170 XB-57067 Pinch Point

C 1 XB-54995 XB-64388 High Pressure Fluid

D 1 XB-50346 XB-50353 Warning

Figure 6

CURBSIDE

Figure 7

ROADSIDE

E 1 XB-62815 XB-62878 Warning - Riding Platform

F 1 XB-50345 XB-50352 Instructions

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

Liftgate Terminology

ITEM DESCRIPTION

Control Station

2 Inner Platform

3 Outer Platform

4 Adjusting Bolts

5 Torsion Spring

6 Compression Member

7 Roller Opener

Lift Frame

ITEM DESCRIPTION

9 Lift Cylinder

10 Step Brace

11 Pump Box Mount

12 Pump Box

13 Travel Hook

14 Main Tube

15 Attaching Plates

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.

+ 19 hidden pages

SAF XL-TG10156UD User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual