XL-TG10156UD - Holland Group Inc.

ContentsContentsPageIntroduction ......................................................................... 3Warranty .............................................................................. 3Notes, Cautions, and Warnings ............................................. 3Section 1 – General Safety Precautions ................................ 4Section 2 – Model and Serial Number .................................. 6Section 3 – Decal Part Numbers ........................................... 7TLV Liftgate Terminology ...................................................... 8Section 4 – Pre-Operation Information ................................. 9Section 5 – Control Switch Operation ................................... 9Section 6 – Raising or Lowering the Platform ..................... 10ContentsPageSection 7 – Unfolding the Platform .................................... 11Section 8 – Platform Loading ............................................. 12Section 9 – Stowing the Platform ....................................... 13Section 10 – Filling the Hydraulic Reservoir ........................ 14Section 11 – Routine Service and Inspection....................... 15Section 12 – Troubleshooting ............................................. 16Section 13 – Pump Hydraulic and Electrical Diagrams ......... 18Section 14 – Pump Hydraulic and Electrical Schematic........ 20Section 15 – Liftgate Components ...................................... 22Section 16 – Hydraulic Components ................................... 24IntroductionThis manual provides you with the information necessary forthe care, maintenance, inspection, and safe operation of theSAF-HOLLAND TL and TG Series Liftgate.NOTE: For liftgate components replacement, contactSAF-HOLLAND Customer Service at:U.S. 888-396-6501Canada 800-503-9847WarrantyRefer to the complete warranty for the country in whichthe product will be used. A copy of the warranty certificateis included with the product as well as on the SAF-HOLLANDwebsite (www.safholland.us and www.safholland.ca). It mayalso be ordered directly from SAF-HOLLAND; the address isshown on the back cover.Notes, Cautions, and WarningsYou must read and understand all of the safety procedures presentedin this manual before operating or starting any work on the liftgate.NOTE: In the United States, workshop safety requirementsare defined by federal and/or state OccupationalSafety and Health Act. Equivalent laws may existin other countries. This manual is written basedon the assumption that OSHA or other applicableemployee safety regulations are followed by thelocation where work is performed.Proper tools must be used to perform the maintenance andrepair procedures described in this manual. Many of theseprocedures may require special tools.IMPORTANT: Read this manual before using thisproduct. Keep this manual in a safelocation for future reference.Failure to follow the instructions andsafety precautions in this manual canresult 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 maybetter understand the manual, those terms are as follows:NOTE: Includes additional information to enableaccurate and easy performance of procedures.IMPORTANT: Includes additional information that ifnot followed could lead to hinderedproduct performance.Used without the safety alert symbol,indicates a potentially hazardous situationwhich, if not avoided, could result inproperty damage.Indicates a potentially hazardous situationwhich, if not avoided, could result in minoror moderate injury.Indicates a potentially hazardous situationwhich, if not avoided, could result in deathor serious injury.XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.3

General Safety Precautions1. General Safety PrecautionsRead and observe all Warning and Caution hazard alert messagesin this publication. They provide information that can helpprevent serious personal injury, damage to components, or both.Please observe the following safety instructions in orderto maintain the operational and road safety of yourSAF-HOLLAND Liftgate:1. You must be fully trained on the capabilities and the limitationsof this equipment to operate the equipment properly.2. When operating the liftgate, always stand to one side ofthe 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 liftgateclear could create a crush and/or pinchhazard which, if not avoided, could resultin death or serious injury.IMPORTANT: DO NOT exceed liftgate capacity whenraising or lowering platform.Failure to avoid overloading the liftgatemay result in platform failure which,if not avoided, could result in death orserious injury.3. Make sure liftgate is in stowed position when not in use.4. NEVER step off moving equipment. Only step off theplatform when it is in contact with the ground or at deckheight when entering the vehicle.Failure to lower the platform to groundlevel before stepping on or off platformcould result in mild to moderate injury.We highly recommend the use of only SAF-HOLLANDOriginal Parts.A list of SAF-HOLLAND Technical Support locations tosupply SAF-HOLLAND Original Parts can be found atwww.safholland.us or by contacting SAF-HOLLANDCustomer Service at U.S. 1-888-396-6501 or Canada1-800-503-9847.Servicing Safety Precautions1. DO NOT work underneath the liftgate without properlysupporting the raised platform and liftframe inaccordance with workplace safety requirements.2. Never strike any part of the liftgate with a steel hammer.3. Safety protection should always be worn as protectionfrom pressurized fluid spray, flying debris, and otherairborne matter when working with tools, power tools,welding equipment, and dangerous chemicals.NOTE: Never operate the liftgate with the vehicle runningunless instructed to by this manual for specificservice items.Failure to turn off vehicle motor beforecommencing work could allow vehicle tomove which, if not avoided, could resultin death or serious injury.4. While servicing or repairing equipment, always disconnectthe electrical power to the pump motor and ensure thatthe platform and liftframe is supported on the ground orsecured in the travel lugs.5. Check for slippery surfaces before stepping off theliftgate platform.6. NEVER jump off the liftgate.7. In an emergency situation, release the control switch tostop 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 vehicleparking brake prior to operating ormaintaining liftgate may allow vehiclemovement which, if not avoided, couldresult in death or serious injury.4 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

General Safety Precautions5. When welding is required, ensure that the battery groundcable is disconnected and that all electrical equipment iscompletely electrically isolated before welding is initiated(Figure 1).6. Before starting any welding, ensure that the area to berepaired is cleaned of debris and combustible material.Have a charged fire extinguisher available and knowhow to use it.7. When searching for an oil leak, wear work gloves anduse a piece of cardboard or wood as a detector. Wear asafety face shield or goggles for eye protection. NEVERuse your bare hands to check for fluid leaks (Figure 2).Failure to properly protect yourself whensearching for hydraulic leaks could resultin fluid injection into the skin which,if not avoided, could result in death orserious injury.8. Pressure can remain in a hydraulic system after the powersource and pump have been shut down. Ensure that thereis no pressure in any of the hydraulic cylinders or hosesbefore performing work on components, or disconnectingany hoses (Figure 3).Failure to depressurize the hydraulicsystem could result in fluid injection intothe skin which, if not avoided, couldresult in death or serious injury.Figure 1Figure 2NOTE: Batteries contain acid that can burn and theyalso produce gas that can explode, follow batterymanufacturers’ provided safety instructions whenworking on your battery.Failure to follow manufacturers’ safetyinstructions when handling batteries mayresult in explosion which, if not avoided,could result in minor to moderate injury.9. Inspect the equipment daily for potential fire hazards andmake any necessary repairs immediately.10. Inspect electrical wiring and connections, and hydraulichose runs to ensure they are secure and not rubbingagainst other components.11. Clean up any excess grease, oil accumulation and spillageimmediately. Use only non-flammable products for cleaningthe liftgate or components.Figure 3XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.5

Model and Serial Number Information2. Liftgate Model and SerialNumber LocationFigure 4Each SAF-HOLLAND liftgate has a stamped metal tag thatidentifies 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 HOLLANDliftgate and its components when communicating withSAF-HOLLAND or your dealer, please record the model, serialnumbers, dealer, and purcahse date and refer to them whenordering replacement parts.MODEL NUMBERXXXXXXXXXX-XXXXSERIAL NUMBERXXXXXModel NumberTLV 27 48Platform Size48" longCapacity2,750 lbs.Figure 5ModelSerial Number after November 1, 200898 02 312 0123Sequence NumberDay of YearYear CodeFacility CodeLIFTGATE MODEL AND SERIALNUMBER TAG LOCATIONEquipment Model No.: _______________________________Serial No.: _________________________________________Purchase Date: _____________________________________Dealer: ____________________________________________6 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

Decal Requirements3. Decal Part NumbersFigure 6IMPORTANT: All decals must be installed, maintained,and kept visible and legible.Prior to placing the vehicle into service, inspect all decalslisted below. Ensure the decals are in the correct location andare legible (Figures 6 and 7). Replace any damaged and/ormissing decals.CURBSIDEA DFECGBIt is the responsibility of the end user to periodically inspectall decals and ensure that they are clean and completelylegible. If any decals are missing, loose, damaged, or difficultto read, contact SAF-HOLLAND Customer Service to orderreplacements immediately.DECAL QTY ENGLISH FRENCH DESCRIPTIONA 2 XB-59726 XB-59727 Maximum Capacity 2,750B 2 XB-51170 XB-57067 Pinch PointFigure 7C 1 XB-54995 XB-64388 High Pressure FluidROADSIDED 1 XB-50346 XB-50353 WarningBE 1 XB-62815 XB-62878 Warning - Riding PlatformAF 1 XB-50345 XB-50352 InstructionsG 1 XB-50344 XB-50349 Caution - Always Stand ClearXL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.7

Liftgate Terminology11615131271493246811510ITEMDESCRIPTIONITEMDESCRIPTION1 Control Station9 Lift Cylinder2 Inner Platform10 Step Brace3 Outer Platform11 Pump Box Mount4 Adjusting Bolts12 Pump Box5 Torsion Spring13 Travel Hook6 Compression Member14 Main Tube7 Roller Opener15 Attaching Plates8 Lift Frame16 Deck Extension8 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

Liftgate Operation Instructions4. Pre-Operation InformationFigure 81. Ensure the platform is clear of obstacles and other personnel.2. Inspect liftgate for any damage, bruised paint orbent components.3. Inspect electrical cables and hydraulic hoses, repair orsecure as necessary.Failure to repair and/or replace worn ordamaged components before use couldresult 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 OperationREAR OF VEHICLECONTROLSTATIONTo operate the liftgate, use the toggle switch on the controlstation located at the rear of the vehicle (Figure 8).Figure 9This toggle switch enables the operator to raise and lower theliftgate platform (Figure 9).Failure to keep clear of the moving liftgatecould create a crush and/or pinch hazardwhich, if not avoided, could result in deathor serious injury.NOTE: If the Operator is required to ride the liftgate,observe and familiarize yourself with the liftgateoperation, decals and manuals. Ensure stablefooting at all times. The switch only allows theoperator to raise or lower the platform.XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.9

Liftgate Operation Instructions6. Raising or Lowering the PlatformFailure to secure load prior to operatingplatform could allow load to shift andstrike operator which, if not avoided,could result in minor or moderate injury.Figure 10CONTROL STATIONIMPORTANT: This unit is intended for loading andunloading cargo only. If personnel arerequired to ride the liftgate, familiarizeyourself with this liftgate manual.UPFailure to ensure stable footing whileriding the liftgate could allow theoperator to fall which, if not avoided,could result in death or serious injury.6.1 Raising the Platform1. 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 theplatform to continue moving upward.2. To stop the platform from moving upward, release thetoggle switch.6.2 Lowering the Platform1. 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 theplatform to continue moving downward.2. To stop the platform from moving downward, release thetoggle switch.TOGGLE SWITCHFigure 11CONTROL STATIONTOGGLE SWITCHDOWN10 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

Liftgate Operation Instructions7. Unfolding the Platform1. Stand clear of the liftgate, and using the control station,raise the stowed platform to relieve any tension on thetravel chain (Figure 12).2. Disengage the travel latch chain hook from the platform(Figure 13).3. With the travel chain clear, lower the unit until theliftgate firmly contacts the ground.Failure to ensure stable footing whileengaging the foot pedal could resultin slipping which, if not avoided, couldresult in minor or moderate injury.4. Grasp the platform to rotate it down. As the platformstarts to rotate, step back to allow the platform to fallinto a horizontal position (Figure 14).Failure to keep feet clear of platformduring operation could create a crushand/or pinch hazard which, if not avoided,could result in death or serious injury.5. While standing clear and to the side grasp the flipover section and rotate it allowing it to fall into ahorizontal position.Figure 12CONTROL STATIONTOGGLE SWITCHFigure 13UPTRAVEL LATCHCHAIN HOOKPLATFORMFigure 14PLATFORMXL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.11

Liftgate Operation Instructions8. Platform LoadingFailure to keep load within platform edgecould create a crush hazard which, if notavoided, may result in damage to the load.Failure to keep loads stable and withindesign capacity could result in falling objectsor component failure which, if not avoided,could result in death or serious injury.When riding the platform, failure to keepfeet within front edge of platform couldcreate a crush hazard which, if not avoided,could result in death or serious injury.8.1 Loading from the Ground1. Using the control station, open the platform from thestowed position and lower it to the ground (Refer toSections 6 and 7).IMPORTANT: Never operate a fork lift truck on or overthe platform.Failure to remove fork lift trucks fromthe liftgate platform area could causecomponent failure which, if not avoided,could result in death or serious injury.2. Load the platform by placing the load center as close to thecenter of the platform as possible and placing the heaviestpart of the load to the front of the platform (Figure 15).3. Using the control station toggle switch at the rear of thevehicle, raise the platform to deck height and unload(Figure 16). If required, repeat procedures to continuewith additional loads.4. When the liftgate has been unloaded, lower and stow theplatform (Refer to Sections 6 and 9).8.2 Loading from the Vehicle1. Using the control station, open and raise the platform todeck height (Refer to Sections 6 and 7).2. Load the platform by placing the load center as close to thecenter of the platform as possible and placing the heaviestpart of the load to the front of the platform (Figure 17).Figure 15FRONT OFPLATFORMFigure 16Figure 17PLACE LOADON CENTEROF PLATFORMDECK HEIGHTIMPORTANT: Never operate a fork lift truck on or overthe platform.Failure to remove fork lift trucks fromthe liftgate platform area could causecomponent failure which, if not avoided,could result in death or serious injury.3. Using the control station toggle switch on the rear of thevehicle, lower the platform to the ground.4. When the liftgate has been unloaded, stow the platform(Refer to Section 9).FRONT OF PLATFORMPLACE LOADON CENTEROF PLATFORM12 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

Liftgate Operation Instructions9. Stowing the PlatformFigure 181. Lower the platform to below waist level, lift the end ofthe flipover section, rotating it about the pivot bolts andallow the flipover to fall onto the platform (Figure 18).Failure to keep feet clear of platformduring operation could create a crushand/or pinch hazard which, if not avoided,could result in death or serious injury.2. Lower the platform to the ground and rotate the innerplatform allowing it to rest against the platform rolleropeners (Figure 19).3. Stand clear and using the control station, raise theplatform until the platform is in fully raised position.PIVOT BOLTSFLIPOVERSECTIONNOTE: When the liftgate is fully retracted to the storedposition, release the control switch.4. Position the travel latch chain hook into the latch hookhole in the side of the platform (Figure 20).Figure 19ROLLER OPENERSFigure 20HOLE INPLATFORMTRAVELLATCHHOOKXL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.13

Filling the Hydraulic Reservoir10. Filling the Hydraulic ReservoirIMPORTANT: Keep dirt, water, and other contaminantsfrom entering the hydraulic system; cleanthe area to prevent contamination of thehydraulic fluid and use a clean funnel witha fine screen mesh.1. Set the vehicle parking brake.2. Using the control station, put the platform in the downand open position (Figure 21).3. Remove the filler cap and add recommended hydraulicfluid to pump reservoir. Check that the hydraulic fluid isat the proper fill level, half full (Figure 22).IMPORTANT: Always use the correct grade of hydraulicfluid. Refer to the chart below forrecommended hydraulic fluid or contactyour SAF-HOLLAND representative.Figure 21TLV MODEL INDOWN AND OPENPOSITIONFigure 22TEMPERATURERECOMMENDED FLUIDSRANGE MANUFACTURER TYPEAbove 0° CAW-32Any(32° F)ISO 32HYDRAUL 50-25 to 65° C(-15 to 150° F)Any Esso, ExxonMobil, ShellDTE 11DONAX TDLow Viscosity-35 to 50 ° C(-30 to 120° F)-45 to 40° C(-50 to 100° F)Exxon, Esso Shell,Petro--CanAny Esso, Exxon,ShellUNIVIS N15TELLUS T15MV ARCTIC 15MIL-H-5606UNIVIS J-13UNIVIS HV1 13FLUID #4FILLER CAP14 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

Routine Service and Inspection11. Routine Service and Inspection11.1 Daily Inspection1. Daily or before each trip, inspect the liftgate for damageto mounting assemblies, mechanical parts, and hydrauliccomponents and hoses. Any noticeable defects must berepaired prior to operation to avoid damage and possibleinjury. Inspect and verify the condition of the followingkey components:• Torsion springs – are not broken or rusted• Stowage lock mechanism – is in working order• Attaching plates – no bends and/or cracked weldsare 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 ingood working order• Shackles – are in proper orientation and properplatform presentation• Platform – no bends are present• Platform – no weld cracks are present• Flipover – no bends are present• Flipover – 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 present2. Inspect and replace any decals that have been removedor have become illegible.11.2 Monthly Inspection1. Every 1000 cycles or 30 days, whichever occurs first, lubricateall pivot points using EP2 chassis grease. In severe winterconditions, 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 oftank with cylinders retracted).4. Verify electrical connections, coat with non aerosoldielectric grease or equivalent.11.3 Yearly Inspection1. Change the oil and oil filter. When filling pump reservoir, usea funnel with a fine mesh screen . Use only recommendedhydraulic fluid (refer to Section 15).2. Lubricate linkage pivot points with light spray lubricant.3. Inspect all decals. Replace any decals that are not clearlyvisible or legible.11.4 Alternate Year Inspection1. Every 24,000 cycles or two (2) years, whichever occursfirst, inspect all pivot points for wear. Replace any pinsor parts that show signs of wear.2. Replace any worn hydraulic hoses, leaking fittings orleaking cylinders.IMPORTANT: Review General Safety Precautions beforeworking on hydraulic or electrical components.11.5 Monthly Hydraulic and Electrical Inspection1. Inspect and remove the coil from the valve and look for signs ofcorrosion. If corrosion is present, clean and repair as necessary.2. Inspect to ensure all hydraulic hoses are tight and notleaking. If hoses are showing signs of wear, replace asnecessary. After torquing the hydraulic hoses, SAF-HOLLANDrecommends putting a line across the fittings for a futurevisual reference that will indicate loose fittings.3. Inspect the filler cap for signs of damage. The foam baffleon the inside of the cap should be flat and in place. Inspectall wire connections on toggles, push buttons or any othercontrols attached to the liftgate. Clean and apply dielectricgrease to all electrical components to help reduce corrosion.4. Inspect all wiring and wiring connections to ensure theyare tight and free of corrosion. If the pump has foreigndebris, clean the entire pump and wire connections. Onceyou are satisfied that all components are clean, applynon-aerosol dielectric grease to all connections. If anywires show signs of deterioration, replace as required.5. SAF-HOLLAND recommends that you flush and replacethe hydraulic oil every year to ensure contaminates areflushed from the system. Remove the pump tank andwipe free with a lint free cloth. If present, clean reservoirmagnet of contaminants. Remove the strainer and flush.Replace the strainer. Remove any contaminates.NOTE: To reduce downtime, bring in your liftgate everytwo to three (2-3) months for quick and simpleinspections. Daily inspections while doing the circlecheck on your vehicle will spot any concernsbefore they become serious failures.XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.15

Troubleshooting12. TroubleshootingPROBLEM POSSIBLE CAUSE RESOLUTIONPlatform lowers slowly or does not lower.Unit will not lift capacity load.Oil expels from reservoir while loading.Pump will not operate.Flow control valve incorrectly installed.Electrical connections loose, disconnected or corroded.Battery does not have enough voltage to activatesolenoid properly.Restriction/blockage of hydraulic hose.Flow control valve blocked.Mechanical components seized or damaged.Incorrect or contaminated oil in system.Hydraulic system not plumbed properly.Hydraulic cylinder leaking internally.Relief valve setting too low.Hydraulic pump worn.Too much oil in reservoir.Wrong flow control fitting.Motor is not running when lowering platform.(Power down option only)Master disconnect switch is turned offBattery does not have enough voltage/current.Electrical wiring to pump is loose, disconnectedor corrodedRemote control switch broken or shorted.Solenoid switch on pump faulty.Electrical coupling to trailer not complete(Tractor/Trailer vehicles only).Check location and direction of arrow on valve.Check connections and wire condition.Verify voltage and recharge or replace battery.Ensure that cables are in good condition withsecure connections.Check hoses for external damage or pinching.Check for blockages in hoses.Clean or replace valve.Lubricate all pivot points and replace alldamaged items.Oil should be clean and for the appropriategeographical climate.Check to see that the hose connected to the ‘A’port is plumbed to the rod end of the cylinder.Replace seals or complete cylinder.Adjust relief valve setting.Change worn parts or pump.Ensure level of oil allows displacement of rods.Check that the number stamped on flow controlvalve is correct as per the appropriate schematic.Check for power at the "down" coilVerify the main power is turned on.Verify voltage and recharge or replace battery.Ensure that cables are in good condition withsecure connections.Check wiring to pump.Check wiring to switch.Check solenoid switch.Connect coupling.16 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

TroubleshootingPROBLEM POSSIBLE CAUSE RESOLUTIONPlatform will not raise.Platform will not raise smoothly.Platform creeps down when stationary.Platform raises slowly.Battery does not have enough voltage/current.Insufficient oil in reservoir.Defective actuating coil on valve.Liftgate is overloaded.Hose or fitting leak.Leaking check valve or relief valve.Worn piston seals.Worn or scored piston.Pivot points seized.Pump is worn out.Broken pump shaft or coupler.Insufficient oil in reservoir.Air lock in hydraulic system.Undue mechanical wear or lack of lubrication.Cylinder seal leak.Worn or dirty check valve.Hose or fitting leakBattery does not have enough voltage/current.Liftgate is overloaded.Faulty cable connections: Electrical connectionscorroded or disconnected.Pump motor not grounded adequately.Hose leaking.Cylinder internal leak.Lack of lubrication or undue mechanical wear.Incorrect relief valve setting.Worn pump.Verify voltage and recharge or replace battery.Ensure that cables are in good condition withsecure connections.With platform on ground, fill tank within 2" (50 mm)of top with Dextron III Automatic Transmission Fluid.Replace actuating coil.Reduce the load on the platform.Check and re-torque fittings.Clean, adjust or replace valve.Replace seals.Replace cylinders.Lubricate.Replace pump.Replace shaft or coupling as necessary.Fill reservoir.Operate ‘Raise Control’ for a few seconds attop of stroke. Repeat two (2) times, pausingbetween operations.Lubricate pivots, replace worn parts.Replace seals or cylinder if scored.Clean or replace valve.Replace hose or tighten fittingVerify voltage and recharge or replace battery.Ensure that cables are in good condition withsecure connections.Reduce load on platform.Check connections.Check grounding to truck frame.Tighten or replace hoses.Replace seals or replace cylinder.Lubricate all pivot points and replace worn parts.Check relief valve setting.Replace pump.XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.17

Pump Hydraulic and Electrical Diagram13. Pump Hydraulic and Electrical DiagramsPower Down OptionFigure 23A PORT (C1) (UP)(TOP VIEW)B PORT (C2) (DOWN)(SIDE VIEW)WHITE WIRE FROM TOGGLE (4W2P) (UP)POWER FROM BATTERYBLACK WIREFROM CONTROL(2W2P) (DOWN)POWER FROMCONTROL (GREEN)(END VIEW)18 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

Pump Hydraulic and Electrical DiagramGravity Down OptionFigure 24OUTLET PORT(TOP VIEW)(SIDE VIEW)WHITE WIRE FROMTOGGLE (UP)BLACK WIRE FROMCONTROL (DOWN)(END VIEW)POWER FROM CONTROL(GREEN)POWER FROM BATTERYXL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.19

Pump Hydraulic Schematic14. Pump Hydraulic and Electrical SchematicPower Down OptionFigure 25 (Hydraulic Schematic)B (DOWN)A (UP)BLACK WIRE(2W2P)34 BAR500 PSIWHITE WIRE(4W2P)193 BAR2800 PSI1.98 CC/REV0.121 IN3/REVFigure 26 (Electrical Schematic)2W2PVALVECOIL FLOWPORT BMOTOR STARTSOLENOIDBLACK (DOWN)FLOW PORT BGREEN (POWER)WHITE (UP)FLOW PORT A+ 12V DC BATTERY(+VE)4W2P VALVE COIL FLOW PORT A20 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

Pump Hydraulic SchematicGravity Down OptionFigure 27 (Hydraulic Schematic)OUTLET PORT3/8-19 BSPP REF172 BAR2500 PSI7.57 LPM2.0 GPM2.31 CC/REV0.137 TN3/REVFigure 28 (Electrical Schematic)2W2PVALVECOILBLACK (DOWN)MOTOR STARTSOLENOIDGREEN (POWER)WHITE (UP)+ 12V DC BATTERY(+VE)XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.21

Liftgate Assembly - Exploded View15. Liftgate Components23252628242221(30 1/2") (30") (29 1/2") (28 3/4")142078 9101627192931181713301265412322 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

Liftgate Assembly - Parts ListsDETAILDESCRIPTIONTLV 2748WGRAVITY DOWNTLV 2748WPOWER DOWN1 Outer Platform Assembly XB-59906-28 XB-59906-28 12 Pin XB-59906-49 XB-59906-49 43 Connector XB-59906-48 XB-59906-48 44 Inner Platform Assembly XB-59906-29 XB-59906-29 15 Shackle, Curbside XB-59906-34 XB-59906-34 26 Spring, Curbside XB-59906-46 XB-59906-46 17 Spring, Roadside XB-59906-47 XB-59906-47 18 Lock Plate, Pin XB-59906-45 XB-59906-45 29 Lock Plate, Pin XB-59906-44 XB-59906-44 210 Adjunct-Arm XB-59906-33 XB-59906-33 211 Spacer XB-59906-38 XB-59906-38 212 Spacer XB-59906-39 XB-59906-39 213 Hose, Gravity Down XB-59906-54 N/A 114 Lock Plate, Pin XB-59906-43 XB-59906-43 215 Lift Frame XB-59906-32 XB-59906-32 116 Cylinder XB-59906-50 2046100000180 117 Pin XB-59906-31 XB-59906-31 218 Right Angle Return Air Joint XB-59906-30 XB-59906-30 119 Bracket, Cylinder & Lift Arm XB-59906-35 XB-59906-35 120 Spacer XB-59906-37 XB-59906-37 221 Lock Plate, Pin XB-59906-41 XB-59906-41 222 Lock Plate, Pin XB-59906-42 XB-59906-42 223 Mounting Plate XB-59906-51 XB-59906-51 124 Insert, Roller Opener 2112360004130 2112360004130 125 Install Strap, Long XB-59906-52 XB-59906-52 126 Install Strap, Short XB-59906-53 XB-59906-53 127 Lock Chain Assembly XB-59906-40 XB-59906-40 128 Extension Plate 2112200003560 2112200003560 129 Pump Box 2112360003570 AK-62864-01 130A 2" Step Bumper XA-50044 XA-50044 230B 3" Step Bumper XA-50045 XA-50045 231 Shackle, Roadside XA-55906-55 XA-55906-55 1QTYXL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.23

Hydraulics Part List16. Hydraulic ComponentsGravity Down Option6534217DETAIL DESCRIPTION PART NO. QTY1 90° Fitting, Air Hose XB-59906-30 12 Air Hose, Gravity Down XB-59906-54 13 Fitting, 90° Elbow, -6 Orb / 1/4" Fnpt XB-57030 14 Flow Control Valve, 2.0 Gpm XB-50032 15 Adapter 1/4" Male Pipe/-4 Male Jic XB-51529 16 Hose Asssembly, 60" Lg XA-51610-60 17 Control Station XA-58359-01 124 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

Hydraulics Parts ListPower Down Option16345 27DETAIL DESCRIPTION PART NO. QTY1 Fitting, 90° Elbow, -6 Orb / -4 Jic XB-51918 12 Hose Assembly, 60" Lg XB-59906-60 13 Fitting, 90° Elbow, -6 Orb / 1/4" Fnpt XB-57030 14 Flow Control Valve, 2.0 Gpm XB-50032 15 Adapter 1/4"Male Pipe/-4 Male Jic XB-51529 16 Hose Assembly, 72" Lg XA-51610-07200 17 Control Station XA-58359-01 1XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.25

Notes26 XL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.

NotesXL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.27

From fifth wheel rebuild kits to suspension bushing repair kits,SAF-HOLLAND Original Parts are the same quality components usedin the original component assembly.SAF-HOLLAND Original Parts are tested and designed to providemaximum performance and durability. Will-fits, look-alikes or, worseyet, counterfeit parts will only limit the performance potential andcould possibly void SAF-HOLLAND’s warranty. Always be sure to specSAF-HOLLAND Original Parts when servicing yourSAF-HOLLAND product.SAF-HOLLAND USA · 888.396.6501 · Fax 800.356.3929www.safholland.usSAF-HOLLAND CANADA · 519.537.3494 · Fax 800.565.7753WESTERN CANADA · 604.574.7491 · Fax 604.574.0244www.safholland.caSAF-HOLLAND MEXICO · 52.55.5362.8743 · Fax 52.55.5362.8743www.safholland.com.mxinfo@safholland.comXL-TG10156UD-en-US Rev A · 2013-04-18 · Amendments and errors reserved. © SAF-HOLLAND, Inc.SAF-HOLLAND USA, INC.1950 Industrial Blvd., Muskegon, MI 49442www.safholland.com