Anthony Liftgates TuckUnder AST-3000 User manual

MADE IN THE USA
For Serial Number XXXXXX and Greater
MODELS
AST-1500
AST-2000
AST-2500
AST-3000
AST-3500
AST-L-1800
AST-L-2500
AST-PLUS-2500
AST-PLUS-3000
AST •AST-L •
AST-PLUS
MAINTENANCE MANUAL
Quality, Reliability, Customer Service

AST, AST-L, and AST-PLUS Models 3 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
Contents
1. General Information .........................4
1.1 Introduction ...........................4
1.2 General Safety.........................4
1.3 State and Federal Regulations ............4
1.3.1 Brakes..........................4
1.3.2 Lighting .........................4
1.3.3 Rear Impact Guards ...............4
1.4 If Maintenance Help is Required ...........4
1.5 Registration ...........................5
1.6 Warranty .............................5
1.7 Replacement Parts and Hazard Decals......5
2. Safety....................................5
2.1 Safety is Your Responsibility ..............5
2.2.1 Personal Protection/Important
Information ......................6
2.2.2 Prohibited Actions . . . . . . . . . . . . . . . . . 6
2.2.3 Hazard Avoidance .................6
2.2 Safety Icons Nomenclature ...............6
2.3 Safety Rules...........................6
2.3.1 Personal Protection................6
2.3.2 Equipment / Tools / Parts ...........7
2.3.3 Battery / Fuel Tank Safety ...........7
2.3.4 Cutting Torch / Welding Safety .......7
2.4 Welding or Grinding Galvanized or
Stainless Steel Material ..................8
2.4.1 Galvanized Metal..................8
2.4.2 Stainless Steel....................8
3. Nomenclature..............................8
4. Maintenance .............................10
4.1 Monthly Inspection.....................10
4.2 Semi-Annual Inspection .................10
4.3 Adjusting Wheel Arm ...................10
4.4 Platform Adjustment....................11
4.5 Replacing the Fuse ....................11
4.6 Checking Motor Start Solenoid and Power
 &XWRႇ6ROHQRLG .......................12
4.7 Checking the Power Cable ..............12
4.8 Checking Lowering Valve Cartridge and
Solenoid .............................12
4.9 Solenoid Valve Screen..................13
4.10 Replacing Solenoid Valve ...............13
4.11 Checking Cylinder Piston Seals
(drifting - caused by seal leakage).........13
4.12 Checking System Pressure ..............13
4.13 Checking Flow Control Valve .............14
4.14 Checking Control Switch Fuse............14
4.15 Power Module Fluid ....................14
4.16 Reattach Control Unit Wires To Appropriate
Terminals ............................15
5. Decals ..................................16
5.1 Installing Decals.......................16
6. Welding Stainless Steel to Galvanized .........20
6.1 Safety...............................20
6.1.1 Welding or Grinding Galvanized
Material ........................20
6.1.2 Welding or Grinding Stainless Steel . . 20
6.2 General Guidelines ....................20
6.2.1 Weld Wire ......................20
6.2.2 Shielding Gas ...................20
6.2.3 Welding Guidelines ...............20
7. Troubleshooting Chart ......................21

Anthony Lifgtates, Inc. 4 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
1. General Information
1.1 Introduction
Congratulations on selecting an Anthony Liftgates
TuckUnder™ liftgate.
All Anthony tuckunder model liftgates are factory
assembled, energized, and tested to ensure the highest
quality performance standards. AST, AST-L, and
AST-PLUS liftgates ship completely assembled for fast,
clean, and easy installation.
To ensure your liftgate will perform to your expectations,
we have provided this Installation Manual, which is
designed to provide you with the necessary installation
instructions and safety precautions for the installation of
the AST, AST-L, or AST-PLUS TuckUnder™ liftgates.
ALI-00355a
Typical Anthony Liftgates Tuckunder Model.
Note: This manual covers all AST model liftgates with a
serial number of XXXXXXX and greater.
1.2 General Safety
WARNING Read, Follow and
Understand the Manual
The success or failure of
this liftgate to properly and efficiently operate will
depend on a thorough and proper maintenance.
Failure to read, understand, and follow the instructions
and safety recommendations in this manual can result
in serious injury or death to the operator or bystander.
Also, read and understand the operating instructions
in the separate Operation Manual before beginning
the installation.
1.3 State and Federal Regulations
1.3.1 Brakes
WARNING When installed, the operation or
weight of this liftgate must not
alter or prevent vehicle
compliance to any existing State or Federal standards,
such as FMVSS 105 – Hydraulic And Electric Brake
Systems. Each truck frame manufacturer’s
recommendations should be consulted for compliance.
Also, make sure the weight of the liftgate and its
fully loaded capacity will not overbalance the truck,
possibly raising the front wheels off the ground.
1.3.2 Lighting
WARNING When installed, the transport
position of this liftgate must not
alter or prevent vehicle
compliance to any existing State or Federal standards
such as FMVS 108 – Lamps, Reflective Devices, and
Associated Equipment. Each truck manufacturer’s
recommendations should be consulted for compliance.
1.3.3 Rear Impact Guards
WARNING When installed, the transport
position of this liftgate must
provide protection against rear
impact, using State or Federal standards such as
FMVSS 223 – Rear Impact Guards and FMVSS 224 –
Rear Impact Protection.
It is the duty of the installer to make sure these guards
are installed to complete the installation process.
Anthony Liftgates offers a bolt-on bumper, which will
meet the requirements of this standard. Each truck
manufacturer’s recommendations should also be
consulted for compliance.
1.4 If Maintenance Help is Required
For additional information, in the form of a quick reference
guide or installation video, refer to the AST TuckUnder™
liftgate website www.anthonyliftgates.com.7R¿QGWKH
most current version of the reference material, choose
LIFTGATES, TUCKUNDER™, AST or AST-L or AST-
PLUS, and then DOWNLOADS.
If you have any doubts or questions about maintenance,
call your authorized dealer. Before doing so, have the
serial number, model number, and lift capacity of your
liftgate available.
For service or ordering replacement parts, contact an
authorized dealer by going to www.anthonyliftgates.com
and selecting the FIND A DEALER tab. Enter your zip
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Anthony Liftgates, Inc.
1037 West Howard Street
Pontiac, Illinois 61764
[phone] or 800-482-0003

AST, AST-L, and AST-PLUS Models 5 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
1.5 Registration
Refer to the Operation Manual for the serial number
information.
1.6 Warranty
For a detailed copy of the Warranty Statement, refer to
either the Operation Manual.
NOTICE The liftgate must be maintained
according to these instructions or
the warranty will be void.
1. Unauthorized modifications may cause improper
operation or other unforeseen problems or dangers.
If any deviation is deemed necessary, written
permission must be obtained from Anthony Liftgates.
2. All decals must be attached and legible, or all
warranties are void.
1.7 Replacement Parts and Hazard Decals
For service or ordering replacement parts, contact an
authorized dealer by going to www.anthonyliftgates.com
and selecting the FIND A DEALER tab. Enter your zip
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SAFETY
INSTRUCTIONS
N
I
NG
AR To prevent the personal
injury of the end user from
not being aware of safety
recommendations, the installer must make sure all
decals are attached to the liftgate and truck and are
legible.
2. Safety
2.1 Safety is Your Responsibility
It is the responsibility of the maintenance personell to
understand proper operating procedures. Be aware of the
inherent dangers in the use of this product and the tools
used to maintain it. Read and understand all Warnings,
Cautions, Notices, Safety Instructions, and Notes in this
manual, on the liftgate, or on the truck.
Accidents can often be avoided by being alert and
recognizing potentially hazardous situations. The safety
information in this manual serves as a basic guide in an
attempt to prevent injury or death.
Anthony Liftgates cannot anticipate every possible
circumstance that might involve a potential hazard. The
warnings in this manual and on the product itself are,
therefore, not all-inclusive. If tools, procedures, work
methods, or operating techniques are used that are not
VSHFL¿FDOO\PHQWLRQHGE\$QWKRQ\/LIWJDWHV\RXPXVW
satisfy yourself that they are safe for you and for others.
DO NOT proceed with any maintenance procedure
if doubt arises about the correct or safe method of
performing any procedure found in this manual. If you
have any doubts or questions about installation, call your
authorized dealer.
Safety Signal Words
3HUVRQDOLQMXU\KD]DUGVDUHLGHQWL¿HGE\WKH
“Safety Alert Symbol” and followed by a signal
word such as WARNING or CAUTION to indicate
the severity of the hazard.
This safety alert icon surrounds an image showing
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These icons are shown in “2.2.3 Hazard
Avoidance” on page 6.
WARNING
Indicates a potentially hazardous
situation which, if not avoided,
COULD result in death or serious
injury.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided,
MAY result in minor or moderate
injury.
NOTICE Indicates that equipment or property
damage can result if instructions
are not followed.
SAFETY
INSTRUCTIONS Indicates specific safety-related
instructions or procedures.
Note: Contains additional information important to a
procedure.

Anthony Lifgtates, Inc. 6 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
2.2 Safety Icons Nomenclature
This manual and the equipment have numerous safety
icons. These safety icons provide important operating
instructions, which alert you to potential personal injury
hazards.
2.2.1 Personal Protection/
Important Information
Read the manual
Eye protection
Face shield / welding
helmet
Breathing protection
Head protection
Protective shoes
Hand protection
Use two people when lifting
heavy objects
Use proper tools
Weight rating
Set parking brake
Remove key
Lockout / prevent use
OEM OEM parts
N
I
NG
AR
Damaged safety sign
2.2.2 Prohibited Actions
Do not alter or modify
Do not weld
No smoking
No open flame
No alcohol
No drugs
2.2.3 Hazard Avoidance
Safety alert symbol
Slipping injury
Tripping injury
Pinch point hazard
Pinch hazard (foot)
Dangerous fumes
Adequate ventilation
Crush hazard
Crush hazard
Crush hazard (chock
wheels)
Chock wheels /rollover
hazard
Fall hazard (truck)
Fall hazard (platform)
Damaged parts hazard
Fire hazard
Sparks / fire hazard
Battery gas hazard
2.3 Safety Rules
2.3.1 Personal Protection
WARNING Do not work under the
liftgate while it is in a
raised position.
Unintentional lowering of the liftgate can cause
serious crushing injuries.
CAUTION
When servicing this unit, wear appropriate personal
protective equipment. This list may include, but is not
limited to:
• A hard hat.
• Protective shoes with slip resistant soles.
• Protective goggles, glasses, or face shield.
• Protective clothing.

AST, AST-L, and AST-PLUS Models 7 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
CAUTION Anthony Liftgates
recommends not
riding the liftgate;
however, if the operation requires it, make sure your
footing is stable before raising or lowering the
platform. Always stand away from the edge. When on
the ground, always stand clear of the liftgate when it
is operating.
Do not attempt to maintain the liftgate
under the influence of drugs or alcohol.
Consult your doctor before using the
liftgate while taking prescription medications.
To prevent personal injury, clean up any
spilled fluids immediately. To avoid
tripping, do not leave tools or
components laying around in the work area.
Failure to prevent the truck from moving
during the maintenance of the liftgate
could result in a serious crushing injury.
Always use/set the truck’s parking brake
and remove the ignition key before
servicing the liftgate. Failure to follow
this recommendation can result in injury.
Do not place hands or feet in pinch points.
Do not place your feet under the liftgate or
between the platform and floor extension.
CAUTION To prevent injury, the
liftgate and its related
components should only
be maintained by a qualified installer having knowledge
and skill in using a lifting device, a cutting torch, and
welding equipment.
N
I
NG
AR To prevent possible injuries due to improper
operation, make sure all decals are attached to
the liftgate and/or truck and are legible at all
times.
2.3.2 Equipment / Tools / Parts
CAUTION Do not operate this unit if
it is damaged. If you
believe the unit has a
defect, which could cause it to work improperly,
you should immediately stop and remedy the
problem before continuing.
Make sure the liftgate or truck will not be
damaged or made unsafe by the maintenance
or use of the liftgate.
Never secure the power cable to anything
which allows it to contact sharp edges, other
wiring, fuel tank, fuel lines, brake lines, air
lines, exhaust system, or any other object that could
cause the power cable to wear or be damaged. A cut
battery cable can cause sparks and/or component
damage resulting in loss of vehicle control, serious
injury, or even death.
CAUTION OEM
If replacement parts are
necessary, genuine
factory OEM replacement
parts must be used to restore the liftgate to the
original specifications. Anthony Liftgates will not
accept responsibility for damages as a result of using
unapproved parts. If non-OEM replacement parts are
used, the warranty will be voided.
2.3.3 Battery / Fuel Tank Safety
WARNING To prevent
serious
bodily injury,
keep sparks, lighted matches, and open flames away
from the top of the battery, because battery gas can
explode. Always follow all the manufacturers’ safety
recommendations when working around the truck’s
battery.
Take precautions to avoid sparks coming into
contact with the truck’s fuel tank, brake lines,
or other flammable components. Sparks can
cause an explosion of combustible materials, resulting
in serious injury or death.
2.3.4 Cutting Torch / Welding Safety
WARNING Take precautions to avoid
sparks from contacting
the truck’s fuel tank, brake
lines, or other flammable components. Sparks can
ignite combustible materials, resulting in serious
injury or death.
Always weld or use a cutting
torch in a well ventilated area and,
if in an enclosed area, vent the
fumes to the outside. Breathing welding smoke and
paint fumes can cause serious injury.
Always follow all State and Federal health and
safety laws and/or local regulations when using
an arc welder, mig welder, or cutting torch. Also,
follow all manufacturers’ safety guidelines. If other
people are present during the installation of the liftgate,
make sure the assembly area is shielded from their view.
To avoid eye injury during welding, always
wear a welding helmet with the proper lens to
protect your eyes.
To avoid eye injury while using a cutting torch,
always use eye protection with the proper lens
to protect your eyes.
SAFETY
INSTRUCTIONS
Do not modify safety
devices. Do not
weld on the liftgate
assembly, except the adapter frame tube. Unauthorized
modifications may impair its function and safety.
Make sure all parts are in good working
condition and properly installed. Replace any
damaged parts immediately.

Anthony Lifgtates, Inc. 8 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
2.4 Welding or Grinding Galvanized or
Stainless Steel Material
2.4.1 Galvanized Metal
CAUTION
Follow all OSHA and other workplace safety standards
when welding galvanized steel, which creates zinc
oxide fumes. Always grind the coating off in the area
to be welded and provide adequate ventilation to
avoid breathing the fumes.
Always wear the proper breathing protection when
grinding or welding. Use ventilation or vacuum
systems to remove any contaminated air from the
work area.
Metal Fume Fever:
When zinc vapor mixes with the oxygen in the air,
it reacts instantly to become zinc oxide, which is
non-toxic and non-carcinogenic.
Zinc oxide that is inhaled is absorbed and
eliminated by the body without complications or
chronic effects.
Exposure to zinc oxide fumes causes a flu-like
illness called metal fume fever.
Symptoms include headache, fever, chills,
muscle aches, nausea, vomiting, weakness, and
tiredness.
There are no long-term health effects. Metal fume
fever typically begins about four hours after
exposure, and full recovery occurs within 48
hours.
2.4.2 Stainless Steel
Follow all OSHA and other workplace safety standards
when welding stainless steel, which creates hexavalent
chromium fumes that can irritate the nose, throat, and
lungs.
Repeated or prolonged exposure can damage the
mucous membranes of the nasal passages and
result in ulcers. In severe cases, exposure causes
perforation of the septum (the wall separating the
nasal passages).
Always wear the proper breathing protection when
grinding or welding. Use ventilation or vacuum
systems to remove any contaminated air from the
work area.
3. Nomenclature
3.1 Platform Nomenclature
ALI-00357a
Gusset
Floor Extension Assembly
Pump Box
Platform Installation Brackets
Gusset
Notched
Mounting
Plate
Notched
Mounting
Plate
Tubular Bumper
Attachment Brackets
Tubular Bumper
Attachment
Unotched
Mounting
Plates
Rubber
Dock Bumper
Pad
Streetside
Dock Bumper
Corner Cap
Rubber
Dock Bumper
Pad
Curbside
Dock Bumper
Corner Cap
Informational
Packet
Main Platform Section
Flip-over Platform Section
Lift Frame
Radius Arm
Wheel
Arm
Adapter Frame
Tube
Bolt-on Floor
Extension
Hardware
(Bolt-On Applications Only)
Transport
Latch Pin

AST, AST-L, and AST-PLUS Models 9 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
3.2 Gravity-Down Power Unit Nomenclature
ALI-00358
Breather
Tube
Hydraulic
Cylinder
Power Up
High-Pressure
Hose
Power Cord w/
200 Amp Fuse
Flow Control
Valve
Control
Switch
Control
Box Wiring
Electric
Motor
Pump
Adjustable Relief
Valve
Motor Start
Solenoid
Power Up
(Raising Valve)
Cartridge
and Solenoid
Fill Port and
Breather
Cap
Reservoir
10 Amp In-Line Fuse
(BLACK wire)
(WHITE wire)
(GREEN wire)
3.3 Power-Down Power Unit Nomenclature
ALI-00370
Hydraulic
Cylinder
Control
Switch
Electric
Motor
Power UP
Valve
Power DOWN
Valve
Fill Port and
Breather
Cap
Reservoir
Power Up
High-Pressure
Hose
Flow Control
Valve
Power Down
High-Pressure
Hose
Motor Start
Solenoid
Pump
Adjustable
Relief
Valves
Control
Box Wiring
10 Amp In-Line Fuse
(BLACK wire)
Power Cord w/
200 Amp Fuse
(WHITE wire)
(RED wire)
(GREEN wire)

Anthony Lifgtates, Inc. 10 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
4. Maintenance
4.1 Monthly Inspection
All Anthony Tuckunder Liftgates are “Service-Free” which
means they have lubrication-free bushings at the major
pivot points.
1. Make sure the liftgate operates freely and smoothly
throughout its entire range of movement.
2. Check for damage to the liftgate, such as bent or
distorted parts. Check for excessively worn parts.
3. Check for cracked welds which may have resulted
from overload or abuse.
4. Check all pins and pivot points. Make sure they
are secured with proper retainers. Replace worn
bushings and/or pins.
5. Make sure platform is angled upward from truck
bed 1/2 to 3/4 inch when raised to bed height. See
Platform Adjustment for shimming procedure, “4.4
Platform Adjustment” on page 11.
6. Make sure all electrical wires, switches, and
connections are in good working condition and
operate properly.
7. Check for oil leaks in the following areas:
a. Hydraulic lift cylinder.
b. Hydraulic hoses. Replace any hose that shows
signs of leakage or excessive abrasion of the
covering.
c. Check all hydraulic fittings for damage or leakage.
Tighten fittings to stop leaks or replace if damaged.
8. Check reservoir oil level and fill as required with
Dexron VI, Dexron III or Hyken Glacial Blue.
a. Gravity down models - With the platform on the
ground, the oil level should be within 1/2 inch of
the top of the reservoir.
b. Power down models - With the platform in the fully
raised position, the oil level should be within
1/2 inch of the top of the reservoir.
NOTICE Use only Dexron VI, Dexron III, or
Hyken Glacial Blue hydraulic fluid in
the power unit reservoir. For cold
weather operation, we recommend Hyken Glacial Blue.
If an emergency situation occurs, any anti-wear hydraulic
fluid can be used, but the system should be flushed and
the fluid changed as soon as reasonably possible.
Hydraulic fluids should not be mixed due to possible
compatibility problems.
The recommended fluids are compatible and may be
mixed,however,thecold weather operating characteristics
of Hyken Glacial Blue will be adversely affected.
DO NOT thin hydraulic fluid with brake fluid, and DO NOT
use brake fluid in place of hydraulic fluid.
9. Check the fluid level of the vehicle battery. Fill as
required.
10. Examine all warning, capacity, and operational
decals. If they are not readable, they should be
replaced. Decals may be obtained free of charge
from Anthony Liftgates, Inc.
11. Oil the roller of the wheel arm and make sure it spins
freely.
4.2 Semi-Annual Inspection
In addition to the items requiring monthly inspection, also
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If the oil in the hydraulic tank is dirty, drain the oil and
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recommended oil outlined in Step 8 of the “Monthly
Inspection” section.
4.3 Adjusting Wheel Arm
The wheel arm helps unfold the platform as it is lowered
from the stored position. The wheel arm can be adjusted
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WARNING Never stand behind the
liftgate when it is opened.
Always stand to the side
and away from the edge of the platform.
When adjusting the position of the wheel arm, consider
that the vehicle may be parked on a upward sloped
surface. Adjust the wheel arm to prevent the platform
from completely unfolding in this type of situation.
1. If adjustment is needed, remove the two bolts and
nuts on the wheel arm.
2. Lengthen or shorten the wheel and channel assembly
on the tube, as desired.
3. Align the two holes in the wheel and channel
assembly with the holes in the tube nearest the
desired position.

AST, AST-L, and AST-PLUS Models 11 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
4. Re-install the two bolts and nuts. Tighten the nuts to
secure the wheel and channel assembly.
4.4 Platform Adjustment
The ramp (outboard) end of the platform should be 1/2 to
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position. If the outboard end of the platform is sagging,
add shims as described below. Shimming is a normal
procedure as the liftgate ages and the parts become
worn.
1/2" to 3/4"
1. When the platform is lowered to the ground, it should
touch at the lift arm end and at the ramp end (arrows).
2. To lower the ramp end:
a. Temporarily position a shim plate in the contact
area (arrows), between the cam plates and
platform, with tape.
ALI-00413
Note: One shim can move the ramp end of the platform
as much as 1/2 inch.
b. Raise and lower the platform to recheck its
position.
c. Weld the steel shim plates to the blocks on the
platform.
3. To raise the ramp end, remove material from the
contact area (arrows shown in Step 2) between the
cam plates and platform.
4. If the platform does not align with the floor extension,
contact Anthony Liftgates for a solution to correct the
problem.
4.5 Replacing the Fuse
WARNING An electric arc can cause
personal injury or property
damage. To avoid personal
injury, disconnect the power cable from the vehicle
battery or batteries before replacing the fuse, or
before disassembling the fuse holder.
1. Slide the rubber boots away from the fuse holder.
2. Unscrew the fuse holder ends from the fuse holder
body and pull it apart.
3. Slide the fuse holder body one direction (left or right)
to expose the damaged fuse.
4. Loosen the screws from each end of the fuse,
remove, and replace the fuse. Retighten the screws.
5. Re-assemble the fuse holder in reverse order. Be
sure the rubber boots are sealed around the fuse
holder and power cable.
6. Re-connect the power after you are certain the liftgate
area is clear.

Anthony Lifgtates, Inc. 12 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
4.6 Checking Motor Start Solenoid and Power
Cut-off Solenoid
Motor start solenoid.
Power cut-off solenoid.
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can be checked by bypassing the solenoid itself.
1. Use jumper cables for this test.
2. Connect one jumper cable to battery side (1) of the
solenoid. Connect the other cable to motor side (2) of
the solenoid.
3. If the liftgate is activated, the solenoid is defective and
should be replaced.
4.7 Checking the Power Cable
To check for a defective power cable, run the motor
directly from a spare battery using jumper cables.
1. Remove the battery connection to the motor.
2. Connect the negative jumper cable (ground) directly
to the liftgate. Connect the positive cable to the
terminal on the motor start solenoid.
3. If the motor operates, the battery cable is defective
and should be replaced.
4.8 Checking Lowering Valve Cartridge and
Solenoid
1. Place the liftgate on the ground in the open position.
2. Place a steel screwdriver over the top of the lowering
valve solenoid.
3. Momentarily activate the control switch in the DOWN
position. The screwdriver should be attracted to the
magnetic field created by the solenoid.
4. If no magnetic pull is produced, the solenoid is
defective and should be replaced. If the solenoid is
activated, check the cartridge valve.
5. Remove the solenoid from the valve assembly.
6. Remove the valve cartridge from the pump body.
7. Clean the cartridge and blow it dry with compressed
air (not greater than 30 psi). Also, blow out the pump
body.
8. Use a small screwdriver and carefully press on the
spool inside the cartridge. If the spool moves freely,
the cartridge is good. If it does not move, replace
the cartridge, as the spool could be bent, pitted, or
damaged in some other way.

AST, AST-L, and AST-PLUS Models 13 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
4.9 Solenoid Valve Screen
If the solenoid is working electrically, check the debris
screen and clean if dirty.
4.10 Replacing Solenoid Valve
1. While installed in the pump, remove nut (1).
2. Remove coil (2) from cartridge (3).
3. Remove cartridge (3) from pump body.
4. O-ring (4) is not required on current models and can
be discarded.
4.11 Checking Cylinder Piston Seals
(drifting - caused by seal leakage)
Gravity Down Models
1. Remove the breather hose (gravity down models
only).
2. Completely raise the liftgate and hold the switch in the
“UP” position while checking for oil flowing out of the
cylinder’s breather port.
3. If a continuous flow of oil comes out of this port
(while the liftgate is all the way up and the switch is
held “UP”), then the piston seals are leaking and the
cylinder should be replaced.
Power Down Models
1. Check the lowering valve. Make sure it is operating
correctly and the valve is not sticking or dirty. Refer
to “4.8 Checking Lowering Valve Cartridge and
Solenoid” on page 12.
2. If the lowering valve is operating properly, then the
drifting is most likely caused by worn piston seals.
Replace the cylinder.
4.12 Checking System Pressure
For gravity down systems there is only one relief valve
(power up). Power down models have two relief valve
settings; one for raising the platform (power up) and one
for lowering the platform (power down).
To check the “power up” pressure setting:
1. Place the liftgate on the ground and remove the
pressure hose from the power up port of the pump.
2. Install a T-fitting (customer supplied) into the power
up port.
3. Connect a pressure gauge and reconnect the
hydraulic hose.
The pressure gauge must be rated above the maximum
pressure of the liftgate. For example, use a 4000 psi
pressure gauge on a 3000 psi maximum capacity liftgate.
4. Raise the liftgate and check the pressure on the
gauge.
Low Pressure Threshold Chart
Model Power Up Power Down
1500, 1800, or 2000 2800 psi
350 psi2500 1850 psi
3000 or 3500 2400 psi

Anthony Lifgtates, Inc. 14 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
WARNING Do not stand or work in
the platform’s work area
while operating the
liftgate. Place the pressure gauge so it can be read
while operating the liftgate from a safe location.
Serious injury or death could result if this action is not
followed.
5. Check the power down relief valve pressure in the
same way as the gravity down system by installing a
T-fitting and pressure gauge.
4.13 Checking Flow Control Valve
If the cylinder does not operate or operates slower than
QRUPDOUHPRYHWKHÀRZFRQWUROYDOYHDQGKRRNWKH
hydraulic hose directly to the cylinder. If the cylinder
RSHUDWHVSURSHUO\UHSODFHWKHÀRZFRQWUROYDOYH
WARNING Do not operate the liftgate
without the flow control
valve. Serious injury or
death could result if this action is not followed.
4.14 Checking Control Switch Fuse
If the control switch is not operating the liftgate, check the
in-line fuse located on the control cable inside the power
unit box.
4.15 Power Module Fluid
Gravity down models - With the platform on the ground,
the oil level should be within 1/2 inch of the top of the
reservoir.
Power down models - With the platform fully raised,
the oil level should be within 1/2 inch of the top of the
reservoir.
ALI-00023
1/2"

AST, AST-L, and AST-PLUS Models 15 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
NOTICE Use only Dexron VI, Dexron III, or
Hyken Glacial Blue hydraulic fluid in
the power unit reservoir. For cold
weather operation, we recommend Hyken Glacial Blue.
If an emergency situation occurs, any anti-wear hydraulic
fluid can be used, but the system should be flushed and
the fluid changed as soon as reasonably possible.
Hydraulic fluids should not be mixed due to possible
compatibility problems.
The recommended fluids are compatible and may be
mixed,however,thecold weather operating characteristics
of Hyken Glacial Blue will be adversely affected.
DO NOT thin hydraulic fluid with brake fluid, and DO NOT
use brake fluid in place of hydraulic fluid.
4.16 Reattach Control Unit Wires To Appropriate
Terminals
Gravity Down.
Power Down.

Anthony Lifgtates, Inc. 16 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
5. Decals
5.1 Installing Decals
SAFETY
INSTRUCTIONS
N
I
NG
AR To prevent possible
injuries due to improper
operation, make sure all
decals are attached to the liftgate and truck and are
legible.
1. Attach decals 4, 6, 8, 9, and 10 to the truck body, as
shown.
ALI-00363
Operationmayrequireusertostandonplatform.
Topreventinjuryordeathofoperatorsorbystanders:
•
Readandfollowoperator/ownermanualforsafety,
operation,inspection,andmaintenanceinstructions.
•
Donotplaceunstableorunsafeloadsonplatform.
•
Donotallowloadstoextendoveredgeofplatform.
•
Donotallowbodypartstocontactmovingcomponents.
•
Ensurefootingisstableandstandawayfromedge
beforeraisingorloweringplatform.
•
Owner/operatorsmustproperlymaintainliftgate.
•
Donotexceedcapacityoruseliftgateforanything
otherthanintendedpurpose.
•
Beawareofsurroundingswhenoperatingliftgate.
WARNING
A-131115
PERSONALINJURYHAZARD
A-13101203/2008
1200 lb.
6
8
10
4
9
2. Make sure factory-installed decals 1, 3, and 7 are
attached to the lift arms and platform.
ALI-00364a
A-150601
A-13101703/2008
1
3
7
3. Make sure the factory-installed fuse changing decal is
on the power cable and is visible near the location of
the fuse.
ALI-00393
11
4. Make sure factory-installed decals 2, 3, 12, and 13
are installed on the power unit and the adapter frame
tube.
ALI-00365a
10AMPFUSE&HOLDER
Protectsagainstdeadshorts
inthis"controlcircuit".
Ifblown,pull"fuseholder
cap",replacefuse,replace
"cap".Iffusecontinuesto
blow,contactaqualified
mechanic,"controlcircuit"
maybedamaged.
FUSIBLEDE10AMPERIOSY
SOPORTE-Protegecontra
cortocircuitosfrancoseneste“circuito
decontrol”.Sielfusiblesequemó,
quitela“tapadelsoportedelfusible”,
cambieelfusibleyvuelvaacolocarla
“tapa”.Sielfusiblecontinúa
quemándose,comuníqueseconun
mecánicocalificado,dadoqueel
“circuitodecontrol”podríaestardañado.
A-131001-C
Weldingongalvanizedandstainless
steelpartsgivesoffespecially
hazardousfumes.
•Removegalvanizingfromareatoweld.
•Providegoodventilation.
•Wearsuitablerespirator.
A-131125
3
13
2
12
Item
Part
Number Description
1* A-131017 Note - Disengage Latch
2* A-131028 Weld Warning
3* A-131034 Anthony Label
4 A-131115 Warning, Personal Injury
5* A-131134 Hydraulic Fluid
6 A-150238 Notice - Protected With Electrical Overload Circuit
Breaker
7* A-150601 Made In The USA
8 ATU-141 After Using Liftgate
9
A-131015
ATU-175
A-131020
ATU-174
ATU-147
ATU-177
1500 Lb. Maximum Capacity
1800 Lb. Maximum Capacity
2000 Lb. Maximum Capacity
2500 Lb. Maximum Capacity
3000 Lb. Maximum Capacity
3500 Lb. Maximum Capacity
10 ATU-423 Operating Instructions
11* A-131036 Warning, 200 Amp Fuse Changing Procedure
(attached to power cable)
12* A-131001 10 Amp Fuse Changing Procedure (attached to
control wiring in pump box)
13* A-131125 Warning, Galvanized Fumes Hazard
*Factory Installed – Installer must make sure all decals are attached, as
shown.

AST, AST-L, and AST-PLUS Models 17 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
1 — A-131017
A-131017
2 — A-131028
A-131028
3 — A-131034
CAUTION SECURE LATCH WHILE IN TRANSIT.
A-131034
4 — A-131115
PERSONAL INJURY HAZARD
Operation may require user to stand on platform.
To prevent injury or death of operators or bystanders:
Read and follow operator/owner manual for safety,
operation, inspection, and maintenance instructions.
•
Do not place unstable or unsafe loads on platform.
•
Do not allow loads to extend over edge of platform.
•
Be aware of surroundings when operating liftgate.
•
Owner/operators must properly maintain liftgate.
•
Ensure footing is stable and stand away from edge
before raising or lowering platform.
•
Do not exceed capacity or use liftgate for anything
other than intended purpose.
•
Do not allow body parts to contact moving components.
•
WARNING
A-131115
5 — A-131134
This hydraulic reservoir is
filled with Dextron ATF
hydraulic fluid. Use ONLY the
same or equivalent fluid.
A-131134
6 — A-150238
NOTICE
THIS LIFTGATE IS PROTECTED
WITH AN ELECTRICAL OVERLOAD
CIRCUIT PROTECTION DEVICE,
EITHER A CIRCUIT BREAKER, OR
A FUSE, AND IS LOCATED NEAR
THE POWER SUPPLY
A-150238

Anthony Lifgtates, Inc. 18 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
7 — A-150601
A-150601
8 — ATU-141
ATU-141
9 — A-131015, A-131020, ATU-147, ATU-175, ATU-174,
ATU-177
A-131015
1500 lb.
ATU-175
MAXIMUM
CAPACITY
1800 lb.
A-131020
2000 lb.
ATU-174
MAXIMUM
CAPACITY
2500 lb.
ATU-147
MAXIMUM
CAPACITY
3000 lb.
ATU-177
MAXIMUM
CAPACITY
3500 lb.
CAUTION Make sure the
proper “MAXIMUM
CAPACITY” decal is
placed on the truck for the appropriate lifting capacity
of the liftgate being installed. Do not put a higher
rated decal on a liftgate with a lower capacity; this
could result in liftgate damage or possibly personal
injury.
10 — ATU-423
ANTHONY TUCKUNDER LIFTGATES
OPERATING INSTRUCTIONS
Raise (twist) latch pin handle
upwards and then slide pin
sideways to release.
Do not force the latch. Liftgate may need to
be slightly raised or lowered to release
pressure on latch pin.
1.
Reverse steps to fold and store
platform. Make sure platform is
locked in storage position with
latch pin after use.
6.
Manually unfold main platform.
Always stand on curbside of truck when
unfolding platform.
3.
Manually unfold flipover section.
Always stand on curbside of truck when
unfolding flipover section.
4.
Raise and lower platform using UP and DOWN
functions of control switch.
5.
Press control switch DOWN until folded platform
rests on ground.
Always stand on curbside of truck when raising or lowering
platform with control switch.
2.
ATU-423

AST, AST-L, and AST-PLUS Models 19 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
11 — A-131036 (attached to power cable)
12 — A-131001 (attached to control cable)
10 AMP FUSE & HOLDER
Protects against dead shorts
in this "control circuit".
If blown, pull "fuse holder
cap", replace fuse, replace
"cap". If fuse continues to
blow, contact a qualified
mechanic, "control circuit"
may be damaged.
A-131001
10 AMP FUSE & HOLDER
Protects against dead shorts
in this "control circuit".
If blown, pull "fuse holder
cap", replace fuse, replace
"cap". If fuse continues to
blow, contact a qualified
mechanic, "control circuit"
may be damaged.
13 — A-131125 (attached only to galvanized
liftgates)
Welding on galvanized and stainless
steel parts gives off especially
hazardous fumes.
• Remove galvanizing from area to weld.
• Provide good ventilation.
• Wear suitable respirator. A-131125

Anthony Lifgtates, Inc. 20 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
6. Welding Stainless Steel to Galvanized
If the installation requires welding galvanized steel parts
to stainless steel, special procedures must be followed
to ensure the safety of the welder and the integrity of the
welds.
6.1 Safety
6.1.1 Welding or Grinding Galvanized Material
CAUTION
Follow all OSHA and other workplace safety standards
when welding galvanized steel, which creates zinc
oxide fumes. Always grind the coating off in the area
to be welded and provide adequate ventilation to
avoid breathing the fumes.
Always wear the proper breathing protection when
grinding or welding. Use ventilation or vacuum
systems to remove any contaminated air from the
work area.
Metal Fume Fever:
When zinc vapor mixes with the oxygen in the air,
it reacts instantly to become zinc oxide, which is
non-toxic and non-carcinogenic.
Zinc oxide that is inhaled is absorbed and
eliminated by the body without complications or
chronic effects.
Exposure to zinc oxide fumes causes a flu-like
illness called metal fume fever.
Symptoms include headache, fever, chills,
muscle aches, nausea, vomiting, weakness, and
tiredness.
There are no long-term health effects. Metal fume
fever typically begins about four hours after
exposure, and full recovery occurs within 48
hours.
6.1.2 Welding or Grinding Stainless Steel
Follow all OSHA and other workplace safety standards
when welding stainless steel, which creates hexavalent
chromium fumes that can irritate the nose, throat, and
lungs.
Repeated or prolonged exposure can damage the
mucous membranes of the nasal passages and
result in ulcers. In severe cases, exposure causes
perforation of the septum (the wall separating the
nasal passages).
Always wear the proper breathing protection when
grinding or welding. Use ventilation or vacuum
systems to remove any contaminated air from the
work area.
6.2 General Guidelines
1. Welders should position themselves upwind of the air
flow that removes the fumes, so that fumes and dust
do not collect inside the welding shield (helmet).
2. In addition to proper positioning, an effective method
to prevent inhaling zinc oxide fumes or hexavalent
chromium fumes is to wear a good fume-rated
respirator.
6.2.1 Weld Wire
:HUHFRPPHQG$:6(7ÀX[FRUHZLUHVXFKDV
Midalloy Mastercor™ E312T1-1/4 or equivalent.
Do not use stainless steel weld wire.
6.2.2 Shielding Gas
100% CO2 or 75/25 Argon/CO2 mix can be used.
6.2.3 Welding Guidelines
1. The welding of galvanized steel is the same as
welding bare steel of the same composition. It uses
the same welding processes, Volts, amps, travel
speed, etc.
Wire
Diameter
(inches) Voltage
(V)
Amperage (Amp)
[Wire Feed Speed (ipm)]
Flat Vertical & Overhead
.045 24-28 130-200 [250-425] 120-160 [225-300]
.062 25-30 180-250 [150-250] 180-220 [150-200]
2. Use a soft disc grinder to remove the galvanized
coating in the area to be welded. This will improve
weld quality and reduce the welder’s exposure to zinc
oxide fumes.
3. No preheating of the dissimilar metals is needed.
4. When welding is complete, and after the area has
cooled, use a cold galvanizing spray to restore
corrosion resistance.