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
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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
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“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.