ANthony AST-1500 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
INSTALLATION 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 Basic Installation Instructions..............4
1.5 If Installation Help is Required .............5
1.5.1 Installation and Maintenance (Dealer). . 5
1.5.2 Customer Service and Parts
(End User).......................5
1.6 Registration ...........................5
1.7 Warranty .............................5
1.8 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. Installation ...............................10
4.1 Tools Required ........................10
4.2 Quick Reference Installation Guide ........10
4.3 Bed Height and Clearance Requirements . . . 10
4.4 Installation ...........................11
4.4.1 Preparation .....................11
4.4.2 Installing Floor Extension ..........13
4.4.3 Positioning the Liftgate ............15
4.4.4 Attaching Liftgate to Truck Frame ....16
4.4.5 Installing Optional DOT Tubular
Bumper ........................19
4.4.6 Mounting Control Switch and Routing
the Power Cable .................19
4.4.7 Adjust the Wheel Arm .............21
4.4.8 Adjust Latch Pin .................22
4.4.9 Installing DOT Lighting, Decals, and
Any Components Not Part of Liftgate . 22
4.4.10 Final Inspection Checklist . . . . . . . . . . 23
 &XW2ႇ6ROHQRLG&RQQHFWLRQ .............24
 &XW2ႇ6ZLWFK&RQQHFWLRQ...............24
4.7 Bolt-On Floor Extension.................25
5. Decals ..................................27
6. Lifting Fixture.............................31
7. Welding Stainless Steel to Galvanized .........32
7.1 Safety...............................32
7.1.1 Welding or Grinding Galvanized
Material ........................32
7.1.2 Welding or Grinding Stainless Steel . . 32
7.2 General Guidelines ....................32
7.2.1 Weld Wire ......................32
7.2.2 Shielding Gas ...................32
7.2.3 Welding Guidelines ...............32

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 and Understand
the Manual
The success or failure of
this liftgate to properly and efficiently operate will
depend on a thorough and proper installation. Failure
to read, understand, and follow the installation
instructions and safety recommendations in this
manual, before installing the liftgate, can result in
serious injury or death to the operator or bystander.
Also, read and understand the operating instructions
in the separate Operation Manual (also found in the
information packet) 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 that guards
are installed, if necessary, to fulfill these standards.
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 Basic Installation Instructions
1. This liftgate should only be installed by someone
with sufficient skills to understand the installation
and operation procedures, along with the use of any
equipment or tools used to install the liftgate. This
manual provides typical installation instructions, which
we believe to be the most desirable sequence. These
instructions cannot replace a qualified installer with
clear thinking and basic knowledge.
2. This manual provides easy-to-follow instructions,
along with photos and illustrations, which will help
guide the installation process. Safety precautions
have been clearly identified throughout each section
of this manual and must be followed.
3. A complete explanation of the safety terminology and
recommendations are included in section “2. Safety”
on page 5 of this manual and should be read
thoroughly before proceeding.
4. We urge the installer to call our qualified personnel if
you have installation questions.

AST, AST-L, and AST-PLUS Models 5 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
5. Most problems occur when positioning the adapter
frame tube and mounting plates. Before completely
welding the mounting plates to the truck frame, call us
if you find the liftgate is not operating properly.
1.5 If Installation Help is Required
1.5.1 Installation and Maintenance (Dealer)
For additional information on installation, in the form of a
quick reference guide or installation video, refer to the AST
TuckUnder™ liftgate website www.anthonyliftgates.com.
7R¿QGWKHPRVWFXUUHQWYHUVLRQRIWKHUHIHUHQFHPDWHULDO
choose LIFTGATES, TUCKUNDER™, AST or AST-L or
AST-PLUS, and then DOWNLOADS.
If you have any doubts or questions about installation,
call us. Before doing so, have the serial number, model
number, and lift capacity of your liftgate available.
Anthony Liftgates, Inc.
1037 West Howard Street
Pontiac, Illinois 61764
[phone] or 800-482-0003
1.5.2 Customer Service and Parts (End User)
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
FRGHWR¿QGWKHQHDUHVWDXWKRUL]HGVHUYLFHORFDWLRQ
1.6 Registration
Refer to the Operation Manual for the serial number
information.
1.7 Warranty
For a detailed copy of the Warranty Statement, refer to
the Operation Manual.
NOTICE The liftgate must be installed
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 by the installer and
legible, or all warranties are void.
1.8 Replacement Parts and Hazard Decals
To order replacement parts or hazard/informational
decals, contact us through your normal dealer channels.
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 installer to understand proper
installation and operating procedures. Be aware of the
inherent dangers in the use of this product and the tools
used to install 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 installation 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 us.
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
DVSHFL¿FW\SHRILQMXU\ZKLFKVKRXOGEHDYRLGHG
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
Set parking brake
Remove key
OEM OEM parts
Properly installed 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
suspended from the lifting
device. Failure of the lifting device could cause
serious crushing injuries. Do not remove the lifting
device until the liftgate is securely tack welded onto
the truck frame.
CAUTION
When installing or operating 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 install 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 installation of the liftgate
could result in a serious crushing injury.
Always use/set the truck’s parking brake
and remove the ignition key before
installing 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 installed 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 install 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 the installation and
remedy the problem before continuing.
Make sure the liftgate or truck will not be
damaged or made unsafe by the installation 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. Installation
4.1 Tools Required
The following is a list of suggested tools that should be
used to install the liftgate:
• Band Cutters
• Overhead Crane or Forklift
• Mig or Stick Welder
• Heavy-Duty C-Clamps
• Tape Measure
• Level (small, magnetic)
• Cutting Torch (in some applications)
• Wrenches (bolt-on models only)
• Grinder (removing galvanized surface before welding)
• 1/2 inch Impact Wrench (bolt-on floor extension)
• Heat Gun or Propane Torch for Shrink Tube (cable lug)
• Crimping Tool (cable lug)
4.2 Quick Reference Installation Guide
A Quick Reference Installation Guide is available online
for experienced installers but should not replace the
detailed installation instructions on the following pages.
WARNING Failure to read,
understand, and follow
the detailed instructions
and safety recommendations in this manual, before
installing the liftgate, can result in serious injury or
death to the installer or bystanders.
4.3 Bed Height and Clearance Requirements
NOTICE To prevent damage to the truck
and/or the liftgate, make sure the
model being installed is compatible
with the bed height of the truck.
1. Place the truck on a flat, level surface with the parking
brake set.
SAFETY
INSTRUCTIONS
Remove the keys to prevent
unwanted movement.
2. Be aware that as part of the installation preparation,
the liftgate will not operate properly if the truck bed
height falls beneath dimension (A). This reduced
height can be the result of a fully loaded truck and/or
a variety of other reasons. Do not proceed if the truck
will not meet the minimum height requirement.
Truck Bed Height Fully Loaded
Model Bed Height (A)
AST 42”
AST-L 36”
AST-PLUS 38”
A
3. Measure the actual height of the unloaded truck,
which must be equal to or less than dimension A
(maximum height). Do not proceed if this dimension
does not fall within the maximum height requirements.
Truck Bed Height Unloaded
Model Bed Height (A)
AST 57”
AST-L 44”
AST-PLUS 56”
4. Use the following illustration and chart to ensure
there is no interference between the liftgate and truck
frame, in the area of dimensions B and C, which
would prevent proper installation.
B
C
Note: The dimensions in the following chart are only a
guide for required clearances.
Mounting Clearance Requirements
Bed Height
(floor surface)
B
Floor Surface to
Bottom of Truck
Frame (minimum)
C
Distance with No
Obstructions
36” - 41” 15-3/4” 29”
42” - 49” 19” 24-1/4”
50” - 51” 20” 23-3/4”
52” - 53” 21” 23-1/4”
54” - 55” 22” 22-5/8”
56” - 57” 23” 22-1/2”

AST, AST-L, and AST-PLUS Models 11 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
4.4 Installation
4.4.1 Preparation
WARNING Failure to
prevent the
truck from
moving during the installation of the liftgate could
result in serious personal injury or death.
SAFETY
INSTRUCTIONS
Use two people to safely
install the liftgate.
NOTICE Check the OEM vehicle manual for
any special requirements prior to
welding on the truck’s frame. If
required, disconnect the battery cable before welding on
the truck frame.
1. Remove the banding securing the liftgate and
loose parts to the pallet. Remove the curbside and
streetside mounting plates, the floor extension, the
dock bumpers, and the side gussets from the liftgate
frame.
Typical Single Liftgate Shipping Pallet (steel liftgate shown).
Typical Multiple Liftgate Shipping Pallet (aluminum liftgates shown).
2. Before proceeding, make sure the complete liftgate
and its related parts have been received, as listed
in the chart. In some cases, related installation parts
will be located on the shipping pallet or they may be
shipped separately. Some parts are also placed inside
the pump box.
Liftgate Installation Package
Description Qty.
Located on Pallet
Floor Extension 1
Streetside Step and Dock Bumper Assembly 1
Curbside Step and Dock Bumper Assembly 1
Streetside Mounting Plate 1
Curbside Mounting Plate 1
Power Cable with 200 Amp Fuse 1
Located Inside Pump Box
Information Packet (contains decals, manuals, shims,
and other related installation information) 1
Plastic Tie Wraps –
ALI-00401
3. Release the latch pin from its storage position.
ALI-00409c
NOTICE The latch pin is only for in-transit
locking of the liftgate. DO NOT slide
the latch pin into the latched position
when the platform is unfolded or raised. If this occurs,
serious damage to the liftgate can occur when the liftgate
is lowered.

Anthony Lifgtates, Inc. 12 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
4. Carefully unfold the liftgate using two people. To
keep the liftgate somewhat level once it’s unfolded,
a wooden block, approximately 12 inches tall, can be
placed under the platform.
Note: A spacing guide is installed over the end of the
cylinder rod. Do not remove this guide until the
liftgate has been tack welded in place on the truck
body.
ALI-00416
5. Some truck body variations may require the frame to
be extended within 12 inches of the rear of the truck,
in order to install the liftgate mounting plates. Always
extend the frame as close to the back of the truck as
possible, without interfering with the operation of the
liftgate (see Step 6).
ALI-00402
0” to 12”
Truck Frame
Wood Filler
Truck Body
Body Long Sill
CAUTION Take precautions to avoid
welding sparks or the
flame from a cutting torch
coming into contact with the truck bed’s wooden floor
or other flammable components.
Note: Before extending the truck frame, make sure the
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manufacturer and that altering the frame will not
void the truck warranty.
6. Most truck bodies require the frame to be either
extended or cut back in order to properly install the
liftgate.
Simply measure 20 inches from the rear edge of the
truck body frame to the long sill. Make a mark on the
long sill and either add or remove material from the
frame.
20”
Body Long Sill
Wood Filler
Truck Frame
Body Crossmembers
Note: Once the liftgate is installed, make sure it will
operate properly, without interfering with the truck
frame or the body long sill.

AST, AST-L, and AST-PLUS Models 13 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
4.4.2 Installing Floor Extension
CAUTION
If a galvanized floor extension and dock bumpers
are being installed, the galvanized material must be
removed prior to welding. Refer to the Installation
manual for the proper procedure.
There is also a special procedure to follow when
welding galvanized material to a stainless steel truck
body sill.
Follow all OSHA and other workplace safety standards
when grinding or 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 a ventilation or vacuum
system to remove any contaminated air from the work
area.
7KLVSURFHGXUHLVIRUZHOGLQJWKHÀRRUH[WHQVLRQWRWKH
truck body. If a bolt-on method is preferred, refer to
section “4.7 Bolt-On Floor Extension” on page 25 for
the complete procedure.
1. If desired, spray the parts of the truck body near the
areas to be welded with anti-splatter spray.
2. Find and mark the center of the truck’s rear sill and
the center of the floor extension with a white marker.
ALI-00371
3. Install the floor extension.
a. Use a white marker to also mark the finish weld
locations with a repeating 2 inch continuous weld
with a 4 inch gap. Make your marks from both
ends inward toward the middle.
b. Using a lifting device, center the white mark on the
floor extension with the white mark on the truck
body.
ALI-00388
c. With the center of the floor extension level with the
floor of the truck, begin tack welding at the center
and work outward. Make sure the extension remains
level and flush with the floor of the truck bed.
Note: 7KHÀRRUH[WHQVLRQKDVDQDWXUDOERZLQLWDQG
must be straightened as it is installed.
CAUTION Tack welds must be strong
enough to hold the weight
of the floor extension (up
to 300 lbs.) until the final welds are completed.
Insufficient welds may not hold the floor extension,
resulting in possible bodily harm.
ALI-00373
112
2
3
434

Anthony Lifgtates, Inc. 14 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
d. Also, make sure the floor extension is level and
parallel to the truck’s rear sill.
ALI-00372
4. Tack weld both the streetside and curbside dock
bumpers onto the floor extension.
e. Once you have verified the floor extension is
straight and level, finish welding it to the sill of the
truck body with 2 inch long welds, every 4 inches.
Weld the dock bumpers to the floor extension and
the truck body sill using a continuous weld.
f. Weld across the bottom of the floor extension in
seven to eight locations.
g. If a walk ramp floor extension is being installed,
weld both sides of the support gussets to the truck
body sill.
ALI-00374
h. If not already installed, weld several installer-
supplied strengthening plates between the
crossmembers and the truck body sill.

AST, AST-L, and AST-PLUS Models 15 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
5. Weld and/or bolt the side gussets to the dock bumper
and the truck body. If welding to the truck body cross-
members, make sure it spans at least three of them.
ALI-00381
ALI-00382
4.4.3 Positioning the Liftgate
Use a forklift or overhead lifting device to lift the liftgate.
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installation process easier and safer.
Note: Refer to “6. Lifting Fixture” on page 31 for a
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WARNING Do not work under the
liftgate while it is
suspended from the lifting
device. The liftgate can weigh up to 1,100 lbs. and
failure of the lifting device could cause serious
crushing injuries.
1. For steel platform liftgates:
a. Place the lifting fixture over the liftgate.
b. Place the threaded rod through the lifting hole in
the platform.
c. Install a washer and nut on the threaded rod.
d. Raise the liftgate, making sure the platform is
almost parallel with the ground. Use the threaded
rod and nut to make the required leveling
adjustments.
2. For aluminum platform liftgates:
a. Place the lifting fixture over the liftgate.
b. Place chains or a lifting strap around the lifting
fixture and the platform.
NOTICE To prevent damage to the liftgate,
use wood or other protective
material between the lifting chain/
strap and the platform to prevent surface damage.
c. Adjust the chains/strap until the liftgate is almost
parallel with the ground.

Anthony Lifgtates, Inc. 16 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
4.4.4 Attaching Liftgate to Truck Frame
1. Raise and position the liftgate against the platform
installation brackets (arrows), which are attached to
the floor extension. Also, push the liftgate against the
spacer portion of the installation brackets.
ALI-00376
Note: The platform installation brackets help to hold
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provide the proper spacing between the liftgate and
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WARNING Do not work under the
liftgate while it is
suspended from the lifting
device. The liftgate can weigh up to 1,100 lbs. and
failure of the lifting device could cause serious
crushing injuries. Do not remove the lifting device
until the liftgate is securely tack welded onto the truck
frame.
2. Center the platform from side-to-side with the truck
body.
3. Clamp the liftgate against the floor extension using
two large C-clamps, as shown.
NOTICE If the liftgate has an aluminum
platform, use wood or other
protective material to prevent
surface damage.
4. Place a lifting device (floor jack shown) under the
wheel arm, as shown.
5. Determine the installed height (B) of the adapter frame
tube using the chart and the illustration in Step 6.
Mounting Requirements
A
Bed Height
(floor surface)
B
Floor Surface to Top of
Adapter Frame Tube
36” - 41” 15-3/4”
42” - 49” 19”
50” - 51” 20”
52” - 53” 21”
54” - 55” 22”
56” - 57” 23”
Note: In some cases, the top of the adapter frame tube
may be against the frame or could be above the
frame. It may be necessary to notch the frame in
order to achieve the required height of the adapter
tube frame.
6. Raise the adapter frame tube to the correct height of
dimension (B), which is based on the height of the
truck bed.
NOTICE Do not bend the wheel arm
during the leveling process.
If the adapter frame tube does not easily raise, it may
be necessary to actuate the control valve to release
hydraulic pressure in the cylinder if the adapter frame
tube will not raise completely.
A
B

AST, AST-L, and AST-PLUS Models 17 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
7. To actuate the control valve, it’s necessary to connect
a 12 Volt slave battery to the motor start solenoid.
Connect the red jumper cable from a 12 Volt slave
battery to the positive (+) terminal of the motor start
solenoid. Connect the black (-) cable to a ground on
the pump box.
8. For gravity-down models, simply press and hold the
control switch in the DOWN position to release the
pressure in the cylinder.
For power-down models, briefly press and release
the control switch in the UP position. Remember that
pressing the UP control will hydraulically raise the
adapter frame tube.
Once the adapter frame tube is at the proper height,
the top of the tube should be slightly angled toward
the back of the truck.
9. Slide the mounting plates over the adapter frame
tube on each side, as shown.
ALI-00415
Note: The mounting plate must extend at least 9 inches
above the bottom of the truck frame. Extend or
shorten the mounting plates, if necessary.
ALI-00360a
9” MIN
10. Tack weld the mounting plates to the frame in the
locations marked “X” (each tack weld should be a
3/8 inch fillet, 1 inch long).
ALI-00360b
CAUTION The tack welds
must be strong
enough to hold the
weight of the liftgate, which can be up to 1,100 lbs.
Insufficient welds may not hold the liftgate in place,
resulting in possible bodily harm.
11. Remove the floor jack.
12. Make sure the latch pin is in the open position.
13. Standing on the curbside of the truck, away from
the platform, actuate the DOWN switch to lower the
platform to the ground. Remove the spacing guide
from the lift cylinder.
ALI-00416

Anthony Lifgtates, Inc. 18 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
14. Completely raise the platform.
The outboard edge of the flip-over section should be
1/2 to 3/4 inches higher than the platform section, as
shown, when correctly installed.
1/2" to 3/4"
15. Completely raise and lower the platform several
times.
ALI-00366
16. The front edge of the flip-over platform section
should lower to the ground and contact the ground at
the points seen below, and the back of the platform
should raise flush to the floor extension. If the front
edge does not touch the ground, refer to the next
step.
17. If the end of the platform does not contact the
ground, adding a shim to the stop block will raise the
outboard end of the flip-over section.
Removing material from the stop blocks will lower
the outboard end of the flip-over section.
ALI-00413
Note: One shim can move the ramp end of the platform
as much as 1/2 inch.
18. If the platform is operating correctly, finish welding
the mounting plates. If the platform does not make
a complete cycle, adjust the mounting plates, as
necessary.
CAUTION Take precautions to avoid
welding sparks coming
into contact with the truck
bed’s wooden floor or other flammable components.
SAFETY
INSTRUCTIONS
For safety purposes, finish
welding the liftgate while the
platform is on the ground, not in
a raised position.
NOTICE Cover the cylinder rod to prevent
weld spatter from damaging it.
19. With the platform on the ground, finish welding the
mounting plates to the truck frame and adapter
frame tube. Use a continuous weld around all sides
of the adapter frame tube and on both sides of the
mounting plates.

AST, AST-L, and AST-PLUS Models 19 Anthony Lifgtates, Inc.
800-482-0003 www.anthonyliftgates.com
20. Remove the installation brackets from the floor
extension.
ALI-00378
4.4.5 Installing Optional DOT Tubular Bumper
1. If desired, install the optional tubular bumper using
the supplied hardware. Make sure the installation is in
compliance with all State and Federal regulations.
ALI-00411
2. With the liftgate in the stored position, attach the
red and white reflective tape.
4.4.6 Mounting Control Switch and Routing the
Power Cable
1. Remove the slave battery’s jumper cables and
disconnect the wires of the control switch from the
power unit.
2. Mount the control switch to the truck’s rear curbside
post, so it can be reached while standing at the
curbside of the truck, away from the liftgate platform.
3. Disconnect the wires of the control switch from the
power unit.
4. Install the protective rubber grommet in the dock
bumper and route the wire through the dock bumper.
5. Reattach the control unit wires to the appropriate
terminals, as shown.

Anthony Lifgtates, Inc. 20 AST, AST-L, and AST-PLUS Models
www.anthonyliftgates.com 800-482-0003
6. Connect the long section of the power cable to the
motor start solenoid.
Connection for gravity down models.
Connection for power down models.
WARNING Improper grounding can
cause an electrical current
to travel through brake
lines, steel braided power steering hoses, or other
truck frame components, causing failure to these
components, which could result in the loss of vehicle
control.
7. If needed, attach a ground strap, the same gauge or
larger as the liftgate power cable, between the pump
box and the truck frame.
WARNING Never secure the power
cable to anything which
allows it to contact sharp
edges, other wiring, the 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,
resulting in the loss of vehicle control, serious injury,
or even death.
8. Route the power cable along the truck frame to the
battery box attaching it with plastic tie wraps or wire
clips.
If the cable is too long, cut it to the desired length.
9. Install the optional cut-off solenoid or cut-off switch, if
desired.
WARNING Anthony Liftgates strong-
ly recommends the instal-
lation of an optional power
cut-off solenoid (“4.5 Cut-Off Solenoid Connection”
on page 24) or cab cut-off switch (“4.6 Cut-Off
Switch Connection” on page 24). Allowing power to
the liftgate when the truck is unattended can result in
serious injury or death.
10. Reconnect the newly-cut end to the fuse.
11. If the power cable requires a cable lug on the end,
follow these steps.
a. Strip the insulation one inch back from the end of
the cable to expose the copper wire.
ALI-00394
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b. Position the cable lug on the exposed wire, as
shown. Crimp the cable lug using a cable crimping
tool (hydraulic or manual).
c. Use the supplied heat shrink tube to insulate the
new connection, leaving only the mounting hole
exposed.
NOTICE Proper wire connection is crucial to
the life and dependability of the
liftgate’s electrical components. A
poor connection can result in low Voltage causing the
liftgate to work improperly. DO NOT crimp (smash) the
cable lug with a hammer to secure it to the cable.