ANthony AST-1500 Installation Manual Download Page 8

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Anthony Lifgtates, Inc.

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

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

Summary of Contents for AST-1500

Page 1: ...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 ...

Page 2: ......

Page 3: ...r 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...

Page 4: ...o 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 manufac...

Page 5: ...nt 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 u...

Page 6: ...e 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 Protec...

Page 7: ... 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 unapprove...

Page 8: ...cts 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 ul...

Page 9: ...enoid 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 So...

Page 10: ...ith 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 r...

Page 11: ...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 Streetsid...

Page 12: ...on 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 H WHQVLRQ PHHWV WKH VSHFL FDWLRQV RI WKH WUXFN manufacturer and that altering the f...

Page 13: ... 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 c...

Page 14: ...aight 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 ...

Page 15: ...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 r...

Page 16: ...tgate 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 ...

Page 17: ...ht 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...

Page 18: ...rd 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 av...

Page 19: ...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 o...

Page 20: ...th 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 wh...

Page 21: ...platform as it is lowered from the stored position The wheel arm can be adjusted VR WKH SODWIRUP XQIROGV ZLWK HLWKHU JUHDWHU RU OHVVHU Hႇ RUW 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 ...

Page 22: ...Installing DOT Lighting Decals and Any Components Not Part of Liftgate 1 Install DOT lighting or other electrical components 2 Install the license plate bracket 3 If required install grab bars or hand rails NOTICE Most liftgates have built in steps to assist in ingress egress of the platform These steps are NOT to be considered all inclusive of any requirements or guidelines regarding proper ingre...

Page 23: ...switch 2 ATU 423 Make sure the platform will fold smoothly and freely tuck under the truck in a stored position and latch Make sure the latch pin works correctly Make sure retainers are properly held in place on all factory installed pivot pins 0DNH VXUH DOO K GUDXOLF WWLQJV DUH WLJKW DQG QRW leaking Hydraulic hoses must be routed to prevent rubbing against any surface while cycling the platform u...

Page 24: ...en Battery and Fuse Assembly 2 Short cable part of solenoid kit 1 Long length of power cable leading to power unit Ground A 1018 Long Power Cable Short Power Cable Short Power Cable Fuse Vehicle Battery Ground Cut Off Solenoid Fuse Box On Off Toggle Switch Liftgate Solenoid Wiring Diagram with Cut Off Solenoid 4 6 Cut Off Switch Connection 7KH LQVWDOODWLRQ RI D FXW Rႇ VZLWFK LV DOVR D UHFRPPHQGHG ...

Page 25: ...he truck body sill A dimensional drawing showing the hole location can be found in this section 2 If the predrilled holes are not in the truck body sill follow these steps a Find and mark the center of the truck body b Center the floor extension on the truck body using the notched cutout ALI 00388 c Mark and drill mating holes ALI 00386b ALI 00387 5 10 20 30 3 Install the flanged bolts through the...

Page 26: ...ed as it is installed Tighten the nuts from the center out keeping the extension flush with the bed of the truck ALI 00390 5 5 1 2 2 3 4 6 6 3 4 5 Install both dock bumpers ALI 00413 6 Bolt the side gussets onto each of the dock bumpers ALI 00382a 7 Weld the top of the side gussets to the truck body frame 8 Make sure all bolts are tightened to standard torque ...

Page 27: ...ube ALI 00365a 10 AMP FUSE HOLDER Protects against dead shorts in this control circuit If blown pull fuse holder cap replace fuse replace cap If fuse continue s to blow contact a qualified mechan ic control circuit may be damage d FUSIBLE DE 10 AMPER IOS Y SOPOR TE Protege contra cortocirc uitos francos en este circuito de control Si el fusible se quemó quite la tapa del soporte del fusible cambie...

Page 28: ... 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 hydrau...

Page 29: ... 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 ...

Page 30: ...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 espec...

Page 31: ...e must satisfy the user to be safe and properly constructed Failure to use the proper materials or material thickness can result in serious injury or death A 1089 36 6 3 12 12 18 8 9 1 2 4 3 1 1 2 5 8 Threaded Rod 32 This lifting fixture is intended for use on liftgates equipped with steel or aluminum platforms Make the lifting WXUH from tubular steel at least 1 4 inch thick or thicker Make the li...

Page 32: ...ch 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...

Page 33: ...AST AST L and AST PLUS Models 33 Anthony Lifgtates Inc 800 482 0003 www anthonyliftgates com Notes ...

Page 34: ...Anthony Lifgtates Inc 34 AST AST L and AST PLUS Models www anthonyliftgates com 800 482 0003 Notes ...

Page 35: ......

Page 36: ... en español también está disponsible en nuestro sitio Web ANTHONY LIFTGATES INC 1037 W HOWARD ST P O BOX 615 PONTIAC IL 61764 0615 PH 815 842 3383 FAX 815 844 3612 TOLL FREE 800 482 0003 WWW ANTHONYLIFTGATES COM AST AST L AST PLUS ...

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