AND OPERATIONuploads.gocdn.us/270_162_MTU-GLR- INSTALL AND TROUBLE SHOOT.pdftion in the Parts manual for MTU-GLR Model Tuckunder Liftgates, form number MTU-GLR P-10/04. For decal placement,

A N T H O N Y L I F T G A T E S , I N C .

I N S TA L L AT I O NAND

O PE R AT I O NMAINTENANCE & TROUBLESHOOTING

I N S TA L L AT I O NAND

O PE R AT I O NMAINTENANCE & TROUBLESHOOTING

Anthony Liftgates, Inc.1037 W. Howard Street • P.O. Box 615 • Pontiac, IL 61764-0615Ph: 815.842.3383 • Fax: 815.844.3612 • Toll Free: 800.482.0003www.anthonyliftgates.com

For Magnum Tuckunder™ Hydraulic Liftgates®For Magnum Tuckunder™ Hydraulic Liftgates®

MODELS

MTU-GLR-3

MTU-GLR-4

KEEP IN VEHICLE WITH LIFTGATE

General Information SectionIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4General Information . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation SectionGeneral Installation Information . . . . . . . . . . . . . . . 6Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . 8Final Inspection Checklist . . . . . . . . . . . . . . . . . . . 24Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Operation SectionGeneral Safety Operating Instructions . . . . . . . . . 30Operating Instructions . . . . . . . . . . . . . . . . . . . . . . 32

Maintenance SectionQuick Check Maintenance Guide . . . . . . . . . . . . . 34Maintenance Procedures . . . . . . . . . . . . . . . . . . . . 35

Safety SectionSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Troubleshooting SectionTroubleshooting Guide . . . . . . . . . . . . . . . . . . . . . 44

815-842-3383 1 Anthony Liftgates, Inc.

Contents

Congratulations on selecting an AnthonyLiftgates Magnum Tuckunder liftgate.Anthony liftgates are among the finest lift-gates available on the market today. Toensure your liftgate will perform to yourexpectations we have provided the follow-ing manuals, designed to provide you withthe necessary instructions and safety pre-cautions to install and operate theTuckunder models of Anthony liftgates.

1. Installation, Operation, Troubleshooting,and Maintenance manual forMTU-GLR Model Tuckunder Liftgates -Form No. MTU-GLR IO-10/04

2. Parts manual for MTU-GLR ModelTuckunder Liftgates - Form No. MTU-GLR P-10/04

Typical Anthony Liftgates’ Magnum TuckunderLiftgate.

This Installation, Operation, andMaintenance manual will provide you easyto follow instructions, along with photosand illustrations. We have included aseries of Tips, which will facilitate theinstallation process. All Safety precau-tions have been clearly identified anddetailed throughout each section.

In addition, a complete explanation of thesafety words and rules are included in theSafety section of this manual. Please turnto this section and read thoroughly beforeproceeding to the next page.

At the bottom of each page is the AnthonyLiftgates Inc. Product Support phone num-ber. If you are unclear about any of theinstructions, please phone AnthonyLiftgates' Product Support.

All Anthony Magnum Tuckunder model lift-gates are factory assembled, tested, andenergized to assure the highest qualityperformance standards. MTU-GLR lift-gates ship completely assembled on skidsfor fast, clean, and easy installation.

MTU-1003

Anthony Liftgates, Inc. 2 815-842-3383

IntroductionGeneral Information Section

Even though the following goes with-out saying, we feel compelled to state:Anthony liftgates should only be installedby those with sufficient skills to understandthe installation and operation of the lift-gate, along with the equipment required toinstall the liftgate. The installation instruc-tions in this manual are intended to givetypical installation instructions to theinstaller for both the operation and whatwe believe to be the most desirablesequence of installation. These instruc-tions cannot replace a qualified person, orclear thinking and the basic knowledgethat must be possessed by the installer.

We urge the installer (or anyone else) tocall us if they have any questions. Wehave qualified personnel at our Pontiac,Illinois, plant to answer any questions thatyou may have. A detailed discussion onthe phone can be far more satisfactorythan a detailed written explanation.

It has been our experience that a knowl-edgeable journeyman following theseinstallation instructions and observing theoperation of the liftgate will have sufficientcomprehension of the liftgate to enablethis person to troubleshoot and correct allnormal problems that may be encoun-tered. However, again we urge you to callus at the Pontiac, Illinois, plant if you findthe liftgate is not operating properly or ifyou do not know how to make the neces-sary repair.

If you have any doubts or questions, callus at:Anthony Liftgates, Inc.1037 West Howard StreetPontiac, Illinois 61764(815) 842-3383www.anthonyliftgates.com


The success or failure of thisliftgate to properly and effi-ciently operate will depend ona thorough and proper instal-lation. Failure to read, under-stand, and follow the installa-tion instructions and safetyrecommendations in thismanual before installing theliftgate can result in seriousinjury or death. Also readand understand the operatinginstructions in the Operationsection.

When installed, this liftgatemust not alter nor preventvehicle compliance to anyexisting state or federal stan-dards, and especially FMVSS105. Each chassis manufac-turer’s recommendationsshould be consulted for com-pliance. Also make sure theweight of the liftgate and itsload will not overbalance thetruck, possibly raising thefront wheels off the ground.

DANGER


Mounting Plate

Main Platform Section

GussetRubber Dock BumperPad

Gusset

Rubber Dock BumperPad

Floor Extension Assembly

Dock Bumper Corner Cap

Dock Bumper Corner Cap

Mounting Plate

Curbside

Streetside

Flip-over Platform Section

Lift Frame

Radius Arm

MTU-1004

Platform nomenclature.

Nomenclature

MTU-1005

High-PressureHose

High-PressureHose

Flow ControlValve

ControlBox Wiring

Pump

AdjustableReliefValve

10 amp Fuse

Motor StartSolenoid

Lowering ValveCartridgeand Coil

Raising ValveCartridgeand Coil

HydraulicCylinder

FillBreather

Port

Reservoir

ControlSwitch

ElectricMotor

Power unit nomenclature.

Warranty

IMPORTANT NOTICEThe liftgate must be installedaccording to the installationinstructions or the warranty willbe void. Unauthorized modifica-tions of the liftgate may cause itto improperly operate or causeother unforeseen problems ordangers. If any deviation isdeemed necessary, written per-mission must first be obtainedfrom Anthony Liftgates.

Fill out and mail in the Warranty Card tovalidate the warranty on your liftgate.

Decals

Safety decals provide a vital role in helpingto reduce injuries and/or possibly evendeath. To ensure the greatest level ofsafety, all decals must be in place and leg-ible at all times. Remember, it is the usersresponsibility to maintain these decals.For a complete part number list and illus-tration of the decals used on the MagnumTuckunder liftgate, refer to the Decals sec-tion in the Parts manual for MTU-GLRModel Tuckunder Liftgates, form numberMTU-GLR P-10/04.

For decal placement, also refer to theDecals section in this manual.

For replacement decals contact:Anthony Liftgates, Inc.1037 West Howard StreetPontiac, Illinois 61764(815) 842-3383www.anthonyliftgates.com

Ordering PartsWe manufacturer a quality liftgate thatrequires very little maintenance or repair.However, should a part break, becomedamaged, or worn our knowledgeable staffcan make sure you receive the part(s) toput your liftgate back into operation.

For questions or to order parts, contact:Anthony Liftgates, Inc.1037 West Howard StreetPontiac, Illinois 61764(815) 842-3383www.anthonyliftgates.com

Tooling RequiredThe following is a list of suggested toolsthat should be used to install the MagnumTuckunder liftgate.

• Overhead Crane or Forklift• Mig or Stick Welder• Heavy-Duty C-Clamps• Tape Measure• Level (small, magnetic)• Cutting Torch (in some applications)


General Information

Make sure all decals areattached to liftgate and/ortruck and are legible at alltimes.

DANGER

Fabricated ToolingTip: A lifting jig, as shown in these pho-

tos, can reduce installation timewhen installing more than oneAnthony Magnum Tuckunder liftgate.A forklift or overhead crane can alsobe used with a bolt and chain.

These photos show a sample lifting jig, butwhen you fabricate a lifting jig it :

• must be made specifically for the typeand design of your particular forklift.

• must be wide enough to support the lift-gate and to accommodate the width ofthe forks on the forklift.

• must be constructed from materials thatare capable of lifting and supporting theAnthony Magnum Tuckunder liftgate.

• must be constructed from tubular steelat least 0.25 inches thick or thicker.

• must be securely fastened to the forklift.• must have a lifting bolt that is long

enough to go through the lifting hole inthe liftgate and allow the lifting jig toremain level.

Tip: Make the lifting bolt from a 5/8 inchthreaded eyebolt. Use a washer andnut to fasten the lifting jig to the lift-gate.

• must satisfy the user that it is safe andproperly constructed.


General Installation InformationInstallation Section

The construction of the liftingjig must satisfy the user to besafe and properly construct-ed. Failure to use the propermaterials or material thick-ness can result in seriousinjury or death to the user(s).

DANGER

Prior To Installation1. Place the truck on a flat, level surface.

Block the wheels to prevent the truckfrom moving while installing a liftgate.

2. Use the Mounting Requirements chartand illustration to make sure there isenough clearance to properly installthe liftgate.

3. Remove the banding securing the lift-gate and the loose parts to the pallet.Remove the curbside and streetsidemounting plates, dock bumpers, andfloor extensions that are stored on theliftgate. Unfold the liftgate platform.

Tip: Check the OEM vehicle manual forany special requirements prior towelding on the truck. If required, dis-connect the battery cable beforewelding on the truck.

Tip: When installing multiple liftgates,consider making a lifting jig as shownin the Fabricated Tooling section ofthis manual.


Mounting Requirements

A B C D EBed Bed to top Mounting (maximum) Chassis

Height of Adapter Plate Rear Sill and BodyFrame Tube Clearance Clearance Cut out

46” 19.5” 14-3/8” 4.5” 13.50”

48” 19.5” 16-3/8” 4.5” 13.50”

50” 19.5” 18-3/8” 4.5” 13.50”

52” 19.5” 20-3/8” 4.5” 13.50”

54” 19.5” 22-3/8” 4.5” 13.50”

57” 19.5” 25-3/8” 4.5” 13.50”

MTU-1036

Failure to prevent the truckfrom moving while installing aliftgate could result in seriouspersonal injury or death fromcrushing the installer(s).

DANGER

Step 1Remove the cover from the power unitbox. Remove all the parts and installationinstructions from inside the box. Someunits are shipped from the factory with ashipping plug in the power unit reservoir.If necessary, replace the shipping plugwith a vent plug.

Tip: The power unit box should containplastic tie wraps for battery cable,two stop brackets, one latch plate,one 150 Amp circuit breaker, andone package containing decals,shims, and manuals.

Step 2Cut off or extend the chassis frame, woodfiller, and body long sill, as shown. Theframe must extend between 0 and 24 inch-es from the rear of the truck body.

Tip: Before modifying the truck chassis,make sure any extensions meet thespecifications of the truck manufactur-er and that altering the frame will notvoid the truck warranty.

Step 3Make sure the "rear sill" of the trailer bodyis flat and straight all the way across therear face of the body. Remove anyobstructions before installation; such as,trailer hitches and brackets, dockbumpers, projections, etc.

0" to 24"

Body Long SillWood Filler

Chassis Frame

MTU-1040

Truck Body


Installation Procedure

Step 4Measure and determine the center of thetruck’s rear sill. Mark this point.

Step 5Install the floor extension.

Tip: Two men can be used in the weldingprocess to reduce the time.

a. Align the “Center Mark” of the floorextension assembly with the centermark of the truck body.

b. Level the floor extension assembly withthe floor of the truck body and tackweld it in three locations (left, center,and right). Make sure the tack weldswill hold the weight of the floor exten-sion, approximately 200 pounds.

c. Use a long straight edge to make surethe floor extension is level and parallelto the floor of the truck body.


Tack welds must be strongenough to hold the weight ofthe extension and the dockbumpers. Insufficient weldsmay not hold the truck exten-sion in place, resulting inbodily harm.

CAUTION

d. Tack weld the gussets under the floorextension to the truck body. If the rearsill is uneven, cut or shim the gussetsor the sill, to maintain a level and par-allel attitude between the floor exten-sion and the floor of the truck body.

e. Finish welding the floor extension tothe truck body. Weld between thewhite dots painted on the floor exten-sion (2 inch long, 1/4 inch fillet welds,on 6 inch centers).

f. Weld the gussets under the floor exten-sion to the truck body using 1/4 inch fillet welds on one side of thegusset.

Step 6Lift and position the liftgate.

a. Attach a lifting device to the liftgate.Tip: While a lifting jig (as shown) is not

required for liftgate installation, it canreduce installation time wheninstalling more than one liftgate.Otherwise, any lifting device, such asa forklift or overhead crane, capableof lifting and holding the liftgate inposition and level can be used with abolt and chain.

b. Raise the platform and position the lift-gate bolster (front edge of platform)tight against the floor extension.

c. Center the platform from side-to-sidewith the truck body.

Step 7Clamp the liftgate to the floor extension.


Do not remove the hoist, forklift, or other lifting deviceused to hold the liftgate inplace during the installationprocedure. NEVER WORKUNDER THE LIFTGATE ORFLOOR EXTENSION whileinstalling or painting the unit.Work so that you would not bein the way if the clamps, weld,etc. should fail.

WARNING

a. Use two large C-clamps, as shown, tohold the liftgate in place.

b. An alternate method of holding the lift-gate is using two, 3 to 4 foot longpieces of heavy-duty angle iron. Thesize of the angle iron should be 3 x 3 x1/4 inch minimum.

Step 8Route the supplied power cable (withattached fuse assembly) from the batteryto the liftgate power supply using one ofthe following procedures:

Step 9 - Direct Battery Connection (notrecommended)

Step 10 - Cut-Off Solenoid ConnectionStep 11 - Cut-Off Switch ConnectionOnly one method is required to completethe wiring installation.

Illustration 7. Power cable and fuse assembly.

CL

A-1042

Platform and floor extensiontight all the way across width.

Angle Iron (one each side)

Center platform with floorextension and truck floor.

Install an eye-bolt in platformand use for hoisting to bed height.


Never secure the power cableto anything which allows it tocontact sharp edges, otherwiring, fuel tank, fuel lines,brake lines, air lines, exhaustsystem, or any other objectthat could cause the powercable to wear or be damaged.A direct short in the batterycable can cause sparksresulting in loss of vehiclecontrol, serious injury, oreven death.

DANGER

Step 9Direct Battery Connection (not recom-mended)

IMPORTANT NOTICEUsing the standard wiring hookupis not recommended because itdoes not cut off power to the lift-gate when the truck is left unat-tended. A cut-off switch or cut-offsolenoid will disable the use ofthe liftgate when the truck is notin use.

Illustration 9. Power cable connected to power unitand battery.

a. Position the fuse assembly near thebattery so the short cable end willreach the positive terminal.

b. Attach the fuse holder to the truck bodylongsill using either Method A or B,shown in this step.

Tip: There are several options for attach-ing the power cable from the plasticfuse assembly. It can be fastenedusing plastic tie wraps or wire clips.The fuse assembly can also be bolt-ed directly onto the body longsill, ifdesired.

+–

LongPowerCable

Fuse

Ground

VehicleBattery

A-1017

LiftgateSolenoid


Anthony Liftgates strongly recom-mends the installation of a power cut-off solenoid or cab cut-off switch. Notcutting off power to the liftgate whenunattended can result in seriousinjury or death to unauthorized usersor others near the liftgate.

DANGER

The liftgate must be properly ground-ed. A ground wire, the same gauge orlarger as the liftgate power cable,must be connected from the negativepost of the battery or batteries to thetruck’s frame. Some trucks may havea properly sized ground wire from thebattery to the frame and would requireno change. If, however, there is noground wire or it is undersize, add thecorrectly sized ground wire.If this Warning is not followed, dam-age to the truck chassis may occur.Improper grounding can cause theelectrical current to travel throughbrake lines, steel braided power steer-ing hoses, or other chassis wiringcausing failure to these components!Failure of these components couldresult in loss of vehicle control.

WARNING

Method A

Fasten the power cable to the truck body.Locate one fastener (battery side) within 3inches of the end of the fuse assembly.Locate the other fastener (power unit side)within 8 inches of the fuse assembly.

Using this method does not require thefuse assembly to be attached to thelongsill.

Method B

Attach the fuse holder to the truck bodylongsill using #10 or #12 self-tappingscrews or bolts, washers, and self-lockingnuts. Fasten the power cable, as needed,to properly hold it in place. Using thismethod requires an extra length of cableon one side of the fuse assembly to permitremoval of the fuse.

c. Run the long end of the power cablefrom the fuse to the motor solenoid. Ifthe power cable is longer thanrequired, cut it to the desired lengthand attach a cable lug according toinstructions listed below.

Illustration 9c. Connect power cable to motor sole-noid.

d. Connect the power cable to the motorsolenoid. Make sure the power cableis connected to the correct motor sole-noid post (one not connected to themotor housing with a metal strap orwire cable.

e. Connect the short end of the powercable to the positive post of the battery.

f. The power unit should now be opera-tional.

g. Coat all terminal ends, studs, and nutswith a Teflon lubricant, grease, or otherelectrical connection sealant to preventcorrosion.

Tip: Do not apply undercoating to powercable or fuse holder! The powercable should be clean near the fuseholder to ensure easy removal of therubber boot seals if fuse needs to bereplaced. For fuse replacement, seethe instructions in the Maintenancesection of this manual.

A-1074

Approx.6"

Approx.6"

A-1073

TO LIFTGATE

Approx. 8"

Approx.3"


Cable Lug Installation1). Strip insulation one inch back from the

end of the cable to expose the copperwire.

Remove one inch of insulation.

2). Position the cable lug on the exposedwire, as shown. Crimp the cable lugusing a cable crimping tool (hydraulicor manual).

Install cable lug.

IMPORTANT NOTICEProper wire connections are cru-cial to the life of the liftgate’spower unit. DO NOT smash thecable lug with a hammer tosecure it to the cable. Poor con-nections can result in low voltage,and any attempt to operate belowthe minimum required voltagecould cause system failure.

3). Use the supplied heat shrink tube toinsulate the new connection. Heat theshrink tubing using a heat gun orpropane torch until it shrinks aroundthe cable insulation and cable lug,leaving only the mounting holeexposed. Do not overheat the heatshrink tubing.

Put heat shrink tubing over connection.

Step 10Cut-Off Solenoid ConnectionThe installation of a cut-off solenoid is arecommended option, by AnthonyLiftgates, for all 12 Volt electric liftgates.Installing a cut-off solenoid will help to pre-vent accidental or unauthorized use of theliftgate.

The optional A-133036 Cut-Off SolenoidKit can be used in any truck, but is essen-tial for tilt cab applications because itrequires only a light weight wire running tothe cab—not a large cable as required bythe cut-off switch.

A-1012

TYPE SGT

TYPE SGT

A-1011

TYPE SGT

TYPE SGT

TYPE SGT

TYPE SGT

A-1010

1"


Cut-off solenoid installed between battery and fuseassembly.(1) Short cable, part of solenoid kit. (2) Short endof power cable leading to fuse.

Follow the installation directions on theInstallation Instruction sheet that comeswith the kit.

Wiring diagram with cut-off solenoid.

Step 11Cut-Off Switch ConnectionThe installation of a cut-off switch is also arecommended option, by AnthonyLiftgates, for all 12 Volt electric liftgates.Installing a cut-off switch will help to pre-vent accidental or unauthorized use of theliftgate.

Follow the installation directions on theInstallation Instruction sheet that comeswith the kit.

Cut-off switch mounted in cab of truck.

Wiring diagram with cab cut-off switch.

A-1019

+–

LongPowerCable

Fuse

Ground

VehicleBattery

CabMountedCut-OffSwitch

ShortPowerCable

ShortPowerCable

LiftgateSolenoid

+–

Ground

A-1018

LongPowerCable

ShortPowerCable

ShortPower Cable

Fuse VehicleBattery

Ground

Cut-OffSolenoid

Fuse Box On/OffToggle Switch

LiftgateSolenoid


Step 12Roughly position the adapter frame tube(6" x 6" tube) to attain the dimensionsshown in the table of Step 2 in the Prior toInstallation section in this manual.

Step 13The liftgate is a power down model andcan use the liftgate cylinder to position theadapter frame tube.

a. Make sure the power cable to the pumpmotor is connected.

b. Connect a ground cable from some-where on the pump (steel) to the frameof the truck. This ensures a goodground to run the pump motor.


c. Now the liftgate control switch can beused to help position the adapter tube.The functions of the control switch willbe opposite from the way they areprinted on the control switch, becausethe platform is clamped to the truckbody.

Step 14Position the adapter frame so the lift cylin-der is extended at least a 1/4". This can bedetermined quickly by looking at theamount of "chrome piston rod" showing onthe lift cylinder. The use of a floor jack canhelp position the adapter frame, as shown.

Tip: To achieve a 1/4” cylinder extensionmay require the mounting plates tobe slightly tilted, forward or back-ward. The "tilt" does not affect thefunction of the liftgate. This stepallows the platform to continue toraise to the "floor extension" level,even after the liftgate ages.

Step 15Slide the "mounting plates" over theadapter frame tube. The "mounting plate"goes toward the front of the vehicle, asshown in Step 16. The mounting platescan be trimmed off the top, if necessary,as long as a 9" minimum contact area ismaintained.

IMPORTANT NOTICEThe height of the truck framemust be tall enough to achieve 9inches (minimum) of verticalcontact between "liftgate mount-ing plates" and "truck frame".

Step 16When the mounting plates are approxi-mately straight up and down, tack weld theplates to the frame as shown. The tackwelds should be a minimum of 3/8" fillet x1" long.


Step 17Remove the C-clamps, angle iron (if thismethod was used), lifting device, and jack.Lower the platform near ground level andremove the two installation bolts from therocker frame weldment, one on each side.

Step 18The liftgate platform must travel correctlythrough its full cycle. (A full cycle is whenyou perform all of these functions, Up,Down, Open, Close, Tilt Down, & Tilt Up.)If it does not travel through the full cycle,replace the clamps and hoisting device.Break the tack welds on the mountingplates, and reposition the adapter tubeassembly. Recheck the operation of theliftgate and repeat this step until the liftgateoperates correctly.

Note: This liftgate platform rides level untilit meets the ground, then as youcontinue to power the liftgate Down,the platform tilts so the taperededge meets the ground. The plat-form again levels itself before liftingduring the Up cycle.

Step 19Weld the liftgate while platform is loweredto the ground, not in raised position. Shieldthe lift cylinder’s chrome piston rods, andhoses, to prevent damage by weld spatter.Use 3/8" fillet welds around the entiremounting plate.

Step 20Cut the chassis frame and body long sill asshown. After making the cut out, makesure the liftgate operates properly withouthitting the chassis frame or body long sill.

MTU-103913.50

11.50


Step 21If necessary, adjustment can be made toreposition the height of the platform in rela-tion to the truck floor. When fully raised,the rear edge of the platform should stop“level" to 3/4 inch higher than the frontedge of the platform. This extra heightallows for deflection when the platform isfully loaded. Shims (approx. size 1/16"thick x 3/4" x 2-1/4" long) can be installedbetween the cam plates and the platformas shown (weld shims to cam plates).

Step 22

IMPORTANT NOTICEThe latch pin is only for in-transitlocking of the liftgate. DO NOTslide the latch pin into thelatched position when the plat-form is unfolded and/or raised.If this occurs, serious damage tothe liftgate can occur when theliftgate is lowered.

Attach the latch plate to the radius arm asfollows:

a. Raise the liftgate to the stored positionand slide the latch pin across the radiusarm.

b. Position and tack weld the locking plateon the streetside radius arm as shown.There should be a 1/16” gap betweenthe radius on the locking plate and thelatch pin.


c. Lower the liftgate to the ground, attachthe ground cable for the welder, andweld the locking plate in two placeswith 3/8” fillet welds, as shown in thefollowing illustrations.

Step 23Mount the control switch to truck’s rearcurbside post so it can be reached whilestanding at the curbside of the truck awayand from the liftgate platform.

Tip: Mount the switch box before attach-ing the dock bumpers. This allowsrouting of the switch box wirethrough the slot in the dock bumper.

Tip: To install a control switch on "flatbed" applications were there is nocorner post, here are a few alterna-tive locations:

a. Under the bed on the "dock bumpergusset" (this requires the gusset to bemounted further in from the side of thebody, for protection).

b. Install a removable, hand-held controlswitch (this is a hand-held control thatwill allow the operator to move aroundwhile controlling the liftgate, this canalso be removed and stored away fromthe liftgate).

c. Use a flush-mount control switch andrecess it into the side of the body frame.

Step 24Weld both the streetside and curbsidedock bumpers onto the floor extension.

a. If necessary, route the control cablethrough the curbside dock bumper asmentioned in Step 24.

b. Position the top of each dock bumperflush with the floor extension andstraight up and down, parallel with thesides of the truck body. Tack weld intoposition.

A-1050

Weld

Radius Arm

Latch Plate


c. Weld dock bumper corners continuous-ly to floor extension and truck body.

Tip: Place a wet shop towel or rag aroundthe switch box control cable whenwelding the curbside dock bumper toprevent burning or melting the con-trol cable.

Step 25Weld the side gussets to the dock bumpercorners and the steel side member of thetruck body or the cross-members of thetruck body. The step shown is a typicalstep and may look different from the actu-al step sent for installation.

a. The recommended method of attachingside gussets, is welding the gusset to thesteel side member of the truck body.

b. The alternate method of attaching theside gussets is to weld the gusset tothe steel cross-members of truck body.Make sure gusset straddle at leastthree cross members. Weld both sidesof each gusset.

A-1038

A-1037


Step 26Attach the four platform support brackets.First, fold the platform in the positionshown in the photo.

a. Raise the ramp edge of the platform (A)about 1/2” from touching the radiusarm.

b. Tack weld a platform support bracket(B) to the outside of each radius arm.You may need to cut the bracket so thewelded end does not extend beyondthe radius arm.

c. Now adjust the platform UP or DOWNuntil the back edge of the platform (C)is about 1/2" from touching the framestructure.

d. Tack weld a rear support bracket (D) tothe outside of each radius arm.

Make sure liftgate operates properly, thenfinish weld all four brackets in place on 3sides of each bracket.

Tip: Keep the hoisting device attached tothe platform for safety. Lower thehoisting device just ahead of the plat-form as it lowers.

Step 27Install lights or other electrical compo-nents, if needed.


For safety purposes, weld theliftgate while the platform ison the floor, not in a raisedposition. Cover the cylinderrods to prevent weld spatterfrom damaging them.

CAUTION

Step 28Install grab bars or hand rails, as may benecessary. Also, install license plate hold-er, as necessary.

IMPORTANT NOTICESome models of Anthony lift-gates may be provided with stepdevices to assist in the ingressor egress of the rear of the truckor trailer. These devices areNOT to be considered all inclu-sive of any requirements orguidelines regarding properingress or egress of trucks andtrailers. These items are provid-ed only as an added feature forinstallers to help simplify themeeting of possible ingress oregress requirements. As thereare many variables in trucksizes and shapes, it is theinstallers responsibility to deter-mine proper ingress and egressrequirements, such as steps,hand grips, grab bars, etc. foreach vehicle receiving anAnthony liftgate.

Step 29Make a final operation check. Rememberthat this liftgate is a power down model,therefore the pump will run while the plat-form is lowering.

a. Make sure the platform will travelthrough a complete cycle, up anddown, smoothly and freely, with theplatform completely open.

b. Make sure the platform will fold andtuck under the truck in a stored posi-tion, and latch. The liftgate must foldsmoothly and freely.

c. Make sure hydraulic hose fittings aretight and hydraulic hose does not rubagainst the liftgate or other parts whilecycling up, down, open, and closed.Adjust as necessary by loosening fittingsand adjusting the position of the hose(s).Retighten fittings.

Step 30Attach all decals, as shown in the Decalsection of this manual.

Step 31Complete the Final Checklist section.


❏❏ Check all welds to make sure they aredone properly.

❏❏ Make sure all pins are in place and heldwith proper retainers.

❏❏ Make sure the power unit reservoir isfilled.

Fill hydraulic tank to within 1/2 inch from the top ofthe tank.

The fluid level should be 1/2” from thetop of the reservoir when the liftgateplatform is in the fully raised position.

❏❏ Install cover on power unit box. Makesure it is secured with a padlock, lockpin, or wire (customer supplied).

❏❏ Operate the liftgate through its entireoperational cycle (Up, Down, Open,Close) several times. Make sure theliftgate operates evenly, freely, andsmoothly throughout the entire operat-ing range and that there is no unusualnoise or vibration while operating theliftgate.

❏❏ Make sure the platform is adjustedproperly (0 to 3/4 inch rise) with thenecessary shims.

❏❏ Make sure all decals are in place andlegible.

❏❏ Make sure license plate bracket isproperly installed, as required by law.

❏❏ Make sure lights are installed and oper-ating properly, per FMVSS 108.

❏❏ Make sure reflectors are re-installed, ifany.

❏❏ Make sure grab handles and otheringress/egress items are properlyinstalled as may be necessary.

❏❏ Make sure the optional cab cut-offswitch or power cut-off solenoid isinstalled.

❏❏ Put Installation, Operation, andMaintenance manual and Parts manualin the vehicle.


Final Inspection Checklist

Do not use the liftgate if anyof the items in the FinalChecklist are not checkedand verified. If you have anyquestions, contact your near-est Anthony distributor, orthe Anthony Liftgates mainoffice.

DANGER

Safety decals provide a vital role in helpingto reduce injuries and/or possibly evendeath. To ensure the greatest level ofsafety, all decals must be in place and leg-ible at all times. Remember, it is the usersresponsibility to maintain these decals.For a complete part number list of thedecals used on the Tuckunder liftgates,refer to the Decals section in the Partsmanual for MTU-GLR Model TuckunderLiftgates, form number MTU-GLR P-11/04.

For replacement decals contact:Anthony Liftgates, Inc.1037 West Howard StreetPontiac, Illinois 61764(815) 842-3383www.anthonyliftgates.com


Decals

Make sure all decals areattached to the liftgate and/ortruck and are legible at alltimes.

DANGER

MTU Tuckunder LiftgateSafety Decals

Item Part No. Description Qty Remarks

1 Q-003013 Urgent Warning - Elevating Gate 1 On side of truck body.Instructions...

2 ATU-423 Operating Instructions 1 On side of truck body.

3 A-150238 Notice - This liftgate is protected... 1 On side of truck body.

4 ATU-141 After Using Liftgate, Secure Latch... 1 On side of truck body.

5 ATU-147 3000 lb. Maximum Capacity 1 On side of truck body on3000 Models Only.

A-171433 4000 lb. Maximum Capacity 1 On side of truck body on4000 Models Only.

6 A-131034 Anthony Hydraulic Lift Gate label 1 On back of liftgate.

7 A-150601 Flag — Made in the USA 1 Inside edge of platform.

8 A-131003 SF Series 1 Inside edge of platform.

9 A-131026 Zero Leak Concept 1 Inside edge of platform.

10 A-131017 Note: Disengage “latch”... 1 On bottom of main platform.

11 ATU-146 Stand Clear Do Not Ride on Lift 2 On bottom of main platformand on bottom of flip-oversection.

12 ATU-424 Reset Circuit Breaker (not shown) 1 On circuit breaker bracket.

13 ATU-143 Secure Latch While in Transit (not shown) 1 Place by latch assembly.

1. Q-003013


2. ATU-423 3. A-150238

4. ATU-141

5. ATU-147


A-171433

IMPORTANT NOTICEMake sure the proper “maximumcapacity” decal goes on theappropriate liftgate. For example,“3000 lb. Maximum Capacity”decal goes on MTU-GLR 3000models only. Do not put a higherrated decal (4000 pound) on asmaller liftgate; this could result inliftgate damage or possibly per-sonal injury.

6. A-131034

7. A-150601

8. A-131003

9. A-131026

10. A-131017


11. ATU-146

12. ATU-424 (located on circuit breaker)

13. ATU-143


The following is a list of Do’s and Don’tsfor the operation of the liftgate.

✔✔ Do’s✔ Read and follow warning decals, oper-

ating decals, and owners manual.

✔ Keep all decals in place and legible andretain the owners manual in the vehicleor all Warranties are void.

✔ Make sure the vehicle is properly andsecurely braked before using the lift-gate.

✔ Keep yourself clear of all moving parts.

✔ Make sure the area in which the plat-form will open and close is clear beforeopening, closing, raising, or loweringthe platform.

✔ Make sure the platform area, includingthe area in which loads may fall from theplatform, is clear before, during, and atall times while operating the liftgate.

✔ Always place the load as close to thecenter of the platform as possible. Also,position the load as close to the centerof the truck’s rear sill as possible.

✔ Only operate the liftgate with the pushbutton/switch controls mounted on thetruck body.

✔ Check the oil level in the hydraulicmonthly. Change it if it is contaminatedor dirty.

✔ Visually inspect your liftgate frequentlyand keep it properly adjusted.

✔ Repair any damage to the liftgate toprevent accidents.

✔ Lock the liftgate into the storage posi-tion with the latch pin when the liftgate isnot in use.

✘✘ Don’ts✘ Do not overload the platform. The maxi-

mum rated capacity is based on anevenly distributed load on the platform’sflat surface.

✘ Do not ride on the liftgate. Always standclear of liftgate when it is operating.

✘ Do not allow children to play around oroperate the liftgate.

✘ Do not allow your liftgate to be used bypersons not familiar with its operation.

✘ Do not use your liftgate if it shows signsof abuse or fails to operate freely.

✘ Do not allow the motor/pump to run afterthe liftgate is closed, or in the up posi-tion.

✘ Do not use brake fluid in the hydraulicreservoir.


General Safety Operating InstructionsOperation Section

Do not stand in the platform’swork area while operating theliftgate. Serious injury ordeath could result if the loadshifts or is unstable on theplatform.

DANGER

✘ Do not bounce the platform by pushingand releasing the control button/switchabruptly.

✘ Do not use the liftgate for anything otherthan its intended use of loading andunloading cargo.

✘ Do not operate lift trucks on or over anypart of the platform.

✘ Do not stand under or place any objectunder the liftgate work area.


Opening and Closing theLiftgate

Step 1Twist and slide the latch pin toward curb-side of the liftgate.

Step 2Stand clear of the platform and lower theliftgate by pressing "Down" on control but-ton/switch.

Step 3Open the platform.

Step 4Open the flipover ramp.

Step 5Press the "Up" switch to raise platform orthe "Down" switch to lower the platform.

Step 6To tuck the liftgate into its storage positionafter use, reverse Steps 1 2, 3, and 4 fromground level.


Operating Instructions

Monthly InspectionSPECIAL NOTE: As of December 1994Anthony Tuckunder Liftgates are “Service-Free”. This means that newer liftgateshave lubrication-free bushings at the majorpivot points which, of course, do notrequire lubrication. Consequently theseliftgates do not have grease zerks.

1. Make sure the liftgate operates freelyand smoothly throughout its entirerange of movement.

2. Check for damage to the liftgate suchas bent or distorted members, or anycracked weld which may have resultedfrom overload or abuse. Check forexcessively worn parts. Replace bush-ings and pins if extremely worn.

3. Check all pins and pivot points. Makesure they are secured with properretainers.

4. Make sure platform is angled upwardfrom truck bed 0 to 3/4 inch whenraised to bed height. See PlatformAdjustment for a shimming procedure.

5. Make sure all electrical wires, switches,and connections are in good workingcondition and operate properly.

6. Check for oil leaks in these areas:a. Hydraulic lift cylinder.b. Hydraulic hoses. Replace if they

show signs of leakage or excessiveabrasion of the covering.

c. Check all hydraulic fittings fordamage or leaks. Tighten fittingsto stop leaks or replace if dam-aged.

7. Check reservoir oil level.a. Place liftgate in the fully raised, the

oil level should be within 1/2 inchof the top of the reservoir.

b. Fill as required with Penzoil AWXAutomatic Transmission Fluid orequivalent.

IMPORTANT NOTICEUse only Penzoil AWXAutomatic Transmission Fluid orequivalent in the power unitreservoir. Do not use brakefluid.

8. Check the fluid level of the vehicle bat-tery. Fill as required.

9. Examine all Warning, Capacity, andOperational Decals. If they are notreadable they should be replaced.Decals may be obtained from AnthonyLiftgates, Inc.

10. Oil the roller wheel and make sure itspins freely.


Quick Check Maintenance GuideMaintenance Section

Checking Battery CableTo check for a bad battery cable, run themotor directly from a spare battery usingjumper cables.

1. Remove the battery connection to themotor.

2. Connect the negative jumper cable(ground) directly to the liftgate.Connect the positive cable to the termi-nal on the motor start solenoid.

3. Depress the switch, if the motor oper-ates, the battery cable is bad andshould be replaced.

Checking the Control SwitchNewer control switches, shown on the leftside of the photo, are permanently sealed(potted) and cannot be checked. If theseswitches are not working properly, replacethem.

The older unpotted switch can be checkedto make sure it is operating properly.

Gravity Down Models (unpotted)1. Connect one end of a continuity tester

to either top terminal (3) or bottom ter-minal (2).

2. Connect the other end of the continuitytester to a chassis ground or the bodyground.

Inside of gravity down control switch.


Maintenance and Troubleshooting Procedures

Stand clear of the liftgatewhen checking the controlswitch. It is possible for theliftgate to activate when test-ing the switch, which couldlead to personal injury.

CAUTION

3. Once connected, flip the switch for thatfunction (up or down). If the switch isgood, the tester will light to indicategood continuity. If the tester does notlight, then that function of the switch isbad.

4. Repeat the procedure for the other ter-minal.

5. If the switch is bad, replace it.

Power Down Models (unpotted)

Inside of power down control switch.

1. Connect one end of a continuity testerto terminal [2 (a or b), 3, or 4].

2. Connect the other end of the continuitytester to a chassis ground or the bodyground.

3. Once connected, flip the switch for thatfunction (up or down). If the switch isgood, the tester will light to indicategood continuity. If the tester does notlight, then that function of the switch isbad.

4. Repeat the procedure for the other twoterminals.

5. If the switch is bad, replace it.

Replacing the FuseTo replace a fuse:

1. Pull back the rubber boots from thefuse holder.

2. Unscrew the fuse holder ends from thefuse holder body and pull it apart.

3. Slide the fuse holder body one direc-tion (left or right) to expose the blownfuse.

4. Loosen the screws from each end ofthe fuse and remove it. Replace thefuse with the same size (Amperage)fuse as the one removed. If you areunsure of the replacement fuse amper-age, contact Anthony for your specificsize fuse. Retighten the screws.

5. Re- assemble the fuse in reverse order.Be sure the rubber boots are sealedaround the fuse holder and cable.

6. Re-connect power after you are certainliftgate area is clear.


Checking Motor Start Solenoidand Power Cut-off Solenoid

Both the motor start solenoid and powercut-off solenoid can be checked bybypassing the solenoid itself.

1. Use jumper cables for this test.2. Connect one jumper cable to the bat-

tery side (2) of the solenoid. Connectthe other cable to the motor side (1) ofthe solenoid.

3. If the liftgate is activated, the solenoidis bad and should be replaced.

Checking Lowering ValveCartridge and Solenoid1. Place liftgate on the ground in the open

position.

2. Place a steel screwdriver over the topof the lowering valve coil.

3. Momentarily activate the control switchin the DOWN position. The screwdriv-er should be attracted to the magneticfield created by the coil.

4. If no magnetic pull is produced, the coilis bad and should be replaced. If thecoil is good, check the cartridge valve.

5. Remove the solenoid from the valveassembly.

6. Remove the valve cartridge from thepump body.

7. Clean the cartridge and blow it dry withcompressed air (not greater than 30psi). Also blow out the pump body.


8. Use a small screwdriver and carefullypress on the spool inside the cartridge.If the spool moves freely, the cartridgeis good. If it does not move, replacethe cartridge, because the spool couldbe bent, pitted, or damaged in someother way.

Checking Cylinder PistonSeals (drifting - caused by seal leak-age)

Piston Rod Seals (Power Down)1. Check the lowering valve. Make sure it

is operating correctly and the valve isnot sticking or dirty.

2. If the lowering valve is operating prop-erly, then the drifting is most likelycaused by worn piston seals. Rebuildthe cylinder and replace the pistonseals.

If the cylinder is under warranty, do notrebuild. In these cases the complete cylin-der will be replaced.

Packing Gland NutOn newer model cylinders, purchasedafter Spring of 2003, there is no packingseal adjustment. If a leak is found, rebuildthe cylinder with a new seal kit.

On older models, if the packing seals areleaking and oil is flowing down the cylinderpiston, this leakage can be stopped inmost cases by tightening the gland nut.

1. Place the platform on the ground.2. Use a pipe wrench or other suitable

wrench to tighten the gland nut 1/4 to1/2 of a turn. Do not tighten the nutmore than 1/2 of a turn at a time.

3. If the packing gland nut continues toleak, tighten the nut again or rebuild thecylinder using a new seal kit.

IMPORTANT NOTICEDo not overtighten the packinggland nut. If the cylinder does notextend or extends very slowly, thepacking gland nut may be tootight. If the leak cannot bestopped by tightening the packinggland nut, rebuild the cylinderand replace the packing glandseal.


Checking and AdjustingSystem PressurePower down models have two relief valvesettings; one for raising the platform(power up) and one for lowering the plat-form (power down).

To check the “power up” pressure setting:

1. Place the liftgate on the ground andremove the pressure hose from thepower up port of the pump.

2. Install a tee (customer supplied) intothe power up port.

3. Connect a pressure gauge and recon-nect the hydraulic hose.

The pressure gauge must be rated abovethe maximum pressure of the liftgate. Forexample, use a 4000 psi pressure gaugeon a 3000 psi maximum capacity liftgate.

4. Raise the liftgate and check the pres-sure. If the pressure is low, adjust thepower-up pressure relief valve (1).

5. With the liftgate on the ground, loosenthe locknut. Use an Allen wrench andturn the pressure adjustment screwcounterclockwise to increase pressureand clockwise to decrease the pres-sure.

If the appropriate pressure cannot bereached, replace the pump.

6. Hold the valve adjustment screw inplace and tighten the locknut. Thismethod will prevent the adjustmentscrew from turning when the locknut istightened.

7. Check the power down relief valvepressure (2) in the same way as thegravity down system by installing a teeand gauge.

8. The power-down pressure should notexceed 400 psi. Turn the adjustingscrew counterclockwise to decreasethe pressure and clockwise to increasethe pressure.


Do not stand or work in theplatform’s work area whileoperating the liftgate. Placethe pressure gauge so it canbe read while operating theliftgate from a safe location.Serious injury or death couldresult if this action is not fol-lowed.

DANGER

Flow Control Valve

If the cylinders do not operate or operateslower than normal, remove the flow con-trol valves and hook the hydraulic hosesdirectly to the cylinders. If the cylindersoperate properly, replace the flow controlvalves.


Do not operate the liftgatewithout the flow controlvalve. Serious injury or deathcould result if this action isnot followed.

DANGER

Safety is Your ResponsibilityIt is the responsibility of the installer/oper-ator to understand and perform properoperating procedures. Be aware of theinherent dangers in the use of this productand the tools used to install it. Read andunderstand all Danger, Warnings,Cautions, and Important Notices in thismanual and on the liftgate or truck.

Safety Signal WordsA signal word or words call attention to thesafety sign and designate a degree orlevel of hazard seriousness. The signalwords for Anthony Liftgates’ product safe-ty signs are DANGER, WARNING, CAU-TION, and IMPORTANT NOTICE.

DANGER: Indicates an imminently haz-ardous situation which, if not avoided, willresult in death or serious injury. This signalword is limited to the most extreme situa-tions.

WARNING: Indicates a potentially haz-ardous situation which, if not avoided,could result in death or serious injury.

CAUTION: Indicates a potentially haz-ardous situation which, if not avoided, mayresult in minor or moderate injury. It mayalso be used to alert against unsafe prac-tices.

IMPORTANT NOTICEIndicates that equipment orproperty damage can result ifinstructions are not followed.

Safety Rules

CAUTION

WARNING

DANGER


To avoid personal injury ordeath, carefully read andunderstand all instructionspertaining to the AnthonyLiftgates product. Do notattempt to install, operate,or maintain our productwithout fully understand-ing all our instructions andsafety precautions. Do notoperate or work on a truckor liftgate unless you readand understand theinstructions and warningsin the Installation,Operation, andMaintenance manual. Ifany doubt or question aris-es about the correct or safemethod of performing any-thing found in this or otherAnthony Liftgates’ manu-als, contact your AnthonyLiftgates’ dealer or call theInside Sales and Servicerepresentatives at our mainheadquarters. Proper careis your responsibility.

DANGER

Safety SectionSafety


To prevent injury, make sureall decals are attached to theliftgate and/or truck and arelegible at all times.

DANGERTo prevent injury, the liftgateshould only be installed by aqualified installer havingknowledge and skill in usingwelding equipment and a cut-ting torch.Always weld in a well ventilat-ed area and, if in an enclosedarea, vent the fumes to theoutside. Breathing weldingsmoke and paint fumes cancause serious injury. Always follow all State andFederal health and safety lawsand/or local regulations whenusing an arc welder, migwelder, or cutting torch. Also,follow all manufacturer’s safetyguidelines. If other people arepresent during the installationof the liftgate, make sure thewelding area is shield fromtheir view. This will help pre-vent serious eye injury from thebright light.To avoid eye injury duringwelding, always wear a weld-ing helmet with the properlens to shield your eyes fromthe bright light.Failure to prevent the truckfrom moving during theinstallation of the liftgatecould result in serious per-sonal injury or crushing ofthe installer(s).

DANGER

To prevent serious bodily injury, keepsparks, lighted matches, and openflames away from the top of the bat-tery, because battery gas canexplode. Always follow all the manu-facturers’ safety recommendationswhen working around the truck’s bat-tery.

Take precautions to avoidsparks coming into contactwith the truck’s fuel tank,brake lines, or other flamma-ble components. Sparks cancause an explosion of com-bustible materials, resultingin serious injury or death.Never secure the power cableto anything which allows it tocontact sharp edges, otherwiring, fuel tank, fuel lines,brake lines, air lines, exhaustsystem, or any other objectthat could cause the powercable to wear or be damaged.A cut battery cable can causesparks resulting in loss ofvehicle control, seriousinjury, or even death.

DANGER


Most accidents involving theoperation, maintenance, or repairof products made by AnthonyLiftgates occur because theinstaller/owner/operator failed toobserve basic safety rules oroperating instructions. Accidentscan often be avoided by beingalert and recognizing potentiallyhazardous situations. Any indi-viduals installing, operating,maintaining, or repairing prod-ucts manufactured by AnthonyLiftgates should have the neces-sary training, skills, and toolsrequired to perform these func-tions properly and safely. Thesafety information in this manualserves as a basic guide in anattempt to prevent injury or death.

Anthony Liftgates cannot antici-pate every possible circum-stance that might involve apotential hazard. The warningsin this manual and on the prod-uct itself are, therefore, not allinclusive. If tools, procedures,work methods, or operatingtechniques that are not specifi-cally mentioned by AnthonyLiftgates are used, you must sat-isfy yourself that they are safefor you and for others. Makesure the liftgate or truck it ismounted onto will not be dam-aged or made unsafe by anyoperation, lubrication, mainte-nance, or repair procedures thatyou choose.

DO NOT proceed, if any doubtarises about the correct or safemethod of performing anythingfound in this or other AnthonyLiftgates’ manuals. Seek outexpert assistance from a quali-fied person before continuing.

WARNINGUse extreme caution if work-ing under the liftgate duringinstallation. Failure to safelysecure the liftgate to the floorextension could cause seri-ous personal injury. Do notremove the lifting device(s)until the liftgate is completelywelded onto the truck.

To prevent personal injury,clean up any spilled fluidsimmediately. To avoid trip-ping, do not leave tools orcomponents laying around inthe work area.Do not place hands or feet inpinch points.

Do not ride on the platform.

Do not place your feet underthe liftgate.

Always use/set the truck’sparking brake before operat-ing the liftgate. Failure to fol-low this recommendation canresult in injury.

WARNING


Many liftgate models providedrivers’ steps as a conven-ience feature. When stepsare present, customer-sup-plied grab handles and otheringress/egress items shouldbe installed.Even though the Anthony lift-gate is easy to install, theinstallation should be donewith at least two people.Take precautions to avoidwelding sparks or the flamefrom a cutting torch cominginto contact with the truckbed’s wooden floor or otherflammable components. Tack welds must be strongenough to hold the weight ofthe individual componentsbeing held in place.Insufficient tack welds maynot hold the parts in place,resulting in possible bodilyharm.

CAUTION

IMPORTANT NOTICEUse only Penzoil AWXAutomatic Transmission Fluidor equivalent in the power unitreservoir. Do not use brakefluid.

Troubleshooting Chart

Problem Possible Cause Possible Solution

Motor does not run when Cab cut-off switch. Turn switch to ON position.control switch is activated.

Dead battery. Make sure battery is fully charged. Check for loose or corroded battery con-nections. Replace or recharge battery.

Main power cable circuit protection Reset circuit breaker or replace fuse.tripped or blown.

10 Amp fuse in power unit box. Replace, if fuse is blown. If problem con-tinues, check for shorts in the electricalsystem.

Control box switch. Check switch using Checking ControlSwitch procedure in Maintenance section.

Motor start solenoid. Check solenoid using the procedure inthe Maintenance section.

Optional power cut-off solenoid. Check solenoid using the procedure inthe Maintenance section.

Battery cable. Connect motor directly to a spare batteryusing the procedure in the Maintenancesection.

Motor. If the motor is determined to be bad, itshould be replaced. Bad motors are typi-cally caused by weak batteries (low volt-age), loose connections, corrosion, or apoor ground.

If liftgate is installed on a semi trailer make sure the battery wire is two gauge orheavier. Smaller wires can reduce the voltage, resulting in motor failures.

If the motor dose not operate in freezing conditions, make sure the motor housingdoes not contain water.

Troubleshooting SectionTroubleshooting Guide



Troubleshooting Chart (continued)


Motor runs, but liftgate will not open Structural damage. Check clearance Fix damage. Replace worn parts.or lower to the ground. between platform and dock bumpers.

Latch pin. Slide the latch pin to the open position.

Control switch box. Check DOWN terminal using the proce-dure in the Maintenance section.

Lowering valve coil. Check the coil using the procedure in theMaintenance section.

Lowering valve cartridge. Check, remove, and clean valve cartridgeusing the procedure in the Maintenancesection.

Flow control valve. Remove flow control valve and hookhydraulic hose directly to the cylinder. Ifthe cylinder operates properly, install anew flow control valve.

Motor runs, but platform will not raisewill not raise rated capacity, or raises,but drifts down when control switch is released.

Structural damage. Replace damaged parts.

Low fluid level. Fill reservoir.

Low Voltage. Inspect the battery connection terminalsand check the battery’s Voltage (9 Voltsminimum).

Lowering valve. Coil or cartridge may need cleaning orreplacement. See Maintenance section.

Bad piston seals. See Maintenance section for CheckingCylinder for Leakage.

Pump relief valve needs adjusted. See Maintenance section for Checkingand Adjusting System Pressure.

Hydraulic pump is worn. Replace hydraulic pump.

Sagging platform. Normal wear. Add shims to platform. See Maintenance section for Platform Adjustment.

Bushing wear where lift arms Replace bushings.connect to platform.


Load capacity has been exceeded. Verify load capacity and adjust loadweight.


Troubleshooting Chart (continued)


Foaming oil. Air in the hydraulic hose(s). Check oil level in reservoir.

Broken or loose fluid return tube. Remove the oil reservoir and make surethe return tube is below the oil level. Ifthe tube has turned or fallen out, reinstallit into the pump housing. Use a centerpunch to “stake” the tube into position.

Hydraulic fluid is leaking from Loose packing gland nut, if so Tighten gland nut.packing gland. equipped.

Latch pin is broken or bent. Operator has lowered platform The latch pin is only used to prevent the without releasing latch pin. liftgate from opening due to a pressure

leak or pressure bleed-off over an extend-ed period of time. Always release latchbefore opening liftgate.

Liftgate raises truck when Power down system pressure is See Maintenance section for Checkinglowered to the ground. set too high. and Adjusting System Pressure.

Liftgate will not open. Platform operating area is not clear. Clear platform operating area.

Pin will not slide free. Activate the “UP” switch and raise the lift-gate to the fully stored position.Open the latch pin free.

Platform lowers extremely slow. Low oil level on power down models. Fill reservoir.

Improper oil in hydraulic reservoir. See Monthly Inspection.

Bushing wear where lift arms Replace bushings.connect to platform.

Damaged or kinked hydraulic hose. Repair or replace.

Cylinder rod is scored, pitted, or bent. Repair or replace.

Flow control valve. Remove flow control valve and hookhydraulic hose directly to the cylinder. Ifthe cylinder operates properly, replacethe valve.

Lowering valve. Solenoid or cartridge may need cleaningor replacement. See Maintenance sec-tion.

Platform raises partially and stops. Load capacity has been exceeded. Verify load capacity and adjust loadweight.


Low Voltage. Recharge battery (if less than 9 volts).

Low fluid level or pressure. Refill reservoir. Check relief valve.

Platform will not lower. Platform operating area is not clear. Clear area.


Low Voltage. Recharge battery (if less than 9 volts).

Lowering valve. See Maintenance section.

Hydraulic pump and motor. Replace power unit.

NOTES


Anthony Liftgates, Inc.1037 W. Howard Street • P.O. Box 615 • Pontiac, IL 61764-0615Ph: 815.842.3383 • Fax: 815.844.3612 • Toll Free: 800.482.0003www.anthonyliftgates.com

Form No. MTU-GLR-IO-10/04

Documents

AND OPERATIONuploads.gocdn.us/270_162_MTU-GLR- INSTALL AND TROUBLE SHOOT.pdftion in the Parts manual for MTU-GLR Model Tuckunder Liftgates, form number MTU-GLR P-10/04. For decal placement,