2-post lift concrete · pdf file2-post lift concrete requirements toll free: 800.648.5438...

Flooring:

Requirements for concrete are 4˝ minimum

depth, with steel reinforcement, 3500 psi, cured

for 28 days per local commercial practice.

Floor should be level within 3/8˝ over the

installation area. No anchors should be

installed within 8˝ of any crack, edge, or

expansion joint. If these conditions cannot

be met, pads can be poured to accommodate

the lift.

Check with local building inspectors and/or

permits offi ce for any special instructions or

approvals required for your installation.

2-Post Lift Concrete Requirements

Toll Free: 800.648.5438Phone: 502.625.0700Fax: 502.625.0711

www.challengerlifts.com

Challenger Lifts, Inc.200 Cabel StreetLouisville, KY 40206

Challenger Lifts, Inc. reserves the right to

make changes without notice and without

making changes retroactive.

2-Post Concrete Requirements 6-05

Rev. 8/22/03

IIIINSTALLATION NSTALLATION NSTALLATION NSTALLATION & O& O& O& OPERATION PERATION PERATION PERATION

MMMMANUAL ANUAL ANUAL ANUAL SSSSUPPLEMENTUPPLEMENTUPPLEMENTUPPLEMENT

Dual Pendant Control

200 Cabel Street, P.O. Box 3944 Louisville, Kentucky 40201-3944 Email:[email protected] Web site:www.challengerlifts.com

Office 800-648-5438 / 502-625-0700 Fax 502-587-1933

IMPORTANT:IMPORTANT:IMPORTANT:IMPORTANT: READ THIS MANUAL COMPLETELY BEFORE INSTALLING or OPERATING LIFT

mailto:[email protected]

http://www.challengerlifts.com/

Dual Pendant Control Installation & Operation Supplement

Page 2 8/22/03 A1205-30.doc

READ ENTIRE MANUAL BEFORE ASSEMBLING, INSTALLING, OPERATING, OR SERVICING THIS EQUIPMENT. PROPER MAINTENANCE AND INSPECTION IS NECESSARY FOR SAFE OPERATION. DO NOT OPERATE A DAMAGED LIFT.

IIIINSTALLATIONNSTALLATIONNSTALLATIONNSTALLATION FOR NEW LIFT OR RETRO-FIT INSTALL TOOLS (MINIMUM REQUIRED FOR RETRO-FIT)

a. 10” adjustable wrench b. 7” adjustable pliers c. Needle nose pliers d. Standard open end wrenches 7/16”, 3/4" e. 5/16” allen wrench f. Sockets: 1/4" (for Ground Screw), 7/8”, 1” g. Drill with 17/64” bit h. 5/16-18NC tap i. Wire stripper j. Crimping tool for solderless terminals

For New Lift Install (If power unit is already equipped with electric lowering valve and has motor wiring box cover mounted relay)

Skip to Step 10) POWER UNIT RE-CONFIGURING 1) Disconnect power to Lift. 2) Remove Motor Wiring Box Cover/Pushbutton

and discard. (This will be replaced by Blank Cover/Relay Assembly)

Fig 1 – Power Unit 3) Remove “knock-outs” from Motor Wiring Box

as indicated for Solenoid Lowering Valve and install supplied Straight Cord Grip (½” NPT x 3/8” O.D. wire), see Fig 1. (Note: ½” NPT cord grip fitting uses 7/8” dia. knock-out and ¾” NPT uses 1 1/8”).

4) Remove Lowering Valve Assembly (handle & valve cartridge), (Fig. 1).

5) Install Solenoid Lowering Valve supplied, (Fig 2).

Fig 2 – Solenoid Lowering Valve 6) Remove “knock-outs” from Motor Wiring Box

as indicated for Overhead Limit Switch and Idler and Power Column Pendants.

7) Install Ground Lug under motor ground screw located in Motor Wiring Box (use ¼” socket to access ground screw through the Idler Column Pendant “knock-out”).

LOCK RELEASE CABLE TAB (THE POWER COLUMN MUST HAVE A CABLE CASING TIE-OFF TAB ADDED BELOW THE LOCK ASSEMBLY) 8) Remove existing Lock Covers and Lock

Pawls and discard. 9) Drill 17/64” diameter hole and tap 5/16-18NC

as indicated in Fig 3. Mount Tab using 5/16-18 x 3/8 Lg. Pan Head Screw and 5/16” Split Lock Washer.

Fig 3 – Lock Release Tab Location


Page 3 8/22/03 A1205-30.doc

LOCKING PAWL 10) Attach 1/2" O.D. Extension Spring to hole

located on bottom side of both supplied Lock Pawls, Fig 4. Install Lock Pawl and Lock Release Clevis on both columns using 5/8” diameter x 1 1/2” lg shoulder bolt and 1/2”-13 nylon lock nut. Attach 3/8” O.D. Extension Spring to upper hole in locking pawl and other end to hole in bracket welded to column as shown in Fig 4.

Fig 4 – Locking Pawl Assembly

Fig 5 – Power Column Lock Release Assembly

DUAL LOCK RELEASE (TWO LOCK RELEASE CABLES WILL BE ROUTED TOGETHER THROUGH THE LIFT. ONE CABLE ATTACHES TO THE TOP OF THE POWER COLUMN LOCK RELEASE CLEVIS AND THE BOTTOM OF THE IDLER COLUMN LOCK PAWL. THE OTHER CABLE ATTACHES TO THE TOP OF THE IDLER COLUMN LOCK RELEASE CLEVIS AND THE BOTTOM OF THE POWER COLUMN LOCK PAWL)

11) Attach Mechanical Lock Release Cable Assembly to Power Column Lock Pawl using the 3/16” diameter x 1/2" long pin and (2) “C” clip retainers found in hardware, Fig 5.

12) Insert threaded sleeve portion of cable assembly in slot located on tab above locking pawl, Fig 5. One jam nut should be located on each side of tab. Position threaded sleeve with ½” of thread below tab as indicated in Fig 5 and tighten jam nuts.

13) Route opposite end of cable assembly up Power Column and into column through access slot in bottom of Column Extension. Following the path of the hydraulic line, route cable assembly across overhead clear of moving parts and back out through access slot in bottom of idler side column extension. Attach Cable Assembly to the hydraulic hose with loosely fit wire ties.

NOTE: DO NOT kink cable assembly when routing. Tighten and trim wire ties after final cable adjustments have been made 14) Attach Adhesive-Backed Tab to Idler Column

left of the lock assembly (Fig 6). Route Lock Release Cable down left side of Idler Column and secure with loosely fit wire tie to Adhesive-Backed Tab. Attach Cable clevis to 1/2" O.D. Extension Spring.

Fig 6 – Idler Column Lock Release Assembly 15) Insert threaded sleeve portion of cable

assembly in slot located on tab below lock pawl, Fig 6. With one jam nut located on each side of tab, adjust the threaded sleeve


Page 4 8/22/03 A1205-30.doc

to begin to pull tension on the ½” O.D. spring. Snug jam nuts by hand.

16) Repeat procedures 11 thru 14 with second Lock Release Cable routing from top of Idler Column Lock to bottom of Power Column Lock, (Figs. 5 & 6).

THE LOCK RELEASE CABLE ADJUSTMENT IS NOT COMPLETE UNTIL THE LIFT HAS BEEN LOWERED AND “FINAL ADJUSTMENTS” HAVE BEEN MADE. PENDANT SWITCHES 17) Hang both pendant switches using supplied

5/16” Line Clamp, 5/16-18 x 3/8 Lg. Pan Head Screw and 5/16” Split Lock Washer (Fig 7).

IMPORTANT: RISK OF EXPLOSION. THE PENDANT CONTROLS HAVE INTERNAL ARCHING OR SPARKING PARTS THAT SHOULD NOT BE EXPOSED TO FLAMMABLE VAPOR. THE PENDANT CONTROLS SHOULD BE LOCATED AT LEAST 18 INCHES (460mm) ABOVE THE FLOOR.

Fig 7 – Pendant Switch Installation 18) Route Idler Column Pendant Switch cord up

and over to the Power Unit following the path of the Lock Release Cable clear of moving parts. Attach with wire ties.

ELECTRICAL 19) Connect the Overhead Limit Switch cord,

Pendant Switch cords, Solenoid Lowering Valve cord and suitable electrical source to Power Unit as shown in Fig 8.

IMPORTANT: After wiring has been completed, test operation of Power Unit, Pendant Switches & Overhead Limit switch. While raising lift, operate Overhead Shutoff Bar. Power Unit Motor should stop when Shutoff Bar is raised.

LOCK RELEASE CABLE 20) Lower lift to the floor and snap plastic cover

over Power Column lock assembly. 21) Pull and release Power Column lock release

handle while watching Idler Column lock. Adjust lower threaded sleeve cable adjuster jam nuts on Idler Column until Idler Column lock disengages and engages fully. When properly adjusted, the idler column lock should just come to rest against the back of the column when engaged and fully out against the tab when disengaged. Tighten Idler Column lower tab jam nuts.

22) Remove plastic lock cover from Power Column and snap plastic cover over Idler Column lock assembly.

(The following step is a repeat of step 21 for Idler Column lock release handle) 23) Pull and release Idler Column lock release

handle while watching Power Column lock. Adjust lower threaded sleeve cable adjuster jam nuts on Power Column until Power Column lock disengages and engages fully. When properly adjusted, the Power Column lock should just come to rest against the back of the column when engaged and fully out against the tab when disengaged. Tighten Power Column lower tab jam nuts.

IMPORTANT: IF LOCK PAWLS DO NOT FULLY DISENGAGE, DAMAGE MAY RESULT TO IDLER SIDE CARRIAGE AND OR CABLE SYNCHRONIZING SYSTEM. 24) Tighten and trim wire ties. 25) Snap plastic cover over each lock assembly

(align lock release cable with notches in lock cover flange).


Page 5 4/2/03 A1205-30.doc

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Page 6 4/2/03 A1205-30.doc

PARTS BREAKDOWN

Fig A. Dual Pendant Control


Page 7 4/2/03 A1205-30.doc

PARTS BREAKDOWN (continued)

ITEM #ITEM #ITEM #ITEM # PART #PART #PART #PART # QTY/ LIFT QTY/ LIFT QTY/ LIFT QTY/ LIFT DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION

A1201PC-15 MODEL CL9 POWER UNIT, 208-230VAC SINGLE PHASE (includes ITEMS 2, 3, 7, 10, 11, & 12) 1

A1201PC-17 1

MODEL CL10 POWER UNIT, 208-230VAC SINGLE PHASE (includes ITEMS 2, 3, 7, 10, 11, & 12)

2 W-135 1 MOTOR WIRING BOX COVER w/RELAY

3 A1205-25 1 GROUND LUG, #8 STUD-TO-1/4" SPADE ADAPTER

4 A1205-26 5 FEMALE CONNECTOR, 10-12AWG x 1/4" SPADE, FULLY INSULATED

5 A1205-27 1 RED WIRE NUT

6 31120 3 YELLOW WIRE NUT

7 A1205-35 1 CORD GRIP - STRAIGHT, 1/2NPT x .35 O.D. WIRE

8 A1205-36 2 CORD GRIP - 90 deg., 1/2NPT x .35 O.D. WIRE

9 A1205-38 1 CORD GRIP - STRAIGHT, 3/4NPT x .50 O.D. WIRE

10 VF-4009 1 120VAC N.C. CARTRIDGE LOWERING VALVE ( w/o COIL)

11 EF-1092 1 120VAC SOLENOID LOWERING COIL

12 2000105 1 LOWERING COIL HIRSCHMANN CONNECTOR w/CORD ASS'Y

A1205-40P 1 PENDANT CONTROL SWITCH - POWER SIDE (5 ft. CORD) 15

A1205-40I 1 PENDANT CONTROL SWITCH - IDLER SIDE (34 ft. CORD)

16 A1205-34 2 "Challenger" DECAL .32x.89

20 A1122-6 2 CABLE CLAMP 5/16" I.D.

21 10335 2 5/16-18NC x 3/8" Lg. PHILIPS PAN HEAD SCREW

22 31331 2 5/16 SPLIT LOCK WASHER

23 A1130 1 TAB (LOCK RELEASE)

25 30020 2 LOCK PIN (5/8 x 1 1/2" Lg. SHOULDER BOLT)

26 37013 2 LOCK PIN RETAINER (1/2-13NC HEX LOCK NUT)

27 A1140 2 LOCK PAWL (DUAL CONTROL)

28 A1131 2 LOCK SPRING (3/8" O.D.)

29 A1132 1 CABLE SPRING (1/2" O.D.)

30 A1141 2 LOCK RELEASE CLEVIS ASSEMBLY

31 A1133 2 LOCK COVER

32 36096 1 BALL HANDLE

33 37119 1 CLEVIS PIN KIT A1135-0 LOCK RELEASE CABLE ASSEMBLY - MODEL CL9 (11'-8" OVERALL HT.)

A1135-1 LOCK RELEASE CABLE ASSEMBLY - MODEL CL9-1 (12'-8" OVERALL HT.)

A1135-2 LOCK RELEASE CABLE ASSEMBLY - MODEL CL9-2 (13'-8" OVERALL HT.) A2135-0 LOCK RELEASE CABLE ASSEMBLY - MODEL CL10 (11'-8" OVERALL HT.)

A2135-2 LOCK RELEASE CABLE ASSEMBLY - MODEL CL10-2 (13'-8" OVERALL HT.)

34

A2135-3

1

LOCK RELEASE CABLE ASSEMBLY - MODEL CL10-3 (14'-8" OVERALL HT.)

Rev. 10/9/03 A2151.doc

IIIINSTALLATIONNSTALLATIONNSTALLATIONNSTALLATION, O, O, O, OPERATION PERATION PERATION PERATION

& M& M& M& MAINTENANCE AINTENANCE AINTENANCE AINTENANCE MMMMANUALANUALANUALANUAL

VersymmetricTM Two Post Surface Mounted Lift

MODEL CL10 10,000 LBS. CAPACITY

2500 LBS. PER ARM


Office 800-648-5438 / 502-625-0700 Fax 502-587-1933




Model CL10 Installation, Operation and Maintenance

Page 2 10/9/03 A2151.doc

GENERAL SPECIFICATIONS

See Figure 1 CL10 CL10-2 CL10-3 A Column Height 11’- 8” 13’- 8” 14’- 8” B Floor to Overhead Switch 11’- 2 1/2 ” 13’- 2 1/2” 14’- 2 1/2” C Rise Height (Screw Pads Highest Position) 74 5/8” D Cylinder Height (Full Stroke) 11’- 11” E Adjustable Overall Width 11’- 11” / 11’ – 6 1/2" F crew Pad Height 4 1/8” to 6 5/8” G Inside of Columns 114 1/2” / 110” Drive Thru Clearance 104 1/2" / 100” Ceiling Height Required 11’- 11 ” 13’- 9” 14’- 9” * Maximum Capacity 10,000 lbs. (2500 lbs. Per Arm) Lifting Time 48 Sec. (approximate)

Motor 2HP, Single Phase, 60Hz, 208/230 Optional – 2HP, Three Phase, 50/60Hz, for 208 or 230 or 460

* Lift capacity ratings are based on loads equally distributed on all four arms.

COLUMN BASE PLATES

144" [12'-0"]MIN.TO

NEARESTOBSTRUCTION

1112" REF

(USE AS REFERENCE ONLY)SEE CHART ABOVE

(INSIDE COLUMN TO COLUMN)SEE CHART ABOVE

144" [12'-0"]MIN. TO

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6' TO NEARESTOBSTRUCTION

OR 7' TO NEAREST WALL

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144" [12'-0"]MIN.TO

NEARESTOBSTRUCTION

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144" [12'-0"]MIN. TO

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144" [12'-0"]MIN.TO

NEARESTOBSTRUCTION

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144" [12'-0"]MIN. TO

NEARESTOBSTRUCTION



COLUMN BASE PLATES



1112" REF

DRIVE ONDIRECTION

144" [12'-0"]MIN.TO

NEARESTOBSTRUCTION

Fig 1a - General Specifications Fig1b - Service Bay Layout


Page 3 10/9/03 A2151.doc

WARNING

VERTICAL CLEARANCE Check the height of the area where the lift is to be installed. Clearance should be calculated based on the full raised height of the lift.

Failure by purchaser to provide adequate clearance could result in

unsatisfactory lift performance, property damage, or personal injury.

FLOORING Be certain you have the proper concrete floor to properly handle the loaded lift. Floor should be in generally good condition with no large cracks, spalling or deterioration. Minimum requirements for concrete are 4 inches minimum depth, with steel reinforcement, 3500 psi, cured for 28 days per local commercial practice. Floor should be level within 3/8 inch over the installation area. No anchors should be installed within 8 inches of any crack, edge, or expansion joint. If these conditions cannot be met, a pad may be poured to accommodate the lift. Check with local building inspectors and/or permits office for any special instructions or approvals required for your installation.

Failure by purchaser to provide the recommended mounting surface could

result in unsatisfactory lift performance, property damage, or personal injury.

ELECTRICAL REQUIREMENTS For lift installation and operation for single phase units, it is necessary to have a dedicated circuit with a double pole 25 amp circuit breaker or time delay fuse.

SAFETY NOTICES AND DECALS For your safety, and the safety of others, read and understand all of the safety notices and decals included here.


Safety decals similar to those shown here are found on a properly installed lift. Be sure that all safety decals have been correctly installed on the Power Unit reservoir. Verify that all authorized operators know the location of these decals and fully understand their meaning. Replace worn, faded, or damaged decals promptly.

Do not attempt to raise a vehicle on the lift until the lift has been correctly

installed and adjusted as described in this manual.

WARNING

WARNING


Page 4 10/9/03 A2151.doc

RECEIVING The shipment should be thoroughly inspected as soon as it is received. The signed bill of lading is acknowledgement by the carrier of receipt in good condition of shipment covered by our invoice. If any of the goods called for on this bill of lading are shorted or damaged, do not accept them until the carrier makes a notation on the freight bill of the shorted or damaged goods. Do this for your own protection. NOTIFY Challenger Lifts AT ONCE if any hidden loss or damage is discovered after receipt. IT IS DIFFICULT TO COLLECT FOR LOSS OR DAMAGE AFTER YOU HAVE GIVEN THE CARRIER A CLEAR RECEIPT. File your claim with Challenger Lifts promptly. Support your claim with copies of the bill of lading, freight bill, and photographs, if available.

Component Packing List

PART # QTY/ LIFT DESCRIPTION

A2001-P 1 Power Column Ass’y

A2001-I 1 Idler Column Ass’y

A2060 1 Overhead Beam

A2005 1 Hardware Box

A2002 1 Arm Pack

A2055-0 Column Extension for CL10

A2055-1 Column Extension for CL10-1

A2055-2

2

Column Extension for CL10-2

A2003-0 Sync Cable Pack for CL10

A2003-1 Sync Cable Pack for CL10-1

A2003-2

1

Sync Cable Pack for CL10-2

A2055 - * 2 Column Extensions

A2003 - * 1 Sync Cable Pack

36035 1 Overhead Shut-Off Bar Ass’y

36027 1 Mercury Switch

A2004 1 Hydraulic Line Pack

A1201-17 A1203-17 1 Power Unit – 1 Phase

Power Unit – 3 Phase

A2150 1 Literature Pack

IIIINSTALLATIONNSTALLATIONNSTALLATIONNSTALLATION IMPORTANT: Always wear safety glasses while installing lift.

TOOLS (MINIMUM REQUIRED) a. Tape measure, 16ft b. Chalk line c. 4ft level d. 10” adjustable wrench e. Standard open end wrenches 7/16”, 1/2", (2) 9/16”, (2) 11/16”, 3/4", 15/16” f. 5/16” allen wrench g. Needle nose pliers h. Hammer drill with 3/4” diameter carbide

tipped bits i. 2lb hammer j. Torque wrench: 150 foot pounds minimum

with 1 1/8” socket k. 12 ft. Step ladder l. Anti-Seize lubricant (for arm pins)

LAYOUT 1) Layout the service bay according to the

architect’s plans or owners instructions (see Fig 1b). Be certain that the proper conditions exist, see page 3.

2) Assemble column extension to column using 3/8-16 x 3/4" lg Hex flange head bolt. repeat for opposite column and extension.

3) Erect both column assemblies. Align the notches in column base, Fig 2, with the installation lines.

ANCHORING 4) The anchor bolts must be installed at least 8”

from any crack, edge, or expansion joint. 5) Use a concrete hammer drill with a 3/4 inch

carbide bit. Tip diameter should conform to ANSI Standard B94.12-1977 (.775 to .787). Do not use excessively worn bits or bits which have been incorrectly sharpened. A core bit may be necessary if an obstruction is encountered. Never substitute with shorter anchor.

6) Recheck “Inside of Columns” dimension, Fig 1. Drill the anchor holes using the base plate as a template. Drill through the floor if possible or to a depth of 5 inches minimum.

7) Vacuum dust from the hole for proper holding power.

8) Shim both columns to plumb using the shims provided as shown in Fig 2. DO NOT shim more than 1/2" at any given point. Use a level no less than 24” in length to plumb columns.

9) Assemble washer and nut to anchor with nut just below impact section of bolt. Drive anchor into hole until nut and washer contact base.


Page 5 10/9/03 A2151.doc

Fig 2 – Column Shimming

10) Tighten power column anchors and recheck column for plumb. Reshim if necessary. Torque to 150 foot pounds to set anchors.

OVERHEAD 11) Before raising overhead into position install 4

each (2 per column) hex flange bolts and nuts in middle hole of column extension (see Fig 3 Installation Aid) for temporary support of overhead. Lift overhead assembly up into position and install with 8 each (4 per column) 3/8-16 x 3/4” lg hex flange bolts and hex flange nuts per side as shown in Fig 3.

Fig 3 – Overhead Assembly 12) Check idler column shimming. Use additional

shims (see Fig. 2) to remove any gaps that may have been created while installing overhead beam. Tighten anchor bolts and re-check column for plumb. Torque to 150 foot pounds.

13) Install Overhead Limit Switch to REAR of Power Column using (1) 3/8” pivot pin, (1) 3/8” flat washer and (1) hairpin cotter pin as shown below. Switch MUST pivot freely on pin for proper function. NOTE switch tube cord is to be oriented above pivot pin as shown in Fig 4a. Leave switch cord hanging at this time.

Fig 4a – Overhead Limit Switch Sub-Assembly

(6) 3/8" FLAT WASHERS(6) 3/8" FLAT WASHERS(6) 3/8" FLAT WASHERS(6) 3/8" FLAT WASHERS

HAIRPIN COTTER PINHAIRPIN COTTER PINHAIRPIN COTTER PINHAIRPIN COTTER PIN

PIVOT HOLE FOR11'-11"

OVER ALL WIDTH

OVER ALL WIDTH11'-6 1/2"PIVOT HOLE FOR

Fig 4b – Overhead Limit Switch Sub-Assembly

IMPORTANT: There are two overall width settings. Insure to place the limit switch and shutoff bar in the proper pivot holes as shown in Fig’s 4a & 4b. 14) Repeat procedure 12 for shut-off bar. Insert

shut-off bar in switch tube on power column side and take other end to idler side. Attach shut-off bar to idler column in same manner as switch tube.

Insure that both switch tube and shut-off assemblies pivot freely for proper operation.


Page 6 10/9/03 A2151.doc

15) Assemble the sheaves and spacers onto the sheave pin as shown in Fig 5. Set in cradle with all assembly parts between the two plates.

SHORT SHEAVE SPACER

SHEAVESHEAVE PIN

LONG SHEAVE SPACER

SHEAVE

WASHER

WASHER

WASHER

WASHER

SPACERSHORT SHEAVE

Fig 5 – Sheave Assembly

LOCKING PAWL 16) Install Power Column locking pawl and lock

release clevis with 5/8” diameter x 1 1/2” lg shoulder bolt and 1/2”-13 nylon lock nut, Fig. 6. Attach 3/8” O.D. extension spring to upper hole in locking pawl and other end to hole in bracket welded to column.

Fig 6 – Locking Pawl Assembly 17) Attach ½” O.D. extension spring to hole

located on bottom side of Idler Column lock pawl and install using 5/8” shoulder bolt and lock nut, Fig 6. Attach 3/8” O.D. spring the same as Power side.

SYNCHRONIZER CABLES 18) Attach one end of synchronizing cable to

carriage. See Fig 7 for proper attachment.

19) Route cable up and over sheave in overhead. Follow across to other sheave on opposite column. Route down through carriage to sheave in bottom of column. Route under sheave and up to cable attachment. Use Fig 7 for proper attachment.

20) Repeat for opposite side.

IMPORTANT:4 1/2" lg STAND-OFFFOR 11'- 6 1/2" WIDTHSETTING ONLY




Fig 7 – Cable Assembly

IMPORTANT: Stand-Offs to be used only on the 11’– 6 ½” Overall Width Setting.

POWER UNIT & HYDRAULIC LINES

5/16"-18 HEX NUT(4) REQUIRED5/16"-18 HEX NUT(4) REQUIRED5/16"-18 HEX NUT(4) REQUIRED5/16"-18 HEX NUT(4) REQUIRED

Fig 8 – Power Unit Mounting 21) Mount Power Unit to power column as shown

in Fig 8. The mounting hardware, (4) 5/16”-18 hex nuts, are pre-installed on power unit mounting bracket.

22) Attach hydraulic tee fitting (in hardware box) to power column cylinder line (factory installed). See Fig 9a. Attach column extension line and power unit line to tee fitting. Secure power unit line to column extension using hydraulic line clamp & ¼” hardware.


Page 7 10/9/03 A2151.doc

Fig 9a – Column Hydraulic Line Assembly

Fig 9b – Hydraulic Line from Power Unit to Power Column Extension

23) Attach elbow fitting (in hardware box) threading 9/16-18 O-ring end to power unit. See fig 9b. CAUTION not to damage rubber O-ring.

24) Secure column extension hydraulic line to tab located inside column extension. See fig 10a. Attach hydraulic union fitting (in hardware box) and overhead line.

Fig 10a – Hydraulic Line fromPower Column Extension to Overhead.

(Sync Cables removed for clarity)

HYD LINE CLAMP FOR3/8" OD HYD LINE

Fig 10b – Hydraulic Line from Idler Column Extension to Overhead.

(Sync cables removed for clarity)

25) Attach LONG hydraulic union (in hardware box) and column extension line to idler column cylinder line (factory installed). See fig 9a. Secure column extension hydraulic line to column extension tab located inside idler column. See fig 10b. Attach overhead hydraulic line to column extension line using a hydraulic union for 11’-6 ½” setting or hydraulic union and 4 ½” long hydraulic extension line for 11’-11” setting.

26) BE CERTAIN ALL FITTINGS AND CONNECTIONS ARE TIGHT. IT IS THE INSTALLERS RESPONSIBILITY TO INSURE SYSTEM IS LEAK-FREE. Fill the Power Unit with three gallons of clean 10wt anti-foam anti-rust hydraulic oil or Dexron III ATF. DO NOT USE OILS WITH DETERGENTS.

FOR LIFTS WITH OPTIONAL DUAL PENDANT CONTROL, SKIP STEPS 26 THRU 36 AND REFER INSTEAD TO THE “DUAL PENDANT CONTROL INSTALLATION & OPERATION MANUAL SUPPLEMENT”. LOCK RELEASE 27) Attach Mechanical Lock Release Cable

Assembly to Power Column Lock Release Clevis using the 3/16” diameter x 1/2" long pin and (2) “C” clip retainers, Fig 11.



Page 8 10/9/03 A2151.doc

Fig 11 – Power Column Lock Assembly 29) Route opposite end of cable assembly up

Power Column and into column through access slot in bottom of Column Extension. Following the path of the hydraulic line, route cable assembly across overhead clear of moving parts and back out through access slot in bottom of idler side column extension. Attach Cable Assembly to the hydraulic hose with loosely fit wire ties.

NOTE: DO NOT kink cable assembly when routing. Tighten and trim wire ties after final cable adjustments have been made 30) Attach Adhesive-Backed Tab to Idler Column


CABLE CLEVIS

1/2" O.D. EXT.SPRING

EXTEND LOOP WHEN INSTALLING AT NARROW OR LOWERED SETTING



CABLE CLEVIS



CABLE CLEVIS



CABLE CLEVIS

Fig 12 – Idler Column Lock Assembly

31) Insert threaded sleeve portion of cable assembly in slot located on tab below lock pawl, Fig 12. With one jam nut located on each side of tab, adjust the threaded sleeve to begin to pull tension on the ½” O.D. spring. Snug jam nuts by hand.

THE LOCK RELEASE CABLE ADJUSTMENT IS NOT COMPLETE UNTIL THE LIFT HAS BEEN LOWERED AND “FINAL ADJUSTMENTS” HAVE BEEN MADE. ARM INSTALLATION 32) Lubricate the arm pin or carriage arm pin

hole with “anti-seize” and install the arms. Insure that the arm restraint gears engage and disengage properly. Arm restraints should disengage when lift is fully lowered. If any binding occurs, insure that the large gear mounted to the arm has been factory installed tight against the arm pin.

ELECTRICAL 33) Wire tie Limit Switch cord to column

extension hydraulic line and power unit line. 34) Connect the Overhead Limit Switch Cord to

Power Unit as shown in Fig 13. 35) Connect Power Unit to suitable electrical

source as shown in Fig 13. 36) IMPORTANT: AFTER WIRING HAS BEEN

COMPLETED, TEST OPERATION OF POWER UNIT & OVERHEAD LIMIT SWITCH. WHILE RAISING LIFT, OPERATE OVERHEAD SHUTOFF BAR. POWER UNIT MOTOR SHOULD STOP WHEN SHUTOFF BAR IS RAISED.

FINAL ADJUSTMENTS HYDRAULICS

37) Lower the lift to the floor and raise the lift approximately one foot.

38) Start with Idler side first. Slowly and carefully loosen the bleed plug on top of the cylinder just enough to allow the entrapped air to escape. Repeat for power side.

39) Raise lift 6 inches. Repeat step 38 until no air comes out of cylinder.

40) Pressure test hydraulic system. Energize power unit, raise lift to full rise and continue to run motor for additional 10 seconds. (NOTE: pressure relief will make a high pitch squeal sound for these 10 seconds.) Check hydraulic system for leaks.

41) Energize power unit again for 10 seconds. With a clean rag, wipe down both cylinder rods. (The cylinders are shipped with a small amount of clear anti-corosive lubricant that will be forced out through the wiper when the lift reaches full rise.) If lubricant is not wiped clean from the cylinder rod, the cylinder will apear to be leaking.


Page 9 10/9/03 A2151.doc

EACH LIFT SHOULD HAVE A DEDICATED CIRCUIT WITH ADOUBLE POLE (THREE POLE FOR 440-480V) BREAKEROR TIME DELAY FUSE SIZED ACCORDING TO THEFOLLOWING CHART

* WIRING MUST COMPLY WITH NEC AND ALL LOCAL ELECTRICAL CODES *

FOR SINGLE PHASE

1Ø208-240V

25amp

BLACK

RAISEPUSH BUTTON

(N.O.)

Wiring Diagram

BLACK

"COMMON" "NORM. OPEN"

OVERHEADLIMIT

SWITCHBLACK

2Hp

WHITE

3Ø220-240V

15amp

1Ø 208-240VAC

3Ø208V

15amp

3Ø440-480V

5amp

* After wiring has been completed, test operation of Power Unit & Overhead Limit Switch. While raising lift, operate Overhead Shutoff Bar. Power Unit Motor should stop when Shutoff Bar is raised.

YELLOW

NOTES:

1) MOTOR IS FACTORY WIRED FOR 208V OR 220-240V SUPPLY

2) MOTOR CONNECTIONS MUST BE RECONFIGURED PER THIS DIAGRAM FOR 440-480V SUPPLY

3) CONTACTOR COIL RATING MUST MATCH SUPPLY VOLTAGE (208V, 220-240V, OR 440-480V)

4) CONTACTOR MUST BE FIELD MOUNTED ON POWER COLUMN (CENTERED SIDE-TO-SIDE TO AVOID INTERFERENCE WITH SLIDE BLOCKS)

5) MOTOR ROTATION IS COUNTER CLOCKWISE FROM TOP OF MOTOR

FOR THREE PHASE

L1 (BLACK)

3Ø50/60HzSUPPLY

L2

L3

GREEN

L1

1Ø 208-240VAC SUPPLY

CONTACTOR ENCLOSURE TO BE FIELD MOUNTEDON POWER COLUMN (CENTERED SIDE-TO-SIDE TOAVOID INTERFERENCE WITH SLIDE BLOCKS)

OVERHEAD LIMIT SWITCH AND CONTACTORFOR OVERHEAD MODELS ONLY

RECONNECTIONS FOR440−480V

BLACK

BLACK

BLACK

FACTORY WIRED FOR208−240V

BLACK

BLACK

BLACK

OVERHEAD

LIMIT

A2

WHITEBLACK

HELDCLOSED

L1

L2

L3

A1

T1

T2

T3

COIL

SEENOTE

RAISESWITCH

RAISESWITCH

2

4

6

6

4

2

1

3

5

5

3

1

GROUND SCREW INMOTOR WIRING BOX

L2 (WHITE)

GROUND

HELDCLOSED

MOTOR ENCLOSURE

M50/60 Hz

50/60 HzM

T1

T2

T3

T1

T2

T7

T3

T8

T9

T5

T8

T4

T7

T6

T9

T6

T4T5

MBLUE

GROUND

L2 (WHITE)

BLACK

L1 (BLACK)

FOR THREE PHASE

NOTES:







FOR SINGLE PHASE



3Ø50/60HzSUPPLY

GREEN

L1

L3

L2


M





A1HELD

CLOSED

OVERHEADLIMIT

WHITE

T3

T2

T1

SEENOTE

COIL

L3

L2

L1

A2

6

4

2

5

3

1

RAISESWITCH

RAISESWITCH

2

4

6

1

3

5

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK


Wiring Diagram

"COMMON"

BLACK

RAISEPUSH BUTTON

(N.O.)"NORM. OPEN"

BLACKWHITE

HELDCLOSED

OVERHEADLIMIT

SWITCHBLACK

BLUE

YELLOW

1Ø208-240V

2Hp 25amp

M50/60 Hz

50/60 HzM

MOTOR ENCLOSURE

T2

T3

T1

T9

T8

T3

T7

T2

T1

T5T4

T6

T4

T9

T6

T7

T8

T5

1Ø 208-240VAC

3Ø220-240V

3Ø208V

15amp 15amp 5amp

3Ø440-480V

GROUND

L2 (WHITE)

BLACK

L1 (BLACK)

FOR THREE PHASE

NOTES:







FOR SINGLE PHASE



3Ø50/60HzSUPPLY

GREEN

L1

L3

L2


M





A1HELD

CLOSED

OVERHEADLIMIT

WHITE

T3

T2

T1

SEENOTE

COIL

L3

L2

L1

A2

6

4

2

5

3

1

RAISESWITCH

RAISESWITCH

2

4

6

1

3

5

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK


Wiring Diagram

"COMMON"

BLACK

RAISEPUSH BUTTON

(N.O.)"NORM. OPEN"

BLACKWHITE

HELDCLOSED

OVERHEADLIMIT

SWITCHBLACK

BLUE

YELLOW

1Ø208-240V

2Hp 25amp

M50/60 Hz

50/60 HzM

MOTOR ENCLOSURE

T2

T3

T1

T9

T8

T3

T7

T2

T1

T5T4

T6

T4

T9

T6

T7

T8

T5

1Ø 208-240VAC

3Ø220-240V

3Ø208V

15amp 15amp 5amp

3Ø440-480V

GROUND

L2 (WHITE)

BLACK

L1 (BLACK)

FOR THREE PHASE

NOTES:







FOR SINGLE PHASE



3Ø50/60HzSUPPLY

GREEN

L1

L3

L2


M





A1HELD

CLOSED

OVERHEADLIMIT

WHITE

T3

T2

T1

SEENOTE

COIL

L3

L2

L1

A2

6

4

2

5

3

1

RAISESWITCH

RAISESWITCH

2

4

6

1

3

5

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK


Wiring Diagram

"COMMON"

BLACK

RAISEPUSH BUTTON

(N.O.)"NORM. OPEN"

BLACKWHITE

HELDCLOSED

OVERHEADLIMIT

SWITCHBLACK

BLUE

YELLOW

1Ø208-240V

2Hp 25amp

M50/60 Hz

50/60 HzM

MOTOR ENCLOSURE

T2

T3

T1

T9

T8

T3

T7

T2

T1

T5T4

T6

T4

T9

T6

T7

T8

T5

1Ø 208-240VAC

3Ø220-240V

3Ø208V

15amp 15amp 5amp

3Ø440-480V



Page 10 10/9/03 A2151.doc

FINAL ADJUSTMENTS (CONTINUED) SYNCHRONIZING CABLES

42) Raise lift and insure carriages lower into same lock position.

43) Adjust synchronizing cables so the tension is equal in both cables and carriages are firmly sitting on locks.

44) Cycle lift to insure that latches operate simultaneously.




IMPORTANT: IF IDLER SIDE LOCK PAWL DOES NOT FULLY DISENGAGE, DAMAGE MAY RESULT TO IDLER SIDE CARRIAGE AND OR CABLE SYNCHRONIZING SYSTEM. 47) Tighten threaded sleeve cable adjuster jam

nuts and install lock release knob. 48) Tighten and trim wire ties. 49) Snap plastic cover over Idler lock assembly

(align release cable with notches in cover). OWNER/OPERATOR CHECKLIST 50) Demonstrate the operation of the lift to the

owner/operator and review correct and safe lifting procedures using the Lifting It Right booklet as a guide.

51) Complete the Installation Checklist/Warranty Validation questionnaire with the owner. Review the terms of the warranty registration card, and return the card and a copy of the questionnaires to:

Challenger Lifts, Inc. 200 Cabel Street

Louisville, KY. 40206

OPERATION PROCEDURE

SAFETY NOTICES AND DECALS This product is furnished with graphic safety warning labels, which are reproduced on page 3 of these instructions. Do not remove or deface these warning labels, or allow them to be removed or defaced. For your safety, and the safety of others, read and understand all of the safety notices and decals included.

OWNER/EMPLOYER RESPONSIBILITIES This lift has been designed and constructed according to ANSI/ALI ALCTV-1998 standard. The standard applies to lift manufactures, as well as to owners and employers. The owner/employer’s responsibilities as prescribed by ANSI/ALI ALOIM-2000, are summarized below. For exact wording refer to the actual standard provided with this manual in the literature pack. The Owner/Employer shall insure that lift operators are qualified and that they are trained in the safe use and operation of the lift using the manufacturer’s operating instructions; ALI/SM 93 -1, ALI Lifting it Right safety manual; ALI/ST-90 ALI Safety Tips card; ANSI/ALI ALOIM-2000, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintenance; ALI/WL Series, ALI Uniform Warning Label Decals/Placards; and in case of frame engaging lifts, ALI/LP-GUIDE, Vehicle Lifting Points/Quick Reference Guide for Frame Engaging Lifts. The Owner/Employer shall establish procedures to periodically inspect the lift in accordance with the lift manufacturer’s instructions or ANSI/ALI ALOIM-2000, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintenance; and the employer shall insure that the lift inspectors are qualified and that they are adequately trained in the inspection of the lift. The Owner/Employer shall establish procedures to periodically maintain the lift in accordance with the lift manufacturer’s instructions or ANSI/ALIOIM-2000, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintenance; and the employer shall insure that the lift maintenance personnel are qualified and that they are adequately trained in the maintenance of the lift. The Owner/Employer shall maintain the periodic inspection and maintenance records recommended by the manufacturer or ANSI/ALI ALOIM-2000, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintenance. The Owner/Employer shall display the lift manufacturer’s operating instructions; ALI/SM 93 -1, ALI Lifting it Right safety manual; ALI/ST-90 ALI Safety Tips card; ANSI/ALI ALOIM-2000, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintenance; and in the case of frame engaging lift, ALI/LP-GUIDE, Vehicle Lifting Points/Quick Reference Guide for Frame Engaging Lifts; in a conspicuous location in the lift area convenient to the operator.


Page 11 10/9/03 A2151.doc

LIFTING A VEHICLE 1) Insure that the lifting arms are parked, out to

full drive thru position. 2) Position the vehicle in the service bay so that

the vehicle’s center of gravity is on a line between the two columns, and so the vehicle is centered between the two columns.

DO NOT EXCEED 2250 POUNDS PER ARM. DO NOT ATTEMPT TO LIFT THE VEHICLE WITH ONLY TWO ARMS, AS THIS WILL VOID THE WARRANTY INSURE THAT THE HIGHEST POINT ON THE VEHICLE WILL CONTACT THE OVERHEAD LIMIT SWITCH BAR. DO NOT PLACE THE VEHICLE IN THE SERVICE BAY BACKWARDS. REFER TO THE VEHICLE MANUFACTURERS SERVICE MANUAL, TECHNICAL BULLETINS, “VEHICLE LIFTING POINTS GUIDE” (ALI/LP-GUIDE) OR OTHER PUBLICATIONS TO LOCATE THE RECOMMENDED LIFTING POINTS. 3) Position the arms and adapters so all four

pads contact the vehicle simultaneously. The vehicle should remain level during lifting. 4) Raise the lift until all four wheels are off the

ground. Test the stability of the vehicle by attempting to rock the vehicle. Check adapters for secure contact with vehicle lift points. If the vehicle seems unstable, lower the lift and readjust the arms. If the vehicle is stable, raise the vehicle to a height a few inches above the desired working height.

5) Lower the vehicle until the safety latches on both columns engage. The vehicle should remain level when both latches are engaged. If one side engages and the other continues to descend, stop lowering the vehicle, raise it several inches, and try again to engage both latches.

Always lower lift into locks before entering the area beneath the vehicle. Always use safety stands when removing or installing heavy components. LOWERING A VEHICLE 1) Insure that the area under the vehicle is clear

of personnel and tools. 2) Raise the vehicle until both latches are free. 3) Disengage the latches by pulling down and

holding the lock release lever. 4) Lower the vehicle by depressing the lowering

valve handle. 5) Continue to lower the vehicle until the

carriages stop against the base plate. Retract the extension arms, and park them.

MAINTENANCE

To avoid personal injury, permit only qualified personnel to perform maintenance on this equipment. The following maintenance points are suggested as the basis of a preventive maintenance program. The actual maintenance program should be tailored to the installation. See ANSI/ALI ALOIM booklet for periodic inspection checklist and maintenance log sheet.

• If lift stops short of full rise or chatters, check fluid level and bleed both cylinders per Installation Instructions.

• Replace all Safety, Warning or Caution Labels if missing or damaged (See Installation instructions page 3.)

Daily • Keep lift components clean. • Check for loose or broken parts. • Check hydraulic system for fluid leaks. • Check adapters for damage or excessive wear.

Replace as required with genuine Challenger Lifts parts.

• Check lock release activation. When properly adjusted, the idler column lock should rest firmly against the back of the column when engaged and against the spring mount tab when disengaged.

Weekly • Check synchronizer cables and sheaves for

wear. Replace as required with genuine Challenger Lifts parts.

• Check lock release cable adjustment per Installation Instructions step 42.

IMPORTANT: IF IDLER SIDE LOCK PAWL DOES NOT FULLY DISENGAGE, DAMAGE MAY RESULT TO IDLER SIDE CARRIAGE AND OR CABLE SYNCHRONIZING SYSTEM. • Check synchronizer cable tension per

Installation Instructions. Adjust if necessary.

Monthly • Torque concrete anchor bolts to 80 ft-lbs. • Check overhead shutoff switch. While raising

lift, operate overhead shutoff bar. Power Unit motor should stop when bar is raised.

• Lubricate carriage slide tracks with heavy viscous grease. (Grease all (4) corners of both columns.)

If any problems are encountered, contact your local service representative.


Page 12 10/9/03 A2151.doc

PARTS BREAKDOWN Fig A. Column & Overhead

ITEM # PART # QTY/LIFT DESCRIPTION A2010-P 1 POWER COLUMN WELD

1 A2010-I 1 IDLER COLUMN WELD A2055-0 COLUMN EXTENSION WELD - CL10 A2055-2 COLUMN EXTENSION WELD - CL10-2 2 A2055-3

2 COLUMN EXTENSION WELD - CL10-3

3 A2060 1 OVERHEAD CHANNEL 4 36074 1 SHUTOFF BAR 5 31129 1 PAD 6 36027 1 OVERHEAD LIMIT SWITCH 7 A1064 2 3/8 DIA x 1 7/8 Lg. CLEVIS PIN (SHUTOFF BAR) 8 40124 2 HAIRPIN COTTER PIN 9 31036 7 3/8" FLAT WASHER 10 A1153 24 3/8-16NC HEX.FLG.HD.C.S X 3/4" Lg. 11 A1154 24 3/8-16NC HEX.FLG.NUT

Replace all worn or broken parts with genuine Challenger Lifts Inc. parts. Contact your local Challenger Lifts Parts Distributor for pricing and availability. (Call Challenger Lifts Inc. (502) 625-0700 for the Parts Distributor in your area)


Page 13 10/9/03 A2151.doc


Fig B. Lock

FOR LIFTS EQUIPPED WITHDUAL PENDANT CONTROL

REFER TO SEPERATE"DUAL PENDANT CONTROL

MANUAL SUPPLEMENT"



MANUAL SUPPLEMENT"



MANUAL SUPPLEMENT"



MANUAL SUPPLEMENT"

ITEM # PART # QTY/LIFT DESCRIPTION A2135-0 LOCK RELEASE CABLE ASSEMBLY - CL10 A2135-2 LOCK RELEASE CABLE ASSEMBLY - CL10-2 20 A2135-3

1 LOCK RELEASE CABLE ASSEMBLY - CL10-3

21 A1140 2 LOCK PAWL 22 A1133 2 LOCK COVER 23 30020 2 LOCK PIN (5/8 x 1 1/2" Lg. SHOULDER BOLT) 24 37013 2 LOCK PIN RETAINER (1/2-13NC HEX LOCK NUT) 25 37119 1 CLEVIS PIN KIT 26 A1131 2 LOCK SPRING (3/8" O.D.) 27 A1132 1 CABLE SPRING (1/2" O.D.) – Idler side ONLY 28 A1141 1 LOCK RELEASE CLEVIS ASSEMBLY – Power side ONLY 29 36096 1 BALL HANDLE – Power side ONLY



Page 14 10/9/03 A2151.doc


Fig C. Hydraulics

ITEM # PART # QTY/LIFT DESCRIPTION A1201-17 POWER UNIT 1ph, 60 Hz, 208-230V

35 A1203-17

1 POWER UNIT 3ph, 60 Hz, 208-230/460V

36 16138 2 CYLINDER (68" STROKE x 2" BORE) 37 A2123 2 CYLINDER LINE 38 A2120 1 PU LINE 39 A2122 1 OH LINE w/4 1/2" EXTENSION

A2121-0 EXTENSION LINE - CL10 A2121-2 EXTENSION LINE - CL10-2 40 A2121-3

2 EXTENSION LINE - CL10-3

41 31116 2 3/8 HYD. TUBE x 9/16-18 0-RING ADAPTER 42 31089 1 O-RING ELBOW 43 31032 1 UNION TEE 44 31047 2 UNION 45 A2124 1 BULKHEAD UNION 46 31025 3 LINE CLAMP 47 A2125 3 1/4-20NC HEX.FLG.HD.C.S. x 3/4 48 40085 3 1/4-20NC HEX.FLG.NUT



Page 15 10/9/03 A2151.doc


Fig D. Synchronizer

ITEM # PART # QTY/LIFT DESCRIPTION A2115-0 SYNCHRONIZER CABLE - CL10 A2115-2 SYNCHRONIZER CABLE - CL10-2 50 A2115-3

2 SYNCHRONIZER CABLE - CL10-3

51 A2116 4 5/8-11NC HEX NUT 52 A2117 4 5/8-11NC HEX JAM NUT 53 A2118 2 CABLE SPACER (4 1/2" LONG) 54 36025 6 SHEAVE ASSEMBLY (5" DIA. X 5/16" GROOVE) 55 36024 2 SHEAVE PIN 56 A1063-S 4 SHORT SHEAVE SPACER 57 A1063-L10 2 LONG SHEAVE SPACER 58 36013 10 1" I.D. SPACER WASHER 59 36014 2 1" EXT. RETAINING RING



Page 16 10/9/03 A2151.doc


Fig E. Carriage & Arms

ITEM # PART # QTY/LIFT DESCRIPTION

70 A2025 2 CARRIAGE WELD

71 31023 16 SLIDE BLOCK

72 A1078 4 ARM PIN WELD

73 A2091 2 REAR FEMALE ARM WELD

74 A1094-R10 2 MALE ARM WELD (REAR)

75 A1104 4 FOOT PAD RUBBER INSERT 76 A1101 4 FOOT PAD WELD

77 31061 8 1/4-20 KEPS NUT

78 39111 4 FOOT PAD RETAINER RING A2086-P 1 FRONT FEMALE ARM WELD (POWER)

79 A2086-I 1 FRONT FEMALE ARM WELD (IDLER)

80 A1094-F 2 MALE ARM WELD (FRONT) 81 31305 4 3/8 MALE ARM RETAINER SCREW

82 31037 4 3/8 LOCK WASHER

83 A1070 4 INNER GEAR

84 12568 8 3/8-16NCx1 Lg. HEX .FLG.LOCK.HD.C.S. GR.5 ZN PLT 85 A1075 4 PULL RING

86 A1073 4 SHAFT 87 31109 4 COMPRESSION SPRING (RESTRAINT SHAFT) 88 A1072 4 OUTER GEAR

89 36014 4 1" EXT. RETAINING RING

A2090 2 REAR ARM ASSY (ITEMS NO: 73, 74, 81, 82) A2085-P 1 FRONT ARM ASSY (POWER) (ITEMS NO: 79, 80, 81, 82) A2085-I 1 FRONT ARM ASSY (IDLER) (ITEMS NO: 79, 80, 81, 82) A1100 4 FOOT PAD ASSY (ITEMS NO: 75, 76, 77) A1077 4 ARM RESTRAINT SHAFT ASSY (ITEMS NO: 85, 86, 87, 88, 89)

Replace all worn or broken parts with genuine Challenger Lifts Inc. parts. Contact your local Challenger Lifts Parts Distributor for pricing and availability.

(Call Challenger Lifts Inc. (502) 625-0700 for the Parts Distributor in your area)

Rev. 10/9/03 A1151.doc

IIIINSTALLATIONNSTALLATIONNSTALLATIONNSTALLATION, O, O, O, OPERATION PERATION PERATION PERATION

& M& M& M& MAINTENANCE AINTENANCE AINTENANCE AINTENANCE MMMMANUALANUALANUALANUAL

VersymmetricTM Two Post Surface Mounted Lift

MODEL CL9 9,000 LBS. CAPACITY

2250 LBS. PER ARM


Office 800-648-5438 / 502-625-0700 Fax 502-587-1933





Page 2 Rev. 10/9/03 A1151.doc

GENERAL SPECIFICATIONS

See Figure 1 CL9 CL9-1 CL9-2

A Adjustable Column Height 11’-8” or 11’-2” 12’-8” or 12’-2” 13’-8” or 13’-2”

B Floor to Overhead Switch 11’-2” or 10’-8” 12’-2” or 11’-8” 13’-2” or 12’-8”

C Rise Height (Screw Pads Highest Position) 74 5/8”

D Cylinder Height (Full Stroke) 11’-11”

E Adjustable Overall Width 11’-2” or 10’-8“ or 10’-2” F Screw Pad Height 4 ¼” to 6 ¾”

G Inside of Columns 109” or 103” or 97” Drive Thru Clearance 89” or 83” or 77” Ceiling Height Required 12’-0” 12’-9” 13’-9” * Maximum Capacity 9,000 lbs. (2250 lbs. Per Arm) ** Lifting Time 60 Sec. (approximate) ** Lowering Time 30 Sec. (approximate)

Motor 2HP, Single Phase, 60Hz, 208/230 Optional – 2HP, Three Phase, 50/60Hz, for 208 or 230 or 460

Dimensions in BOLD are “Standard” settings. Installing the lift at a narrow setting (E = 103” or 97”) may adversely affect ability to reach some vehicle pick up points and requires cutting the overhead shutoff bar. * Lift capacity ratings are based on loads equally distributed on all four arms. ** Lifting and lowering speeds may vary depending on weight of vehicle.





F

EE

F

E

F

E

F

GGGG

CCCC

AD

BB

DA

B

DA

B

DA

144" [12'-0"]MIN. TO

NEARESTOBSTRUCTION

144" [12'-0"]MIN. TO

NEARESTOBSTRUCTION

144" [12'-0"]MIN. TO

NEARESTOBSTRUCTION

144" [12'-0"]MIN. TO

NEARESTOBSTRUCTION



1012" REF

108" [9'-0"]MIN.TO

NEARESTOBSTRUCTION

108" [9'-0"]MIN.TO

NEARESTOBSTRUCTION

1012" REF



108" [9'-0"]MIN.TO

NEARESTOBSTRUCTION

1012" REF



108" [9'-0"]MIN.TO

NEARESTOBSTRUCTION

1012" REF




COLUMN BASE PLATESCOLUMN BASE PLATES


COLUMN BASE PLATES


COLUMN BASE PLATES


DRIVE ONDIRECTIONDRIVE ONDIRECTIONDRIVE ONDIRECTIONDRIVE ONDIRECTION

Fig 1a - General Specifications Fig1b - Service Bay Layout


Page 3 Rev. 10/9/03 A1151.doc

WARNING

VERTICAL CLEARANCE Check the height of the area where the lift is to be installed. Clearance should be calculated based on the full raised height of the lift.

Failure by purchaser to provide adequate clearance could result in

unsatisfactory lift performance, property damage, or personal injury.

FLOORING Be certain you have the proper concrete floor to properly handle the loaded lift. Floor should be in generally good condition with no large cracks, spalling or deterioration. Minimum requirements for concrete are 4 inches minimum depth, with steel reinforcement, 3500 psi, cured for 28 days per local commercial practice. Floor should be level within 3/8 inch over the installation area. No anchors should be installed within 8 inches of any crack, edge, or expansion joint. If these conditions cannot be met, pads can be poured to accommodate the lift. Check with local building inspectors and/or permits office for any special instructions or approvals required for your installation.

Failure by purchaser to provide the recommended mounting surface could

result in unsatisfactory lift performance, property damage, or personal injury.

ELECTRICAL REQUIREMENTS For lift installation and operation for single phase units, it is necessary to have a dedicated circuit with a double pole 25 amp circuit breaker or time delay fuse.

SAFETY NOTICES AND DECALS For your safety, and the safety of others, read and understand all of the safety notices and decals included here.


Safety decals similar to those shown here are found on a properly installed lift. Be sure that all safety decals have been correctly installed on the Power Unit reservoir. Verify that all authorized operators know the location of these decals and fully understand their meaning. Replace worn, faded, or damaged decals promptly.

Do not attempt to raise a vehicle on the lift until the lift has been correctly

installed and adjusted as described in this manual.

WARNING

WARNING


Page 4 Rev. 10/9/03 A1151.doc

RECEIVING The shipment should be thoroughly inspected as soon as it is received. The signed bill of lading is acknowledgement by the carrier of receipt in good condition of shipment covered by our invoice. If any of the goods called for on this bill of lading are shorted or damaged, do not accept them until the carrier makes a notation on the freight bill of the shorted or damaged goods. Do this for your own protection. NOTIFY Challenger Lifts AT ONCE if any hidden loss or damage is discovered after receipt. IT IS DIFFICULT TO COLLECT FOR LOSS OR DAMAGE AFTER YOU HAVE GIVEN THE CARRIER A CLEAR RECEIPT. File your claim with Challenger Lifts promptly. Support your claim with copies of the bill of lading, freight bill, and photographs, if available.


PART # QTY/ LIFT DESCRIPTION

A1001-P 1 Power Column Ass’y

A1001-I 1 Idler Column Ass’y

A1060 1 Overhead (Mid Section)

A1061 2 Overhead (End Section)

A1005 1 Hardware Box

A1002 1 Arm Pack

A1055-0 Column Extension for CL9

A1055-1 Column Extension for CL9-1

A1055-2

2

Column Extension for CL9-2

A1003-0 Sync Cable Pack for CL9

A1003-1 Sync Cable Pack for CL9-1

A1003-2

1

Sync Cable Pack for CL9-2

36035 1 Overhead Shut-Off Bar Ass’y

36027 1 Mercury Switch

A1004 1 Hydraulic Hose Pack

A1201-15 A1203-15 1 Power Unit – 1 Phase

Power Unit – 3 Phase

A1150 1 Literature Pack

IIIINSTALLATIONNSTALLATIONNSTALLATIONNSTALLATION IMPORTANT: Always wear safety glasses while installing lift.

TOOLS (MINIMUM REQUIRED) a. Banding Cutter b. Tape measure, 16ft c. Chalk line d. 4ft level e. 10” adjustable wrench f. Standard open end wrenches 7/16”, 1/2", (2) 9/16”, (2) 11/16”, 3/4" g. 5/16” allen wrench h. Needle nose pliers i. Hammer drill with 3/4” diameter carbide

tipped bit j. 2lb hammer k. Torque wrench: 150 foot pounds minimum

with 1 1/8” socket l. 12 ft. Step ladder m. Pull wire or fish tape n. Anti-Seize lubricant (for arm pins) o. 3/4” O.D. Pipe cutter (if installing lift at narrow

width setting)

LAYOUT

1) Layout the service bay according to the architect’s plans or owners instructions (see Fig 1b). Be certain that the proper conditions exist, see page 3.

2) Assemble column extension to column using 3/8-16 x 3/4" lg Hex flange head bolt. repeat for opposite column and extension.

3) Erect both column assemblies. Align the notches in column base, Fig 2, with the installation lines. (HINT: It may be easier to install the lower synchronizer cable, Fig 7b, before columns are raised)

ANCHORING 4) The anchor bolts must be installed at least 8

inches from any crack, edge, or expansion joint.

5) Use a concrete hammer drill with a 3/4 inch carbide bit. Tip diameter should conform to ANSI Standard B94.12-1977 (.775 to .787). Do not use excessively worn bits or bits which have been incorrectly sharpened. A core bit may be necessary if an obstruction is encountered. Never substitute with shorter anchor.

6) Recheck “Inside of Columns” dimension, Fig 1. Drill the anchor holes using the base plate as a template. Drill through the floor if possible or to a depth of 5 inches minimum.

7) Vacuum dust from the hole for proper holding power.


Page 5 Rev. 10/9/03 A1151.doc

8) Shim both columns to plumb using the shims provided as shown in Fig 2. DO NOT shim more than 1/2" at any given point. Use a level no less than 24” in length to plumb columns.

ALIGNMENT NOTCHALIGNMENT NOTCHALIGNMENT NOTCHALIGNMENT NOTCH

ALIGNMENT NOTCHALIGNMENT NOTCHALIGNMENT NOTCHALIGNMENT NOTCH

Fig 2 – Column Shimming 9) Assemble washer and nut to anchor with nut

just below impact section of bolt. Drive anchor into hole until nut and washer contact base.

10) Tighten power column anchors and recheck column for plumb. Reshim if necessary. Torque to 150 foot pounds to set anchors.

OVERHEAD BEAM 11) Assemble the (3) part overhead with (12) 3/8-

16 x 3/4” lg hex flange head bolts and (12) hex flange nuts using Fig 1 on page 2 as reference for proper width. Before raising overhead into position install 4 each (2 per column) hex flange bolts and nuts in middle hole of column extension (see Fig 3 Installation Aid) for temporary support of overhead. Lift overhead assembly up into position and install with 6 each (3 per column) 3/8-16 x 3/4” lg hex flange bolts and hex flange nuts per side as shown in Fig 3.

Fig 3 – Overhead Assembly

12) Check idler column shimming. Use additional shims (see Fig. 2) to remove any gaps that may have been created while installing overhead beam. Tighten anchor bolts and re-check column for plumb. Torque to 150 foot pounds.

13) Install Overhead Limit Switch to Power Column using (1) 3/8” pivot pin, (1) 3/8” flat washer and (1) hairpin cotter pin as shown in Fig 4a.

IMPORTANT: switch tube cord is to be oriented above pivot pin as shown below.

HAIRPIN COTTER PIN

PROPER ORIENTATION

TUBE CORD MUST BEABOVE PIVOT PIN FOR

3/8" FLAT WASHER

PROPER ORIENTATION

3/8" FLAT WASHER

PROPER ORIENTATION

ABOVE PIVOT PIN FORTUBE CORD MUST BE

PROPER ORIENTATION

HAIRPIN COTTER PIN

3/8" FLAT WASHER

PROPER ORIENTATION


PROPER ORIENTATION

HAIRPIN COTTER PIN

3/8" FLAT WASHER

PROPER ORIENTATION


PROPER ORIENTATION

HAIRPIN COTTER PIN

Fig 4a – Overhead Limit Switch Sub-Assembly

IMPORTANT: The “standard” setting for the INSIDE OF COLUMNS dimension is 109 inches. If the lift is to be installed at 103” or 97”, use tubing cutter to shorten the end opposite where attachment hole is. See chart below for cut length.

Inside of Column 109” 103” 97” Shutoff Bar Length 107 ¼” 101 ¼” 95 ¼”

14) Insert shut-off bar in switch tube on power column side and take other end to idler side. Attach shut-off bar to idler column with (1) 3/8” pivot pin, (6) 3/8” flat washer and (1) hairpin cotter pin as shown in Fig 4b.

Insure that both switch tube and shut-off assemblies pivot freely for proper operation.

3/8" PIVOT PIN

SHUTOFF BAR

(6) 3/8" FLAT WASHERS

HAIRPIN COTTER PINHAIRPIN COTTER PIN


SHUTOFF BAR

3/8" PIVOT PIN

HAIRPIN COTTER PIN


SHUTOFF BAR

3/8" PIVOT PIN

HAIRPIN COTTER PIN


SHUTOFF BAR

3/8" PIVOT PIN

Fig 4b – Overhead Limit Switch Sub-Assembly


Page 6 Rev. 10/9/03 A1151.doc

15) Assemble the sheaves, spacers and washers onto the sheave pin as shown in Fig 5. Set in cradle with all assembly parts between the two plates.

SHORT SHEAVE SPACER

SHEAVESHEAVE PIN

LONG SHEAVE SPACER

SHEAVE

SHORT

WASHER

WASHER

WASHER

WASHER

SPACERSHEAVE

WASHERSHORT SHEAVE SPACER

SHEAVESPACER

WASHER

SHORT

SHEAVE

LONG SHEAVE SPACER

WASHERSHEAVE PIN

SHEAVE

WASHER


SHEAVESPACER

WASHER

SHORT

SHEAVE

LONG SHEAVE SPACERWASHER

SHEAVE PINSHEAVE

WASHER


SHEAVESPACER

WASHER

SHORT

SHEAVE

LONG SHEAVE SPACER

WASHERSHEAVE PIN

SHEAVE

WASHER

Fig 5 – Sheave Assembly

LOCKING PAWL 16) Install Power Column locking pawl and lock

release clevis with 5/8” diameter x 1 1/2” lg shoulder bolt and 1/2”-13 nylon lock nut, Fig. 6. Attach 3/8” O.D. extension spring to upper hole in locking pawl and other end to hole in bracket welded to column.

Fig 6 – Locking Pawl Assembly 17) Attach ½” O.D. extension spring to hole

located on bottom side of Idler Column lock pawl and install using 5/8” shoulder bolt and lock nut, Fig 6. Attach 3/8” O.D. spring the same as Power side.

SYNCHRONIZER CABLES 18) Manually raise the carriages approximately

32 inches to gain access to the cable-tie-off tabs located on the carriage ladder. Insure that the top of the hydraulic cylinder is out of the way but still retained in the opening of the top plate of the carriage as shown in Fig 7a.

19) Route synchronizing cables using Fig 7a and attach ends to cable-tie-off tabs using Fig’s 7b & 7c.

Fig 7a – Cable Routing

Fig 7b – Attaching Cable from Below

Fig 7b – Attaching Cable from Above


Page 7 Rev. 10/9/03 A1151.doc

SYNCHRONIZER CABLE ADJUSTMENT This method requires adjusting the cable ends at the power column only 20) At the power side carriage adjust the Cable

from Above until the power column carriage is 1/8” off its locking pawl.

NOTE: The Lower Cable should NOT be tight before beginning this step. 21) Now adjust the Cable from Below until the

power column carriage contacts its locking pawl. Grab the back of the locking pawl and wobble it. Continue tightening until the lock pawl is tight.

When the cables have been adjusted properly, neither locking pawl will wobble by hand. (tighten the power column lower cable to tighten the power column locking pawl or the power column upper cable for the idler column locking pawl. 22) Tighten the thin Jam Nuts against the Cable

Adjustment Nut. POWER UNIT & HYDRAULIC HOSE 23) Mount Power Unit to power column as shown

in Fig 8. The mounting hardware, (4) 5/16”-18 hex nuts, are pre-installed on power unit mounting bracket.

5/16"-18 HEX NUT(4) REQUIRED5/16"-18 HEX NUT(4) REQUIRED5/16"-18 HEX NUT(4) REQUIRED5/16"-18 HEX NUT(4) REQUIRED

Fig 8 – Power Unit Mounting

24) Attach hydraulic elbow fitting (in hardware box) threading the 9/16-18 O-ring end to power unit. See Fig 9. CAUTION not to damage rubber O-ring.

BULKHEAD BRANCH TEEMALE #6 (9/16-18)

SAE (JIC) 37° FLARE(FACTORY INSTALLED)







Fig 9 – Hydraulic Hose from Power Unit to Power Column.

IMPORTANT – To insure proper hose fitting seal without damage to the fitting follow this procedure for each hose connection: Screw flared fitting on finger tight. Rotate flared fitting 1 1/2 hex flats (90 deg.). Back the flared fitting off one full turn. Again tighten flared fitting finger tight, then rotate flared fitting 1 1/2 hex flats (90 deg.). 25) Thread power unit hydraulic hose (22” lg in

hardware box) into elbow on power unit. Thread opposite end of hose into male #6 fitting (factory installed) attached to power column as shown in Fig 9.

26) From Idler Column route the hydraulic hose (factory installed from cylinder to top of column) up to Overhead. LOOSEN FACTORY INSTALLED CLAMP AT TOP OF IDLER COLUMN AND GENTLY PULL UP ANY SLACK FROM HOSE. Install a hose clamp in column extension and in overhead beam with (1) 3/8”-16 x 3/4" lg. hex flange bolt and hex flange nut per clamp as shown in Fig 10a.

SNAKE EXCESS HOSEIN OVERHEAD WHEN INSTALLING AT NARROW OR LOWERED SETTING

HYDRAULIC HOSE CLAMP WITH3/8"-16 HEX FLANGE BOLT & NUTHYDRAULIC HOSE CLAMP WITH3/8"-16 HEX FLANGE BOLT & NUT


HYDRAULIC HOSE CLAMP WITH3/8"-16 HEX FLANGE BOLT & NUT


HYDRAULIC HOSE CLAMP WITH3/8"-16 HEX FLANGE BOLT & NUT


Fig 10a – Hydraulic Hose from Idler Column to

Overhead. (Sync cables removed for clarity)


Page 8 Rev. 10/9/03 A1151.doc

27) Route hydraulic hose from Idler column across Overhead to the Power Column and down inside of Power Column (routing is identical to Idler Column) to male #6 JIC bulkhead “T” fitting. Loosely attach hose to “T”. If this is an extended height lift (model CL9-1 or CL9-2), an extension hose (supplied) will connect the Idler hose to the “T” fitting.

28) While gently pulling slack up from the “T” fitting to the top of the power column extension, twist the hose until it lays flat in the overhead beam. (When installing lift at narrow or low setting, excess hose should be snaked in bottom of overhead, Fig 10a. When installing at narrow and low setting, form a loop in the column extension between the overhead support plate and the inside wall of the column extension, Fig 10b.) Install hose clamps identical to idler side, one hose clamp at the top of the column, one at the top of the column extension and one at the end of the overhead. Fig 10b. Tighten connection at “T” fitting.


HYDRAULIC HOSE CLAMP WITH 3/8"-16 HEX FLANGE BOLT & NUT

LOOP EXCESS HOSEIN COLUMN EXT. WHEN INSTALLING AT NARROW AND LOWERED SETTING










Fig 10b – Hydraulic Hose from Overhead to

Power Column. (Sync cables removed for clarity)

29) BE CERTAIN ALL FITTINGS AND CONNECTIONS ARE TIGHT. IT IS THE INSTALLERS RESPONSIBILITY TO INSURE SYSTEM IS LEAK-FREE. Fill the Power Unit with three gallons of clean 10wt anti-foam anti-rust hydraulic oil or Dexron III ATF. DO NOT USE OILS WITH DETERGENTS.

FOR LIFTS WITH OPTIONAL DUAL PENDANT CONTROL, SKIP STEPS 26 THRU 31 AND REFER INSTEAD TO THE “DUAL PENDANT CONTROL INSTALLATION & OPERATION MANUAL SUPPLEMENT”.

LOCK RELEASE 30) Attach Mechanical Lock Release Cable

Assembly to Power Column Lock Release Clevis using the 3/16” diameter x 1/2" long pin and (2) “C” clip retainers, Fig 11.


Fig 11 – Power Column Lock Assembly

32) Route opposite end of cable assembly up left side of Power Column and into column through access slot (3/8”x4” Lg.) in bottom of Column Extension. Following the path of the hydraulic line, route cable assembly across overhead clear of moving parts and back out through access slot in bottom of idler side column extension (again use left slot when viewed from outside of column). Attach Cable Assembly to the hydraulic hose with loosely fit wire ties.

NOTE: DO NOT kink cable assembly when routing. Tighten and trim wire ties after final cable adjustments have been made. 33) Attach Adhesive-Backed Tab to Idler Column



Page 9 Rev. 10/9/03 A1151.doc

Fig 12 – Idler Column Lock Assembly

34) Insert threaded sleeve portion of cable assembly in slot located on tab below lock pawl, Fig 12. With one jam nut located on each side of tab, adjust the threaded sleeve to begin to pull tension on the ½” O.D. spring. Snug jam nuts by hand.

THE LOCK RELEASE CABLE ADJUSTMENT IS NOT COMPLETE UNTIL THE LIFT HAS BEEN LOWERED AND “FINAL ADJUSTMENTS” HAVE BEEN MADE. ARM INSTALLATION 35) Lubricate the arm pin or carriage arm pin

hole with “anti-seize” and install the arms. Insure that the arm restraint gears engage and disengage properly. Arm restraints should disengage when lift is fully lowered. If any binding occurs, insure that the large gear mounted to the arm has been factory installed tight against the arm pin.

ELECTRICAL 36) Wire tie Limit Switch cord to Power Column

hose inside column and down to hose “T” fitting. Route cord out slot and tie to Power Unit hose.

37) Connect the Overhead Limit Switch Cord to Power Unit as shown in Fig 13.

38) Connect Power Unit to suitable electrical source as shown in Fig 13.

39) IMPORTANT: AFTER WIRING HAS BEEN COMPLETED, TEST OPERATION OF POWER UNIT & OVERHEAD LIMIT SWITCH. WHILE RAISING LIFT, OPERATE OVERHEAD SHUTOFF BAR. POWER UNIT MOTOR SHOULD STOP WHEN SHUTOFF BAR IS RAISED.

FINAL ADJUSTMENTS HYDRAULICS

40) Lower the lift to the floor and raise the lift approximately one foot.

41) Start with Idler side first. Slowly and carefully loosen the bleed plug on top of the cylinder just enough to allow the entrapped air to escape. Repeat for power side.

42) Energize the power unit and raise 6 inches. Repeat previous step until no air comes out of cylinder.

43) Pressure test hydraulic system. Energize power unit, raise lift to full rise and continue to run motor for additional 10 seconds. (NOTE: pressure relief will make a high pitch squeal sound for these 10 seconds.) Check hydraulic system for leaks.

44) Energize power unit again for 10 seconds. With a clean rag, wipe down both cylinder rods. (The cylinders are shipped with a small amount of clear anti-corosive lubricant that will be forced out through the wiper when the lift reaches full rise.) If lubricant is not wiped clean from the cylinder rod, the cylinder will apear to be leaking.

SYNCHRONIZING CABLES 45) Cycle lift to insure that latches operate

simultaneously. Lower lift onto locks and insure that neither lock will wobble (it is possible for one carriage to be resting on its lock while the other carriage is being supported by the synchronizing cable).




IMPORTANT: IF IDLER SIDE LOCK PAWL DOES NOT FULLY DISENGAGE, DAMAGE MAY RESULT TO IDLER SIDE CARRIAGE AND OR CABLE SYNCHRONIZING SYSTEM. 48) Tighten threaded sleeve cable adjuster jam

nuts and install lock release knob. 49) Tighten and trim wire ties. 50) Snap plastic cover over Idler lock assembly

(align idler side lock release cable with notches in lock cover flange).


Page 10 Rev. 10/9/03 A1151.doc



NOTES:






FOR THREE PHASE

FOR SINGLE PHASE

L1 (BLACK)

3Ø50/60HzSUPPLY

L2

L3

GREEN

L1



1Ø208-240V

25amp



BLACK

BLACK

BLACK


BLACK

BLACK

BLACK

OVERHEAD

LIMIT

A2

WHITEBLACK

HELDCLOSED

L1

L2

L3

A1

T1

T2

T3

COIL

SEENOTE

RAISESWITCH

RAISESWITCH

2

4

6

6

4

2

1

3

5

5

3

1


BLACK

RAISEPUSH BUTTON

(N.O.)

Wiring Diagram

L2 (WHITE)

GROUND

BLACK

"COMMON" "NORM. OPEN"

OVERHEADLIMIT

SWITCH

BLACK

HELDCLOSED

2Hp

WHITE

MOTOR ENCLOSURE

M50/60 Hz

50/60 HzM

T1

T2

T3

T1

T2

T7

T3

T8

T9

T5

T8

T4

T7

T6

T9

T6

T4T5

3Ø220-240V

15amp

1Ø 208-240VAC

3Ø208V

15amp

M

3Ø440-480V

5amp


YELLOW

BLUE


GROUND

L2 (WHITE)

BLACK

L1 (BLACK)

FOR SINGLE PHASE

FOR THREE PHASE

NOTES:








3Ø50/60HzSUPPLY

GREEN

L1

L3

L2


M





A1HELD

CLOSED

OVERHEADLIMIT

WHITE

T3

T2

T1

SEENOTE

COIL

L3

L2

L1

A2

6

4

2

5

3

1

RAISESWITCH

RAISESWITCH

2

4

6

1

3

5

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

Wiring Diagram


"COMMON"

BLACK

RAISEPUSH BUTTON

(N.O.)"NORM. OPEN"

BLACKWHITE

HELDCLOSED

OVERHEADLIMIT

SWITCHBLACK

BLUE

YELLOW

1Ø208-240V

2Hp 25amp

M50/60 Hz

50/60 HzM

MOTOR ENCLOSURE

T2

T3

T1

T9

T8

T3

T7

T2

T1

T5T4

T6

T4

T9

T6

T7

T8

T5

1Ø 208-240VAC

3Ø220-240V

3Ø208V

15amp 15amp 5amp

3Ø440-480V


GROUND

L2 (WHITE)

BLACK

L1 (BLACK)

FOR SINGLE PHASE

FOR THREE PHASE

NOTES:








3Ø50/60HzSUPPLY

GREEN

L1

L3

L2


M





A1HELD

CLOSED

OVERHEADLIMIT

WHITE

T3

T2

T1

SEENOTE

COIL

L3

L2

L1

A2

6

4

2

5

3

1

RAISESWITCH

RAISESWITCH

2

4

6

1

3

5

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

Wiring Diagram


"COMMON"

BLACK

RAISEPUSH BUTTON

(N.O.)"NORM. OPEN"

BLACKWHITE

HELDCLOSED

OVERHEADLIMIT

SWITCHBLACK

BLUE

YELLOW

1Ø208-240V

2Hp 25amp

M50/60 Hz

50/60 HzM

MOTOR ENCLOSURE

T2

T3

T1

T9

T8

T3

T7

T2

T1

T5T4

T6

T4

T9

T6

T7

T8

T5

1Ø 208-240VAC

3Ø220-240V

3Ø208V

15amp 15amp 5amp

3Ø440-480V


GROUND

L2 (WHITE)

BLACK

L1 (BLACK)

FOR SINGLE PHASE

FOR THREE PHASE

NOTES:








3Ø50/60HzSUPPLY

GREEN

L1

L3

L2


M





A1HELD

CLOSED

OVERHEADLIMIT

WHITE

T3

T2

T1

SEENOTE

COIL

L3

L2

L1

A2

6

4

2

5

3

1

RAISESWITCH

RAISESWITCH

2

4

6

1

3

5

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

Wiring Diagram


"COMMON"

BLACK

RAISEPUSH BUTTON

(N.O.)"NORM. OPEN"

BLACKWHITE

HELDCLOSED

OVERHEADLIMIT

SWITCHBLACK

BLUE

YELLOW

1Ø208-240V

2Hp 25amp

M50/60 Hz

50/60 HzM

MOTOR ENCLOSURE

T2

T3

T1

T9

T8

T3

T7

T2

T1

T5T4

T6

T4

T9

T6

T7

T8

T5

1Ø 208-240VAC

3Ø220-240V

3Ø208V

15amp 15amp 5amp

3Ø440-480V



Page 11 Rev. 10/9/03 A1151.doc

OWNER/OPERATOR CHECKLIST 51) Demonstrate the operation of the lift to the

owner/operator and review correct and safe lifting procedures using the Lifting It Right booklet as a guide.

52) Complete the Installation Checklist/Warranty Validation questionnaire with the owner. Review the terms of the warranty registration card, and return the card and a copy of the questionnaires to:

Challenger Lifts, Inc. 200 Cabel Street

Louisville, KY. 40206

OPERATION PROCEDURE

SAFETY NOTICES AND DECALS This product is furnished with graphic safety warning labels, which are reproduced on page 3 of these instructions. Do not remove or deface these warning labels, or allow them to be removed or defaced. For your safety, and the safety of others, read and understand all of the safety notices and decals included.

OWNER/EMPLOYER RESPONSIBILITIES This lift has been designed and constructed according to ANSI/ALI ALCTV-1998 standard. The standard applies to lift manufactures, as well as to owners and employers. The owner/employer’s responsibilities as prescribed by ANSI/ALI ALOIM-2000, are summarized below. For exact wording refer to the actual standard provided with this manual in the literature pack. The Owner/Employer shall insure that lift operators are qualified and that they are trained in the safe use and operation of the lift using the manufacturer’s operating instructions; ALI/SM 93 -1, ALI Lifting it Right safety manual; ALI/ST-90 ALI Safety Tips card; ANSI/ALI ALOIM-2000, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintenance; ALI/WL Series, ALI Uniform Warning Label Decals/Placards; and in case of frame engaging lifts, ALI/LP-GUIDE, Vehicle Lifting Points/Quick Reference Guide for Frame Engaging Lifts.

The Owner/Employer shall establish procedures to periodically inspect the lift in accordance with the lift manufacturer’s instructions or ANSI/ALI ALOIM-2000, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintenance; and the employer shall insure that the lift inspectors are qualified and that they are adequately trained in the inspection of the lift. The Owner/Employer shall establish procedures to periodically maintain the lift in accordance with the lift manufacturer’s instructions or ANSI/ALIOIM-2000, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintanence; and the employer shall insure that the lift maintenance personnel are qualified and that they are adequately trained in the maintenance of the lift. The Owner/Employer shall maintain the periodic inspection and maintenance records recommended by the manufacturer or ANSI/ALI ALOIM-2000, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintenance. The Owner/Employer shall display the lift manufacturer’s operating instructions; ALI/SM 93 -1, ALI Lifting it Right safety manual; ALI/ST-90 ALI Safety Tips card; ANSI/ALI ALOIM-2000, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintenance; and in the case of frame engaging lift, ALI/LP-GUIDE, Vehicle Lifting Points/Quick Reference Guide for Frame Engaging Lifts; in a conspicuous location in the lift area convenient to the operator.


Page 12 Rev. 10/9/03 A1151.doc

LIFTING A VEHICLE 1) Insure that the lifting arms are parked, out to

full drive thru position. 2) Position the vehicle in the service bay so that

the vehicle’s center of gravity is on a line between the two columns, and so the vehicle is centered between the two columns.

DO NOT EXCEED 2250 POUNDS PER ARM. DO NOT ATTEMPT TO LIFT THE VEHICLE WITH ONLY TWO ARMS, AS THIS WILL VOID THE WARRANTY INSURE THAT THE HIGHEST POINT ON THE VEHICLE WILL CONTACT THE OVERHEAD LIMIT SWITCH BAR. DO NOT PLACE THE VEHICLE IN THE SERVICE BAY BACKWARDS. REFER TO THE VEHICLE MANUFACTURERS SERVICE MANUAL, TECHNICAL BULLETINS, “VEHICLE LIFTING POINTS GUIDE” (ALI/LP-GUIDE) OR OTHER PUBLICATIONS TO LOCATE THE RECOMMENDED LIFTING POINTS. 3) Position the arms and adapters so all four

pads contact the vehicle simultaneously. The vehicle should remain level during lifting. 4) Raise the lift until all four wheels are off the

ground. Test the stability of the vehicle by attempting to rock the vehicle. Check adapters for secure contact with vehicle lift points. If the vehicle seems unstable, lower the lift and readjust the arms. If the vehicle is stable, raise the vehicle to a height a few inches above the desired working height.

5) Lower the vehicle until the safety latches on both columns engage. The vehicle should remain level when both latches are engaged. If one side engages and the other continues to descend, stop lowering the vehicle, raise it several inches, and try again to engage both latches.

Always lower lift into locks before entering the area beneath the vehicle. Always use safety stands when removing or installing heavy components. LOWERING A VEHICLE 1) Insure that the area under the vehicle is clear

of personnel and tools. 2) Raise the vehicle until both latches are free. 3) Disengage the latches by pulling down and

holding the lock release lever. 4) Lower the vehicle by depressing the lowering

valve handle. 5) Continue to lower the vehicle until the

carriages stop against the base plate. Retract the extension arms, and park them.

MAINTENANCE

To avoid personal injury, permit only qualified personnel to perform maintenance on this equipment. The following maintenance points are suggested as the basis of a preventive maintenance program. The actual maintenance program should be tailored to the installation. See ANSI/ALI ALOIM booklet for periodic inspection checklist and maintenance log sheet.

• If lift stops short of full rise or chatters, check fluid level and bleed both cylinders per Installation Instructions.

• Replace all Safety, Warning or Caution Labels if missing or damaged (See Installation instructions page 3.)

Daily • Keep lift components clean. • Check for loose or broken parts. • Check hydraulic system for fluid leaks. • Check adapters for damage or excessive wear.

Replace as required with genuine Challenger Lifts parts.

• Check lock release activation. When properly adjusted, the idler column lock should rest firmly against the back of the column when engaged and against the spring mount tab when disengaged.

Weekly • Check synchronizer cables and sheaves for

wear. Replace as required with genuine Challenger Lifts parts.

• Check lock release cable adjustment per Installation Instructions step 42.

IMPORTANT: IF IDLER SIDE LOCK PAWL DOES NOT FULLY DISENGAGE, DAMAGE MAY RESULT TO IDLER SIDE CARRIAGE AND OR CABLE SYNCHRONIZING SYSTEM. • Check synchronizer cable tension per

Installation Instructions. Adjust if necessary.

Monthly • Torque concrete anchor bolts to 80 ft-lbs. • Check overhead shutoff switch. While raising

lift, operate overhead shutoff bar. Power Unit motor should stop when bar is raised.

• Lubricate carriage slide tracks with heavy viscous grease. (Grease all (4) corners of both columns.)

If any problems are encountered, contact your local service representative.


Page 13 Rev. 10/9/03 A1151.doc

PARTS BREAKDOWN Fig A. Column & Overhead

ITEM # PART # QTY/LIFT DESCRIPTION A1010-P 1 POWER COLUMN WELD

1 A1010-I 1 IDLER COLUMN WELD A1055-0 COLUMN EXTENSION WELD – CL9 A1055-1 COLUMN EXTENSION WELD – CL9-1 2 A1055-2

2 COLUMN EXTENSION WELD – CL9-2

3A A1060 1 OVERHEAD CHANNEL (MID SECTION) 3B A1061 2 OVERHEAD CHANNEL (END SECTION) 4 36074 1 SHUTOFF BAR 5 31129 1 PAD 6 36027 1 OVERHEAD LIMIT SWITCH 7 A1064 2 3/8 DIA x 1 7/8 Lg. CLEVIS PIN (SHUTOFF BAR) 8 40124 2 HAIRPIN COTTER PIN 9 31036 7 3/8" FLAT WASHER 10 A1153 36 3/8-16NC HEX.FLG.HD.C.S X 3/4" Lg. 11 A1154 36 3/8-16NC HEX.FLG.NUT



Page 14 Rev. 10/9/03 A1151.doc


Fig B. Lock



MANUAL SUPPLEMENT"



MANUAL SUPPLEMENT"



MANUAL SUPPLEMENT"



MANUAL SUPPLEMENT"

ITEM # PART # QTY/LIFT DESCRIPTION A1135-0 LOCK RELEASE CABLE ASSEMBLY – CL9-0 A1135-1 LOCK RELEASE CABLE ASSEMBLY – CL9-1 20 A1135-2

1

LOCK RELEASE CABLE ASSEMBLY – CL9-2 21 A1140 2 LOCK PAWL 22 A1133 2 LOCK COVER 23 30020 2 LOCK PIN (5/8 x 1 1/2" Lg. SHOULDER BOLT) 24 37013 2 LOCK PIN RETAINER (1/2-13NC HEX LOCK NUT) 25 37119 1 CLEVIS PIN KIT 26 A1131 2 LOCK SPRING (3/8" O.D.) 27 A1132 1 CABLE SPRING (1/2" O.D.) – Idler side ONLY 28 A1141 1 LOCK RELEASE CLEVIS ASSEMBLY – Power side ONLY 29 36096 1 BALL HANDLE – Power side ONLY



Page 15 Rev. 10/9/03 A1151.doc


Fig C. Hydraulics


A1201-15 POWER UNIT 1ph, 60 Hz, 208-230V 35

A1203-15 1

POWER UNIT 3ph, 60 Hz, 208-230/460V 36 16167 1 HYD ELBOW, 9/16 O-RING MALE TO #6 MALE FLARE 37 A1123-PU 1 HYD HOSE ASSEMBLY, POWER UNIT (22” LONG) 38 A1120 1 BULKHEAD TEE, #6 MALE 37 DEGREE FLARE

39101-024 1 COLUMN EXTENSION HOSE, CL9-1 (24” LONG) 39

39101-048 1 COLUMN EXTENSION HOSE, CL9-2 (48” LONG) 40 A1123-I 1 HYD HOSE ASSEMBLY, IDLER COLUMN (326” LONG) 41 A1122-12 7 HOSE CLAMP 42 16138 2 CYLINDER (68” STROKE X 2” BORE) 43 A1121 2 STRAIGHT ADAPTER, 9/16 MALE O-RING TO #6 MALE FLARE 44 A1123-P 1 HYD HOSE ASSEMBLY, POWER COLUMN (81” LONG)



Page 16 Rev. 10/9/03 A1151.doc


Fig D. Synchronizer

ITEM # PART # QTY/LIFT DESCRIPTION A1115-0 SYNCHRONIZER CABLE – CL9-0 (32’-8”) [ Cable Pack #A1003-0 ] A1115-1 SYNCHRONIZER CABLE – CL9-1 (34’-8”) [ Cable Pack #A1003-1 ] 50 A1115-2

2 SYNCHRONIZER CABLE – CL9-2 (36’-8”) [ Cable Pack #A1003-2 ]

51 A1116 4 ½-20NF HEX NUT 52 A1117 4 ½-20NF HEX JAM NUT 53 A1041 6 SHEAVE ASSEMBLY (3 ½” DIA. X ¼” GROOVE) 54 A1062 2 SHEAVE PIN 55 A1063-S 4 SHORT SHEAVE SPACER 56 A1063-L 2 LONG SHEAVE SPACER 57 36013 10 1" I.D. SPACER WASHER 58 36014 2 1" EXT. RETAINING RING



Page 17 Rev. 10/9/03 A1151.doc


Fig E. Carriage & Arms


70 A1025 2 CARRIAGE WELD

71 A1040 16 SLIDE BLOCK

72 A1078 4 ARM PIN WELD

73 A1091 2 REAR FEMALE ARM WELD

74 A1094-R 2 MALE ARM WELD (REAR)

75 A1104 4 FOOT PAD RUBBER INSERT

76 A1101 4 FOOT PAD WELD 77 31061 8 1/4-20 KEPS NUT

78 39111 4 FOOT PAD RETAINER RING A1086-P 1 FRONT FEMALE ARM WELD (POWER)

79 A1086-I 1 FRONT FEMALE ARM WELD (IDLER)

80 A1094-F 2 MALE ARM WELD (FRONT)

81 31305 4 3/8 MALE ARM RETAINER SCREW 82 31037 4 3/8 LOCK WASHER

83 A1070 4 INNER GEAR

84 12568 8 3/8-16NCx1 Lg. HEX .FLG.LOCK.HD.C.S. GR.5 ZN PLT 85 A1075 4 PULL RING

86 A1073 4 SHAFT

87 31109 4 COMPRESSION SPRING (RESTRAINT SHAFT) 88 A1072 4 OUTER GEAR

89 36014 4 1" EXT. RETAINING RING

A1090 2 REAR ARM ASSY (ITEMS NO: 73, 74, 81, 82) A1085-P 1 FRONT ARM ASSY (POWER) (ITEMS NO: 79, 80, 81, 82) A1085-I 1 FRONT ARM ASSY (IDLER) (ITEMS NO: 79, 80, 81, 82) A1100 4 FOOT PAD ASSY (ITEMS NO: 75, 76, 77) A1077 4 ARM RESTRAINT SHAFT ASSY (ITEMS NO: 85, 86, 87, 88, 89)


Challenger Lifts, Inc.

MODELS 15000 & 18000

TWO POST SURFACE MOUNTED LIFT

OPERATION, INSTALLATION & MAINTENANCE MANUAL

IMPORTANT

READ THIS MANUAL COMPLETELY BEFORE INSTALLING OR OPERATING THE LIFT

200 CABEL STREET, P.O. BOX 3944

LOUISVILLE, KENTUCKY 40201-3944

OFFICE (502) 625-0700 FAX (502) 587-1933

Models 15000 & 18000 Installation, Operation and Maintenance

P/N 12091 Rev. 3/03 2

General Specifications Maximum Capacity* (Model 15000) .............. 15000 US Pounds (3750 Pounds Per Arm) Maximum Capacity* (Model 18000) .............. 18000 US Pounds (4500 Pounds Per Arm) Lifting Time**......................................................................Approximately 1 1/2 Minutes Lowering Time** .....................................................................Approximately 60 Seconds Motor ....................................................................... 2HP, 230 Volts, Single Phase, 60 Hz. Optional-2HP, 208 or 240 or 480 Volt, 3 Phase, 50/60 Hz.

Dimensions Overall Width ...............................................................................................154 3/4 Inches Overall Height........................................................................ 174 Inches (15000 & 18000) 198 Inches (15002 & 18002) Height at Full Rise ..........................................................................................85 1/2 Inches Overhead Clearance............................................................... 167 Inches (15000 & 18000) 191 Inches (15002 & 18002) Drive Through Clearance..............................................................................106 3/4 Inches Pick-Up Pad Height ............................................................... 6 1/4 Inches to 16 1/2 Inches

* Lift capacity ratings are based on loads equally distributed on all four arms. ** Lifting and lowering speeds may vary depending on the type and viscosity of the oil in the system and the

temperature of the oil.

COMPONENT PACKING LIST

PART # 15000 18000 #/LIFT DESCRIPTION

12001 12001-18 1 POWER COLUMN ASSY 12002 12002-18 1 IDLER COLUMN ASSY

12004 1 OVERHEAD PACK 12005 1 HARDWARE BOX 12006 1 ARM PACK 12102 COLUMN EXTENSION (14'-6" O.A. Ht.) 12022 2 COLUMN EXTENSION (16'-6" O.A. Ht.) 12074 1 OVERHEAD SHUTOFF BAR ASSY 12045 1 MERCURY SWITCH 12019 SYNCHRONIZER CABLE ASSY (16'-6" O.A. Ht.) 12100 2 SYNCHRONIZER CABLE ASSY (14'-6" O.A. Ht.) 12069 4 ADAPTER EXTENSION (4") 12068 2 ADAPTER EXTENSION (8") 12071 2 ADAPTER RACK 12093 4 ARM RESTRAINT ASSEMBLY

12119 12087-19 POWER UNIT - SINGLE PHASE 12089 12089-19 1 POWER UNIT - THREE PHASE

12090 1 LITERATURE PACK


P/N 12091 Rev. 3/03 3

Important! Before You Install

1. Before installing your Challenger 2-Post lift, read the manual(s) thoroughly. Inspect the lift

to insure that it is complete and undamaged. Challenger 2-Post lifts are shipped ready to assemble to facilitate shipping and reduce damage. If it is apparent that the lift has been mishandled in shipment, or if parts or assemblies are missing, note the damage or missing part(s) on the shipping papers and notify Challenger Lifts, Inc. Immediately.

2. Be certain that the wiring in your building will handle the current required to operate this unit

(Fig 8).

3. Be certain that you have the proper concrete floor to handle the loaded lift. The floor should be in generally good condition with no large cracks, spalling or deterioration. The minimum requirements for concrete are 4 inches minimum depth, with steel reinforcement, 3500 PSI, cured for a minimum of 28 days. The floor should be level within 3/8 inch over the installation area. No anchors should be installed within 8 inches of any crack, edge, or expansion joint. If these conditions cannot be met, pads can be poured.

4. Check with the local building inspectors and/ or Permits office for any special instructions or



P/N 12091 Rev. 3/03 4

Installation Procedure 1. Break down the packaging with the columns by supporting the upper column and using a 3/4"

wrench, remove the bolts at the top and bottom of the column. Carefully remove the top cap. 2. Layout the service bay according to the architect’s plans or owner’s instructions (see Fig 1). Be

certain that the proper conditions exist per the section entitled “Before You Install”.

Figure 1


P/N 12091 Rev. 3/03 5

3. Assemble a column extension to each column using 3/8 x 1 bolts, flat washers, lock washers, and nuts.

4. Erect both column assemblies. Align the columns with the installation lines and drill the holes

for the anchors using the base plate as a template. Clean the dust from the holes. Obtain the anchor bolts from the hardware box and assemble the nut and washer to the bolt, leaving about 1/4" of thread above the nut. Insert the anchors into each hole as it is drilled and tap it down to the base plate. If the floor is excessively uneven, you may wish to leave more thread exposed.

5. Shim both columns to plumb using the shims provided (Fig. 2). Do not shim more than ½” at

any point. Use a level no less than 24" in length to plumb the columns.

Figure 2 6. Back the nuts on the anchors up until the threads are flush with the top of the nut and tap them

down against the base plate. Using a torque wrench, tighten the anchors to 150 ft-lbs to set the anchors. Check the columns for plumb after torquing the bolts and adjust by shimming if necessary.

7. Lift the overhead up into position and install with 3/8 x 1 bolts, flat washers, lock washers, and

nuts. 8. Place the mercury switch inside the switch tube by folding the pigtail along side the switch

housing and placing the cord end of the switch into the tube. Then attach the tube to the bracket on the power column side using the 3/8 x 1 ½” shoulder bolt and 5/16-18 Keps nut. Obtain the 1 3/8" snap bushing from the hardware box and place it into the hole in the top of the column to protect the wires. Run the free end of the wire up through the overhead and through the hole in the top of the column.


P/N 12091 Rev. 3/03 6

9. Take the shutoff bar to the idler column side and first insert the end of the bar into the open end of the switch tube, then attach the other end to the bracket on the idler side of the overhead using the 3/8 x 1 ½” shoulder bolt, 5/16 dia. washer and 5/16-18 Keps nut.

10. Install the locking pawl, actuator and spring (Fig. 3). Adjust air cylinder clevis to retract lock

against inside back of column when air cylinder is fully extended. Tighten air cylinder clevis jam nut against clevis.

Figure 3


P/N 12091 Rev. 3/03 7

11. Manually raise the carriages to a comfortable working height and set in locks at equal heights. Route the synchronizer cables (Fig. 4).

ROUTE CABLE FROM TIE-OFF NUT ON TOPOF CARRIAGE DOWN TO COLUMN PULLEYAND UP TO OVERHEAD PULLEY




Figure 4

12. Install the power unit and button valve bracket assembly on the power column (Fig 5).

Figure 5


P/N 12091 Rev. 3/03 8

13. Connect the extension hydraulic lines to the cylinder lines in each column. Install the overhead line with a 90 degree elbow on the idler side and a tee on the power side (Fig. 6). Install the power unit line to the tee in the top of the power column and to the power unit outlet port. Make sure the cables clear during operation.

Figure 6 Idler Side

14. BE CERTAIN ALL FITTINGS AND CONNECTIONS ARE TIGHT. Fill the power unit with four (4) gallons of clean 10wt anti-foam anti-rust hydraulic oil or Dexron III ATF. DO NOT USE OILS WITH DETERGENTS.


P/N 12091 Rev. 3/03 9

15. Route the 1/8" air line (Fig. 7). Be certain not to kink or pinch the hose. Connect the button valve to a source of clean, dry air using the hose barb and clamp provided. Snap the covers onto the column.

Figure 7

16. Center one adapter rack on the back of each column 28” up from the top of the column base. Using the adapter rack as a template, mark and drill mounting holes. Use 3/8 x 1 bolts, flat washers, lock washers, and nuts to mount racks.


P/N 12091 Rev. 3/03 10

17. Connect the overhead shutoff switch to the power unit (Fig. 8).

18. Connect the power unit to a suitable electrical power (Fig. 8).

FOR SINGLE PHASE

FOR THREE PHASE

FOR SINGLE PHASE

FOR THREE PHASE

FOR SINGLE PHASE

FOR THREE PHASEFOR THREE PHASE

FOR SINGLE PHASE

6

4

2

2

4

6

Wiring Diagram

6

4

2

2

4

6

Wiring Diagram

6

4

2

2

4

6

Wiring DiagramWiring Diagram

6

4

2

2

4

6

T1

T2

T3

T1

T2

T3

T1

T2

T3T3

T2

T1L1

L2

L3

L1

L2

L3

L1

L2

L3L3

L2

L1

A1A1A1A1 A2A2A2A2

T5

T8

T4

T7

T6

T9

T6

T4T5

T5

T8

T4

T7

T6

T9

T6

T4T5

T5

T8

T4

T7

T6

T9

T6

T4T5T5T4

T6

T9

T6

T7

T4

T8

T5









1

3

5

1

3

5

1

3

55

3

1

5

3

1

5

3

1

5

3

11

3

5

M

M

M

M

M

MM

MT1T1T1T1

T2

T3

T2

T3

T2

T3T3

T2

T1

T2

T7

T3

T8

T9

T1

T2

T7

T3

T8

T9

T1

T2

T7

T3

T8

T9T9

T8

T3

T7

T2

T1

MMMMT4

T1

T4

T1

T4

T1T1

T4

T5T5T5T5

Figure 8


P/N 12091 Rev. 3/03 11

19. Energize the power unit until the carriages are lifted and run them up about 3 feet. Caution!

Wear eye protection while bleeding the cylinders! Slowly and carefully loosen the bleed plug to allow the entrapped air to escape from the cylinder, first on the idler side and then the power side. Energize the power unit again to raise the carriages about 1-2 inches and loosen the plugs to bleed again. Repeat until no air comes out of the plug.

20. Lower the lift completely and top off the hydraulic oil (5 gallon total tank capacity). Raise the lift until both carriages are in the locking range and engage the safety latches. Make certain that the carriages are at the same height. Adjust the synchronizer cables so that the tension is equal in both cables and both carriages are firmly on the locks. Cycle the lift to ensure that the latches operate simultaneously.

21. Install the arms and arm restraints (Fig. 9). Install spacer washers above the restraint lock mechanism for proper alignment of the link rod.

Figure 9 22. Demonstrate the operation of the lift to the owner/operator and review correct and safe lifting

procedures using the Lifting It Right booklet as a guide.

23. Complete the Installation Checklist/Warranty Validation Questionnaire with the owner. Review the terms of the warranty with the owner. Complete the warranty registration card, and return the card and a copy of the questionnaire to:


200 Cabel Street Louisville, KY 40206


P/N 12091 Rev. 3/03 12

Operation Procedure Notice: This Challenger 15000/15002 Surface Mounted lift has been designed and constructed according to ANSI/ALI ALCTV-1998 standard to insure that it is safe to use. The standard applies to lift manufactures, as well as to owners and employers. The owner/employer’s responsibilities, as prescribed by ANSI/ALI ALCTV-1998, are summarized below. For exact wording, refer to the actual standard in the literature pack. The Owner/Employer shall ensure that the lift operators are instructed in the safe use and operation of the lift using the manufacturer’s instructions and the “Lifting It Right” and “Safety Tips” supplied with the lift. The Owner/Employer shall display the operating instructions and “Lifting It Right” and “Safety Tips” supplied with the lift in a conspicuous location in the lift area convenient to the operator. The Owner/Employer shall establish procedures to periodically maintain, inspect, and care for the lift in accordance with the manufacturer’s recommended procedures to ensure its continued safe operation. The Owner/Employer shall provide necessary lockout/tag-outs of energy sources per ANSI Z244.1-1982 before beginning any repairs. The Owner/Employer shall not modify the lift in any manner without the prior written consent of the manufacturer. This product is furnished with graphic safety warning labels, which are reproduced in these instructions. Do not remove or deface these warning labels, or allow them to be removed or defaced.


P/N 12091 Rev. 3/03 13

1. Lifting a Vehicle

Ensure that the lifting arms are parked, out of the way of the vehicle. Position the vehicle in the service bay so that the vehicle=s center of gravity is on a line between the two columns, and so the vehicle is centered between the two columns.

Do not place the vehicle in the service bay backwards.

Do not attempt to lift the vehicle with only two arms, as this will void the warranty

Refer to the vehicle manufacturer=s service manual, technical bulletins, or other publications to locate the recommended lifting points.

Position the arms so that all four pads contact the vehicle simultaneously.

The vehicle should remain level during lifting.

Raise the lift until all four wheels are off the ground. Test the stability of the vehicle by attempting to rock the vehicle. If the vehicle seems unstable, lower the lift and readjust the arms. If the vehicle is stable, raise the vehicle to a height a few inches above the desired working height.

When the vehicle has reached the desired working height, release the power pack button, and lower the vehicle until the safety latches on both columns engage. The vehicle should remain level when both latches are engaged. If one side engages and the other continues to descend, stop lowering the vehicle, raise it several inches, and try again to engage both latches.

Always lower lift into locks before entering the area beneath the vehicle.

Removal of large components of the vehicle could cause a change in the center of gravity

resulting in an unsafe condition. If this is intended, vehicle support stands are recommended.


P/N 12091 Rev. 3/03

14

2. Lowering a vehicle

Ensure that the area under the vehicle is clear of personnel and tools.

Raise the vehicle until both latches are free.

Disengage the latches by depressing the palm button and holding it.

Lower the vehicle by depressing the lowering valve handle.

Continue to lower the vehicle until the carriages stop against the base plate. Retract the extension arms, and park them. It is important to fully lower the lift to release hydraulic pressure on the system.

Maintenance

The following maintenance points are suggested as the basis of a preventive maintenance program. The actual maintenance program should be tailored to the installation.

Daily

Inspect the lift for loose anchor bolts (If loose tighten to 80 ft-lbs), fluid leaks, and loose connections. All anchor bolts should take full torque. Check for fluid leaks and loose connections. Check for broken parts

Weekly

Check fluid level in power pack reservoir. Check for lock release activation.

Monthly

Check synchronizer cables for wear and tension, adjust if necessary. Lubricate cable sheaves or chain sprockets with light oil to reduce drag. Lubricate carriage slide tracks with heavy viscous grease.


P/N 12091 Rev. 3/03

15

Appendix A

Hydraulic Fitting Assembly Hydraulic line sets are prefabricated to allow easy assembly in the field. Follow the steps outlined below for reliable, leak-free joint: 1. Remove any shipping plugs or caps, insuring that no remnants of the plugs or caps remain

in the tube. 2. Lubricate the threads and seat of the fitting with hydraulic oil or a compatible lubricant.

Do not use pipe dope or Teflon tape on these fittings. 3. Align the tubing joints so that the tubing and sleeve assemblies can be inserted easily into

the fitting. 4. Insert the tubing and sleeve assemblies into the fitting and start the fitting nut by hand.

CAUTION: If the fitting nut cannot be started by hand, the joint is not aligned properly. Attempting to start a misaligned fitting with a wrench is likely to damage the fitting and result in a leaking joint.

5. Tighten the fitting nut until the force required to turn it rises sharply. 6. Tighten the fitting nut 1/4 turn past the point noted in the previous step. Only if the joint

leaks in operation should the joint be tightened further.

CAUTION: Do not over tighten the hydraulic fittings.


P/N 12091 Rev. 3/03

16

Appendix B Anchor Bolt Installation 1. Insure the concrete has had sufficient time to cure - 28 days minimum. 2. Always wear safety glasses. 3. Follow the drill manufacturers safety instruction. 4. Use only solid carbide-tipped drill bits meeting ANSI B94 tip diameter standards. 5. Drill the anchor bolt holes perpendicular to the work surface. To assure full holding

power, do no ream the hole or allow the drill to wobble. 6. Drill the hole at least as deep as the full length of the anchor, completely through the slab

if possible. 7. Clean the hole, using compressed air and a wire brush. A clean hole is necessary for

proper performance. 8. Assemble the washer and nut on the anchor bolt so that the anchor protrudes slightly

beyond the nut. The anchor should drop easily into the hole, requiring no more than a slight tap to seat it fully. 9. Tap the anchor through the fixture (lift base plate) and into the hole, making sure that the

nut rests solidly against the fixture. 10. Tighten the nut to 150 ft-lbs for 3/4 inch diameter bolts and to 75 ft-lbs for 3/8 inch

diameter bolts.


P/N 12091 Rev. 3/03

17


P/N 12091 Rev. 3/03

18

PARTS BREAKDOWN MODEL 15000/18000

PART #

ITEM # 15000 18000 #/LIFT DESCRIPTION

12025 1 POWER COLUMN WELD 1 12026 1 IDLER COLUMN WELD 2 12033 2 LOCK WELD 3 12037 2 LOCK RETAINER 12073 4 5/16-18NC BUT.HD.CS X 1/2 LG 37025 2 AIR CYLINDER ASSEMBLY 12088 2 EXTENSION SPRING

12102 2 COLUMN EXTENSION WELD (14'-6" O.A. Ht.) 4 12022 2 COLUMN EXTENSION WELD (16'-6" O.A. Ht.) 31035 28 3/8-16NC X 1 HEX HD. CAP SCREW 31036 28 3/8 FLAT WASHER 31038 28 3/8-16NC HEX NUT

5 12038 1 OVERHEAD WELD 12074 1 OVERHEAD SHUTOFF BAR ASSY 12045 1 MERCURY SWITCH 12019 2 SYNCHRONIZER CABLE ASSY (16'-6" O.A. Ht.) 12100 2 SYNCHRONIZER CABLE ASSY (14'-6" O.A. Ht.)

6 31019 6 CABLE PULLEY 31020 6 WASHER 31021 6 RETAINER RING

7 12007 12007-18 2 CARRIAGE WELD 8 12021 16 SLIDE BLOCK 9 12046 4 ARM PIN WELD

10 12049 4 FEMALE ARM WELD 11 12054 4 MALE ARM WELD

12072 4 1/2-13NC SHCS X 5/8 LG 12 12069 4 EXTENSION (4")

12068 2 EXTENSION (8") 13 12062 4 ADAPTER ASSEMBLY

12071 2 ADAPTER RACK 31305 4 3/8-16NC X 5/8 PHIL. PAN HD. SCREW 12093 4 ARM RESTRAINT ASSEMBLY 12119 12087-19 POWER UNIT - SINGLE PHASE 12089 12089-19 POWER UNIT - THREE PHASE

Replace worn or broken parts with genuine CHALLENGER LIFTS INC. parts Contact your local Challenger Lifts Parts Distributor for pricing and availability (Call CHALLENGER LIFTS INC. (502) 625-0700 for the Parts Distributor in your area)


MODEL 12000

TWO POST SURFACE MOUNTED LIFT

OPERATION, INSTALLATION & MAINTENANCE MANUAL

IMPORTANT

READ THIS MANUAL COMPLETELY BEFORE INSTALLING OR OPERATING THE LIFT

200 CABEL STREET, P.O. BOX 3944

LOUISVILLE, KENTUCKY 40201-3944

OFFICE (502) 625-0700 FAX (502) 587-1933

Model 12000 Installation, Operation and Maintenance

P/N 12580 Rev. 12/99 2

General Specifications Maximum Capacity*........................................ 12000 US Pounds (3000 Pounds Per Arm) Lifting Time**..............................................................................Approximately 1 Minute Lowering Time** .....................................................................Approximately 45 Seconds Motor ....................................................................... 2HP, 230 Volts, Single Phase, 60 Hz. Optional-2HP, 208 or 240 or 480 Volt, 3 Phase, 50/60 Hz.

Dimensions Overall Width .....................................................................................................142 Inches Overall Height....................................................................................... 164 Inches (12000) 176 Inches (12001) 188 Inches (12002) Height at Full Rise ..........................................................................................85 1/4 Inches Overhead Clearance.............................................................................. 157 Inches (12000) 169 Inches (12001) 181 Inches (12002) Drive Through Clearance..............................................................................104 1/4 Inches Pick-Up Pad Height ............................................................... 5 1/4 Inches to 13 1/4 Inches

* Lift capacity ratings are based on loads equally distributed on all four arms. ** Lifting and lowering speeds may vary depending on the type and viscosity of the oil in the system and the

temperature of the oil.

11412

188 [15'-8"] (12002)176 [14'-8"] (12001)164 [13'-8"] (12000)

Figure 1


P/N 12580 Rev. 12/99 3


PART # #/LIFT DESCRIPTION 12505 1 POWER COLUMN ASSY 12506 1 IDLER COLUMN ASSY 12507 1 OVERHEAD PACK 12508 1 HARDWARE BOX 12503 1 ARM PACK 12502 2 COLUMN EXTENSION PACK 12542 1 OVERHEAD SHUTOFF BAR ASSY 12045 1 MERCURY SWITCH 12531 2 SYNCHRONIZER CABLE ASSY 12574 2 CABLE EXTENSION (12001) 12574 4 CABLE EXTENSION (12002) 12561 2 ADAPTER EXTENSION (6") 12562 4 ADAPTER EXTENSION (3") 12567 2 ADAPTER RACK 31052 4 ARM RESTRAINT ASSEMBLY 31368 1 POWER UNIT - SINGLE PHASE 31355 POWER UNIT - THREE PHASE 12581 1 LITERATURE PACK

Important! Before You Install

1. Before installing your Challenger 2-Post lift, read the manual(s) thoroughly. Inspect the lift

to insure that it is complete and undamaged. Challenger 2-Post lifts are shipped ready to assemble to facilitate shipping and reduce damage. If it is apparent that the lift has been mishandled in shipment, or if parts or assemblies are missing, note the damage or missing part(s) on the shipping papers and notify Challenger Lifts, Inc. Immediately.

2. Be certain that the wiring in your building will handle the current required to operate this unit

(Fig 9).

3. Be certain that you have the proper concrete floor to handle the loaded lift. The floor should be in generally good condition with no large cracks, spalling or deterioration. The minimum requirements for concrete are 4 inches minimum depth, with steel reinforcement, 3500 PSI, cured for a minimum of 28 days. The floor should be level within 3/8 inch over the installation area. No anchors should be installed within 8 inches of any crack, edge, or expansion joint. If these conditions cannot be met, pads can be poured.

4. Check with the local building inspectors and/ or Permits office for any special instructions or



P/N 12580 Rev. 12/99 4

Installation Procedure 1. Break down the packaging with the columns by supporting the upper column and using a 3/4"

wrench, remove the bolts at the top and bottom of the column. Carefully remove the top cap. 2. Layout the service bay according to the architect=s plans or owner=s instructions (see Fig 2). Be

certain that the proper conditions exist per the section entitled ABefore You Install@.

Figure 2


P/N 12580 Rev. 12/99 5

3. Assemble a column extension to each column using 3/8 x 1 bolts, flat washers, lock washers, and nuts.

4. Erect both column assemblies. Align the columns with the installation lines and drill the holes

for the anchors using the base plate as a template. Clean the dust from the holes. Obtain the anchor bolts from the hardware box and assemble the nut and washer to the bolt, leaving about 1/4" of thread above the nut. Insert the anchors into each hole as it is drilled and tap it down to the base plate. If the floor is excessively uneven, you may wish to leave more thread exposed.

5. Shim both columns to plumb using the shims provided (Fig. 3). Do not shim more than 2" at

any point. Use a level no less than 24" in length to plumb the columns.

Figure 3

6. Back the nuts on the anchors up until the threads are flush with the top of the nut and tap them

down against the base plate. Using a torque wrench, tighten the anchors to 150 ft-lbs to set the anchors. Check the columns for plumb after torquing the bolts and adjust by shimming if necessary.

7. Lift the overhead up into position and install with 3/8 x 1 bolts, flat washers, lock washers, and

nuts. 8. Place the mercury switch inside the switch tube by folding the pigtail along side the switch

housing and placing the cord end of the switch into the tube. Then attach the tube to the bracket on the power column side using the 3/8 x 1 ½ shoulder bolt, 5/16 dia. washer and 5/16-18 Keps nut. Obtain the 1 3/8" snap bushing from the hardware box and place it into the hole in the top of the column to protect the wires. Run the free end of the wire up through the snap bushing.


P/N 12580 Rev. 12/99 6

9. Take the shutoff bar to the idler column side and first insert the end of the bar into the open end

of the switch tube, then attach the other end to the bracket on the idler side of the overhead using the 3/8 x 1 � shoulder bolt, 5/16 dia. washer and 5/16-18 Keps nut.

10. Install the locking pawl, actuator and spring (Fig. 4). Adjust air cylinder clevis to retract lock

against inside back of column when air cylinder is fully extended. Tighten air cylinder clevis jam nut against clevis.

Figure 4


P/N 12580 Rev. 12/99 7

11. Manually raise the carriages to a comfortable working height and set in locks at equal heights. Route the synchronizer cables (Fig. 5). For Models 12001 & 12002 (extended height models) cable extensions are required. Install one extension inside each carriage for both models and an additional extension on top of each carriage for Model 12002. Install one jam nut to cable end before threading cable end 1 inch minimum into extension. Lock all cable extensions to cable ends using the jam nut.

Figure 5

12. Install the power unit and button valve bracket assembly on the power column (Fig 6).

Figure 6


P/N 12580 Rev. 12/99 8

13. Connect the extension hydraulic lines to the cylinder lines in each column using a straight union

on the idler side and a tee on the power side. Install the overhead line with the longer leg on the idler side. Install the power unit line to the tee in the power column and to the power unit outlet port. Adjust the tab in the overhead (Fig. 7). Make sure the cables clear during operation.

Figure 7

14. BE CERTAIN ALL FITTINGS AND CONNECTIONS ARE TIGHT. Fill the power unit

with three (3) gallons of #10 weight hydraulic oil or Dexron III. DO NOT USE OILS WITH DETERGENTS.


P/N 12580 Rev. 12/99 9

15. Route the 1/8" air line (Fig. 8). Be certain not to kink or pinch the hose. Connect the button valve to a source of clean, dry air using the hose barb and clamp provided. Snap the covers onto the column.

Figure 8

16. Center one adapter rack on the back of each column 27” up from the top of the column base.

Using the adapter rack as a template, mark and drill mounting holes. Use 3/8 x 1 bolts, flat washers, lock washers, and nuts to mount racks.


P/N 12580 Rev. 12/99 10

17. Connect the overhead shutoff switch to the power unit (Fig. 9).

18. Connect the power unit to a suitable electrical power (Fig. 9).

FOR SINGLE PHASE

FOR THREE PHASE

FOR SINGLE PHASE

FOR THREE PHASE

FOR SINGLE PHASE

FOR THREE PHASEFOR THREE PHASE

FOR SINGLE PHASE

6

4

2

2

4

6

Wiring Diagram

6

4

2

2

4

6

Wiring Diagram

6

4

2

2

4

6

Wiring DiagramWiring Diagram

6

4

2

2

4

6

T1

T2

T3

T1

T2

T3

T1

T2

T3T3

T2

T1L1

L2

L3

L1

L2

L3

L1

L2

L3L3

L2

L1

A1A1A1A1 A2A2A2A2

T5

T8

T4

T7

T6

T9

T6

T4T5

T5

T8

T4

T7

T6

T9

T6

T4T5

T5

T8

T4

T7

T6

T9

T6

T4T5T5T4

T6

T9

T6

T7

T4

T8

T5









1

3

5

1

3

5

1

3

55

3

1

5

3

1

5

3

1

5

3

11

3

5

M

M

M

M

M

MM

MT1T1T1T1

T2

T3

T2

T3

T2

T3T3

T2

T1

T2

T7

T3

T8

T9

T1

T2

T7

T3

T8

T9

T1

T2

T7

T3

T8

T9T9

T8

T3

T7

T2

T1

MMMMT4

T1

T4

T1

T4

T1T1

T4

T5T5T5T5

Figure 9


P/N 12580 Rev. 12/99 11

19. Energize the power unit until the carriages are lifted and run them up about 3 feet. Caution!

Wear eye protection while bleeding the cylinders! Slowly and carefully loosen the bleed plug to allow the entrapped air to escape from the cylinder, first on the idler side and then the power side. Energize the power unit again to raise the carriages about 1-2 inches and loosen the plugs to bleed again. Repeat until no air comes out of the plug.

20. Lower the lift completely and top off the hydraulic fluid (4 gallon total tank capacity). Raise the lift until both carriages are in the locking range and engage the safety latches. Make certain that the carriages are at the same height. Adjust the synchronizer cables so that the tension is equal in both cables and both carriages are firmly on the locks. Cycle the lift to ensure that the latches operate simultaneously.

21. Install the arms and arm restraints (Fig. 10).

Figure 10 22. Demonstrate the operation of the lift to the owner/operator and review correct and safe lifting

procedures using the Lifting It Right booklet as a guide.

23. Complete the Installation Checklist/Warranty Validation Questionnaire with the owner. Review the terms of the warranty with the owner. Complete the warranty registration card, and return the card and a copy of the questionnaire to:


200 Cabel Street Louisville, KY 40206


P/N 12580 Rev. 12/99 12

Operation Procedure Notice: This Challenger 12000 Surface Mounted lift has been designed and constructed according to ANSI/ALI ALCTV-1998 standard to insure that it is safe to use. The standard applies to lift manufactures, as well as to owners and employers. The owner/employer=s responsibilities, as prescribed by ANSI/ALI ALCTV-1998, are summarized below. For exact wording refer to the actual standard in the literature pack. The Owner/Employer shall ensure that the lift operators are instructed in the safe use and operation of the lift using the manufacturer=s instructions and the ALifting It Right@ and ASafety Tips@ supplied with the lift. The Owner/Employer shall display the operating instructions and ALifting It Right@ and ASafety Tips@ supplied with the lift in a conspicuous location in the lift area convenient to the operator. The Owner/Employer shall establish procedures to periodically maintain, inspect, and care for the lift in accordance with the manufacturer=s recommended procedures to ensure its continued safe operation. The Owner/Employer shall provide necessary lockout/tag-outs of energy sources per ANSI Z244.1-1982 before beginning any repairs. The Owner/Employer shall not modify the lift in any manner without the prior written consent of the manufacturer. This product is furnished with graphic safety warning labels, which are reproduced in these instructions. Do not remove or deface these warning labels, or allow them to be removed or defaced.


P/N 12580 Rev. 12/99 13

1. Lifting a Vehicle

Ensure that the lifting arms are parked, out of the way of the vehicle. Position the vehicle in the service bay so that the vehicle=s center of gravity is on a line between the two columns, and so the vehicle is centered between the two columns.

Do not place the vehicle in the service bay backwards.

Do not attempt to lift the vehicle with only two arms, as this will void the warranty

Refer to the vehicle manufacturer=s service manual, technical bulletins, or other publications to locate the recommended lifting points.

Position the arms so that all four pads contact the vehicle simultaneously.

The vehicle should remain level during lifting.

Raise the lift until all four wheels are off the ground. Test the stability of the vehicle by attempting to rock the vehicle. If the vehicle seems unstable, lower the lift and readjust the arms. If the vehicle is stable, raise the vehicle to a height a few inches above the desired working height.

When the vehicle has reached the desired working height, release the power pack button, and lower the vehicle until the safety latches on both columns engage. The vehicle should remain level when both latches are engaged. If one side engages and the other continues to descend, stop lowering the vehicle, raise it several inches, and try again to engage both latches.

Always lower lift into locks before entering the area beneath the vehicle.

Removal of large components of the vehicle could cause a change in the center of gravity

resulting in an unsafe condition. If this is intended, vehicle support stands are recommended.


P/N 12580 Rev. 12/99

14

2. Lowering a vehicle

Ensure that the area under the vehicle is clear of personnel and tools.

Raise the vehicle until both latches are free.

Disengage the latches by depressing the palm button and holding it.

Lower the vehicle by depressing the lowering valve handle.

Continue to lower the vehicle until the carriages stop against the base plate. Retract the extension arms, and park them. It is important to fully lower the lift to release hydraulic pressure on the system.

Maintenance

The following maintenance points are suggested as the basis of a preventive maintenance program. The actual maintenance program should be tailored to the installation.

Daily

Check for fluid leaks and loose connections. Check for broken parts

Weekly

Check fluid level in power pack reservoir. Check for lock release activation. Inspect the lift for loose anchor bolts (If loose tighten to 80 ft-lbs). All anchor bolts should take full torque.

Monthly

Check synchronizer cables for wear and tension, adjust if necessary. Lubricate cable sheaves or chain sprockets with light oil to reduce drag. Lubricate carriage slide tracks with heavy viscous grease.


P/N 12580 Rev. 12/99

15

Appendix A

Hydraulic Fitting Assembly Hydraulic line sets are prefabricated to allow easy assembly in the field. Follow the steps outlined below for reliable, leak-free joint: 1. Remove any shipping plugs or caps, insuring that no remnants of the plugs or caps remain

in the tube. 2. Lubricate the threads and seat of the fitting with hydraulic oil or a compatible lubricant.

Do not use pipe dope or Teflon tape on these fittings. 3. Align the tubing joints so that the tubing and sleeve assemblies can be inserted easily into

the fitting. 4. Insert the tubing and sleeve assemblies into the fitting and start the fitting nut by hand.

CAUTION: If the fitting nut cannot be started by hand, the joint is not aligned properly. Attempting to start a misaligned fitting with a wrench is likely to damage the fitting and result in a leaking joint.

5. Tighten the fitting nut until the force required to turn it rises sharply. 6. Tighten the fitting nut 1/4 turn past the point noted in the previous step. Only if the joint

leaks in operation should the joint be tightened further.

CAUTION: Do not over tighten the hydraulic fittings.


P/N 12580 Rev. 12/99

16

Appendix B Anchor Bolt Installation 1. Insure the concrete has had sufficient time to cure - 28 days minimum. 2. Always wear safety glasses. 3. Follow the drill manufacturers safety instruction. 4. Use only solid carbide-tipped drill bits meeting ANSI B94 tip diameter standards. 5. Drill the anchor bolt holes perpendicular to the work surface. To assure full holding

power, do no ream the hole or allow the drill to wobble. 6. Drill the hole at least as deep as the full length of the anchor, completely through the slab

if possible. 7. Clean the hole, using compressed air and a wire brush. A clean hole is necessary for

proper performance. 8. Assemble the washer and nut on the anchor bolt so that the anchor protrudes slightly

beyond the nut. The anchor should drop easily into the hole, requiring no more than a slight tap to seat it fully. 9. Tap the anchor through the fixture (lift base plate) and into the hole, making sure that the

nut rests solidly against the fixture. 10. Tighten the nut to 150 ft-lbs for 3/4 inch diameter bolts and to 75 ft-lbs for 3/8 inch

diameter bolts.


P/N 12580 Rev. 12/99

17


P/N 12580 Rev. 12/99

18

PARTS BREAKDOWN MODEL 12000

ITEM # PART # #/LIFT DESCRIPTION

1 12510 1 POWER COLUMN WELD 12511 1 IDLER COLUMN WELD

2 12516 2 LOCK WELD 3 12518 2 LOCK RETAINER 12073 4 5/16-18NC BUT.HD.CS X 1/2 LG 37025 2 AIR CYLINDER ASSEMBLY 12088 2 EXTENSION SPRING

4 12534 2 COLUMN EXTENSION WELD 31035 28 3/8-16NC X 1 HEX HD. CAP SCREW 31036 28 3/8 FLAT WASHER 31038 28 3/8-16NC HEX NUT

5 12540 1 OVERHEAD WELD 12542 1 OVERHEAD SHUTOFF BAR ASSY 12045 1 MERCURY SWITCH 12531 2 SYNCHRONIZER CABLE ASSY 12574 2 CABLE EXTENSION (model 12001) 12574 4 CABLE EXTENSION (model 12002)

6 31019 6 CABLE PULLEY 31020 6 WASHER 31021 6 RETAINER RING

7 12521 2 CARRIAGE WELD 8 31023 16 SLIDE BLOCK 9 12544 4 ARM PIN WELD

10 12547 4 FEMALE ARM WELD 11 12552 4 MALE ARM WELD

12072 4 1/2-13NC SHCS X 5/8 LG 12 12562 4 EXTENSION (3")

12561 2 EXTENSION (6") 13 12563 4 ADAPTER ASSEMBLY

12567 2 ADAPTER RACK 31052 4 ARM RESTRAINT ASSEMBLY 31368 POWER UNIT - SINGLE PHASE 31355 POWER UNIT - THREE PHASE

Replace worn or broken parts with genuine CHALLENGER LIFTS INC. parts Contact your local Challenger Lifts Parts Distributor for pricing and availability (Call CHALLENGER LIFTS INC. (502) 625-0700 for the Parts Distributor in your area)

File: Lift Maintenance Checklist 12/02

LLLLIFT IFT IFT IFT MMMMAINTENANCE AINTENANCE AINTENANCE AINTENANCE CCCCHECKLISTHECKLISTHECKLISTHECKLIST

To avoid personal injury, permit only qualified personnel to perform maintenance on this equipment. The following maintenance points are suggested as the basis of a preventive maintenance program. The actual maintenance program should be tailored to the installation. See ANSI/ALI ALOIM booklet (blue) for periodic inspection checklist and maintenance log sheet provided with each lift. • If lift stops short of full rise or chatters, check fluid level and bleed cylinder(s) per Installation

Instructions. • Replace all Safety, Warning or Caution Labels if missing or damaged

DDDDAILYAILYAILYAILY • Keep lift components clean. • Check for loose or broken parts. • Check hydraulic system for fluid leaks. • Check adapters for damage or excessive wear. Replace as required with genuine Challenger

Lifts parts. • Check lock release activation. On 2 Post above ground when properly adjusted, the idler

column lock should rest firmly against the back of the column when engaged and against the spring mount tab when disengaged.

WWWWEEKLYEEKLYEEKLYEEKLY • Check lifting/synchronizer chains/cables and sheaves for wear. Replace as required with

genuine Challenger Lifts parts. • Check lifting/synchronizer chains/cables tension per Installation Instructions. Adjust if

necessary.

MMMMONTHLYONTHLYONTHLYONTHLY • Torque concrete anchor bolts to 80 ft-lbs. • Check overhead shutoff switch (2 Post Lifts only). While raising lift, operate overhead shutoff bar.

Power Unit motor should stop when bar is raised. • Lubricate carriage slide tracks (2 Post Lifts only) with heavy viscous grease. (Grease all (4)

corners of both columns.)

SemiSemiSemiSemi----AnnuallyAnnuallyAnnuallyAnnually • Check power unit hydraulic fluid level per Installation Instructions.

IIIIF ANY PROBLEMS ARE EF ANY PROBLEMS ARE EF ANY PROBLEMS ARE EF ANY PROBLEMS ARE ENCOUNTEREDNCOUNTEREDNCOUNTEREDNCOUNTERED, , , , CONTACT YOUR LOCAL SCONTACT YOUR LOCAL SCONTACT YOUR LOCAL SCONTACT YOUR LOCAL SERVICE REPRESENTATIVERVICE REPRESENTATIVERVICE REPRESENTATIVERVICE REPRESENTATIVEEEE....

2-post lift concrete · pdf file2-post lift concrete requirements toll free: 800.648.5438...

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