Challenger - NYTech Supply
Contents
1. ADHESIVE AND WIRE TIE MOSS Se LAS N EN UNION TEE WIRE TIE ADHESIVE TAB f AND WIRE TIE ON D SN ROUTE AIR LINE ROUTE AIR LINE WITH HYDRAULIC LINE WITH ADHESIVE TABS POWER COLUM IDLER 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 9 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 17 Connect the overhead shutoff switch to the power unit Fig 8 18 Connect the power unit to a suitable electrical power Fig 8 Wiring Diagram CLOSED EACH LIFT SHOULD HAVE A DEDICATED CIRCUIT WITH A SE EE DOUBLE POLE THREE POLE FOR 440 480V BREAKER OR TIME DELAY FUSE SIZED ACCORDING TO THE 2Hp 25 15 15 Samp FOLLOWING CHART WIRING MUST COMPLY WITH ALL LOCAL ELECTRICAL CODES RAISE FOR SINGLE PHASE PUSH BUTTON OVERHEAD For 50 6042 TB N O LIMIT Motor ONLY NORM SWITCH ary Aas BUCK _ Es T4 208 240VAC BLACK BLACK 5 16 50 60Hz L1 M 208 240VAC 1 50 60Hz suP2. Challenger Lifts Inc MODELS 15000 amp 18000 TWO POST SURFACE MOUNTED LIFT OPERATION INSTALLATION amp MAINTENANCE MANUAL G Challenger Lifts Aud Me Wor 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 amp 18000 Installation Operation and Maintenance 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 bin oM Approximately 1 1 2 Minutes Lowertnb KEE Approximately 60 Seconds e te 2HP 230 Volts Single Phase 60 Hz Optional 2HP 208 or 240 or 480 Volt 3 Phase 50 60 Hz Dimensions Overall eege eae ee ta SA eee 154 3 4 Inches Ovetall Het A E 174 Inches 15000 amp 18000 198 Inches 15002 amp 18002 Height at Pull Rise T n 85 1 2 Inches Overhead Clearance na unai ashuan amasisa t na 167 Inches 15000 amp 18000 191 Inches 15002 amp 18002 Drive Through Cette eegene gege 106 3 4 Inches Pick Up Pad Height insine pe setenta severe 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 oi
3. Fig 5 y 92 EA s af I eh 3E MIT uf SAL wih E 7 pu ir Sr d st ip tt 10 z E 8 07 gt SY Figure 5 P N 12091 7 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 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 HYDRAULIC LINE SUPPORT TABS MUST BE FIELD ADJUSTED TO SUPPORT WEIGHT OF VERTICAL HYDRAULIC LINES AFTER CONNECTING ALL HYDRAULIC LINES TOGETHER BEND TAB TO PROPER POSITION AND INSTALL HYDRAULIC LINE CLAMPS HYDRAULIC LINE CLAMP 36069 up OVERHEAD CHANNEL 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 8 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 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
4. PLv L2 WHITE GROUND GROUND SCREW IN MOTOR WIRING BOX OVERHEAD LIMIT SWITCH AND CONTACTOR FOR THREE PHASE FOR OVERHEAD MODELS ONLY CONTACTOR ENCLOSURE TO BE FIELD MOUNTED x ne ON POWER COLUMN CENTERED SIDE TO SIDE TO OVERHEAD AVOID INTERFERENCE WITH SLIDE BLOCKS d l BLACK AMIN WHITE j MOTOR ENCLOSURE E CLOSED RAISE FACTORY WIRED FOR 208 240V T1 BLACK T7 l 1 l I L1 age Jt 6 0 4 I 2 1 I 2 L2 SST BLACK 30 I 483 T8 50 60Hz i Wb 50 60 Hz SUPPLY 5 MEN eg Loge I i 1 6 5 DIE GREEN li 1 NOTES RAISE RECONNECTIONS FOR SWITCH 440 480V 1 MOTOR IS FACTORY WIRED FOR 208V OR gt 220 240V SUPPLY 1 I BLACK T1 2 MOTOR CONNECTIONS MUST BE RECONFIGURED EIE 1 4 PER THIS DIAGRAM FOR 440 480V SUPPLY BLACK T2 3 CONTACTOR COIL RATING MUST MATCH SUPPLY mmc 2 VOLTAGE 208V 220 240V OR 440 480V 50 60 Hz I I BLACK e 4 CONTACTOR MUST BE FIELD MOUNTED ON POWER 6 5 COLUMN CENTERED SIDE TO SIDE TO AVOID d INTERFERENCE WITH SLIDE BLOCKS 5 MOTOR ROTATION IS COUNTER CLOCKWISE FROM TOP OF MOTOR Figure 8 P N 12091 10 Rev 3 03 T4 T5 T6 T9 PSS STS Sa SS SSS SSS SS SS SR SRT dem SSeS mec S Ba Models 15000 amp 18000 Installation Operation and Mainten
5. Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 17 P N 12091 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance PARTS BREAKDOWN MODEL 15000 18000 PART ITEM 15000 18000 LIFT DESCRIPTION 1200 1 POWER COLUMN WELD 120200 1 IDLER COLUMN WELD 120700 4 BM 48NCBUTHDCSXI2lG 37055 2 ARCYLINDERASSEMBY 1208 2 EXTENSIONSPRING o ESSE EET vU EXTENSION WELD 14 6 O A Ht 12022 2 COLUMN EXTENSION WELD 16 6 Ht 31085 _ 28 B amp NCX1HEXHD CAPSCREW 3106 28 BIBFLATWASHER 28 B amp NCHEXNUT 12074 OVERHEAD SHUTOFFBARASSY 120 1 MERCURYSWTCH 12019 2 SYNCHRONIZER CABLE ASSY 16 6 O A Ht e See CABLE ASSY 14 6 O A Ht 6 3119 6 DABEPULEY 3120 6 WASHR 31 6 RETANERRING 8 1202 16 SIDEBOCK 9 12046 4 ARMPINWELD 12072 4 VZ13NCSHCSXS BLG 1208 2 EEN 2 ADAPTER RACK ano 4 3 8 16 5 8 _ 1205 4 ARMRESTRAINTASSEMBLY 12119 12087 19 POWER UNIT SINGLE 12089 12089 19 POWER UNIT Replace worn or broken parts with genuine CHALLENGER LIFTS INC parts Contact your local Chall
6. 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 12 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 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 inc
7. ance 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 lt SN d gt 7 L a Buc 1 2 Z E t i i IL 3 LINK Pt 1 2 WASHERS AS NEEDED TEM INSERT 1 2 X 1 1 2 BOLT 1 2 X 1 1 2 BOLT SPRING b sn d Wf SLEEVE e 2 J 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
8. enger Lifts Parts Distributor for pricing and availability Call CHALLENGER LIFTS INC 502 625 0700 for the Parts Distributor in your area 18 P N 12091 Rev 3 03
9. he 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 2 at any point Use a level no less than 24 in length to plumb the columns 23 fn mS Y amp amp Y 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 Liftthe 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 1 2 shoulder bolt and 5 16 18 Keps nut Obtain the 3 8 snap bushing from the ha
10. hes 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 P N 12091 resulting in an unsafe condition If this is intended vehicle support stands are recommended 13 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 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 bo
11. l in the system and the temperature of the oil COMPONENT PACKING LIST PART 15000 18000 3HLIFT DESCRIPTION EE ANE EXTENSION 14 6 O A Ht 12022 COLUMN EXTENSION 16 6 O A Ht 12005 1 MERCURY SWITCH EE ER c CABLE ASSY 16 6 O A Ht 12100 SYNCHRONIZER CABLE ASSY 14 6 O A Ht 12071 2 ADAPTER RACK 12089 12089 19 POWER UNIT THREE PHASE 12090 LITERATURE PACK P N 12091 2 Rev 3 03 P N 12091 Models 15000 amp 18000 Installation Operation and Maintenance Important Before You Install 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 Be certain that the wiring in your building will handle the current required to operate this unit Fig 8 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 instal
12. lation 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 Check with the local building inspectors and or Permits office for any special instructions or approvals required for your installation 3 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 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 WALL OR BENCH 168 14 0 MINIMUM RECOMMENDED 120 10 0 INSIDE COLUMN TO COLUMN COLUMN BASE PLATES 19 1 7 REFERENCE USE AS REFERENCE ONLY 1542 WALL OR ADJACENT LIFT Y K lt AMPpM WgCeIW C IXI XUUU TU I amp II lt SI OI lt I I gt II lt GIIYCC I I Iz I zIZ IOORIII III XWIQ OOOI ees Figure 1 P N 12091 4 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 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 t
13. lts 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 14 P N 12091 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 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 P N 12091 Remove any shipping plugs or caps insuring that no remnants of the plugs or caps remain in the tube 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 Align the tubing joints so that the tubing and sleeve assemblies can be inserted easily into the fitting 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 Tighten the fitting nu
14. rdware 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 5 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 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 Lo 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 6 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 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 INSIDE Gu 5 COLUMN E CARRIAGE UP TO OVERHEAD PULLEY AND OVERHEAD PULLEY LJ 3 Figure 4 12 Install the power unit and button valve bracket assembly on the power column
15. t until the force required to turn it rises sharply 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 15 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 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 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 T 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 Ibs for 3 4 inch diameter bolts and to 75 ft Ibs for 3 8 inch diameter bolts 16 P N 12091
16. 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 Challenger Lifts Inc 200 Cabel Street Louisville KY 40206 P N 12091 11 Rev 3 03 Models 15000 amp 18000 Installation Operation and Maintenance 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
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