Challenger CL9 9k 2-Post
Contents
1. OVERHEAD BLACK UT i B m Bena CLOSED i RAISE FACTORY WIRED FOR SWITCH 208 240V 1 zm rx cy 1 1 1 5 p BLACK T7 2 1 ua MET 3 4 3 50 60Hz lt 50 60 Hz SUPPLY L3 i 1 1 5 We Bk Be i 1 GREEN li CENE i NOTES RAISE RECONNECTIONS FOR i SWITCH 440 480V 1 MOTOR IS FACTORY WIRED FOR 208V OR LIN VE T4 220 240V SUPPLY 1 l I BLACK e T 1 2 MOTOR CONNECTIONS MUST BE RECONFIGURED l 2 i 1 PER THIS DIAGRAM FOR 440 480V SUPPLY 1 55 oo T2 3 COIL RATING MUST MATCH SUPPLY 4 3 VOLTAGE 208V 220 240V OR 440 480V 50 60 Hz 1 o xe 4 CONTACTOR MUST BE FIELD MOUNTED ON POWER l 6 5 COLUMN CENTERED SIDE TO SIDE TO AVOID MEC es 4 INTERFERENCE WITH SLIDE BLOCKS 5 MOTOR ROTATION IS COUNTER CLOCKWISE m DE m 2 n m FROM TOP OF MOTOR i Electrical Wiring Diagram Fig 13 Electrical Wiring Diag Page 10 Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance 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 que2. 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 A WARNING 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 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 Page 3 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 dec
3. 81 LONG 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 15 Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance PARTS BREAKDOWN continued Fig D Synchronizer 2227 JJJ 7 7 07 17 27 7 07 07107070717 925 ITEM PART QTY LIFT DESCRIPTION A1115 0 SYNCHRONIZER CABLE CL9 0 32 8 Cable Pack A1003 0 50 A1115 1 2 SYNCHRONIZER CABLE CL9 1 34 8 Cable Pack A1003 1 A1115 2 SYNCHRONIZER CABLE CL9 2 36 8 Cable Pack A1003 2 51 A1116 4 Ve 20NF HEX NUT 52 A1117 4 20 HEX JAM NUT 53 A1041 6 SHEAVE ASSEMBLY 3 1 2 DIA X 14 GROOVE 54 A1062 2 SHEAVE PIN 55 A1063 S 4 SHORT SHEAVE SPACER 56 A1063 L 2 LONG SHEAVE SPACER 57 36013 10 1 1 D SPACER WASHER 58 36014 2 1 EXT RETAINING RING 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 Page 16 Model CL9 Installati
4. Attach 3 8 O D spring the HERE FOR oni same as Power side INSTALLATION SYNCHRONIZER CABLES P LOCK PAWL 18 Manually raise the carriages approximately HYDRAULIC 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 EAS top plate of the carriage as shown in Fig 7a Q 19 Route synchronizing cables using Fig 7a and attach ends to cable tie off tabs using Fig s 7b amp 7c Fig 7b Attaching Cable from Above Page 6 Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance SYNCHRONIZER CABLE ADJ USTMENT 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 Nu
5. 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 LOCK RELEASE CABLE 46 Lower lift to the floor and snap plastic cover over Power Column lock assembly 47 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 IMPORTANT IF IDLER SIDE LOCK
6. than 1 2 at any given point Use a level no less than 24 in length to plumb columns ALIGNMENT NOTCH V R ALIGNMENT 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 Ig 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 Ig hex flange bolts and hex flange nuts per side as shown in Fig 3 Installation Aid INSTALL 3 8 HEX FLANGE BOLT amp NUT FOR SUPPORT OF OVERHEAD REMOVE cw AFTER INSTALLATION BOTH COLUMNS INSTALL 4th BOLT LATER WITH HYDRAULIC HOSE CLAMP BOTH COLUMNS 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
7. to begin to pull tension on the 7 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 amp OVERHEAD LIMIT SWITCH WHILE RAISING LIFT OPERATE OVERHEAD SHUTOFF BAR PowER UNIT MOTOR SHOULD STOP WHEN SHUTOFF BAR IS RAISED Page 9 FINAL ADJ USTMENTS 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
8. washers onto the sheave pin as shown in Fig 5 Set in cradle with all assembly parts between the two plates SHORT SHEAVE SPACER ADJUSTMENT WASHER Fig 5 Sheave Assembly LOCKING PAWL LI H L LONG SHEAVE SPACER T WASHER ADJUSTMENT SHEAVE LI ES lg WASHER i bs gt SHORT E us SHEAVE SPACER i M H H LI L L L L H 16 Install Power Column locking pawl and lock Fig 7a Cable Routing release clevis with 5 8 diameter x 1 1 2 Ig shoulder bolt and 1 2 13 nylon lock nut SAME FOR Fig 6 Attach 3 8 O D extension spring to POWER SIDE 2 INSTALL CABLE upper hole in locking pawl and other end to AND REDUCED HEIGH hole in bracket welded to column IDLER SIDE INSTALLATION 13 NYLON KOTE INSTALL CABLE HEX NUT REGULAR NUT en dtr O D EXT LOCK PAWL HYDRAULIC CYLINDER LOCK PAWL LOCK RELEASE CLEVIS ASS Y POWER COL ONLY Ne S L 56 DIA x 16 19 SHOULDER BOLT Fig 7b Attaching Cable from Below SAME FOR Bop ext POWER SIDE HEREFOR IDLER COL ONLY ee NN Fig 6 Locking Pawl Assembly INSTALL GABLE 17 Attach 7 extension spring to hole REDUCED WIDTH located on bottom side of Idler Column lock INSTACSATION pawl and install using 5 8 shoulder bolt and INSTALL CABLE lock nut Fig 6
9. INSTALLATION OPERATION amp MAINTENANCE MANUAL MODEL CL9 9 000 LBS CAPACITY 2250 LBS PER ARM 200 Cabel Street P O Box 3944 Louisville Kentucky 40201 3944 Email ales challengerlifis com Web site www challengerlifts com Office 800 648 5438 502 625 0700 Fax 502 587 1933 IMPORTANT READ THIS MANUAL COMPLETELY BEFORE INSTALLING or OPERATING LIFT Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance GENERAL SPECIFICATIONS See Figure 1 CL9 CL9 1 CL9 2 A Adjustable Column Height 11 8 or 11 2 12 8 or 12 2 137 8 or 13 2 B Floor to Overhead Switch 117 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 Oylinder Height Full Stroke 11 11 E Adjustable Overall Width 117 2 or 10 8 or 10 2 F Screw Pad Height 4 to 6 34 G Inside of Columns 109 or 103 or 97 Drive Thru Clearance 89 or 83 or 77 Ceiling Height Required 12 0 12 9 137 9 Maximum Capacity 9 000 Ibs 2250 Ibs 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 103 97 may adversely affect abili
10. 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 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 14 Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance PARTS BREAKDOWN continued Fig C Hydraulics ITEM PART QTY LIFT A1201 15 A1203 15 39 ONLY USED ON CL9 1 CL9 2 DESCRIPTION POWER UNIT 1ph 60 Hz 208 230V POWER UNIT 3ph 60 Hz 208 230 460V 16167 HYD ELBOW 9 16 O RING MALE TO 6 MALE FLARE A1123 PU HYD HOSE ASSEMBLY POWER UNIT 22 LONG A1120 BULKHEAD TEE 6 MALE 37 DEGREE FLARE 39101 024 COLUMN EXTENSION HOSE CL9 1 24 LONG 39101 048 COLUMN EXTENSION HOSE CL9 2 48 LONG A1123 HYD HOSE ASSEMBLY IDLER COLUMN 326 LONG A1122 12 HOSE CLAMP 16138 CYLINDER 68 STROKE X 2 BORE 1121 STRAIGHT ADAPTER 9 16 MALE O RING 6 MALE FLARE A1123 P HYD HOSE ASSEMBLY POWER COLUMN
11. P GUIDE Vehicle Lifting Points Quick Reference Guide for Frame Engaging Lifts Page 11 The Owner Employer shall establish procedures to periodically inspect the lift in accordance with the lift manufacturers 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 manufacturers 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 Maint
12. 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 Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance After wiring has been completed test operation of Power Unit amp Overhead Limit Switch While raising lift operate Overhead Shutoff Bar Power Unit Motor should stop when Shutoff Bar is raised EACH LIFT SHOULD HAVE A DEDICATED CIRCUIT WITH A 10 30 30 DOUBLE POLE THREE POLE FOR 440 480V BREAKER 208 50 2080 2200 11 440 480V OR TIME DELAY FUSE SIZED ACCORDING TO THE 2Hp 25amp iBamp 15 Samp FOLLOWING CHART WIRING MUST COMPLY WITH NEC AND ALL LOCAL ELECTRICAL CODES RAISE FOR SINGLE PHASE PUSH BUTTON OVERHEAD N O LIMIT COMMON BENE NORM SWITCH 5 dL OPEN BLACK WHITE YELLOW e e 1 208 240VAC BLACK BLAGK OE HELD L1 BLACK CLOSED 1 208 240VAC BLUE SUPPLY L2 WHITE GROUND GROUND SCREW IN MOTOR WIRING BOX OVERHEAD LIMIT SWITCH AND CONTACTOR FOR THREE PHASE Z FOR OVERHEAD MODELS ONLY CONTACTOR ENCLOSURE TO BE FIELD MOUNTED m ON POWER COLUMN CENTERED SIDE TO SIDE TO AVOID INTERFERENCE WITH SLIDE BLOCKS
13. RT QTY LIFT DESCRIPT A1010 P POWER COLUMN WELD A1010 IDLER COLUMN WELD A1055 0 COLUMN EXTENSION WELD CL9 1055 1 COLUMN EXTENSION WELD CL9 1 A1055 2 COLUMN EXTENSION WELD CL9 2 A1060 A1061 36074 31129 36027 A1064 OVERHEAD CHANNEL MID SECTION OVERHEAD CHANNEL END SECTION SHUTOFF BAR PAD OVERHEAD LIMIT SWITCH 3 8 DIA x 1 7 8 Lg CLEVIS PIN SHUTOFF BAR 40124 HAIRPIN COTTER PIN 31036 3 8 FLAT WASHER A1153 3 8 16NC HEX FLG HD C S X 3 4 Lg 1154 3 8 16NC HEX FLG NUT cioj ojoj alo 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 Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance PARTS BREAKDOWN continued Fig B Lock ITEM FOR LIFTS EQUIPPED WITH DUAL PENDANT CONTROL REFER TO SEPERATE DUAL PENDANT CONTROL MANUAL SUPPLEMENT PART QTY LIFT DESCRIPTION A1135 0 LOCK RELEASE CABLE ASSEMBLY CL9 0 20 A1135 1 LOCK RELEASE CABLE ASSEMBLY CL9 1 A1135 2 LOCK RELEASE CABLE ASSEMBLY CL9 2 21 A1140 2 LOCK PAWL 22 A1133 2 LOCK COVER 23 30020 2
14. als and fully understand their meaning Replace worn faded or damaged decals promptly Do not attempt to raise a A WARNING vehicle on the lift until the lift has been correctly installed and adjusted as described in this manual SAFETY INSTRUCTIONS 9 Proper maintenance and inspection is necessary for safe operation SAFETY INSTRUCTIONS Read operating and safety manuals before using lift SAFETY INSTRUCTIONS The messages and pictographs own are hazards comm automot lifts regardless of specific style Funding for the development and validation of these labels was provided by the Automotive Lift Institute PO Box 33116 Indialantic FL 32003 They are protected by copynght Set of labels may be obtained from Do not operate ALI or its member companies a damaged lift 1992 by AL Inc ALIWLIOS CAUTION CAUTION 5 Lift to be used gt T Authorized personnel only in lift area A CAUTION Clear area if vehicle is in danger of falling Position vehicle by trained operator only A CAUTION midway between adapters Use vehicle manufacturer s Always use safety stands when removing or installing heavy components Avoid excessive rocking of vehicle while on lift Remain clear of lift when raising or lowering vehicle lift points Use height extenders when necessary to ensure good contact Auxiliary adapters may reduce load ca
15. cle to a height a few inches above the desired working height 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 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 Page 12 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 e f lift stops short of full rise or chatters check fluid level and bleed both cylinders per Installation Instructions Replace all Safety Warning or Ca
16. e jam nut should be located on each side of tab Position threaded sleeve with 12 of thread below tab as indicated Fig 11 and tighten jam nuts narrow or low setting excess hose should be LOCK RELEASE snaked in bottom of overhead Fig 10a CABLE ASS Y When installing at narrow and low setting form a loop in the column extension between ED 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 JAM NUT the top of the column extension and one at jas a CABLE the end of the overhead Fig 10b Tighten ve CLEVIS PIN pu GN connection at fitting d LOCK RELEASE HYDRAULIC HOSE CLAMP CLEVIS ASS Y SNAKE EXCESS HOSE WITH 3 8 16 HEX FLANGE IN OVERHEAD WHEN BOLT amp NUT INSTALLING AT NARROW T OR LOWERED SETTING DN P N LZ Fig 11 Power Column Lock Assembly ee 32 Route opposite end of cable assembly up left E side of Power Column and into column n through access slot 3 8 x4 Lg in bottom of Hl Column Extension Following the path of the LOOP EXCESS HOSE i hydraulic line route cable assembly across PM UM overhead clear of moving parts and back out AND LOWERED SETTING through access slot in bottom of idler side j column extension again use left slot when i viewed from outside of co
17. enance 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 Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance 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 vehi
18. foot pounds Page 5 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 NTS 3 8 FLAT WASHER WA j A OVERHEAD LIMIT SWITCH OW t T TUBE CORD MUST BE SOLER X ABOVE PIVOT PIN FOR PROPER ORIENTATION eS PROPER ORIENTATION 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 1014 95 ve 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 6 3 8 FLAT WASHERS SHUTOFF BAR gt 3 8 PIVOT PIN Fig 4b Overhead Limit Switch Sub Assembly Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance 15 Assemble the sheaves spacers and
19. 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 HYDRAULIC HOSE CLAMP WITH 3 8 16 HEX FLANGE BOLT amp NUT SNAKE EXCESS HOSE IN OVERHEAD WHEN INSTALLING AT NARROW OR LOWERED SETTING Fig 10a Hydraulic Hose from Idler Column to Overhead Sync cables removed for clarity Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance 27 Route hydraulic hose from Idler column LOCK RELEASE across Overhead to the Power Column and 30 Attach Mechanical down inside of Power Column routing is identical to Idler Column to male 6 bulkhead T fitting Loosely attach hose to If this is an extended height lift model CL9 1 or CL9 2 an extension hose supplied will connect the Idler hose to the 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 Lock Release Cable Assembly to Power Column Lock Release Clevis using the 3 16 diameter x 1 2 long pin and 2 clip retainers Fig 11 31 Insert threaded sleeve portion of cable assembly in slot located on tab above locking pawl Fig 11 On
20. ing and availability Call Challenger Lifts Inc 502 625 0700 for the Parts Distributor in your area Page 17 Rev 10 9 03 A1151 doc
21. lumn Attach Cable Fig 10b Hydraulic Hose from Overhead to Assembly to the hydraulic hose with loosely Power Column fit wire ties Sync cables removed for clarity NOTE DO NOT kink cable assembly when routing Tighten and trim wire ties after final cable 29 BE CERTAIN ALL FITTINGS AND CONNECTIONS adjustments have been made ARE TIGHT IT IS THE INSTALLERS RESPONSIBILITY TO INSURE SYSTEM IS LEAK 33 Attach Adhesive Backed Tab to Idler Column FREE Fill the Power Unit with three gallons of left of the lock assembly Fig 12 Route clean 10wt anti foam anti rust hydraulic oil or Lock Release Cable down left side of Idler Dexron III ATF Do Nor USE OILS WITH Column and secure with loosely fit wire tie to DETERGENTS Adhesive Backed Tab Attach Cable clevis to 1 2 O D Extension Spring FOR LIFTS WITH OPTIONAL DUAL PENDANT CONTROL SKIP STEPS 26 THRU 31 AND REFER INSTEAD TO THE DUAL PENDANT CONTROL INSTALLATION amp OPERATION MANUAL SUPPLEMENT Page 8 Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance ADHESIVE TAB _1 2 O D EXT SPRING CABLE CLEVIS THREADED SLEEVE EXTEND LOOP WHEN INSTALLING NARROW OR LOWERED SETTINC 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
22. on Operation and Maintenance PARTS BREAKDOWN continued Fig E Carriage amp Arms OD 79 81182 ITEM 71 80 PART QTY LIFT VS 74 DESCRIPTION 70 A1025 2 CARRIAGE WELD 71 1040 16 SLIDE BLOCK 72 1078 4 ARM PIN WELD 73 1091 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 79 A1086 P 1 FRONT FEMALE ARM WELD POWER A1086 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 1075 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 Replace all worn or broken parts with genuine Challenger Lifts Inc parts Contact your local Challenger Lifts Parts Distributor for pric
23. pacity Do not override self closing lift controls Keep feet clear of lift while lowering own are generic in nature and are meant The messages and pictograp ar mon to abtomotive lifts regardless of to generally represent hazar pan specific style Funding for the development and validation of these labels was provided by P e and the the Automotive Lit Instituta PO Box 33116 Indialantic FL 32903 t he and variae the Automotive Lift Institute PO Box 33116 Indialantic FL 32903 They are protected by copyright Set of labels may be obtained from ALI its member companies copyright Set ol labais may be obtained from ALI or 1002 by Ine Aurore Rev 10 9 03 A1151 doc with center of gravity nature and are meant automotive lifts rogardless of n of these labels was provided by Model CL9 Installation Operation and Maintenance 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 afte
24. r 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 Cry 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 2 Column Extension for CL9 1 A1055 2 Column Extension for CL9 2 A1003 0 Sync Cable Pack for CL9 A1003 1 1 Sync Cable Pack for CL9 1 A1003 2 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 1 Power Unit 1 Phase A1203 15 Power Unit 3 Phase A1150 1 Literature Pack Page 4 INSTALLATION IMPORTANT Always wear safety glasses while installing lift TOOLS MINIMUM REQUIRED Banding Cutter Tape measure 16ft Chalk line 4ft level 10 adjustable wrench Standard open end wrenches 7 16 1 2 2 9 16 2 11 16 3 4 5 16 allen wrench Needle nose pliers i Hammer drill with 3 4 diameter carbide tipped bit 2lb hammer k Torque wrench 150 foot pounds minimum with 1 1 8 socket I 12 ft Step ladder m Pull wire or fish tape n Anti Seize lub
25. ricant for arm pins o 3 4 O D Pipe cutter if installing lift at narrow width setting ooocpn 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 Ig 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 Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance 8 Shim both columns to plumb using the shims provided as shown in Fig 2 DO NOT shim more
26. stionnaire 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 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 manufacturers 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 L
27. t POWER UNIT amp 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 N 5 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 Page 7 BULKHEAD BRANCH TEE MALE 6 9 16 18 SAE JIG 37 FLARE FACTORY INSTALLED 22 in lg HYDRAULIC HOSE FEMALE 6 9 16 18 SAE JIC 37 FLARE BOTH ENDS FROM POWER UNIT TO COLUMN ao lt N 48 9 16 18 O RING ELBOW x MALE 6 9 16 18 SAE JIC 37 FLARE 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 19 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
28. ty 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 6 TO NEAREST OBSTRUCTION OR 7 TO NEAREST WALL 108 9 0 I DRIVE ON MIN TO DIRECTION NEAREST 1 OBSTRUCTION 10 REF B ei E D i PS COLUMN BASE PLATES A Y INSIDE COLUMN TO COLUMN SEE CHART ABOVE C USE AS REFERENCE ONLY SEE CHART ABOVE 144 12 0 mF MIN TO Y NEAREST pt i amp OBSTRUCTION Fig 1a General Specifications Fig1b Service Bay Layout Page 2 Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance 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 WARNING provide adequate unsatisfactory lift clearance could result in 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
29. ution Labels if missing or damaged See Installation instructions page 3 Daily Keep lift components clean e Check for loose or broken parts e Check hydraulic system for fluid leaks e Check adapters for damage or excessive wear Replace as required with genuine Challenger Lifts parts e 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 e Check synchronizer cables and sheaves for wear Replace as required with genuine Challenger Lifts parts e 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 e Check synchronizer cable tension per Installation Instructions Adjust if necessary Monthly e Torque concrete anchor bolts to 80 ft lbs e Check overhead shutoff switch While raising lift operate overhead shutoff bar Power Unit motor should stop when bar is raised e 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 Rev 10 9 03 A1151 doc Model CL9 Installation Operation and Maintenance PARTS BREAKDOWN Fig A Column amp Overhead ITEM PA
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