Challenger Lifts 44000 Instruction manual

INSTALLATION, OPERATION
& MAINTENANCE MANUAL
200 Cabel Street, P.O. Box 3944 Louisville, Kentucky 40201-3944
email: [e-mail] web site:
www.challengerlifts.com
Office 800-648-5438 / 502-625-0700 Fax [phone]
IMPORTANT:
IMPORTANT:IMPORTANT:
IMPORTANT: READ THIS MANUAL COMPLETELY BEFORE
INSTALLING or OPERATING LIFT
Rev. 7/19/04
Four
FourFour
Four-
--
-Post
PostPost
Post
Surface Mounted Lift
Surface Mounted LiftSurface Mounted Lift
Surface Mounted Lift
M
MM
MODEL
ODELODEL
ODEL 44000
4400044000
44000
Chain Drive
(12,000 lb Capacity)

Model 44000
Installation, Operation & Maintenance
44150.doc - 2 - Rev 7/19/04
GENERAL SPECIFICATIONS
SPECIFICATIONS 44XAX 44XFX 44EAX 44EFX 44XRX
Length Overall (A) 271 3/4" 271 3/4” 244 1/4” 244 1/4” 271 3/4"
Max. Wheelbase* 210” 210” 182 1/2" 182 1/2" 210”
Max. 2 Wheel
Alignment* 194” - 166 1/2" - -
Max./Min. 4 Wheel
Alignment* 158” / 88” - 158” / 88” - -
Width Overall (B) 144”
Inside of Columns (C) 128 1/2"
Maximum Capacity 12,000 lbs.
Height of Columns/
Overall Height 89”/107”
Runway Height at Full
Rise 78 3/4"
Runway Width (D) 20”
Width Between
Runways (E) 42”
Lifting Time 72 Sec. (approximate)
Motor 2HP, Single Phase, 60Hz, 208/230VAC
Optional – 2HP, Three Phase, 50/60Hz, for 208 or 230 or 460V
* Wheelbase is based on a tire diameter of 30”
Dimensions listed below are for layout purposes only.
Actual dimensions may vary.
REARREAR REARREAR
FRONTFRONT FRONTFRONT
Fig 1
(Overall Lift Dimensions)

Model 44000
Installation, Operation & Maintenance
44150.doc - 3 - Rev 7/19/04
WARNING
IMPORTANT!!!
BEFORE YOU INSTALL
Before installing your Challenger 4-Post lift, read the manual(s) thoroughly. Inspect the lift to
insure that it is complete and undamaged. Challenger 4-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.
Determine the location for the lift installation. Fig. 1 gives the overall dimensions of the lift,
including the drive on ramps. There must be free access to load and unload the vehicles.
There must be enough overhead clearance to raise vehicles six feet above the floor.
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 handle the loaded lift. The 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 per
local commercial practice, 3500 psi, cured for 28 days. Floor should be level within 3/8 inch
over the installation area. The columns must be on the same plane to level the lift. This may
be done by shimming, grouting or pouring new pads. No anchors should be installed within 8
inches of any crack, edge, or expansion joint. If these conditions cannot be met, pads may be
poured to accommodate the lift. Pads must be two feet square with a minimum thickness
of twelve inches, concrete must be 3500 psi and reinforced as above. These pads must
be mechanically attached to the existing floor. 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 of single-phase units, it is necessary to have a dedicated
circuit with a double pole 25-amp circuit breaker or time delay fuse.
WARNING

Model 44000
Installation, Operation & Maintenance
44150.doc - 4 - Rev 7/19/04
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.
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

Model 44000
Installation, Operation & Maintenance
44150.doc - 5 - Rev 7/19/04
Installation Procedure
1 Refer to Fig. 2, General Arrangement. For muffler work, it is satisfactory to erect the lift
with the cylinder beam on the left, or driver’s side. For alignment and work, which
require access to the front seat of the car, the top rail can be positioned on the right side
so it is out of the way.
(Models 44EFX, 44XFX,
44XRX, 44EAX and 44XAX) (Models 44EFX, 44XFX Only)
(Models 44EFX, 44XFX,
44XRX, 44EAX and 44XAX) (Models 44EFX, 44XFX Only)
(Models 44EFX, 44XFX,
44XRX, 44EAX and 44XAX) (Models 44EFX, 44XFX Only)
(Models 44EFX, 44XFX,
44XRX, 44EAX and 44XAX) (Models 44EFX, 44XFX Only)
Fig 2
(General Arrangement)
2 Refer to Fig. 3 to get the dimensions for the post base locations. Refer to Fig. 1 to
determine where to locate the sides and ends of the post base plate with respect to
walls and other obstacles at the installation. Include additional clearance where
required near walls and obstacles.
Models 44E Models 44X
Models 44E Models 44X
Models 44E Models 44X
Models 44E Models 44X
Fig 3
(Post Base Location)

Model 44000
Installation, Operation & Maintenance
44150.doc - 6 - Rev 7/19/04
3 Once the location is determined, use a chalk line to mark base line A-B to locate one
side of the lift, refer to Fig 4. Use the width dimension from Fig 3 to measure off the
dimensions A-D and B-C. Draw arcs as illustrated in Fig. 4. Draw a chalk line D-C
tangent to the two arcs to establish the other side of the lift.
C
C
C
C3 3
3
3
BBBB2222
4
4
4
4DDDD
1
1
1
1AAAA
CCCC3333
BBBB2222
4444DDDD
1111AAAA
C
C
C
C3 3
3
3
BBBB2222
4
4
4
4DDDD
1
1
1
1AAAA
CCCC3333
BBBB2222
4444DDDD
1111AAAA
Fig 4
(Chalk Line layout)
4 Mark on one of the two parallel lines the points 1 and 2 to establish the ends of the post
base plate as determined from Figs. 1 and 3. From points, 1 and 2 measure diagonally
to the opposite parallel line to determine points 3 and 4. Draw a chalk line between
points 1 and 4 and points 2 and 3. The four lines locate the four outside corners of the
post base plates.
5 Position the cylinder beam and the two power side posts as shown in Fig. 5. The power
side post, which has the bracket on one side, is the power unit post. Loosely bolt the
cylinder beam to the main side posts using ½-13 x 1 1/4 flange head bolts and nuts
supplied.
Fig 5
(Cylinder Beam / Power Side Post Assembly)

Model 44000
Installation, Operation & Maintenance
44150.doc - 7 - Rev 7/19/04
6 Lift the assembled cylinder beam to the upright position. Place the post base plate into
their corners of the chalk line rectangle.
7 Review the concrete anchor bolt instructions below. Drill, install, but do not tighten the 4
anchor bolts for the Power Post. DO ONLY THE POWER SIDE POSTS AT THIS
TIME.
Anchor Bolt Installation
a) Insure the concrete has had sufficient time to cure - 28 days minimum.
b) Always wear safety glasses.
c) Follow the drill manufacturers safety instruction.
d) Use only solid carbide-tipped drill bits meeting ANSI B94 tip diameter standards.
e) 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.
f) Drill the hole at least as deep as the full length of the anchor, completely through the
slab if possible.
g) Clean the hole, using compressed air and a wire brush or vacuum. A clean hole is
necessary for proper performance.
h) Assemble the washer and nut on the anchor bolt so that the anchor protrudes
slightly beyond the nut.
i) Tap the anchor through the fixture (lift base plate) and into the hole, making sure
that the nut rests solidly against the fixture.
j) Torque the nut to 150 ft-lbs.
8 Plumb the post. Using a level, check both side-to-side and front to rear. Use shims
provided or, 3/4" steel flat washers to plumb. Tighten the anchor bolts and recheck for
plumb. Adjust if necessary.
9 Align the Power Side Post with the chalk lines. Check and adjust plumb of this post.
The base plate may vary from the measured dimensions slightly, but it is more
important that the post be plumb and parallel with the other post. Install the anchor
bolts in the Power Side Post and tighten. With both power side posts anchored and
plumb, tighten the ½-13 hardware attaching the cylinder beam, shimming if necessary
to avoid twisting the cylinder beam.

Model 44000
Installation, Operation & Maintenance
44150.doc - 8 - Rev 7/19/04
10 Support and position the crossbeams off the ground and in their approximate locations
as seen in Fig 6. The lift chain block must be at the Power Side Post location.
Fig 6
(Crossbeams)
11 Use a pull wire to pull the crossbeam chain through the crossbeam tube. The chain
runs over the sheave at the power side end and under the sheave at the idler side end.
See Fig. 7. Repeat for the other crossbeam.
Fig 7
(Crossbeam Chain Arrangement)

Model 44000
Installation, Operation & Maintenance
44150.doc - 9 - Rev 7/19/04
12 Attach the crossbeam chains to the main side post chain anchors with the 5/16 x 1
shoulder bolts and ¼-20 nylon locknuts provided, insuring the bolt passes through all
three chain leafs. See Fig. 8.
Fig 8
(Crossbeam Chain Attachment)
13 Position a 2 x 4 block under the safety latch on the power side end of the cross rail as
shown in Fig. 9. Remove the safety rod from the column assembly. Turn the 7/8-9 jam
nut to the bottom of the thread. Remove the packing pin from the cross rail end
assembly. Insert the safety rod into the space previously occupied by the packing pin in
the cross rail end assembly. Slide the crossbeam and safety rod into the column until
the anti-sway wear button is against the back of the column. Insert the threaded end of
the safety rod into the hole at the top back of the power side post. Secure the top of the
safety rod with a 7/8-9 nut. The nut should be flush with the end of the safety rod and
the jam nut should be tightened against the post top cap. Remove the wooden block.
Repeat.
Fig 9
(Safety Rod Installation)

Model 44000
Installation, Operation & Maintenance
44150.doc - 10 - Rev 7/19/04
14 Remove the cap from the front cylinder port. Manually extend the cylinder ram. Attach
the lifting chains to each Lift Chain Block using the 5/16 x 2 shoulder bolts and ¼-20
lock nuts provided. See Fig. 9.
15 Place the runways on the crossbeams with the jack rails facing one another and loosely
attach with the ½-13 hex flange head bolts provided. See Fig 10.
Fig 10
(Runway Placement)
16 Position a 2 x 4 block under the safety latch on the idler side end of the cross rail as
before in Fig. 9. Remove the safety rod from the column assembly. Turn the 7/8-9 jam
nut to the bottom of the thread. Remove the packing pin from the cross rail end
assembly. Insert the safety rod into the space previously occupied by the packing pin in
the cross rail end assembly.
17 Place the Idler side columns in their approximate positions on the chalk lines. Insert the
threaded end of the safety rod into the hole at the top back of the idler side post.
Secure the top of the safety rod with a 7/8-9 nut. The nut should be flush with the end
of the safety rod and the jam nut should be tightened against the post top cap. Remove
the wooden block. Repeat.

Model 44000
Installation, Operation & Maintenance
44150.doc - 11 - Rev 7/19/04
18 Install the synch chain adjustment lug to the free end of the crossbeam chain with the 5-
16 x 1 shoulder bolt and ¼-20 lock nut provided. Attach this adjustment lug to the top
cap with the 1-8 lock nut provided. See Fig 11. Hold the chain with a crescent wrench
and tighten the nut to remove most of the slack from the chain. Repeat for the other
crossbeam.
Fig 11
(Idler Side Column Installation)
19 Attach the power unit to the Power Post using the 5/16" hardware provided. Attach the
hydraulic hose between the fitting at the rod end of the cylinder and the fitting just above
the power unit tank. Secure the hose to the cylinder with the tie wraps. See Fig. 12.
Connect the power unit to a dedicated 25-amp electrical branch circuit, using wiring
methods prescribed by local codes. Refer to Fig. 13 for wiring schematic.
Fig 12
(Power Unit and Hose)

Model 44000
Installation, Operation & Maintenance
44150.doc - 12 - Rev 7/19/04
RECONNECTIONS FOR
440−480V
T3
T2
T1
T7
T1
T9
T8
T3
T2
FACTORY WIRED FOR
208−240V
M
43
56
FOR THREE PHASE
FOR SINGLE PHASE
43
12
65
12
Wiring Diagram
YELLOW
BLUE
T8
M
T9
T6
T6
M
T5
T7
T4
T5
T4
Fig 13
(Wiring Schematic)
20 Fill the reservoir with 11 quarts of 10W hydraulic oil or Dexron III. DO NOT OVERFILL
THE RESERVOIR. The oil level should be no higher than 2 inches below the mounting
flange of the tank.
21 Using the power unit, raise the crossbeams and runways off of the supports about 6
inches. Position the Idler Side Posts so that the crossbeam chain hangs straight in the
Idler Side Posts and lift chain hangs straight in the Power Side posts. Level the
crossbeams by adjusting the crossbeam chain tension at the top of the Idler Side Posts.
Use a level to check the crossbeams. Square the runways to one another and tighten
the ½-13 hex flange head bolts.
DO NOT DRILL OR INSTALL THE ANCHOR BOLTS AT THIS TIME FOR THE IDLER
SIDE POSTS. THE LIFT MUST BE CYCLED UP AND DOWN AND CHECKED FOR
CORRECT ALIGNMENT BEFORE THE BOLTS ARE INSTALLED.

Model 44000
Installation, Operation & Maintenance
44150.doc - 13 - Rev 7/19/04
THE IDLER SIDE POSTS MAY VARY SLIGHTLY FROM THE CHALK LINE LAYOUT
POSITIONS. IT IS MORE IMPORTANT THAT THE POSTS BE SQUARE AND
PLUMB AND THE LIFT CYCLES FREELY.
22 Raise the lift to the top of its travel. Check the positioning of the crossbeams in the
posts as the lift is raised. The single point safety release will move across the rack at
the bottom of the cylinder beam. At the top of the lifts travel, pull down the safety
release until the cam locks it in this position. Lower the lift. Check the operation and
positioning of the lift as it is being lowered. Correct any problems by adjusting the
position of the Idler Side Posts. When the lift is operating correctly, drill and install the
anchor bolts for the Idler Side Posts.
23 Complete the installation of Models 44EFX and 44XFX by installing the runway end
chocks and the approach ramps. The wheel stops are bolted through at the front end of
each runway. The approach ramps are installed with a hinge pin and cotter pins
provided.
24 Cycle the lift fully three times to bleed the air from the hydraulic system.
Alignment Runways (Models 44EAX and 44XAX)
1 Position Front Turn Plates (SOLD SEPARATELY) and install Guide Bars to runway
using (3) #10-24 x 1” Socket Head Cap Screws and lock nuts provided. Ensure that
the Turn Plates will slide freely and tighten Guide Bars.
2 Attach Work Step to each runway. (The Work Step may be located in three different
positions on each runway.)
3 Install Handle to Drop-In Spacer and position behind rear Guide Bar. The Drop-In
Spacer is provided for “Roll Back” alignment.
Fig 14
(Alignment Runway)

Model 44000
Installation, Operation & Maintenance
44150.doc - 14 - Rev 7/19/04
Modular Lube Rack (Model 44XRX)
1 The Modular Lube Racks can be set on 14’-8” centers or 16’-8” centers joining as
many lifts together as is required. Refer to Fig 15 to determine position of lifts that
will be joined. Install all lifts following steps 1-24 above.
Fig 15
(Lift Spacing)
2 Raise unit to a comfortable working height that will give access to the inside of the
runways. Loosely attach each of the Catwalk Gussets to the runway with the ½-13 x
1 ¼ Hex Flange Bolts and Nuts provide. Level each gusset using ½” washers
(provided) as shims. The open side of the gusset faces forward on the driver side
and rearward on the passenger side. See Fig 16. Repeat for additional lifts.
Fig 16
(Catwalk Gussets)

Model 44000
Installation, Operation & Maintenance
44150.doc - 15 - Rev 7/19/04
3 Assemble Catwalk Deck to gussets with #14 (¼-20) Self Tapping Screws provided.
Loosely assemble Catwalk Posts to the Gussets and Decking using the 5/16-18
hardware provided. Loosely install the Catwalk Rail with the 5/16 hardware
provided. Once all decking, posts and rails are in place, tighten all loose hardware
and check decking, railing and post for level. Install Support Channel with #14 (¼-
20) Self-Tapping Screws. Place Crossover Deck on the Jack Rail in the full forward
position. Raise unit to full stroke to insure passenger side rail misses the cylinder
beam and latch assembly. Adjust if necessary. Finish installation by installing a
plastic tube plug in each post. See Fig 17. Repeat for additional lifts.
Fig 17
(Catwalk)

Model 44000
Installation, Operation & Maintenance
44150.doc - 16 - Rev 7/19/04
4 Completely lower lift. Lift Mezzanine into position on the front posts and loosely
attach with the ½-13 x 1 ¼ Hex Flange Head Bolts and Nuts (4 per column)
provided. Loosely attach the mezzanine gussets to the underside of the mezzanine.
Center Mezzanine left to right and Level (1st lift). For additional lifts the mezzanine
may not be completely centered but rather butted against the stair landing of the
adjacent lift. Mark and drill 9/16” diameter hole in front columns for the Mezzanine
Gusset. Install ½-13 x 1 ¼ Hex Flange Head Bolt and Nut through the mezzanine
gusset and front columns. Recheck level of deck. Tighten all hardware. See Fig
18. Do not repeat this step for additional lifts until the stair landing are in place
(Steps 6 and 7).
Fig 18
(Mezzanine Deck)

Model 44000
Installation, Operation & Maintenance
44150.doc - 17 - Rev 7/19/04
5 Loosely attach the (4) End Posts and (8) Mezzanine posts (7 w/ Offset Storage Unit.
See Fig. 24) to the Mezzanine Deck with the 5/16-18 x 2 Hex Head Bolts And
Flange Nuts provided. Loosely attach the (2) End Rails (opposite stair landing), (8)
Mid Rails (4 w/Offset Storage Unit), (4) Long Rails and (4) Short Rails using the
appropriate hardware provided. Use 5/16-18 x 2 ½” Bolts where two rails meet at a
post and 5/16-18 x 2” Bolts elsewhere. Tighten all Hardware once all pieces are
fitted together. Install the Transition Plates into the corresponding slots of the deck.
Install (2) Short 13 ½”, (1) Mid 74 ½” and (1) Long 144” Toe Board using the 5/16-18
x 2 Bolts and Flange Nuts provided. Install Plastic Tube Plug in end of each post.
Refer to Fig 19.
Fig 19
(Mezzanine Assembly)

Model 44000
Installation, Operation & Maintenance
44150.doc - 18 - Rev 7/19/04
6 Determine the proper Stair landing to be used based on the lift spacing 2’-8” or 4’-8”.
See Fig 15. Support the landing in position at the end of the mezzanine. The front
face should be flush with the front of the mezzanine. Attach Stair Landing to end of
Mezzanine Deck using (3) ½-13 x 1 ¼ Hex Flange Head Bolts and Nuts. See Fig
20.
Fig 20
(Stair Landing)

Model 44000
Installation, Operation & Maintenance
44150.doc - 19 - Rev 7/19/04
7 Attach Stair Weld to the back of the Stair Landing using the ½-13 x 1 ¼ Hex Flange
Bolts and Nuts provided. See Fig 21.
Fig 21
(Stair Assembly)

Model 44000
Installation, Operation & Maintenance
44150.doc - 20 - Rev 7/19/04
8 Assemble (4) Banister Posts, (2) Banister Welds, (4 – 56”, 2 – 32”) Rear Landing Posts, (2)
Front Landing Posts, (2) Front Landing Rail, and (4 – 56” Landing Only) Rear Landing Rail
with the appropriate hardware provided. Use 5/16-18 x 4 where two posts are side-by-
side bolting all the way through both posts, and 5/16-18 x 2” Bolts elsewhere.
Tighten all Hardware once all pieces are fitted together. See Fig 22. Repeat Steps
4-8 for remaining lifts.
Fig 22
(Stair Railing Assembly)