Challenger Lifts 44012LR User manual

MANUAL FOR
44012LR
EXT. 4 POST
LUBE RACK LIFT
Challenger Lifts, Inc
200 Cabel Street
Louisville, KY. 40206
Phone: [phone] Fax: [phone]
E-MAIL: [email protected]

Rev. -
INTRODUCTION
The four post lift consists of four vertical posts with runway tracks between
the posts. The lifting is done by a hydraulic cylinder coupled to heavy duty
leaf chains, which roll over sealed roller bearings. A 2 H.P. power unit
supplies up to 2,500 p.s.i. to the cylinder for the lifting. Each post is
equipped with a spring loaded safety latch that is activated only when there
is slack in the chains. There is also a safety latch on the cylinder in case of a
hydraulic failure.
The installation is a relatively simple task that can be accomplished by 2
men in just a few hours. A forklift or a fourth man will be helpful while
raising the toprail into place and installing the runways.
TO PREVENT MISTAKES AND SAVE TIME, PLEASE READ THIS
MANUAL COMPLETELY BEFORE BEGINNING THE
INSTALLATION.
LIFT LOCATION
Choose your installation site carefully. Keep in mind doors, power supply,
and overhead obstructions. These are all important considerations that will
help make the lift the most valuable tool in your shop.
The most important thing to look for is a good concrete floor. It should be a
minimum of 4” thick and 3,000 p.s.i. with steel reinforcement. Pads must be
at least 30”x 30”x 4” thick with steel reinforcement.
There must be adequate overhead clearance to raise vehicles 6 feet above the
ground. The recommended minimum ceiling height is 10 feet.
The toprail can be placed on the left or right side.
2

TOOLS REQUIRED
Concrete rotary hammer drillwith 3/4” carbide bit
Open end wrenches: 1/2”, 9/16”, 11/16”, 3/4”
Ratchet driver
Sockets: 3/4”, 1/2” deep
12” crescent wrench
Hammer
Needle nose pliers
Level
Fish tape
25’ tape measure
Chalk line
Small drift punch
Step ladder
4 wooden blocks (2 x 4’s)
4 gallons non-detergent hydraulic fluid 10 wt.
(example: Mobil DTE 25, Texaco HD 46, or Dextron II & III ATF)
3

ANCHORING TIP SHEET
1. Anchors must be at least 5” from the edge of the slab or any seam.
2. Use a concrete hammer drill with a 3/4 carbide bit.
3. Do not use a worn bit.
4. Drill in a perpendicular line with the hole.
5. Do not apply excessive pressure to the drill. Let the drill do the
work.
6. Lift the drill up and down occasionally to remove residue and to
reduce binding.
7. Drill the hole to a depth equal to the length of the anchor, or
completely through the slab.
8. For better holding power, blow all dust and residue from hole before
driving anchor into hole.
9. Place a flat washer over threaded end of anchor. Spin nut 1/2” down
past end of anchor. Carefully tap anchor into the concrete until nut and
flat washer are against base plate. Do not use an impact wrench to
tighten.
4

INSTALLATION
1. Determine the location for the lift. Keep in mind overhead clearances.
Ten feet is the minimum recommended ceiling height. Allow 4 in. for
approach ramp.
2. Determine which side of the lift the toprail and power unit are to be on.
This is called the MAINSIDE. The other side is referred to as the OFFSIDE.
Ease of entry and exit from vehicles, type of work being done, and required
placement of the power unit on the toprail side are all considerations.
3. After determining the location, and remembering to allow for the
approach ramp, chalk a rectangular square using the appropriate dimensions
given in Fig.1. Measure diagonally to check for squareness. The four
chalked corners represent the outside leg base corners of each post.
4. After determining the mainside (the side the toprail is to be placed on),
stand the two mainside legs upright inside the chalk lines, with each leg
facing inside. One of the two legs comes with a factory installed power unit
mount. This leg is to be placed as follows:
If toprail/mainside is to be on the left as you approach, this post must be
at the left front corner. See Fig 2.
If toprail/mainside is to be on the right as you approach, this post must be
a the right rear corner. See Fig 2a.
This manual will show the toprail/mainside being on the left side. See
Fig 3.
5. With both mainside legs on the chalk lines, lay both legs down toward the
inside as shown in Fig. 4.
6. Lay toprail on 2 x 4 blocks in front of mainside legs as shown in Fig. 5.
Align holes on toprail plate with holes on top of mainside leg as shown in
Fig. 6.
7. Bolt the toprail to the mainside legs using the 1/2 x 1 ¾” NC bolts,
washers, lock washers, and nuts as shown in Fig. 7. These were used in
5

shipping. NOTE: The set of holes nearest the safety rod hole will not take
a flat washer.
8. Raise toprail/leg assembly by pressing and walking the unit into the
upright position. Make sure the safety rod holes referred to in Fig. 7 are still
aligned. Make sure both legs are still on the chalk lines.
9. Read the anchoring tip sheet before anchoring. Using the 3/4 carbide bit,
drill through the 4 holes in the base plate to a minimum depth of 4-1/2”. As
soon as you complete drilling a hole, set and drive an anchor bolt into the
drilled hole. DO NOT TIGHTEN ANCHOR BOLTS YET !!
10. After drilling and setting all 4 anchors in the first post only, plumb the
post so that it is perpendicular. Use the level to check the post from side to
side, and front to back. You should also check distance measurements from
top of one leg to the top of the other leg, and from bottom to bottom. Adjust
legs to within 1/8”. Use shims sent in the packaging for shimming lift.
Keep shims as close to anchors as possible. Now you may tighten the
anchor bolts on first leg only. Do not use an impact wrench. Recheck for
plumbness and adjust if necessary.
11. After anchoring the first mainside leg, align the other mainside leg in
the chalk line. The leg may vary from the chalk line slightly. It is most
important that the legs be perpendicular and parallel with the other leg.
Check measurements at leg tops and bottoms again. Drill, set, and anchor
the other mainside leg. Level and plumb leg as before, then tighten anchors
on 2nd leg.
DO NOT DRILL OR ANCHOR OFFSIDE LEGS YET.
12. Set crossrails on 2 x 4 blocks in front of mainside legs, with the
machined crossrail connector towards the mainside leg as shown in Fig. 8.
13. Use a fish tape to pull the crossrail chain through the crossrail tube. The
chain runs under the roller on the offside and over the roller on the mainside.
Repeat with the other crossrail. Feed the fish tape through the crossrail
starting from the mainside by going over the mainside roller and through the
crossrail tube, then under the offside roller and straight up. See Fig. 8.
6

14. Position both crossrails in front of a mainside leg, with the machined
connector towards the mainside leg. Using the Master Link provided,
connect the crossrail chain to the chain anchor welded to the base plate of
the mainside leg. See Fig. 9.
***** IMPORTANT *****
THE MASTER LINK MUST HAVE THE CENTER LINK, AND IT MUST
BE IN A VERTICAL POSITION. IT CAN NOT BE COCKED
TOWARDS THE FRONT OF THE CHAIN ANCHOR. SEE FIG. 10.
15. Starting with the safety latch ear towards the mainside legs, place a 2 x 4
block under the latch as shown in Fig. 11.
16. Take a safety rod and remove one of the two nuts. Turn down the
remaining nut to the bottom of the threads. Remove packing dowel pin from
the crossrail safety latch. Insert safety rod (where packing dowel was
removed) into top of cross rail safety latch.
17. Each safety rod corners with 2 nuts on one end. Remove the top nut,
turn the other nut down to bottom of threads. Guide the free threaded end of
safety rod into the rear hole at the top of the mainside leg. Tighten the nut
just removed until the safety rod is flush with the top of the nut. Tighten the
bottom nut against the leg top. Remove the 2 x 4 block. Repeat steps 15, 16
and 17 on the other mainside leg and crossrail.
18. Position each offside leg 6” from the end of each crossrail, but do not
drill or anchor. Place 2 x 4 blocks under each safety latch. Repeat steps 16
and 17 for the offside legs. DO NOT ANCHOR OFFSIDE LEGS YET.
19. Assemble threaded chain connector to free end of chain. Run threaded
chain connector into the inside hole at top of offside leg. Run 1” nut all the
way down until connector is into the nylon. Repeat on other crossrail. See
Fig. 11.
20. Stand up cylinder reset on toprail. Remove the fitting or plug from rear
of the cylinder as shown in Fig. 12. Extend cylinder rod by either pulling on
rod or by applying air to cylinder port where fitting or plug was removed.
Make sure long chain is not twisted inside toprail tube. Attach loose end of
7

chain to each crossrail connector using 5/16 x 3 1/2” Shoulder bolt and nuts.
Do not substitute this bolt!!!! Repeat on other crossrail. Replace fitting on
cylinder.
21. Attach the power unit at its location on the mainside leg with supplied
hardware.
22. Before connecting the hydraulic hoses from the power unit to the
cylinder you must first install two 90 deg. fittings (2501-06-06) on the
cylinder and two 90 deg. fittings with o-rings (6801-LL-06-06) on the power
unit. Now the pressure and return hoses can be attached. The 108” pressure
hose (ALIF-412-029) goes from the fitting on the cylinder next to the rod to
the fitting of the power unit on the side of the handle (pressure port). The
48” return hose (ALIF-412-030) goes from the fitting of the cylinder next to
the power unit to the fitting of the power unit on the opposite side of the
handle (return port).
23. Have electricity hooked up to the power unit -220 single phase. We
recommend a 30 amp breaker and a 30 amp twist lock plug be installed near
the power unit.
24. Remove breather cap from power unit. Place a funnel into hold. Fill
reservoir with 14 qts of non-detergent 10 wt. hydraulic fluid or ATF
transmission fluid. Install breather cap.
OFFSIDE LEGS ARE NOT ANCHORED YET.
25. Position tracks on the cross rails. Raise the lift up about 12”. Place a
level on the crossrail and level the crossrail by adjusting the nut on the
crossrail connector.
26. After leveling cross rails, adjust and plumb the offside legs so that the
cross rail chains in the offside legs hang straight. Use a level. Cycle the lift
all the way up and down making sure that each corner is running freely. The
offside legs may vary from the chalk line slightly. It is more important that
the legs are square and plumb, and that the lift moves up and down freely.
27. Raise the lift to the top of its travel. Check the positioning of the cross
rails in the legs as the lift is raised. The single point toprail safety latch will
8

move across the rack at the bottom of the toprail. At the top of the lift’s
travel, pull down the toprail safety latch banjo until the Reset locks it open.
Adjust and plumb cross rails and legs as necessary. When you are positive
the lift is moving freely, you may finally drill and install the anchor bolts in
the offside legs.
28. The next phase is to locate and install the tracks, ramps and stops on the
lube rack lift. See Track, Ramp & Stop Assy. drawing. Step #1 is make
sure the tracks are centered on the cross rails and are 36” apart on the holes
where the bridge mounts. See Fig. #13. Secure track using ½” U-bolts.
29. Step #2 is to bolt the Bridge Weldm’t. to the tracks using the 5/16-
18UNC x 1” bolts and 5/16 lock washers. See Fig. #14.
30. Step #3 & #4 is to raise the lift about 30” and bolt the Long and Short
Walkway on the tracks using the 1/2-13UNC x 1¼” bolts, ½ flat washers
and ½ lock washer as shown in Fig. #14.
31. Step #5 is to bolt the ladder on the short walkway as shown in Fig. #14
using the ½-13UNC x 1¼” bolt, flat washer & nylon lock nut.
32. Step #6, #7 & #8 is to bolt the long, short and ladder handrail to the
walkways and ladder as shown in Fig. #15. Use the 3/8-16UNC x 1 ¼”
bolts, 3/8 flat washers and 3/8 lock washers.
33. Step #9 and #10 is to bolt the gatepost and hinge the LH/RH gates as
shown in Fig. #15. Use the 3/8-16UNC x ¾” bolts and 3/8 lock washers.
34. Now that the lift is fully assembled, cycle the lift to it’s maximum
height and back to the ground at least 3 full cycles without any load to
remove air from the hydraulic system.
SAFETY AND OPERATING PROCEDURES
Before attempting to operate this lift, be familiar with it is basic operational
and safety procedures.
1. Prior to lifting a vehicle, walk around the lift and check for any
9

objects that might interfere with the operation of the lift and it’s safety
latches such as: tools, air hoses, shop equipment, etc.
2. Slowly drive the vehicle fully onto the tracks. Have someone outside the
vehicle guide the vehicle down the tracks.
3. After vehicle is secured, begin raising lift by pressing the UP button on
the power unit. UNDER NO CIRCUMSTANCES SHOULD ANY
PERSONNEL RIDE THE LIFT UP OR DOWN.
4. Pay close attention to the locking mechanism as the unit rises.
The operator should be able to listen for the safety locks acting against the
latch rack as the unit goes up.
5. To back vehicle off the lift: Slowly drive vehicle fully off the lift.
PERIODIC MAINTENANCE
1. Anchor bolts: During the first week of use, check and tighten anchors
daily. Do not use an impact wrench. After first week, check anchors once
a month.
2. Concrete: Check concrete for stress cracks daily for the first two weeks
of use. Thereafter, check monthly.
3. Check all bolts and nuts monthly.
4. If your lift will raise all the way to the top, your lift has enough oil.
Hydraulic oil should be changed and the suction filter cleaned once a year.
If the lift environment is outside or dusty, change hydraulic oil and clean
suction filter every six months.
5. Chain: Check chain every 3 months for any sign of rust or wear,
especially if lift is located outside. Lubricate with a chain lube spray.
6. Bearings: The bearings on your lift are sealed roller bearings, which
do not require any additional lubrication. Check bearings every 3 months
for
10

excessive wear between the chain and roller.
PARTS & SHIPPING LIST
PART NUMBER DESCRIPTION QTY.
2501-06-06 3/8MNPT x 3/8MJIC 90 Deg. Adapter 2 HK
5304ZZ DS Bearings 4 HK
6801-LL-06-06 0.375M x 0.375F 90 Deg. NPT Adapter w/O-ring 2 HK
7130K55 11” Black Ties 6 HK
80050 BL634 Master Link 4 HK
90126A033 ½ SAE Flat Washer 6 HK
90473A036 ¾-10UNC Hex Nut Grd. 2 4 HK
90473A223 ½-13UNC Hex Nut Grd. 2 20 HK
90640A130 5/16-18UNC Hex Nylon Lock Nut Grd. 2 4 HK
91102A033 ½ Lock Washer 4 HK
91102A036 ¾ Lock Washer 4 HK
91247A583 5/16-18UNC x 1 HHCS Grd. 5 4 HK
91578A501 ¾-10UNC x 5 ½ Wedge Anchor Set 16 HK
92865A718 ½-13UNC x 1 3/4 Lg. (Full Thrd) HHCS Grd. 5 4 HK
92865A841 ¾-10UNC x 1 3/4 Lg. (Full Thrd) HHCS Grd. 5 4 HK
95462A538 ¾-10UNC Hex Nut Grd. 5 8 HK
95462A555 1-14UNF Hex Nut Grd. 5 4 HK
95473A030 5/16-18UNC Hex Nut Grd. 2 4 HK
98338A140 3/32 x 1 Cotter Pin 8 HK
98410A128 ¾ “ Retainer Ring 6 HK
AH-1008 Power Unit 1 PKG
ALGF-412-031-XX Ramp Weldm’t. 2 PKG
ALGF-412-034 Ramp Pivot Pin 2 PKG
ALIF-412-001-XX Front Stop 2 PKG
ALIF-412-029 0.375FJICS x 0.375FJICS Hose x 108” 1 PKG
ALIF-412-030 0.375FJICS x 0.375FJICS Hose x 48” 1 PKG
ALIG-412-099 Sq. U-Bolts 8
PKG
ALRK-412-012L/R-X LH/RH Lube Track Weldm’t. 1/1 PKG
ALRK-412-019-XX Short Walkway Weldm’t. 1 PKG
ALRK-412-020-XX Long Walkway Weldm’t. 1 PKG
ALRK-412-025-XX Long Handrail 1 PKG
ALRK-412-030-XX Short Handrail 1 PKG
ALRK-412-036-XX Gate Post 2 PKG
ALRK-412-040-XX Ladder Handrail 1 PKG
ALRK-412-043-XX Gate Latch 1 PKG
ALRK-412-047-XX 72” Ladder Weldm’t. 1 PKG
ALRK-412-057A-X LH Gate 1 PKG
ALRK-412-057B-X RH Gate 1 PKG
ALRK-412-060-XX Bridge Weldm’t. 1 PKG
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GL-9-056 1/16 x 1 x 2 ¾ Steel Shim 16 PKG
GL-9-112 ¼ x 1 x 2 ¾ Steel Shim 12 PKG
GL-12-002-XX Mainside Leg Weldm’t. 1 PKG
GL-12-003-XX Mainside Leg Weldm’t. with P/U Mount 1 PKG
GL-12-004-XX Offside Leg Weldm’t. 2 PKG
GL-12-049 Offside Leg Chain Connector 2 PKG
GL-12-052 Safety Latch Rod 4 PKG
ALRK-412-BHDWE Lube Rack Bolt Box Kit 1 HK
90126A031 3/8 SAE Flat Washer 14 HK
90126A033 ½ SAE Flat Washer 22 HK
90126A036 ¾ SAE Flat Washer 2 HK
90473A223 ½-13UNC Hex Nut Grd. 2 22 HK
90640A131 3/8 -16UNC Hex Nylon Lock Nut Grd. 2 1 HK
90640A133 ½ -13UNC Hex Nylon Lock Nut Grd. 2 2 HK
91102A030 5/16 Lock Washer 4 HK
91102A031 3/8 Lock Washer 22 HK
91102A033 ½ Lock Washer 22 HK
91247A634 3/8–16UNC x 2 ½ Lg. HHCS Grd. 5 1 HK
92865A583 5/16-18UNC x 1 Lg. (Full Thrd) HHCS Grd. 5 4 HK
92865A622 3/8-16UNC x 3/4 Lg. (Full Thrd) HHCS Grd. 5 8 HK
92865A626 3/8-16UNC x 1 1/4 Lg. (Full Thrd) HHCS Grd. 5 14 HK
92865A714 ½-13UNC x 1 1/4 Lg. (Full Thrd) HHCS Grd. 5 24 HK
9565K15 1 ¼ x 1.120 ID Sq. Plug Poly 14 HK
9565K28 1 ¼ x 1.010 ID Sq. Plug Poly 2 HK
98410A128 ¾ “ Retainer Ring 2 HK
GL-12-103 Top Rail Assy. 1 PKG
AA-3515001 3.50 Dia. 72” Stroke Hyd. Cylinder 1
90126A036 ¾ SAE Flat Washer 2
94945A235 ¾-16UNF Thin Nylon Lock Nut 3
98410A133 1.000 Dia. Retainer Ring 1
98410A249 1.375 Dia. Retainer Ring 5
98381A593 0.313 Dia. x 2.5 Lg. Dowel Pin 2
GL-12-005-XX Top Rail Weldm’t. 1
GL-12-030-XX Safety Latch Banjo 2
GL-12-046-XX Top Rail Reset 1
GL-12-048 Latch Pin 1
GL-12-050 Cylinder Chain Connector 1
GL-12-053-XX 5.5 Dia. Top Rail Wheel 2
GL-12-056 4.0 Dia. Pulley 3
GL-12-095 Std. BL646, 129 Pitch Male Ends, Short Top Rail Chain 1
GL-12-096 Std. BL646, 347 Pitch Male Ends, Long Top Rail Chain 1
GL-12-100 1 Dia. Cylinder Pin 1
GL-12-101 1 3/8 Dia. Pulley Pin 3
ALRK-412-104 Cross Rail Assy. 2 PKG
12

90108A036 ¾ USS Flat Washer 8
97801A104 1/8 x 2 Lg. Nail 8
98410A128 0.750 Dia. Retainer Ring 10
ALIF-412-012 Packing Pin 4
C1100-112-4500M 1.10 O.D. x 4 ½” Safety Latch Spring 4
ALRK-412-002-XX Cross Rail Weldm’t. 2
GL-12-055 2.25 Dia. Pulley 4
GL-12-057 Cross Rail Chain Connector 2
GL-12-078 Safety Stop Plate 4
GL-12-089-XX Safety Latch 4
GL-12-098 Safety Latch / Bearing Pin 2
GL-12-099 Safety Latch Pin 6
ALRK-412-094 BL634, 271 Pitch Male Ends, Cross Rail Chain 2 PKG
91259A587 0.313 Dia. 1.50 Lg. Shoulder Bolt 2 HK
90640A129 ¼-20UNC Nylon Lock Nut 2 HK
*** Note: All hardware unless specified is grade 2. All hardware is
zinc coated unless specified. Parts with PKG at the end are packed on
the lift and parts with HK at the end are packaged in a box and put on
the lift.
13

4 "
M I N .
2 ' -6 "
1
7 ' -2 "
4
1
2
1 2 ' -4
1
4
2 ' -7 3/4 "1 ' - 1 0 "
24 ' -8 "
1
5 ' -6 "
1
9 ' -8
1
2
"
1
6 ' -4 "
1
' -7 "
2 1 ' - 1
3
4
"
11
' - 11
8
"
I
NS I DE LEG
W ELDM ' T .
1 ' -7
1
4
REQU I RED AREA EXT .
1 5 ' -6 " X 24 ' -8 "
W FP 1 2LRR-E LAYOUT &
I NSTALLAT I ON SPEC I F I CAT I ON
Ma i ns i de Leg
w/Power Un i t
Ma i ns i de Leg
w/o Power Un i t
Offs i de Leg
Offs
i de Leg
( Opt i ona l - Ma i ns i de
Leg Locat
i on )
Load i ng
End
3 ' -4 1 /2 " M I N .
CENTER OF
JACK RA
I L

2 X 4
BLOCKS
F
I G . #5

CHALK L
I
NE
MA
I
NS
I
DE
ENTRANCE
F
I
G
.
#3
FRONT
PO
W
ER UN
I
T
MOUNT
PO
W
ER UN
I
T
MOUNT
F
I
G
.
#4
ENTRANCE
MA
I
NS
I
DE
CHALK L
I
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REAR

OFFS
I
DE
MA
I
NS
I
DE
ENTRANCE
F
I
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.
#2A
F
I
G
.
#2
ENTRANCE
MA
I
NS
I
DE
OFFS
I
DE

F
I
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.
#6
SAFETY ROD
HOLE
9
0
473A223 4X
1
/2-
1
3UNC HEX NUT
9
11
0
2A
0
33 4X
1
/2 LOCK
W
ASHER
9
0
1
26A
0
33 6X
1
/2 SAE FLAT
W
ASHER
92865A84
1
4X
1
/2-
1
3UNC X
1
3/4 HHCS
** NO FLAT
W
ASHER ON TOP
.
(
SAFETY ROD S
I
DE
)
F
I
G
.
#7

MA I NS I DE LEG
CROSS RA
I L
CROSS RA
I L
CHA
I N
MA
I NS I DE
OFFS
I DE
MACH
I NE CROSS RA I L
CONNECTOR
LATCH EAR
SH
I PP I NG
DO
W EL P I N
SPR
I NG STEEL
MASTER L
I NK
F I G . #8

MA I NS I DE LEG
OFFS
I DE LEG
CROSS RA
I L
CROSS RA
I L
CHA
I N
MA
I NS I DE OFFS
I DE
MACH
I NE CROSS RA I L
CONNECTOR
LATCH EAR
SAFETY ROD
SPR
I NG STEEL
F I G . #9
MASTER L I NK
THREADED CHA
I N
ANCHOR