Challenger Lifts 68000 Instruction manual

Rev. 7/14/05
68030.doc
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
Pad Engaging
Surface Mounted Pit Lift
MODEL 68000
6,000 LBS. CAPACITY
200 Cabel Street, P.O. Box 3944 Louisville, Kentucky 40201-3944
Email:[email protected] Web site:www.challengerlifts.com
Office 800-648-5438 /502-625-0700 Fax [phone]
IMPORTANT: READ THIS MANUAL COMPLETELY BEFORE
INSTALLING or OPERATING LIFT

Model 68000
Installation, Operation and Maintenance
GENERAL SPECIFICATIONS
Rise Height 25”
Three Locking Heights 14 ½”, 19, & 24”
Lowered Height 5”
Rearward Movement 12”
Overall Length 86"
Adjustable Distance Between Structures 39” max.
Overall Width (at max. width setting) 76”
4 Adapter Blocks (included) 1 ½” x 4” x 6 ¼”
* Maximum Capacity 6,000 lbs.
Lifting Time 40 Sec. (approximate)
Motor 1HP, Single Phase,
60Hz, 115V
Page 2 7/14/05
* Lift capacity ratings are based on loads equally distributed on all four pads.
HOSE #2
MASTER
SIDE
SLAVE
SIDE
POWER UNIT
LOCATE ON EITHER
SIDE OF PIT
HOSE #1
HOSE #3
HOSE #2
MASTER
SIDE
SLAVE
SIDE
HOSE #1
POWER UNIT
LOCATE ON EITHER
SIDE OF PIT
HOSE #3
HOSE #2
MASTER
SIDE
SLAVE
SIDE
HOSE #1
POWER UNIT
LOCATE ON EITHER
SIDE OF PIT
HOSE #3
HOSE #2
MASTER
SIDE
SLAVE
SIDE
HOSE #1
POWER UNIT
LOCATE ON EITHER
SIDE OF PIT
HOSE #3
Fig 1 – General Specifications and Service Bay Layout
68030.doc

Model 68000
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
provide adequate
clearance could result in
t performance, property
damage, or personal injury.
fade
Page 3 7/14/05
WARNING
unsatisfactory lif
FOORING the floor is capable of handling the
anchor bolts may be used for
l building inspectors and/or
aser to
result in unsatis
Eoperation, it is
S y of others, read
UAL BEFORE
HIS
TENANCE AND R SAFE
RATE A DAMAGED LIFT
d, or damaged d mpt to raise a
L
Be certain
loaded lift, see Fig 1. Floor should be in generally
good condition with no large cracks, spalling or
deterioration.
The supplied
the following minimum concrete
specifications: 4 inches minimum depth, with
steel reinforcement, 3500 psi, cured for 28
days per local commercial practice. Floor
should be level within 1/4 inch over the
installation area.
Check with loca
permits office for any special instructions or
approvals required for your installation.
Failure by purch
provide the recommended
mounting surface could
factory lift performance,
property damage, or personal injury.
LECTRICAL REQUIREMENTS
For lift installation and
necessary to have a dedicated 115V single
phase 60 cycle circuit with a 15 amp circuit
breaker or time delay fuse.
AFETY NOTICES AND DECALS
For your safety, and the safet
and understand all of the safety notices and
decals included here.
READ ENTIRE MAN
ASSEMBLING, INSTALLING,
OPERATING, OR SERVICING T
EQUIPMENT.
PROPER MAIN
INSPECTION IS NECESSARY FO
OPERATION.
DO NOT OPE .
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,
ecals promptly.
Do not atte
WARNING
vehicle on the lift until the
lift has been correctly
installed and adjusted as described in this
manual.
WARNING
68030.doc

Model 68000
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 after
receipt.
IT IS DIFFICULT TO COLLECT FOR LOSS OR
DAMAGE AFTER YOU HAVE GIVEN THE
CARRIER A CLEAR RECEIPT.
File your claim with Challenger Lifts promptly.
Support your claim with copies of the bill of
lading, freight bill, and photographs, if available.
INSTALLATION
IMPORTANT:Always wear safety glasses while installing lift.
TOOLS (MINIMUM REQUIRED)
NOTE: HOSES ARE NOT SUPPLIED (see “Layout” section
for details)
a. Hammer drill with 1/2” diameter carbide
tipped bits
b. Tape measure, 16ft
c. Chalk line
d. 4ft level
e. 10” & 12” adjustable wrench
f. Standard open end wrenches (2) 1/2",
9/16”, (2) 11/16”, 3/4"
g. Hammer
h. Torque wrench: 40 foot pounds minimum
with 3/4” socket
LAYOUT
1) Lay out the service bay according to the
architect’s plans or owner’s instructions (see
Fig 1). Be certain that the proper conditions
exist, see page 3.
NOTE: At full rise, the lift will move the vehicle
rearward 12” as shown in Fig. 2.
Page 4 7/14/05
Fig. 2 – Rearward Movement
2) Determine hose lengths. The three (3)
required hoses are NOT SUPPLIED
because their lengths will be based on the
position of the power unit with respect to the
lift and the route chosen between the master
and slave sides. Hoses may be routed
around the front or rear of the pit opening,
across the pit opening with a stationary
structural member, or piped down to the
basement floor, under the platform and back
up. When determining the route, consider
options that will best guard the hoses from
damage, minimize any tripping hazards, and
minimize the length. Excess hose #2 length
may result in poor equalization of the two lift
structures. The power unit may be mounted
on either side of the lift on the stand provided
or on a wall with the motor at a minimum of
18” above the floor. (Purchase the
appropriate mounting hardware to match the
wall construction.)
Each hose should be rated for 3000psi minimum
working pressure with a 12000psi minimum burst
pressure and have the same fitting on both ends,
female #6 (9/16-18) J.I.C. 37°flare.
HOSE #1 (3/8”I.D) Power Unit to Master Cyl.
.Add 30" to the distance from top of floor at
power unit stand to top of floor at master
cylinder base.
HOSE #2 (1/4”I.D) Master Cyl. to Slave Cylinder
Add 45" to the distance from top of floor at
master cylinder base to top of floor at slave
cylinder base)
HOSE #3 (3/8”I.D) Slave Cylinder to Power Unit
Add 55" to the distance from top of floor at
slave cylinder base to top of floor at power unit
stand)
68030.doc

Model 68000
Installation, Operation and Maintenance
POWER UNIT
3) Install the power unit stand using concrete
anchors provided. Mount the power unit to
the stand with 5/16 hardware provided.
4) Remove the high pressure port steel plug (#6
O-Ring port) from the left side of the valve
block and reinstall in the right side in place of
the plastic shipping plug, Fig 3. Install the 90
degree high pressure line adapter, Fig 4, into
the left side of the valve block (#6 O-Ring
port).
Fig. 3 – Power Unit Fittings
MALE #6 J.I.C. 37° FLARE
MALE #6 J.I.C. 37° FLARE
MALE #6 J.I.C. 37° FLARE
MALE #6 J.I.C. 37° FLARE
Fig. 4 – High Pressure Line Elbow
5) Remove the 3/8NPT steel hex socket plug
from the left side of the valve block, Fig 3,
and discard. Install the 90 degree return line
adapter elbow, Fig 5, (male 3/8NPT x male
#6 J.I.C. 37°flare) to the return port on the
power unit (3/8NPT).
MALE #6 J.I.C. 37° FLARE
MALE #6 J.I.C. 37° FLARE
MALE #6 J.I.C. 37° FLARE
MALE #6 J.I.C. 37° FLARE
Fig. 5 – Return Line Elbow
6) Manually raise both structures to the second
lock position and ensure that both locks are
properly engaged.
7) Install a 90 degree cylinder adapter elbow,
Fig 6, (male 1/4BSPT x male #6 J.I.C. 37°
flare) to the upper and lower ports (1/4BSPT)
of both the master and slave cylinders.
MALE #6 J.I.C. 37° FLARE
MALE #6 J.I.C. 37° FLARE
MALE #6 J.I.C. 37° FLARE
MALE #6 J.I.C. 37° FLARE
Fig. 6 – Cylinder Adapter Elbow
8) Install hoses. Be careful to avoid tight bends
and moving parts that could damage the
hose. Do not leave a hose exposed to the
path of the automobile tire. Guard hoses
where necessary.
9) Fill the reservoir with 6 quarts clean 10wt
anti-foam, anti-rust hydraulic oil or Dexron III
ATF. DO NOT USE OILS WITH DETERGENTS.
10) Plug power unit cord into a dedicated 115V
single phase 60 cycle circuit with a 20 amp
circuit breaker or time delay fuse.
11) Actuate the power unit and raise the lift fully.
The first time the lift is raised, the master side
will rise completely before the slave side
even begins. This is normal. Notice that the
fluid flows from the power unit to the bottom
side of the master cylinder piston, from the
top side of the master cylinder piston to the
bottom side of the slave cylinder piston, and
from the top side of the slave cylinder piston
back to the power unit. Once a cylinder is at
full stroke, fluid is allowed to pass thru the
piston. So the power unit will not make the
normal screeching sound (fluid flowing thru
the relief valve) when the lift is fully raised.
12) After both sides have been fully raised,
continue running the power unit for 30
seconds to ensure that all lines have been
filled with fluid.
13) Release both locks (pull outward on lock
release handle) and lower the lift to
approximately 6” rise. Look at the poison of
the top structure and the front ramp and
ensure that lowering the lift will not damage
the hydraulic hoses or fittings. Raise lift and
lower into a lock if fittings need adjustment.
Page 5 7/14/05
68030.doc

Model 68000
Installation, Operation and Maintenance
ANCHORING
14) There are (5) holes provided in the base of
both frames, Fig 1. The holes are sized for
1/2” anchor bolts. Use the holes as a
template when drilling into floor.
NOTE:
The pad lift frame must not be twisted, bent or
otherwise misaligned by unlevel floors when
anchoring. This will cause damage to the lift.
Maximum out-of-level is 1/4” between all anchor
points. If this is exceeded, the lift must be
shimmed with steel washers at the anchors and
grouted under the base frame.
15) Drill the anchor holes and install the lift
anchor bolts. Torque to 40 foot pounds.
16) Raise and lower lift a few times and Check
for binding, misalignment or damage. Check
hoses and fittings for leaks and tighten if
required.
CAUTION The power unit operates at high
pressure. Correct any unusual condition before
raising vehicle.
Note that the hydraulic system has not
developed working pressure until a load is
placed on the lift.
OWNER/OPERATOR CHECKLIST
17) 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.
18) Complete the Installation Checklist/Warranty
Validation questionnaire with the owner.
Review the terms of the warranty registration
card, and return the card and a copy of the
questionnaires to:
Challenger Lifts, Inc.
200 Cabel Street
Louisville, KY. 40206
OPERATION PROCEDURE
Page 6 7/14/05
SAFETY NOTICES AND DECALS
This product is furnished with graphic safety
warning labels, which are reproduced on
page 3 of these instructions. Do not remove
or deface these warning labels, or allow them
to be removed or defaced. For your safety,
and the safety of others, read and understand
all of the safety notices and decals included.
OWNER/EMPLOYER RESPONSIBILITIES
This lift has been designed and constructed according
to ANSI/ALI ALCTV-1998 standard. The standard
applies to lift manufactures, as well as to owners and
employers. The owner/employer’s responsibilities as
prescribed by ANSI/ALI ALOIM-2000, are summarized
below. For exact wording refer to the actual standard
provided with this manual in the literature pack.
The Owner/Employer shall insure that the lift
operators are qualified and that they are trained
in the safe use and operation of the lift using the
manufacturer’s operating instructions; ALI/SM 93-
1, ALI Lifting It Right Safety Manual; ALI/ST-90
ALI Safety Tips Card; ANSI/ALI ALOIM-2000;
American National Standard for Automotive Lifts-
Safety Requirements for Operation, Inspection
and Maintenance; ALI/WL Series, ALI Uniform
Warning Label Decals/Placards; and in case of
frame engaging lifts, ALI/LP-GUIDE, Vehicle
Lifting Points/Quick Reference Guide for Frame
Engaging Lifts.
The Owner/Employer shall establish procedures to
periodically inspect the lift in accordance with the
lift manufacturer’s instructions or ANSI/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 they are adequately trained in the
inspection of the lift.
The Owner/Employer shall establish procedures to
periodically maintain the lift in accordance with
the lift manufacturer’s instructions or
ANSI/ALOIM-2000, American National Standard
for Automotive Lifts-Safety Requirements for
Operation, Inspection and Maintenance; and the
employer shall insure that the lift maintenance
personnel are qualified and they are adequately
trained in the inspection of the lift.
The Owner/Employer shall maintain the periodic
inspection and maintenance records
recommended by the lift manufacturer or
ANSI/ALOIM-2000, American National Standard
for Automotive Lifts-Safety Requirements for
Operation, Inspection and Maintenance.
The Owner/Employer shall display the lift
manufacturer’s operating instructions; ALI/SM 93-
1, ALI Lifting It Right Safety Manual; ALI/ST-90
ALI Safety Tips Card; ANSI/ALI ALOIM-2000;
American National Standard for Automotive Lifts-
Safety Requirements for Operation, Inspection
and Maintenance; and in 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.
68030.doc

Model 68000
Installation, Operation and Maintenance
LIFTING A VEHICLE
1) Be sure lift is fully lowered and service bay is
clear of all personnel before the vehicle is
driven on to lift.
2) Position the vehicle in the service bay so that
the vehicle’s center of gravity is centered front
to rear and side-to-side over the two pad
structures.
DO NOT EXCEED 3000 POUNDS PER SIDE.
DO NOT ATTEMPT TO LIFT ONLY A PORTION OF THE
VEHICLE. LIFT IS INTENDED TO RAISE THE ENTIRE
VEHICLE CENTERED ON THE LIFT.
ENSURE THAT THE HIGHEST POINT ON THE VEHICLE
WILL NOT CONTACT THE CEILING OR ANY
OBSTRUCTION ABOVE THE VEHICLE.
MOST SPECIALTY OR MODIFIED VEHICLES CANNOT BE
RAISED ON A FRAME ENGAGING OR PAD LIFT.
CONTACT VEHICLE MANUFACTURER FOR RAISING OR
JACKING DETAILS.
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 spacer pads (1 ½”x4”x6”) so all
four pads contact the vehicle simultaneously.
CAUTION Always use minimum number of
spacer pads to clear obstruction. Spacer pads
should never be stacked more than (2) pads high
in any combination.
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. If the vehicle is stable, raise the
vehicle to full height.
To ensure proper synchronization between
the two lift structures, always raise the lift to
the top of its stroke before lowering into
locks.
5) Lower the vehicle until the locking legs on
both sides engage. The vehicle should
remain level when both locks are engaged. If
one side engages and the other continues to
descend, stop lowering the vehicle, raise it
several inches, and try again to engage both
latches.
Always lower lift into locks before entering
the area beneath the vehicle.
Always use safety stands when removing or
installing heavy components.
LOWERING A VEHICLE
1) Insure that the area under the vehicle is clear
of personnel and tools.
2) Raise the vehicle until both latches are free.
3) Disengage both latches by pulling the lock leg
release lever outward against the outer guide.
NOTE:
The lock bar will reset automatically only when
the lift is fully lowered. If during the lowering
process the lift is stopped before it gets to the
fully lowered position. The lock bar MUST be
reset by raising the lock release handle and
pushing the locking leg inward.
4) Lower the vehicle by depressing the lowering
valve handle. Continue to lower the vehicle
until both sides have completely lowered.
CAUTION Lowering handle must be held down to
continue to lower lift. DO NOT override self-
closing lift controls.
5) Be sure lift is fully lowered and service bay is
clear of all personnel before the vehicle is
driven off the lift.
MAINTENANCE
To avoid personal injury, permit only qualified
personnel to perform maintenance on this equipment.
The following maintenance points are suggested as
the basis of a preventive maintenance program. The
actual maintenance program should be tailored to the
installation. See ANSI/ALI ALOIM booklet for periodic
inspection checklist and maintenance log sheet.
• If lift stops short of full rise or chatters, check
fluid level and bleed both cylinders by raising
empty lift to full rise and continue running the
power unit for 1 minute.
• Replace all Safety, Warning or Caution Labels
if missing or damaged (See page 3.)
Daily
• Keep lift components clean.
• Check for loose or broken parts.
• Check hydraulic system for fluid leaks.
• Check spacer blocks for damage or excessive
wear. Replace as required with genuine
Challenger Lifts parts.
• Check lock mechanism for damage or binding.
Weekly
• Inspect all lift parts for signs of damage due to
improper use.
Monthly
• Check concrete anchor bolt torque (30 ft-lbs.)
• Lubricate all hinge joints if any signs of rust.
If any problems are encountered, contact
your local service representative.
Page 7 7/14/05
68030.doc

Model 68000
Installation, Operation and Maintenance
PARTS BREAKDOWN
MASTER SIDE (RH)
SLAVE SIDE (LH)
SLAVE SIDE (LH)
MASTER SIDE (RH)
SLAVE SIDE (LH)
MASTER SIDE (RH)
SLAVE SIDE (LH)
MASTER SIDE (RH)
Page 8 7/14/05
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Model 68000
Installation, Operation and Maintenance
ITEM # PART # QTY/LIFT DESCRIPTION
68003-1LH 1 BASE FRAME WELDMENT (SLAVE SIDE)
1 68003-1RH 1 BASE FRAME WELDMENT (MASTER SIDE)
2 68002-3 16 LEG HINGE PIN
3 68002-4 32 COTTER PIN
4 68002-1 2 REAR LEG / RAMP
5 68002-2IS 2 FRONT LEG (INSIDE)
6 68002-2OS 2 FRONT LEG (OUTSIDE)
7 68002-5 2 SPRING
68006-0 1 SLAVE CYLINDER (LH)
8 68007-0 1 MASTER CYLINDER (RH)
68008-1LH 1 LOCKING LEG (SLAVE SIDE)
9 68008-1RH 1 LOCKING LEG (MASTER SIDE)
10 68006-13 2 CYLINDER / LOCK LEG PIN
11 68006-15 2 SNAP RING
12 68004-1 2 FRONT RAMP WELDMENT
13 68004-2 2 RAMP HINGE PIN
14 68004-4 2 RAMP SLIDE
15 68004-5 8 SCREW (M6 x 20)
16 68004-6 8 NUT (M6)
17 68004-7 8 LOCK WASHER (M6)
18 68001-3 4 RUBBER PAD
19 68001-4 32 SCREW (M6 x 10)
68001-1LH 1 SUPERSTRUCTURE WELDMENT (SLAVE SIDE)
20 68001-1RH 1 SUPERSTRUCTURE WELDMENT (MASTER SIDE)
67010 1 POWER UNIT 115VAC, 60Hz
16167 1 90°ELBOW ADAPTER (#6 O-RING x #6 J.I.C.) (PU pressure port)
68031 4 90°ELBOW ADAPTER (1/4BSPT x #6 J.I.C.) (upper & lower cylinder ports)
68032 1 90°ELBOW ADAPTER (3/8NPT x #6 J.I.C.) (PU return line port)
68009-20 2 CYLINDER RESTRICTOR VALVE
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. [phone] for the Parts Distributor in your area)
Page 9 7/14/05
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