Harmar Mobility AL055 Operating instructions

INSTALLATION & OWNER’S MANUAL
Read manual thoroughly before attempting to install or operate lift.
Serial Number:
Dealer:
AL 055
MICRO INSIDE LIFT
CAPACITYY: 200 lbs
AL 055 AL 065
MICRO INSIDE-OUTSIDE LIFT
CAPACITY: 200 lbs
AL 065
This manual has been provided to assist you
with lift installation and operation.
For further assistance please contact your
authorized Harmar Mobility dealer or
Harmar’s Technical Service Department.
Fax: [phone]
Tech: 866-378-6648
Email: [email protected]
Harmar
2075 47th ST
Sarasota, FL 34234
Tel: [phone]
P/N: 999-3B05-AA Rev B

TABLE of CONTENTS
TECHNICAL INFORMATION
PREPARATION
INSTALLATION
OPERATION
TOOLS RECOMMENDED .................................................p 2
UN-PACKING THE LIFT .....................................................p 3
WIRING THE VEHICLE ......................................................p 4
TRIAL FIT PROCEDURE .....................................................p 5
INSTALLATION .................................................................p 6-7
DOCKING DEVICES ........................................................p 8
OPERATION ......................................................................p 9-10
SAFETY & MAINTENANCE ..................................................p 11
TROUBLE-SHOOTING .........................................................p 12
EXPLODED VIEWS / PARTS BREAKOUT .................................p 13-15
ELECTRICAL......................................................................p 16
SERVICE NOTES.................................................................p 17-18
1

TOOLS RECOMMENDED
THE FOLLOWING IS A SUGGESTION OF BASIC TOOLS RECOMMENDED TO HAVE ON HAND DURING INSTALLATION
AS WELL AS A GUIDE TO PORTRAY COMPLEXITY OF THIS TYPE OF INSTALLATION
THIS IS, BY NO MEANS, MEANT TO REPRESENT THE REQUIREMENTS AS A WHOLE, AS EACH INSTALLATION WILL
VARY TO SOME DEGREE. HARMAR LIFTS ARE DESIGNED TO INSTALL WITH AS LITTLE ASSEMBLY AS POSSIBLE.
SAE SOCKET SAE WRENCH
7/16”
1/2”
9/16”
3/4”
7/16”
1/2”
9/16”
3/4”
SAE ALLEN WRENCH
5/32”
1/8”
3/16”
5/16”
38”
#2 FLAT HEAD
SCREWDRIVER
#2 PHILLIPS HEAD
SCREWDRIVER
SMALL HACKSAW ELECTRIC DRILL
WIRE CUTTERS
NEEDLE NOSE
PLIERS
MARKING
IMPLEMENT TAPE MEASURE DRILL BITS METAL FILE
PILOT DRILL BIT
3/8” DRILL BIT
9/16” DRILL BIT
As always, if you have any questions, concerns or comments, please feel free to contact
Harmar's Technical Service Department at 866-378-6648 or "[email protected]"
2

UNPACKING THE LIFT
AL-055
AL-065
BE SURE TO CHECK THE CONTENTS OF THE BOX
AGAINST THE PACKAGE CHECK LIST TO BE SURE
THAT ALL THE PARTS ARE INCLUDED WITH THE LIFT
THAT ARE REQUIRED FOR PROPER INSTALLATION
IF ANY PARTS ARE MISSING OR IF ANY DAMAGE IS NOTED,
IMMEDIATELY CONTACT THE DISTRIBUTOR FROM WHICH
YOU PURCHASED YOUR LIFT. DO NOT ATTEMPT TO INSTALL
OR USE THE LIFT WITH ANY MISSING OR DAMAGED PARTS
VEHICLE
HARNESS
INSTALLATION
WASHERS
3x
1 - HHCS, 1/4-28 x 3.00”L, ZP STEEL G5
3 - HHTB, 3/8-16 x 3-1/2”L, ZP STEEL G5
1 - NUT, NYLOC, 1/4-28, ZP STEEL
3 - NUT, NYLOC, 3/8-16, ZP STEEL
3 - WASHER, FLAT, 3/8”, ZP STEEL
10 - 14” CABLE TIES
4 - 4-1/2” CABLE TIES
1 - INSTALLATION & OWNER’S MANUAL
w/ WARRANTY SHEET
1 - RUBBER GROMMET
1 - WIRE HARNESS INSTRUCTION
1 - 4” Velcro
END
CONNECTOR
HARDWARE PACK
FLANGE BUSHING
BUSHING
COLLAR
POST
HAND
CONTROL
HARNESS
BASE
ARM ASSEMBLY
ARM ASSEMBLY
HAND
CONTROL
HARNESS
FLANGE
BUSHING
(X2)
POST
SHAFT
COLLAR
MOUNTING FLANGE
MOUNTING ARM
1 - VEHICLE HARNESS
1 - WIRE CONNECTOR
1 - ROCKER STOPPER
2- HHCS, 1/4-20 x 4.00”L, ZP STEEL G5
1 - HHCS, 1/4-28 x 3.00”L, ZP STEEL G5
2 - NUT, NYLOC, 1/4-20, ZP STEEL
1 - NUT, NYLOC, 1/4-28, ZP STEEL
10 - 14” CABLE TIES
4 - 4” CABLE TIES
4 - CORD CLIPS
1 - INSTALLATION & OWNER’S MANUAL
w/ WARRANTY SHEET
1 - RUBBER GROMMET
1 - WIRE HARNESS INSTRUCTION
1 - 6” Velcro
HARDWARE PACK
STANDARD CLASS 3
HITCH ADAPTER
33

B=BLACK, A=RED
IMPROPER WIRING IS THE #1 CAUSE OF PROBLEMS IN THE OPERATION OF A VEHICLE LIFT.
FOLLOW THE WIRING INSTRUCTIONS CAREFULLY
BLACK WIRE ONLY
SIDE MOUNT
BLACK WIRE
ONLY
OR
TOP MOUNT
LETTERS ARE
MOLDED INTO
PLASTIC
HINGED
RETAINER
A
B
BLACK WIRE
RED WIRE
Protective
tubing
CORRECT
ADJUST BY
PRYING OUT
SLIGHTLY
IF NEEDED
PROBING FOR 12 VOLTS MAY INDICATE
A CONNECTION, BUT NOT NECESSARILY
A SUFFICIENT CONNECTION.
THE LIFT’S MOTOR CAN DRAW UP TO
30 AMPS AT SOME POINTS, REQUIRING
ALL OF THE AVAILABLE TO FLOW
PROPER CURRENT. POOR CONNECTIONS
ARE THE #1 PROBLEM ASSOCIATED WITH
A SLOW, INTERMITTENT, WARM,
POORLY PERFORMING MOTOR.
NOT ONLY WILL THE MOTOR PERFORM POORLY,
BUT WILL PREMATURELY DETERIORATE.
IF A SINGLE STRAND OF A MULTI-
STRAND WIRE IS MAKING CONTACT,
12V WILL APPEAR ON THE METER, OR TEST LIGHT,
BUT WILL NOT ALLOW THE MOTOR TO OPERATE.
IT IS ALWAYS BEST TO TEST BOTH
CURRENT AND VOLTAGE, OR RUN THE MOTOR
WITH KNOWN GOOD SHOP BATTERY OR POWER
SOURCE WHEN TESTING FOR POWER.
WIRE
WHEN THE INSTALLATION
REQUIRES THE WIRING
HARNESS BE RUN ON THE
UNDERSIDE OF THE VEHICLE,
ROUTE THE HARNESS AWAY
FROM THE EXHAUST SYSTEM,
BRAKE LINES, FUEL LINES< GAS
TANK, PINCH POINTS, AND SHARP
EDGES. LOCATE THE WIRING
HARNESS WHERE IT CAN NOT
BE SNAGGED BY ROAD DEBRIS
NEVER ATTEMPT
TO CONNECT
THE HARNESS
TO A SECONDARY
POWER SOURCE.
ALWAYS CONNECT
BOTH LEADS
DIRECTLY TO THE
BATTERY
TO BATTERY
END
CONNECTOR
20 AMP SELF
RESETTING
CIRCUIT
BREAKER
SEALS
LOCATED IN THE HARDWARE PACK IS THE VEHICLE WIRING
HARNESS. THE HARNESS IS MANUFACTURED TO, AND COMPLIES
WITH, THE SAE J1128 REQUIREMENTS. THE WIRE HARNESS IS
APPROXIMATELY 23 ft LONG AND WILL ACCOMMODATE MOST VEHICLES.
YOUR WIRING HARNESS HAS BEEN LEFT UN-ASSEMBLED
FOR EASE OF INSTALLATION. THE END CONNECTOR HAS BEEN
INCLUDED SEPARATELY FROM THE HARNESS TO ALLOW
THE INSTALLER TO THE RUN THE WIRE UNDER AND THROUGH
THE VEHICLE WITH THE SMALLEST HOLE POSSIBLE. FOLLOW
THESE INSTRUCTIONS TO ASSURE PROPER INSTALLATION.
DO NOT CONNECT RED WIRE UNTIL THE VERY END.
UNWIND THE HARNESS AND LAY IT FLAT.
ONE END OF THE HARNESS HAS 2 COVERED PINS.
THIS IS THE LIFT END OF THE HARNESS AND
GOES TO THE REAR CARGO AREA WHERE THE LIFT
WILL MOUNT.
BEGIN ROUTING THE WIRING HARNESS AT THE VEHICLE BATTERY.
ATTACH THE BLACK WIRE TO THE NEGATIVE TERMINAL ON THE BATTERY.
DO NOT ATTACH THE RED WIRE UNTIL THE END.
RUN THE WIRING HARNESS UNDER OR WHEN POSSIBLE THROUGH
THE VEHICLE, BACK TO THE REAR CARGO AREA / TRUNK. ALWAYS
LOCATE THE WIRING WHERE IT CAN NOT BE SNAGGED BY ROAD
DEBRIS AND AWAY FROM THE GAS TANK. THROUGH THE VEHICLE
IS BEST, GAINING ENTRY INTO THE VEHICLE THROUGH THE FIREWALL.
HOWEVER IF YOU WISH TO RUN THE HARNESS UNDER THE VEHICLE,
A HOLE WILL MOST LIKELY NEED TO BE DRILLED TO GET THE WIRE
INTO THE REAR CARGO AREA / TRUNK. IF THE HARNESS IS TOO LONG
FOR THE VEHICLE, COIL THE EXCESS WIRE AND SECURE IT TO THE
VEHICLE FRAME WITH SUPPLIED TIE WRAPS.
DO NOT CUT OR SHORTEN THE HARNESS.
ONCE THE HARNESS IS RUN INTO
THE VEHICLE, REMOVE PIN’S
PROTECTIVE TUBING.
INSPECT THE PIN’S RETAINING FLANGES.
THE MAY HAVE BECOME DEFORMED
WHILE RUNNING THEM THROUGH THE VEHICLE.
THESE ARE CRITICAL TO SECURE THE PINS INSIDE
THE END CONNECTOR. ADJUST AS NEEDED.
FLIP OPEN END CONNECTOR’S HINGED RETAINER.
INSERT PINS AS SHOWN:
WIRING THE VEHICLE
RED WIRE
RED WIRE
OR
LAST
SIDE MOUNT TOP MOUNT
11
2
2
3
3
4
4
5
5
6
6
AL055, AL065 Install and Owner's Manual
4

CHAIR’S WIDTH,
HEIGHT,
ETC...
HEIGHT,
ETC...
½ WIDTH,
PRIOR TO ANY HOLES BEING DRILLED, IT IS HIGHLY RECOMMENDED THAT
THE LIFT BE RUN THROUGH ITS RANGE OF MOTION IN A “TRIAL FIT.”.
WITH THE HELP OF AN ASSISTANT, ASSEMBLE THE LIFT, AND PLACE IT IN THE
MOST REAR CORNER OF THE CARGO SPACE CLOSEST TO THE BUMBER.
(THIS WILL YIELD THE GREATEST AVAILABLE LOADING AREA)
( PASSENGER SIDE SHOWN. DRIVER’S
SIDE IDENTICAL BUT MIRRORED )
THE AlL-055 WILL REQUIRE 3 HOLES TO BE DRILLED
INTO THE VEHICLE, TO BOLT THE LIFT’S BASE TO THE FLOOR.
THE POSITIONING OF THE BASE IS VERY IMPORTANT
TO A SUCCESSFUL INSTALLATION AND OPERATION OF THIS LIFT.
ONCE IT HAS BEEN VERIFIED EACH OF THE HELD MEASUREMENTS DOES NOT
INTERFERE WITH THE VEHICLE’S CARGO AREA / OPENING,
MARK THE 3 LOCATIONS IN WHICH TO DRILL
TRIAL FIT PROCEDURE
FOLD THE CHAIR OR SCOOTER’S SEAT BACK ( or REMOVE SEAT ) PREFERABLY
WITH DOCKING DEVICE INSTALLED TO ROUGHLY OBSERVE THE CHAIR’S
TRANSPORTABLE DIMENSIONS.
MEASURE LENGTH, WIDTH, AND HEIGHT
SIMULATE EACH OF THE CHAIR’S DIMENSIONS
( LENGTH, WIDTH, and HEIGHT ) WHILE RUNNING
THE LIFT THROUGH ITS FULL RANGE OF MOTION
IN AND OUT OF THE VEHICLE’S CARGO AREA
WIDTH
LENGTH
HEIGHT
5

ONCE CONFIDENCE HAS BEEN GAINED ON THE POSITION OF THE LIFT,
AND THE “TRIAL FIT” PROCEDURE HAS BEEN COMPLETED, THREE 3/8”
HOLES WILL NEED TO BE DRILLED IN THE MARKED LOCATIONS
ONCE HOLES ARE DRILLED, FASTEN BASE TO VEHICLE
FLOOR USING SUPPLIED HARDWARE IN THE HARDWARE
PACK. BE SURE TO TIGHTEN ALL FASTENERS.
AL-055 INSTALLATION
ALL THREAD KIT MAY BE REQUIREDALL THREAD KIT MAY BE REQUIRED
SOME VEHICLES HAVE STORAGE
COMPARTMENTS IN THE REAR CARGO
AREA, POTENTIALLY EFFECTING LIFT
PLACEMENT. MOST OF THESE CAN BE
OVERCOME WITH THE AID OF AN
ALL THREAD KIT. SHOWN ABOVE IS THE
TYPICAL APPLICATION FOR
OVERCOMING THESE STORAGE
COMPARTMENTS OR WELLS.
SPARE TIRE STORAGE:
SOME VEHICLES STORE
THE SPARE TIRE UNDER
THE FLOOR OF THE VEHICLE.
MAKE SURE THAT THE BASE
CAN BE BOLTED THROUGH
A STEEL FLOOR OR FRAME.
AT-01
STORAGE
WELL
LID
Vehicle
Floor
Vehicle
Floor
Vehicle
Floor
INSTALLATION TIP:
CHOOSE A SAFE LOCATION IN WHICH TO
DRILL A SINGLE PILOT HOLE FROM ABOVE
IN ONE OF THE 3 MARKED LOCATIONS.
LOOK UNDERNEATH THE VEHICLE
AND MEASURE OUT THE SPECIFIED
DISTANCE FROM THE PILOT HOLE.
IF ALL IS CLEAR IN THAT AREA, CONTINUE
TO DRILL PILOT HOLES IN REMAINING
LOCATIONS.
INSPECT ALL THREE PILOT HOLES FROM
UNDER THE VEHICLE. IF ALL CLEAR, DRILL
3/8” HOLES IN PILOT LOCATIONS
CAUTION! AVOID THE VEHICLE
WIRING, FUEL LINES, FUEL TANKS
SPARE TIRES, ETC. WHEN DRILLING
CAUTION! AVOID THE VEHICLE
WIRING, FUEL LINES, FUEL TANKS
SPARE TIRES, ETC. WHEN DRILLING
PLACE POST INTO BASE.
SLIDE SHAFT COLLAR OVER POST
TIGHTEN SET SCREW.
SLIP-ON ARM ASSEMBLY ONTO BASE..
ADJUST ARM HEIGHT WITH SET SCREW
AS NEEDED (POST MAY BE
CUT IF REQUIRED).
ONCE REQUIRED HEIGHT IS
DETERMINED, DRILL 1/4” HOLE
THRU POST USING SHAFT COLLAR
AS A GUIDE.
BOLT SHAFT COLLAR TO POST
USING SUPPLIED 1/4” BOLT AND NUT.
ARM ASSEMBLY
COLLAR
SET
SCREW
POST
BASE
BUSHINGS
6

AL-065 INSTALLATION
OR
OR
OR
HIGHER TO
GROUND
LOWER TO
GROUND
FLIP
FLIP
ASSEMBLE HITCH ADAPTER
TO MOUNTING FLANGE AND
BOLT ARM / BASE TO MOUNTING FLANGE
(LEAVE LOOSE FOR ADJUSTMENT)
ARM / BASE
MOUNTING
FLANGE
CLASS 3
HITCH
ADAPTER
CLASS 2
HITCH
ADAPTER
PINCH BOLT
TUBE
(CLASS 3 ONLY)
(ADJUST AS NECESSARY)
PLACE POST INTO BASE
SLIP FRAME ONTO POST
ADJUST ARM HEIGHT WITH SET SCREW
AS NECESSARY..
ONCE REQUIRED HEIGHT AND ROTATION IS
DETERMINED, DRILL 1/4” HOLE
THRU POST USING SHAFT COLLAR
AS A GUIDE.
(ADJUST AS NECESSARY)
POST
ARM ASSEMBLY
BASE
(ADJUST AS NECESSARY)
HITCH
STABILIZER
TIGHTEN HITCH STABILIZER
ON HITCH LIP AND BOTTOM
OF HITCH ADAPTER
FOR DRIVER’S SIDE:
FLIP MOUNT BASE,
SO ARM IS ON
OPPOSING SIDE.
COLLAR
BOLT SHAFT COLLAR TO POST
USING SUPPLIED 1/4” BOLT AND NUT.
ONCE ALL ADJUSTMENTS
ARE COMPLETE,
TIGHTEN ALL FASTENERSTIGHTEN ALL FASTENERS
7

DOCKING DEVICES
DD-21
Spreader Bar &
Bridles
DD-19
C-Arm
The Docking Device is the interface between the lift and the Chair / Scooter.
Most chairs / scooters can be lifted either by the center seat post
or the 4 post seat frame.
Although most chairs / scooters can be lifted by the above Docking Devices,
Many specific devices exist making the application even easier.
Please consult the instruction provided with your Docking Device, or contact our technical
service department to find out exactly how this device is right for you.
8

AL-055 OPERATION
POST
ARM ASSEMBLY
TO MOTOR
TO VEHICLE
HARNESS
ROTATE ARM OUT
OF VEHICLE
INSPECT LIFTING STRAP
BEFORE EACH USE
INSPECT LIFTING STRAP
BEFORE EACH USE
CONNECT POWER
TO LIFTING MOTOR
OPEN TRUNK OR
CARGO DOOR
PLACE POST
INTO BASE
PLACE ARM
ASSEMBLY
ONTO POST
PARK CHAIR
CLOSE TO
VEHICLE
LOWER
STRAP
TO CHAIR’S
HEIGHT
KEEP HANDS AND FEET FROM UNDER THE SCOOTER
OR POWER CHAIR AS IT IS BEING LIFTED
FOLD SEAT
BACK DOWN /
TAKE SEAT OFF
ATTACH
DOCKING DEVICE
OR
ATTACH LIFTING
HOOK TO DOCKING
DEVICE
RAISE CHAIR
ABOVE BUMPER
MANUALLY ROTATE
ARM INTO VEHICLE
ENSURE THE LIFTING STRAP IS SECURE AND THAT IT
POINTS STRAIGHT DOWN. FAILURE TO DO SO COULD
RESULT IN THE SCOOTER OR CHAIR SWINGING
CAUSING DAMAGE TO OPERATOR OR VEHICLE
STOP LIFTING BEFORE THE STRAP HOOK CONTACTS THE STRAP ROLLER MOUNTED ON THE
LIFTING ARM. CONTACT WILL DAMAGE THE LIFT. A PROPERLY ADJUSTED LIFT WILL AVOID THIS
ELIMINATE EXCESS STRAP BY PRESSING THE “UP” BUTTON
UNTIL THE HOOK IS ABOUT 1 INCH FROM THE TOP OF THE LIFTING
ARM, MAKING DIS-ASSEMBLY EASIER.
IF PREPARATIONS ARE NEEDED TO SECURE THE SCOOTER OR CHAIR
FOR TRANSPORT SUCH AS PARKING BRAKES OR WHEEL CHOCKS,
THE DEALER SHOULD INSTRUCT OPERATORS ON HOW.
DUE TO THE WIDE VARIETY OF SCOOTERS, POWER CHAIRS, AND VEHICLES,
YOUR DEALER MAY OFFER A DIFFERENT METHOD FOR LOADING AND UNLOADING
YOUR MOBILITY DEVICE. PLEASE FOLLOW THE GUIDELINES THEY HAVE OFFERED.
UNLOADING IS THE REVERSE OF LOADING.
REMOVE ARM & POST ASSEMBLIES
AND STORE INSIDE TRUNK OR
CARGO AREA
CLOSE TRUNK / CARGO DOOR
DISCONNECT POWER
TO LIFTING MOTOR
LOWER CHAIR
INTO VEHICLE
REMOVE HOOK
FROM DOCKING
DEVICE
9