Harmar Mobility AL625HD Operating instructions

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AL625 & AL625HD
INSTALLATION & OWNER’S MANUAL
These instructions are provided to assist you in the installation of the AL625. If you require
further assistance, our trained staff is ready to provide you with quick, efficient service. Call our
toll-free number:
866.378.6648
Monday thru Friday, 8:00 AM –8:00 PM (Except holidays) E.S.T
Before calling please have your serial number available.
2012 Harmar

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TABLE OF CONTENT
SECTION TITLE PAGE #
REQUIREMENTS AND CONSIDERATIONS BEFORE INSTALLATION ……………………………………3
SAFETY FIRST …………………………………………………………………………………………………….4
TOOLS AND SUPPLIES REQUIRED FOR INSTALLATION ……………………………………………………. 4
STEP 1 ELECTRICAL WIRING 5
STEP 2 INSTALLING THE MOUNTING BARS 6
MOUNTING THE TRACKER DIRECTLY TO THE VEHICLE’S FLOOR 7
STEP 3 POSITION THE TROLLEY ASSEMBLY ON THE MOUNTING BARS 8
STEP 4 ATTACH LEVELING FEET TO THE TROLLEY ASSEMBLY 9
STEP 5 POSITION THE TROLLEY ASSEMBLY AND BOLT IT DOWN 10
STEP 6 RAISE THE BOOM AND INSTALL THE BOLT 11&12
STEP 7 MOUNTING THE PLATFORM ASSEMBLY TO THE TROLLEY ASSEMBLY 13
STEP 8 CHECK CLEARANCES WITHOUT LOAD 14
STEP 9 ADJUST PLATFORM ANGLE TO SUIT LOAD (if necessary) 15
STEP 10 ADJUSTING THE VERTICAL –HORIZONTAL TRANSITION (if necessary) 16
STEP 11 CONFIRMING HOME POSITION AND LOCKING PIN ALIGNMENT 17
STEP 12 INSTALLING THE STRAP SYSTEM 18-19
FUSE FOR RF REMOTE CONTROL CIRCUIT ………………………..………………………………………… 20
TRAINING THE END-USER ……………………………………………………………………………………… 20
MAINTAINING THE LIFT ……………………………………………………………………………………….. 20
TROUBLESHOOTING ……………………………………………………………………………………………. 21
ELECTRONIC CONTROL BOX WIRING DIAGRAM ...…………………………..……………………………. 22
FOR YOUR RECORDS
SALESPERSON______________________________________
TELEPHONE________________________________________
PURCHASE DATE_________________________________LIFT SERIAL #______________________________________
CUSTOMER #_____________________________________ORDER #___________________________________________

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REQUIREMENTS AND CONSIDERATIONS BEFORE INSTALLATION
The Freedom Lift Trackeris designed to work with a variety of vehicles. Since each vehicle is different, the
success of each installation is largely determined by the care and forethought of the installer. Before beginning any
installation, please read through this manual to familiarize you with the installation procedure. This will save you
time and result in a quality installation.
Before beginning installation, open the boxes and check that the contents match those on the packing list.
ITEM
DESCRIPTION
1
TROLLEY ASSEMBLY
2
PLATFORM ASSEMBLY
3
INTERLOCK INSTALL KIT (not shown)
4
CONTROL PENDANT (not shown)
5
HARDWARE KIT (not shown)
6
REMOTE CONTROL (not shown)
7
BATERY CHARGER (not shown)
8
MOUNTING BARS (not shown)

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SAFETY FIRST
1. The power chair must have the brake engaged and be securely attached to the lift during transport. The
straps, when properly adjusted and maintained, are intended to constrain the power chair or scooter. The straps
should be checked to make certain they are in good condition before each use.
WARNING: FAILURE TO ENGAGE THE BRAKE AND SECURELY STRAP THE
POWER CHAIR/SCOOTER TO THE LIFT DURING TRANSPORT
COULD RESULT IN SERIOUS PERSONAL INJURY OR DAMAGE
TO THE LIFT, THE POWER CHAIR, AND VEHICLES.
2. After the Power Chair/Scooter has been lifted into the vehicle, turn the control cut-off switch off. This will
prevent inadvertent operation of the lift by remote control and/or hand held pendant. Remember for the
control cut-off switch –“RED IS ON.”
ALWAYS PUSH THE POWER CUT-OFF SWITCH TO THE OFF POSITION WHEN
NOT OPERATING THE LIFT.
3. The Trackerlift has a maximum weight lifting limit of 350 pounds.
WARNING: DO NOT EXCEED THE MAXIMUM CAPACITY OF LIFT OR DAM-
AGE TO THE LIFT AND/OR SERIOUS INJURIES MAY OCCUR.
4. The Trackerlift has been designed to lift power chairs and scooters. It has not been designed or intended to
lift any other object. Lifting people or objects other than power chairs may be dangerous.
5. Keep the area underneath of the lift clear at all times.
TOOLS AND SUPPLIES REQUIRED FOR INSTALLATION
___DRILL ___ASSORTED DRILL BITS
___SMALL FLASHLIGHT ___ELECTRICAL TAPE
___ASSORTED WRENCHES AND SOCKETS (7/16”, 9/16” and 3/4" are important)
___ 5/32”, 3/16, 1/4”, and 5/16” ALLEN WRENCHES
___STANDARD SCREWDRIVER
___PHILLIPS HEAD SCREWDRIVERS, #1 & #2 ___PORTABLE VACUUM
___SILICON CAULK (RTV)
___ TAPE MEASURE

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STEP 1
WIRING THE LIFT

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STEP 2
INSTALLING THE MOUNTING BARS
The Tracker rests on top of a pair of mounting bars, which together with the U-bolt brackets, allow installation using
the vehicle’s existing seat attachment points.
To install the Mounting Bars:
a) Position the (2) MOUNTING BARS over the vehicle’s rear seat attachment points.
b) Attach the (4) “U” BOLTS provided, around the seat attachment points and the MOUNTING
BARS. Depending on the vehicle’s seat hooks, you may need to add the ½” long tube
spacers provided between the 3/8-16 Hex Nuts and the plate (see photo below), in order for
the nuts to be on the U-bolt threads. Hand-tighten the bolts enough to hold them in place, but
loose enough to slide the bars side to side for adjustment.
c) Center the threaded holes in the MOUNTING BARS with the sides of the cargo area to center
the lift.
Example: Mounting Bars Installed

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NOTE: IF YOU ARE INSTALLING THE TRACKER INTO A DODGE GRAND
CARAVAN (OR SIMILAR CHRYSLER VAN), READ THE INSTRUCTIONS PAGE 13
ABOUT POSITIONING THE TRACKER TO LEAVE THE SPARE TIRE RELEASE
BOLT ACCESSIBLE.

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MOUNTING THE TRACKER DIRECTLY TO THE VEHICLE’S FLOOR
The Tracker may be installed by bolting the Side Mounting Rails of the Trolley Assembly to the vehicle’s
floorboard if there is a suitable mounting surface and are no obstructions (fuel tank, brake lines, etc.)
WARNING:
CHECK FOR VEHICLE COMPONENTS UNDER THE FLOORBOARD BEFORE
DRILLING ANY HOLES. CHECK THE AREA BENEATH THE VEHICLE IN THE
INTENDED INSTALLATION LOCATION TO BE SURE YOU WILL NOT PIERCE OR
CONTACT THE FUEL TANK, ELECTRICAL WIRING, BRAKE LINES, ETC.
CHECK FOR RUST DAMAGE OR COLLISION REPAIR THAT MAY COMPROMISE
THE VEHICLE’S STRUCTURAL INTEGRITY.
Fold back or remove the carpet in the area to expose the metal floorboard. The Trolley Assembly must be mounted
to a relatively flat surface. Small irregularities, such as stiffening channels, may be shimmed with washers when the
Trolley Assembly is bolted down. On most installations, the carpet can be folded back into place and trimmed
around the Side Mounting Rails so that it will be captured neatly against the Trolley Assembly. Use your best
judgment and strive for a neat installation.
Place the Trolley Assembly in the desired position on the floor of the vehicle’s cargo area and mark the four hole
locations with a 3/8” center punch. Remove the Trolley Assembly and drill the four holes for the mounting bolts
using a 3/8” drill bit. BE VERY CAREFUL NOT TO DAMAGE ANYTHING ON THE UNDERSIDE OF THE
TRUNK WHEN THE DRILL BIT PUNCHES THROUGH THE METAL FLOOR.
Install the Trolley Assembly with the 3/8” X 2.5” Bolts, 3/8” Flat Washers, Hex Washer Plates and 3/8” Locking
Nuts provided. If shims are necessary (to compensate for irregularities in the trunk floor or to level the Trolley
Assembly) use additional 3/8” ID Flat Washers (not included). Attach a 3/8” Washer and a 3/8” Self-Locking Nut
to the Hex Washer Plate and Bolt from the underside of the vehicle and tighten securely. At this time, the washers
and nuts that mate to the underside of the vehicle should be sealed with silicone sealant to prevent moisture from
entering the holes and rusting the vehicle’s floor or Trolley Assembly.
CAUTION: FAILURE TO SECURELY FASTEN ALL THE BOLTS MAY RESULT IN
DAMAGE TO THE LIFT OR VEHICLE’S FLOOR. THIS CONDITION MAY CAUSE
THE UNIT TO FAIL UNDER LOAD, THUS RISKING PERSONAL INJURY TO THE
OPERATOR AND DAMAGE TO THE POWER CHAIR/SCOOTER AND/OR TO THE
VEHICLE.
STEP 3

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POSITION THE TROLLEY ASSEMBLY ON THE MOUNTING BARS
Place the trolley assembly into the vehicle, laying it on top of the mounting bars. Arrange the trolley assembly so it
is facing as shown in the figure below.
STEP 4

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ATTACH LEVELING FEET TO THE TROLLEY ASSEMBLY
Place the adjusting feet (found in the hardware bag) in the holes of the SIDE MOUNTING RAILS, near the front of
the Tracker.
If the floor of the vehicle is level all the way, insert the feet with a 3/8 washer on each directly through the mounting
rail as shown in the figure below. Secure the mounting feet with a 3/8 washer and Nylock nut on top.
If you need to elevate the feet in order to level the trolley assembly, put a 3/8-16 hex jam nut and 3/8 washer onto
the leveling foot first, then insert the threaded portion of the foot through the side mounting rail, as shown in the
figure below.
If removing the High threshold Feature you will have to saw off threads of leveling feet to clear platform.
Turn the additional 3/8-16 jam nut & nylock nut to adjust the height of each leveling foot. Adjust the height of the
feet so that the weight of the Trolley Assembly is evenly distributed on both of the mounting bars and leveling feet.
Next- set the final position of the Trolley Assembly in the cargo area and tighten down all of the nuts and bolts.
STEP 5

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POSITION THE TROLLEY ASSEMBLY AND BOLT IT DOWN
Align the front of the Trolley Assembly as far rearward in the opening of the cargo area as possible. This is
important so that the Tracker PLATFORM ASSEMBLY will clear the vehicle’s bumper when operating.
Slide the trolley assembly on the mounting bars and adjust its position, aligning the holes in the Side mounting rails
with the holes in the mounting bars. Check the distance from the side mounting rails of the trolley assembly to the
sides of the cargo area, to make sure the trolley assembly is centered. To adjust the side-to-side distance, loosen the
3/8 nuts on the U-bolts and slide the trolley assembly & mounting bars to one side or the other.
Secure the side mounting rails to the mounting bars using the (4) 3/8-16 x 5/8” bolts; hand tighten only at this point.
Do one final check of the side-to-side alignment and distance to the threshold/sill, adjusting if needed, and then
tighten down all of the hex nuts on the U-bolts, and the 3/8 bolts on the mounting bars.

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STEP 6
RAISE THE BOOM AND INSTALL THE BOLT
Have an assistant hold the front boom up off the lead screw OR put a small board under the front boom to prop it up
off of the lead screw/collar assembly; this will avoid plowing the front boom into the end of the track if you
accidentally press OUT instead of IN.
Now, using the pendant to control the lift, press “IN” to extend the actuator.
CAUTION: As you are raising the lift, watch the boom head to make certain it will not contact the roof of the
cargo area.

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After the actuator is extended, lift the Front Boom Weldment and swing the Upper Boom Frame onto the Front
Boom Weldment and align the holes; put the bolt in. Secure the bolt with the nylon insert locknut.
Move unit out approximately 2” & remove (2) wood blocks located in tracks used to prevent
shipping damage.
Next you will determine if you should remove the High Threshold Kit that comes with your Trolley Assembly.

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STEP 7
MOUNTING THE PLATFORM ASSEMBLY TO THE TROLLEY ASSEMBLY
Using the pendant to control the lift, press “OUT” to move the lift out & down to the position shown.
With the help of an assistant –Lift the platform assembly sliding the deck pivot vertical tube into the slot on the
boom head on the trolley assembly. Use the 2 lower holes on the Vertical Tube. Insert the 3/8-16 Hex Head Cap
Screws (Bolts) and washers; tighten the 3/8-16 nyloc nuts to hold the tube in place.

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STEP 8
CHECK CLEARANCES WITHOUT LOAD
Operate the Tracker without a load and check the clearance of the platform over the bumper and threshold of the
vehicle.
Check the side-to-side clearances. To adjust the side-to-side distance, loosen the 3/8 nuts on the U-bolts and slide
the trolley assembly & mounting bars to one side or the other.

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STEP 9
ADJUST PLATFORM ANGLE TO SUIT LOAD –Power Chair or Scooter
You will need a ¼” socket wrench to adjust the set screws. Adjust the platform so that it is level while the
customer’s power chair/scooter is on it.

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STEP 10
ADJUSTING THE VERTICAL –HORIZONTAL TRANSITION
The relay circuit in the Tracker is designed to end lifting and begin horizontal travel into the vehicle when the limit
switch in the back boom weldment is contacted. The Tracker is shipped with a factory setting for this limit switch.
Depending on the weight of the power chair/scooter you may need to adjust the point where the lift ends, especially
if the load being carried is near the weight limit of 350 pounds.
To adjust, loosen the jam nut on the screw, and turn the contact screw inward to increase the upward lift, OR
outward to reduce the upward lift.

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STEP 11
CONFIRMING HOME POSITION AND LOCKING PIN ALIGNMENT
The Tracker is in its home position when the horizontal motion is completed. The movement stops when the stop
rod (mentioned in Step 11) contacts the back end of the trolley assembly, and activates a limit switch.
When the Tracker is in its home position, it is important that the alignment pins are captured in the holes in the front
plate/high threshold plate (see figure below)
If the pins are not captured in the holes, adjust the angle of the platform (Step 12) Make certain you adjust the
angle of the platform with the load (power chair/scooter) on.
WARNING: THE ALIGNMENT PINS SECURE THE PLATFORM, AND TOGETHER
WITH THE STRAPS, SECURE THE POWER CHAIR/SCOOTER TO THE TROLLEY
ASSEMBLY DURING TRANSPORT. AN UNSECURED POWER CHAIR/SCOOTER
CAN CAUSE SERIOUS INJURIES.

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STEP 12
INSTALLING THE STRAPS FOR THE CUSTOMER’S POWER CHAIR/SCOOTER
Buckle (above) Latch Plate & Adjustable Strap (below)
In general, Power Chairs will use straps mounted near the center of the platform, and for Scooters the straps will be
mounted off to one side. Locate the straps on the platform where they will be able to buckle across the seat of the
customer’s power chair or scooter.
Note: It is strongly recommended that the buckle be attached to the side closest to the vehicle (van, minivan) so that
the adjustable strap is easy to reach.
POWER CHAIR SCOOTER
Installing Straps in the Center Positions
Installing the side near the trolley assembly. Use 5/16 –18 x 1” Button Head Socket Screw, 5/16 – 18 nylon insert
lock nut, and one 5/16 SAE flat washers.

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Installing the side towards the outside of the vehicle. Use the 5/16 –18 x 1.25” flat head screw, five 5/16 SAE flat
washers (to space the strap away from the deck), another 5/16 SAE flat washer and finally a 5/16 –18 nylon insert
lock nut to secure the metal plate of the buckle side of the strap as shown.
Installing Straps off to the side in the Loop Positions
Installing the loop, on the side near the trolley assembly. Use 3/8 –16 x 1.5” Hex Cap Screw, 3/8 – 16 nylon insert
lock nut, and two 3/8 x 1.25 fender washers, as shown below:
Installing the side towards the outside of the vehicle. Use the 3/8 –16 x 1.5” Hex cap screw, two 3/8 SAE flat
washers, two 3/8 x 1.25 fender washers, and a 3/8 –16 nylon insert lock nut to secure the metal plate of the latch
plate to the loop as shown below: The fender washers must contact the loop.