Harmar Mobility AL815CC Operating instructions

Truck Lifts
ALCC, AL, ALCC, AL
Installation & Owner’s Manual www.harmar.com | 800-833-0478
AL835
Standard Cab
Truck Lift - Heavy Duty
Capacity: 350 lbs
AL825
Standard Cab
Truck Lift -Performance
Capacity: 210 lbs
AL825CC
Crew Cab
Truck Lift -Heavy Duty
Capacity: 225 lbs
AL815CC
Crew Cab
Truck Lift - Performance
Capacity: 135 lbs
Available for both driver-side
and passenger-side installation
Standard Cab Models: Crew Cab Models
Read and understand this manual thoroughly before
attempting to install or operate the lift. If you have any
questions, please contact your Authorized Harmar Dealer or
Harmar’s Technical Service Department.
P 800-833-0478 | F 866-234-5680 | [e-mail]
Dealer Name & Contact Information:
Serial # of Your Lift:
Install Date:

SECTION 1: OWNER
OPERATING YOUR LIFT
Docking Devices ..........................3-4
Loading/Securing .........................5-6
Raising Your Chair / Scooter................7-8
SAFETY & MAINTENANCE 9
SECTION 2: INSTALLER
PREPARATION
Tools Required ............................ 10
Unpacking the Lift ........................ 11
Installation Overview...................... 12
INSTALLATION
Wiring the Vehicle ......................13-15
Installing the Base......................16-19
Post Installation ........................20-21
Installing the Lifting Arm ...............22-23
Installing the Control Box ...............24-26
TROUBLESHOOTING 29
EXPLODED VIEWS & PARTS LISTS
AL815CC...............................30-31
AL825 .................................32-33
AL825CC...............................34-35
AL835 .................................36-37
Power Base - All ........................38-39
Electrical...............................40-41
SECTION 3: WARRANTY
WARRANTY 43
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Table of Contents
Read & Understand this Manual Prior to Installation or Operation. Please read, follow, and fully understand
the installation section of this manual before beginning. Knowing the lift’s adjustments and the tips on
proper installation and operation techniques will save time, energy and avoid possible injury. If you do not
understand any portion of installation or operation, please consult our technical service department or
authorized mobility dealer.
NOTE: The following symbols indicate areas where you should take special care to avoid danger to
individuals or property.
WARNING
Hazardous situation. If not avoided,
could result in serious injury to
installer or user.
CAUTION
Hazardous situation. If not avoided,
could result in serious damage to
property.

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SECTION 1 : OWNER Operating Your Lift
Docking Devices
The Docking Device is the interface
between the lift and the chair or scooter.
Most chairs/ scooters can be lifted either
by the center seat post [Figure 3-1] or the
four-post seat frame. [Figure 3-2]
Any Harmar Docking Device can be used
DD-19
C-Arm
with the truck lift’s double strap hook. Simply remove
the bolt as shown. [Figure 3-3]
The Docking Device may also be left
permanently attached to the lifting arm on the
pick-up truck lift. [Figure 3-4]
[Figure 3-1]
[Figure 3-2]
[Figure 3-3]
[Figure 3-4]
DD-21
Spreader Bar &
Bridles

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SECTION 1 : OWNER
Operating Your Lift
Types of Docking Devices
The Docking Devices shown are two of the most
common and can lift most power chairs and
scooters.However, many other devices are available.
[Figures 4-1 thru 4-5]
Please consult the instructions provided with your
Docking Device or contact our technical service
department to nd the specic device that will work
best for your application.
[Figure 4-1]
[Figure 4-2]
[Figure 4-4]
[Figure 4-5]
[Figure 4-3]

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SECTION 1 : OWNER Operating Your Lift
Loading & Securing
Your Chair / Scooter
Position chair / scooter parallel with vehicle. Press the
‘UP’ button on the remote control to bring the lifting
arm above the side wall of the truck bed. [Figure 5-1]
Lock the wheels of the chair / scooter (if applicable)
and turn the power o.
Press the ‘OUT’ button on the remote control to move
the lifting arm out and around to the parallel position
of the truck. [Figure 5-2]
Use caution when moving the arm out of the truck
bed. Be sure the lifting arm is high enough to clear the
truck bed side wall.
[Figure 5-1]
[Figure 5-2]
CAUTION
Arm Must Clear Truck Bed Wall
Before lowering the lift, be sure that
the lift has completely rotated and
will not collide with the truck.
Press the ‘DOWN’button on the remote control to lower
the lifting arm close enough to the chair or scooter so
that you can attach the Docking Device. [Figure 5-3]
WARNING
Be sure no people, children or
animals are under the payload
before lowering
[Figure 5-3]

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SECTION 1 : OWNER
Operating Your Lift
Some applications may require the seat back be
folded. [Figure 6-1]
Attach the Docking Device specic to your
application. [Figure 6-2]
NOTE: Some applications may leave the Docking
device attached to the lifting hook. Please follow
the instructions provided by your dealer, or call the
technical service department number on the front
cover of this manual.
OR
[Figure 6-1]
Pull the quick pin from the lifting hook. Align the
docking device and lifting hook as indicated. Replace
the quick pin. [Figure 6-3]
[Figure 6-2]
[Figure 6-3]

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SECTION 1 : OWNER Safety & Maintenance
Raising the Chair
Press the ‘UP’ button on the remote control to raise
the chair / scooter. Continue to raise until the bottom
of the chair/ scooter will clear the side wall of the
truck bed. [Figure 7-1]
[Figure 7-1]
CAUTION
Chair/Scooter on Lifting Arm Must
Clear Truck Bed Wall
Before lowering, verify the lift with its
chair/scooter has completely rotated
and will not collide with the truck.
Press the ‘IN’button on the hand remote to rotate the
lifting arm in and over the truck bed side wall. Use
caution while rotating the arm; be sure that the chair/
scooter is high enough so that the wheels clear the
top of the truck bed side. [Figure 7-2]
[Figure 7-2]

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SECTION 1 : OWNER
Operating Your Lift
When the chair/scooter reaches the desired position,
lower the chair/scooter by pressing the‘DOWN’
button on the remote control. [Figure 8-1]
Stop lowering when about ¾ of the chair/scooter’s
weight is on the oor. The best transportation
position for the chair/scooter will be with the lifting
arm holding the chair in position, as well as most of
the chair/scooter resting on the oor of the truck
bed. The lifting straps should remain taut. [Figure8-2]
To unload the chair, follow the steps in reverse, and
reverse the direction of the arrows.
[Figure 8-1]
[Figure 8-2]
CAUTION
Do NOT expose Remote Control to
rain or snow. If remote control is
plugged directly into the lift, remove
hand control after each use and store
it in the cab.

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SECTION 1 : OWNER Safety & Maintenance
Safety & Maintenance
CAUTION
Do NOT operate this lift until your
dealer/installer has clearly instructed
you in its proper operation.
Safety
Your truck lift has been engineered and designed for
years of trouble-free use. However, like all mechanic
equipment, everyday use may result in some parts
becoming damage or worn.
IMPORTANT: Check regularly for any worn, loose
or damaged parts on your lift. If you observe any
issues, do NOT use the lift. Contact your dealer or
installer to make repairs. Failure to act may result
in severe injury.
Use your lift only to load and unload the scooters
and power chairs for which it is designed. Do NOT
add or modify any part of the lift system without
rst contacting the lift manufacturer. Modications
may void any warranties as well as aect the
structural integrity of the lift.
WARNING
Always check the lifting straps
before each use for damage or
wear.
Make sure the vehicle’s parking brake is rmly set
before operating the lift.
Ensure that the lifting strap is secure and taut and that
it points straight down before lifting the scooter or
power chair. Failure to do so could result in the scooter
or chair swinging toward the operator of the vehicle.
When using the lift, keep your hands and feet from
under the scooter or power chair as it is being loaded
and unloaded.
CAUTION
The rotational motor is equipped with
a Manual Override in case of a power
failure. To use override, disconnect
power before removing cap. This
prevents accidental restoration of
power and serious injury.
Ensure that the scooter or chair is rmly sitting on the
vehicle’s oor and is not suspended by the lift. If the
scooter or chair is not rmly on the truck bed oor, it
may move during transportation and cause damage
to the lift, scooter / chair, vehicle, or passengers.
Maintenance
This Truck Lift is designed to be as trouble-free as
possible, but as with any mechanical device, regular
maintenance will help ensure that it continues to oer
reliable and safe use for years to come.
Schedule a preventative maintenance inspection.
Have your dealer inspect the lift at least once a year,
including motors, lift frame, wiring harness, and all
moving parts.
Check for paint chips and touch up bare metal. Use
a good gloss black enamel or lacquer to inhibit rust.
You may need to do this more frequently if your lift is
subject to salt air, road salt, or debris.
Always check lifting straps before use. If you notice any
wear or fraying, do not use the lift. Contact the installer
or dealer for repair. Failure to act may cause damage to
the vehicle or severe injury.
Do not expose hand control units to the weather.
If the cab entry wiring harness is not installed, and
the control is connected directly to the lift, remove
the hand control each time the lift is used; it should
never be exposed to the elements. If your lift did not
include the cab entry wiring harness, contact Harmar’s
technical service department or your dealer / installer
to have one installed.

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SECTION 2 : INSTALLER
Preparation
Professional Installation Recommended
NOTE: The following section is designed for the professional installer. We strongly recommend that a
certied dealer install the lift and instruct the user on correct operation as well as establish a safety and
maintenance schedule.
If you do not understand any portion of installation or operation, please consult our technical service
department or authorized mobility dealer. Do not attempt to install or use this lift with any hesitation or
question. Serious injury or damage can result if proper procedures are not followed.
Read & Understand this Manual Prior to Installation or Operation.
Having an overall understanding of the lift and proper installation techniques will help you save time, energy,
and avoid possible injury.
SOCKET SET
Specically
WRENCH SET
Specically
15/16"
3/4”
9/16'
7/16"
15/16"
7/16”
3/4”
9/16"
ALLEN WRENCH
Specically
1/8”
3/16”
5/16”
#0,#2 FLAT HEAD
SCREWDRIVER
#2 PHILLIPS HEAD
SCREWDRIVER
WIRE CUTTERS NEEDLE NOSE
PLIERS
ELECTRIC DRILL
w/ 3/8" Drill bit
MARKING
IMPLEMENT TAPE MEASURE
Tools Required
Installations may vary to some degree, but below are the basic tools to have on hand
for an Outside Lift installation.

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SECTION 2 : INSTALLER Preparation
Unpacking The Lift
Check the box contents. Review each part against the packaging
checklist to ensure that all parts have been included.
If any parts are missing or damaged, immediately contact the
dealer who sold the lift.
Do not attempt to install or use a lift that has missing or damaged
parts.
HARDWARE
PAC KCHECK LIST /
INSPECTION SHEET
VERTICAL POST
BASE ADAPTER
( DRIVER's SIDE or
PASSENGER's SIDE )
POWER BASE
ASSEMBLY
LEG EXTENSIONS
LIFTING ARM
ARM
EXTENSION

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SECTION 2 : INSTALLER
Preparation
Installation Overview
WARNING
Never attempt to pick up the lift from the box, ground or on/o a
vehicle alone.
Two people should work together to place this lift inside a vehicle.
If only one person is available, please follow the short disassembly
procedure below.
1. Choose a Location. Place
base and leg extensions in the
far corner of the truck bed.
Driver's Side
Base Required
Passenger Side
Base Required
FRAME
FRAME
FRAME
Overview of Recommended Installation Procedure
Examine under the truck where
three to ve holes will need to
be drilled. (Number of holes
depend on payload)
Wherever possible, incorporate
the frame rails of the truck. This
is a requirement when lifting
heavier chairs and scooters.
2. Install Vehicle Wiring Harness. Installing the wiring harness rst will allow powered movement of the lift,
aiding in the installation. [See page 13]
3. Install Lift Components.
Install power base assembly
onto base mounted to truck
bed. [See pages 19 ]
Install vertical post so that
bottom horizontal bar just clears
truck side wall.
Install lifting arm using bolts
provided.
Driver's Side
Base Shown

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SECTION 2 : INSTALLER Wiring the Vehicle
The vehicle wiring harness is located in the hardware
pack. The harness is manufactured to comply with
SAE J1128 requirements. It is approximately 23 feet
long and will accommodate most vehicles.
The wiring harness is unassembled for easier
installation. The end connector is included separately
from the harness to enable the installer to run the
wire under and through the vehicle with the smallest
clearance possible
Wiring The Vehicle
IMPROPER WIRING IS THE #1 CAUSE OF PROBLEMS IN THE OPERATION OF A
VEHICLE LIFT.
FOLLOW THE WIRING INSTRUCTIONS CAREFULLY
Unwind the wiring harness and lay it at.
One end of the harness has 2 covered pins. This is the
lift end and goes to the rear cargo area where the lift
will mount. [Figure 13-1]
1. Route the wire harness beginning at the battery.
Attach the black wire to the negative terminal on the
battery. [Figure 13-2]
Do NOT attach the red wire until the very end of
installation.
CAUTION
Do NOT connect the red wire until
the very end.
TO BATTERY
END
CONNECTOR
20 AMP SELF
RESETTING
CIRCUIT
BREAKER
BLA
CK WIRE ONLY
SIDE MOUNT
OR
TOP MOUNT
BLACK WIRE ONL
Y
Never attempt to connect the harness to a
secondary power source. Always connect both leads
directly to the battery.
[Figure 13-1]
[Figure 13-2]

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SECTION 2 : INSTALLER
Wiring the Vehicle
2. Run the vehicle harness under and, when
possible, through the vehicle back to the rear
cargo area/trunk.
Run the wire under and through the vehicle
whenever possible, gaining entry into the vehicle
through the rewall
Do NOT run wiring where it can be snagged by
road debris.
Do NOT run wiring near the gas tank.
If you want to run the harness under the vehicle, you
will most likely need to drill a hole to get the wire
into the truck bed. Use the supplied grommet in the
hole to protect the wire.
If the harness is too long for the vehicle, coil the
excess wire and secure it to the vehicle frame with
the supplied tie wraps. [Figure 14-1]
Do NOT cut or shorten the harness.
CAUTION
Coil Excess Wire.
Do NOT cut or shorten the harness
NOTE: 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 harness where it can not be snagged by
road debris.
[Figure 14-1]
3. When harness is through the vehicle, remove
the pin’s protective tubing. [Figure 14-2]
Pr
otective
tubing
[Figure 14-2]
4. Inspect the pin’s retaining anges.
The anges may have been deformed while being
run through the vehicle. These are critical to secure
the pins inside the connector. Adjust as needed.
[Figure 14-3]
CORRECT
ADJUST BY
PRYING OU
T
SLIGHTLY
IF NEEDED
[Figure 14-3]

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SECTION 2 : INSTALLER Installation
5. Flip open end connector’s hinged retainer. Insert
pins as shown. [Figure 15-1 ]
Verify the wires cannot be pulled out by moderately
pulling on the wires. Be sure rubber seals are inside
the back of the connector.
Close the hinged retainer.
Plug connector into lift.
LETTERS ARE
MOLDED INTO
PLASTIC
HINGED
RETAINER
BA
BLACK WIRE
RED WIRE
SEALS
B=BLACK A=RED
RED WIRE
RED WIRE
OR
LAST
SIDE MOUNT
TOP MOUNT
6. Last, attach red wire to the positive terminal on
the battery. [Figure 15-2]
[Figure 15-1]
[Figure 15-2]
NOTE: Troubleshooting with a test light or voltage meter may give a false indication.
When you probe for 12 volts, the reading may indicate a connection, even if the connection is not necessarily
sucient. The lift’s motor can draw up to 30 amps at some points, requiring all of the available wire to ow
proper current. Poor connections are the #1 problem associated with a slow,
intermittent, warm, poorly performing motor which will also deteriorate
prematurely.
If a single strand of a multi-strand wire is making contact, 12V will appear on a
meter or test light, but it 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 troubleshooting.

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SECTION 2 : INSTALLER
Installation
Base Installation
1. Place base in corner of truck bed
as shown. Attempt to position as close
to the corner as possible. Leave at least
1” around on all sides. [Figure 16-1]
Driver's Side Base
Pa
ssenger's Side Base
( sold as option )
OR
2. Install leg extensions into base tubes as far as
they will go. Set screws can be hand-tightened at this
time. [Figure 16-2]
3. Plan drilling. Three 3/8” holes will need to be
drilled through the truck bed and, when possible,
through the frame of the truck in the down
locations. [Figure 16-3]
Two more 3/8”holes will need to be drilled through
the truck bed if frame is not captured, bed material is
too thin, and/or application is very heavy.
[Figure 16-1]
[Figure 16-3]
[Figure 16-2]

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SECTION 2 : INSTALLER Installation
NOTE: If the application will be lifting a heavier chair
/ scooter, drilling and bolting through the frame
becomes mandatory. [Figure 17-1] Please consult
the technical service department listed on the front
cover of this manual if you are unsure whether this is
required.
Recommended practice before drilling.
With base in position, take a tape measure and
estimate distance in both directions from an exterior
reference point (Ex: outside body panel) to all three
potential bolt holes.
Climb under vehicle and recreate measurements of
the three bolt holes.
Examine areas for framing, bracing, or other closely
available thickened structure to mount the lift
through.
Adjust position of base and leg extensions to capture
as much frame as possible while avoiding vehicle’s gas
tank, spare tire, suspension components, etc.
When you are condent of the position for all three
holes, climb into the truck bed. Using the base as
a template, mark the three locations with a pencil.
Remove base.
Drill down through truck bed with pilot holes in the
marked locations.
Climb under truck and inspect location of pilot holes.
Once again, be sure the larger hole will avoid vehicle’s
gas tank, spare tire, suspension components, etc.
Finish drilling all three holes with a 3/8” or slightly
larger drill bit.
POSSIBLE USE
FOR HEAVIER
APPLICATIONS
POSSIBLE USE
FOR HEAVIER
APPLICATIONS
[Figure 17-1]
CAUTION
USE EXTREME CAUTION
Avoid Gas Tank, Fuel / Brake /
Electrical Lines
[Figure 17-3]
[Figure 17-2]

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SECTION 2 : INSTALLER
Installation
Figure 18-1]
Base Installation (con’t)
4. Secure base to the truck bed using hardware
indicated below. Tighten all hardware (except
temporary hex nut) to approx. 30 ft. lbs.
Temporary
3/8-16
All-Thread
3/8-16
All-Thread
3/8-16
All-Thread
Installation
Washer
Installation
Washer
Installation
Washer
3/8 Split
Loc Washer
3/8 SPLIT
Loc Washer
3/8 Split
Loc Washer
3/8 Split
Loc Washer
3/8 Split
Loc Washer
3/8-16
Hex Nut
3/8-16
Hex Nut
3/8-16
Hex Nut
3/8-16
Hex nut
3/8-16
Hex nut
3/8-16
Hex Nut
TRUCK
BED
FLOOR /
FRAME
TRUCK
BED
FLOOR /
FRAME
TRUCK
BED
FLOOR /
FRAME
or
or
3/8-16 x 3.50
Hex HEad
Cap Screw
3/8-16 x 3.50
Hex Head
Cap Screw

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SECTION 2 : INSTALLER Installation
Figure 19-3
Figure 19-4
Wherever possible incorporate the frame rails of the
truck. This is a requirement when lifting heavier chairs
and scooters. [Figure 19-1]
FRAME
FRAME
FRAME
As a last resort, if the truck frame cannot be used in
the mounting, adding these two anchor brackets will
help stabilize the lift and help prevent the truck bed
from tearing. [Figure 19-2]
3/8-16 x 3.50
Hex Head
Cap Screw
3/8-16 x 3.50
Hex Head
Cap Screw
Installation
Washer
Installation
Washer
3/8 Split
Loc Washer 3/8-16
Hex nut
3/8-16
Hex nut
TRU CK
BED
FLOOR /
FRAME
Anchor
Bracket
Anchor
Bracket
Temporary
3/8-16
HEX NUT
3/8 Split
Loc Washer
(x3)
3/8-16 x 2-3/4"L
Socket Head
Cap Screw (x3)
Remove
5. Remove temporary hex nut. Attach Power Base
Assembly as shown. Tighten bolts to approx. 30 ft. lbs.
6. Finish assembly with one more loc washer and hex
nut in corner as shown. Tighten to approx. 30 ft. lbs.
Cut o excess all thread if desired.
3/8 Split
Loc Washer
3/8-16
Hex Nut
Figure 19-1
Figure 19-2

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SECTION 2 : INSTALLER
Installation
Post Installation
1. Loosen set screws and insert vertical post.
[Figure 20-3 ]
The average installation will require approximately 180 degrees
of rotation as shown. [Figures 20-1 & 20-2]
180
2" Increments
1" Fine Tuning
Increment
Loosen
Set Screws
(x4)
Adjust set screws until
post is vertically level.
3/8-16 x 3-1/2"L
Hex Head Cap Screw
3/8-16
Nyloc Nut
MINIMAL
2. Plug in the hand control and turn the lift‘On.’
Press the 'In /Out' button to test the post height.
[Figure 20-4]
Ideally, the post’s horizontal tubing should just
clear the truck’s bed side wall. Adjust height as
required.
Figure 20-1 Figure 20-2
Figure 20-3
Figure 20-4