Challenger Lifts E12 Gebrauchsanweisung

Rev. 11/29/16

INSTALLATION,OPERATION &MAINTENANCE MANUAL

Two Post

Surface Mounted Lift

MODEL E12

12,000 LBS.CAPACITY

3000 LBS.PER ARM

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 502-587-1933

IMPORTANT: READ THIS MANUAL COMPLETELY BEFORE

INSTALLING or OPERATING LIFT

Model E12

Installation, Operation and Maintenance

Page 2

Rev. 11/29/16

E12-IOM-A.doc

GENERAL SPECIFICATIONS

* Lift capacity ratings are based on loads equally distributed on all four arms.

** Lifting and lowering speeds may vary depending on the weight of the vehicle.

Fig 1a - General Specifications Fig1b - Service Bay Layout

See Figure 1 E12 E12 w/ 2 Ft. Ext. Kit

ARise Height (Screw Pads Highest Position) 77 3/4"

(1975 mm)

BOverall Height 13’-10"/14’-7”

(4216 mm/4445 mm) 15’-10"/16’-7”

(4826mm/ 5055mm)

COverall Width 139 3/4"

(3550 mm)

DDrive-Thru Clearance 103"

(2616 mm)

EFloor to Overhead Switch 13’-3 ½"/14’-½”

(4051mm/4280 mm) 15’-3 ½"/16’-½”

(4661mm /4890mm)

FMinimum Arm Reach 35 3/4"

(910 mm)

GMaximum Arm Reach 54 1/2"

(1386 mm)

HScrew Pad Height 5 1/4"/ 6 3/4"

(133mm/171mm)

KInside of Columns 115"

(2921 mm)

Lifting Capacity *

(Hydraulic Pressure at Cap.) 12,000 lbs.

(2600 psi)

Ceiling Height Required 167"/176”

(4242mm/4470mm) 191"/200”

(4852mm/ 4890mm)

Motor 2HP, Single Phase, 60Hz

Voltage 208-230

Speed of Rise ** 84 seconds

Max Load Per Arm 3000 lbs

(1360 kg)

Model E12

Installation, Operation and Maintenance

Page 3

Rev. 11/29/16

E12-IOM-A.doc

WARNING

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

unsatisfactory lift performance, property

damage, or personal injury.

FLOORING

Be certain you have the proper concrete floor to

properly handle the loaded lift. Floor should be in

generally good condition with no large cracks,

spalling or deterioration.

Minimum requirements for concrete are 4

inches minimum depth, with steel

reinforcement, 3500 psi, cured for 28 days per

local commercial practice. Floor should be

level within 3/8 inch over the installation area. No

anchors should be installed within 8 inches of any

crack, edge, or expansion joint. If these

conditions cannot be met, a pad may be poured

to accommodate the lift.

Check with local building inspectors and/or

permits office for any special instructions or

approvals required for your installation.

A qualified person should be consulted to

address seismic loads and other local or state

requirements. Failure by purchaser to

provide the recommended

mounting surface could

result in unsatisfactory lift performance,

property damage, or personal injury.

LOCATION

This lift has been evaluated for indoor use only

with an operating ambient temp. range of 5 –

40°C (41–104°F)

ELECTRICAL REQUIREMENTS

For lift installation and operation it is necessary to

have a dedicated circuit with circuit breaker or

time delay fuse. Refer to wiring diagram for

circuit sizing.

SAFETY NOTICES AND DECALS

For your safety, and the safety of others, read

and understand all of the safety notices and

decals included here.

READ ENTIRE MANUAL BEFORE ASSEMBLING,

INSTALLING,OPERATING,OR SERVICING THIS

EQUIPMENT.

PROPER MAINTENANCE AND INSPECTION IS

NECESSARY FOR SAFE OPERATION.

DO NOT OPERATE A DAMAGED LIFT.

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

columns as described in this installation manual.

Verify that all authorized operators know the

location of these decals and fully understand their

meaning. Replace worn, faded, or damaged

decals promptly. Do not attempt to raise a

vehicle on the lift until the

lift has been correctly

installed and adjusted as described in this

manual.

WARNING

Model E12

Installation, Operation and Maintenance

Page 4

Rev. 11/29/16

E12-IOM-A.doc

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.

Component Packing List

PART # QTY/ LIFT DESCRIPTION

JSJ6-02-00 1

Power Column

Assembly

JSJ6-02-00f 1 Idler Column Assembly

JSJ6-03-00 1 Overhead Assembly

E12-HW-A 1 Hardware Box

JSJ6-02-02-00 1

Power Column

Extension

JSJ6-02-02-00f 1 Idler Column Extension

JSJ6-09-00 4 Arm Assemblies

JSJ6-04-00 2

Synchronizer Cable

Assembly

E12-HP 1 Hydraulic Hose Pack

JSJ5-02-14A 2 Lock Covers

INSTALLATION

IMPORTANT:Always wear safety glasses while installing lift.

TOOLS (MINIMUM REQUIRED)

a. Tape measure, 16ft

b. Chalk line

c. 4ft level

d. 10” adjustable wrench

e. Metric open end wrenches 10mm, 13mm,

14mm, 15mm, 17mm, 18mm, 19mm and

24mm

f. Metric Allen Wrenches 4mm, 5mm, 6mm,

and 8mm.

g. Needle Nose pliers

h. Snap Ring pliers

i. Hammer drill with 3/4” diameter carbide

tipped bits

j. 2lb hammer

k. Torque wrench: 150 foot pounds minimum

with 1 1/8” socket

l. 12 ft. Step ladder

m. Anti-Seize lubricant (for arm pins and foot

pad screw threads and stop rings)

LAYOUT

1) Layout the service bay according to the

architect’s plans or owners instructions (see

Fig 1b). Failure to install in this

orientation can result in personal and

property damage. Be certain that the

proper conditions exist, see page 3.

2) Assemble column extension to column using

M12 x 30 Hex bolts. Repeat for opposite

column and extension. Install power column

extension on power column. NOTE: install

with nut and washer on the exterior of the

column.

3) Using the Overall Width (C) Dimension from

Fig 1, chalk two parallel lines on the floor

within 1/8” tolerance. Erect both column

assemblies. Align the base plate edges to the

chalk lines.

Fig 1 – Column Layout

Model E12

Installation, Operation and Maintenance

Page 5

Rev. 11/29/16

E12-IOM-A.doc

ANCHORING

4) The anchor bolts must be installed at least 8”

from any crack, edge, or expansion joint.

5) Use a concrete hammer drill with a 3/4 inch

carbide bit. Tip diameter should conform to

ANSI Standard B94.12-1977 (.775 to .787).

Do not use excessively worn bits or bits

which have been incorrectly sharpened. A

core bit may be necessary if an obstruction is

encountered. Never substitute with shorter

anchor.

6) Recheck “Inside of Columns” dimension,

Fig 1. Drill the anchor holes using the base

plate as a template. Drill through the floor if

possible or to a depth of 5 inches minimum.

7) Vacuum dust from the hole for proper holding

power.

8) Shim both columns to plumb using the shims

provided as shown in Fig 2. DO NOT shim

more than 1/2" at any given point. Use a level

no less than 24” in length to plumb columns.

9) Assemble washer and nut to anchor with nut

just below impact section of bolt. Drive

anchor into hole until nut and washer contact

base.

Fig 2 – Column Shimming

10) Tighten power column anchors and recheck

column for plumb. Re-shim if necessary.

Torque to 150 foot-pounds to set anchors.

OVERHEAD

11) Raise and install Overhead Assembly using

M12 x 30 Hex Bolts.

12) Install Overhead Limit Switch and Shutoff Bar

under the Overhead Beam as shown in

Fig 3.

13) Check idler column shimming. Use additional

shims (see Fig. 2) to remove any gaps that

may have been created while installing

overhead beam. Tighten anchor bolts and re-

check column for plumb. Torque to 150 foot-

pounds.

Fig. 3 - Limit Switch

SYNCHRONIZER CABLES

14) Manually raise each carriage into the second

lock position.

15) At the upper beam sheave locations

disassemble and reassemble the cable

trapping rod to install the cable onto the

sheave, See Fig 4. To install the cable

bottom sheave will need to be removed then

reassembled.

Fig 4-Cable Trapping

16) Attach one end of synchronizing cable to

carriage. See Fig 5 for proper attachment.

17) Route cable up and over sheave in

overhead. Follow across to other sheave on

opposite column. Route down through

carriage to sheave in bottom of column.

Route under sheave and up to cable

attachment. Lower attachment point is used

for Standard Height Installation (175”) and

the Upper attachment point is used for

Reduced Height Installation (166”). Use Fig

5for proper attachment.

Model E12

Installation, Operation and Maintenance

Page 6

Rev. 11/29/16

E12-IOM-A.doc

18) Repeat for opposite side.

Fig 5 – Synchronizing Cables

POWER UNIT &HYDRAULIC LINES

Fig 6 – Power Unit Mounting

19) Mount Power Unit to power column as shown

in Fig 6. The mounting hardware, (4) M8 hex

nuts, are pre-installed on power unit

mounting bracket.

20) Attach Hydraulic elbow fitting threading the

O-Ring end into the power unit.

21) The hydraulic hose from the idler cylinder to

the tee fitting are slightly larger and have a

different size fitting. Note during installation

to attach the hoses in the correct end of the

tee. Fig 7.

Fig 7 – Hyd. Tee Fitting

22) IMPORTANT – To insure proper hose

fitting seal without damage to the fitting

follow this procedure for each hose

connection: Screw flared fitting on finger

tight. Rotate flared fitting 1 ½ flats or 90

degrees. Back the flared fitting off one full

turn and repeat.

23) Thread power unit hose (short) to elbow in

power on power unit.

24) Note: If lift is set to the tallest column height

an 18½” extension hose must be used at the

base of the Idler hydraulic cylinder.

Beginning on the idler side start with the Idler

Column Hose (long) up the backside of the

column through the two capture rings and

guide at the top of the extension. Continue

across the overhead through each of the

guides as shown and down the backside of

the power column. See Fig 8.

Fig 8 – Hose Routing (Power Side)

25) Route the remaining Power column hose

beginning at the elbow fitting at the base up

the backside of the column. Join the three

hoses with the supplied union tee.

26) BE CERTAIN ALL FITTINGS AND CONNECTIONS

ARE TIGHT. IT IS THE INSTALLERS

RESPONSIBILITY TO INSURE SYSTEM IS LEAK-

FREE. Fill the Power Unit with three gallons of

clean 10wt anti-foam anti-rust hydraulic oil or

Dexron III ATF. DO NOT USE OILS WITH

DETERGENTS.

Model E12

Installation, Operation and Maintenance

Page 7

Rev. 11/29/16

E12-IOM-A.doc

LOCK RELEASE

27) Install Lock Release Stud and Knob to the

Powre Column Lock using one M10 Nut.

28) Attach Mechanical Lock Release Cable

Assembly to each lock pawl. See Fig 9.

Fig 9 – Lock Assembly

THE LOCK RELEASE CABLE ADJUSTMENT IS NOT

COMPLETE UNTIL THE LIFT HAS BEEN LOWERED AND

“FINAL ADJUSTMENTS”HAVE BEEN MADE.

ARM INSTALLATION

29) Lubricate the arm pin or carriage arm pin

hole with “anti-seize” and install the arms.

Insure that the arm restraint gears engage

and disengage properly. Arm restraints

should disengage when lift is fully lowered. If

any binding occurs, insure that the large gear

mounted to the arm has been factory

installed tight against the arm pin.

30) Extend the footpad to both extents and apply

anti-seize to the three retaining rings and

where the double screw makes contact with

the base of the footpad.

ELECTRICAL

31) Refer to Fig 10 Wiring Diagram for all steps

under this heading.

Single Phase

32) Connect the Overhead Limit Switch Cord to

Power Unit as shown.

33) Connect Power Unit to suitable electrical

source as shown.

Three Phase

34) Power unit is factory wired for 240 volt.

Refer to wiring diagram or motor plate for

optional voltages.

35) Connect Contactor Enclosure to column.

Mounting hardware should be centered on

the column side to side to avoid the path of

the slide blocks.

36) Connect Overhead Limit Switch Cord to

Contactor as shown.

37) Connect Contactor to Power unit as shown.

Connect Contactor to suitable electrical

source as shown.

IMPORTANT:AFTER WIRING HAS BEEN

COMPLETED,TEST OPERATION OF POWER UNIT &

OVERHEAD LIMIT SWITCH.WHILE RAISING LIFT,

OPERATE OVERHEAD SHUTOFF BAR.POWER UNIT

MOTOR SHOULD STOP WHEN SHUTOFF BAR IS

RAISED.

COLUMN DECAL PLACEMENT

38) Clean the surface of the columns before

placing the decals.

39) Apply the Safety Decals (Pg. 3) 48” above

the base plate on the power column and the

Logo Decal 48” above the base plate on the

idler column. Fig 11.

Fig 11 – Safety & Logo Decal Placement

FINAL ADJUSTMENTS

HYDRAULICS

40) Lower the lift to the floor and raise the lift

approximately one foot.

41) Start with Idler side first. Slowly and carefully

loosen the bleed plug on top side of the

cylinder just enough to allow the entrapped

air to escape. Repeat for power side.

42) Raise lift 6 inches. Repeat step 40 until no air

comes out of cylinder.

43) Pressure test hydraulic system. Energize

power unit, raise lift to full rise and continue

to run motor for additional 10 seconds.

(NOTE: pressure relief will make a high pitch

squeal sound for these 10 seconds.) Check

hydraulic system for leaks.

44) Energize power unit again for 10 seconds.

With a clean rag, wipe down both cylinder

rods. (The cylinders are shipped with a small

amount of clear anti-corosive lubricant that

will be forced out through the wiper when the

lift reaches full rise.) If lubricant is not

Model E12

Installation, Operation and Maintenance

Page 8

Rev. 11/29/16

E12-IOM-A.doc

wiped clean from the cylinder rod, the

cylinder will apear to be leaking.

SYNCHRONIZING CABLES

45) Raise lift and insure carriages lower into

same lock position.

46) Adjust synchronizing cables so the tension is

equal in both cables and carriages are firmly

sitting on locks.

47) Cycle lift to insure that latches operate

simultaneously.

LOCK RELEASE CABLE

48) Raise lift to a lock position but don’t set into

the lock. Pull and release Power Column

lock release handle while watching Idler

Column lock. Adjust Cable tension by

removing slack and retightening cable clamp

at the power side. IMPORTANT: IF IDLER SIDE

LOCK PAWL DOES NOT FULLY DISENGAGE,DAMAGE

MAY RESULT TO IDLER SIDE CARRIAGE AND OR CABLE

SYNCHRONIZING SYSTEM.

49) Tighten and trim wire ties.

50) Remove lock release knob and install both

covers. Replace lock release knob.

ARM PIN KEEPER INSTALL

51) Slide the arm pin into the carriage, arm, and

collar. Fig 12.

52) Once the set screw is finger tight against the

arm pin, tighten ¼ turn with tool.

Fig 12 –Arm Pin Keeper Install

OWNER/OPERATOR CHECKLIST

53) 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.

54) 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

Model E12

Installation, Operation and Maintenance

Page 9

Rev. 11/29/16

E12-IOM-A.doc

Wiring Diagram

A2A1

FACTORY WIRED FOR

208−240V

RECONNECTIONS FOR

440−480V

FOR THREE PHASE

(Normally Open)

FOR SINGLE PHASE

FIELD

CONECTIONS

FIELD

CONECTIONS

Fig 10 –Electrical Wiring Diagram

Model E12

Installation, Operation and Maintenance

Page 10

Rev. 11/29/16

E12-IOM-A.doc

OPERATION PROCEDURE

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-2011 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-2008, 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 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-2008,

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/ALI ALOIM-2008, 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 that 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/ALIOIM-2008, 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

that they are adequately trained in the

maintenance of the lift.

The Owner/Employer shall maintain the

periodic inspection and maintenance records

recommended by the manufacturer or ANSI/ALI

ALOIM-2008, 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-2008,

American National Standard for Automotive Lifts-

Safety Requirements for Operation, Inspection

and Maintenance; and in the 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.

IMPORTANT SAFETY INSTRUCTIONS

When using your garage equipment, basic safety

precautions should always be followed, including

the following:

1. Read all instructions.

2. Care must be taken as burns can occur from

touching hot parts.

3. To reduce the risk of fire, do not operate

equipment in the vicinity of open containers

of flammable liquids (gasoline).

4. Keep hair, loose clothing, fingers, and all

parts of body away from moving parts.

5. Use only as described in this manual. Use

only manufacturer’s recommended

attachments.

6. ALWAYS WEAR SAFETY GLASSES.

Everyday eyeglasses only have impact

resistant lenses, they are not safety glasses.

SAVE THESE INSTRUCTIONS

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