Challenger Lifts CL10 Manuale di istruzioni

Installation, Operation, & Maintenance Manual

Versymmetric

TM Two Post

Surface Mounted Lift

MODEL CL10

WITH DUAL PENDANT CONTROL

10,000 LBS.CAPACITY

2500 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

Rev.4/22/11

IMPORTANT: READ THIS MANUAL COMPLETELY BEFORE

INSTALLING or OPERATING LIFT

Model CL10 with Dual Pendant Control

Installation, Operation, and Maintenance

GENERAL SPECIFICATIONS

See Figure 1 CL10 CL10-2 CL10-3

AColumn Height 11’- 8” 13’- 8” 14’- 8”

BFloor to Overhead Switch 11’- 2 1/2 ” 13’- 2 1/2” 14’- 2 1/2”

CRise Height (Screw Pads Highest Position) 75 1/8”

DCylinder Height (Full Stroke) 11’- 11”

EAdjustable Overall Width 11’- 11” / 11’ – 6 1/2"

FScrew Pad Height 3 7/8” to 7 1/8”

GInside of Columns 114 1/2” / 110”

Drive Thru Clearance 104 1/2" / 100”

Ceiling Height Required 11’- 11 ” 13’- 9” 14’- 9”

* Maximum Capacity 10,000 lbs. (2500 lbs. Per Arm)

Lifting Time 48 Sec. (approximate)

Motor 2HP, Single Phase, 60Hz, 208/230

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

COLUMN BASE PLATES

144" [12'-0"]

MIN.TO

NEAREST

OBSTRUCTION

1112" REF

(USE AS REFERENCE ONLY)

SEE CHART ABOVE

(INSIDE COLUMN TO COLUMN)

SEE CHART ABOVE

144" [12'-0"]

MIN. TO

NEAREST

OBSTRUCTION

6' TO NEAREST

OBSTRUCTION

OR 7' TO

NEAREST WALL

DRIVE ON

DIRECTION

144" [12'-0"]

MIN. TO

NEAREST

OBSTRUCTION

(INSIDE COLUMN TO COLUMN)

SEE CHART ABOVE

(USE AS REFERENCE ONLY)

SEE CHART ABOVE

COLUMN BASE PLATES

6' TO NEAREST

OBSTRUCTION

OR 7' TO

NEAREST WALL

1112" REF

DRIVE ON

DIRECTION

144" [12'-0"]

MIN.TO

NEAREST

OBSTRUCTION

144" [12'-0"]

MIN. TO

NEAREST

OBSTRUCTION

(INSIDE COLUMN TO COLUMN)

SEE CHART ABOVE

(USE AS REFERENCE ONLY)

SEE CHART ABOVE

COLUMN BASE PLATES

6' TO NEAREST

OBSTRUCTION

OR 7' TO

NEAREST WALL

1112" REF

DRIVE ON

DIRECTION

144" [12'-0"]

MIN.TO

NEAREST

OBSTRUCTION

144" [12'-0"]

MIN. TO

NEAREST

OBSTRUCTION

(INSIDE COLUMN TO COLUMN)

SEE CHART ABOVE

(USE AS REFERENCE ONLY)

SEE CHART ABOVE

COLUMN BASE PLATES

6' TO NEAREST

OBSTRUCTION

OR 7' TO

NEAREST WALL

1112" REF

DRIVE ON

DIRECTION

144" [12'-0"]

MIN.TO

NEAREST

OBSTRUCTION

POWER UNIT MAY BE MOUNTED ON EITHER SIDE

OF BAY. SEE INSTALLATION STEP 1 FOR DETAILS

POWER UNIT MAY BE MOUNTED ON EITHER SIDE

OF BAY. SEE INSTALLATION STEP 1 FOR DETAILS

POWER UNIT MAY BE MOUNTED ON EITHER SIDE

OF BAY. SEE INSTALLATION STEP 1 FOR DETAILS

POWER UNIT MAY BE MOUNTED ON EITHER SIDE

OF BAY. SEE INSTALLATION STEP 1 FOR DETAILS

Fig 1a - General Specifications Fig1b - Service Bay Layout

Page

Rev. 4/22/11

CL10DPC-IOM-A.doc

Model CL10 with Dual Pendant Control

Installation, Operation, and Maintenance

Page 3

Rev. 4/22/11

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.

WARNING

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.

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

A single phase 208-240VAC, 60Hz dedicated

circuit with a double pole 25 amp circuit breaker

or time delay fuse is required.

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 at

both points of operation. Verify that all authorized

operators know the location of these decals and

fully understand their meaning. Replace worn,

faded, or damaged decals promptly.

WARNING 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

CL10DPC-IOM-A.doc

Model CL10 with Dual Pendant Control

Installation, Operation, and Maintenance

Page 4

Rev. 4/22/11

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

A2001-DPC-57-P1 Power Column Ass’y

A2001-57-I1 Idler Column Ass’y

A2060 1 Overhead Beam

B2202 1 Arm Pack

A2055-57-0 Column Extension for CL10

A2055-57-2 Column Extension for CL10-2

A2055-57-3

Column Extension for CL10-3

A2003-0 Sync Cable Pack for CL10

A2003-2 Sync Cable Pack for CL10-2

A2003-3

Sync Cable Pack for CL10-3

36035 1 Overhead Shut-Off Bar Ass’y

CL10DPC-HW 1 Hardware Box

CL10DPC-LP 1 Literature Pack (in Hardware Box)

A1207-17 1 Power Unit – 1 Phase

A1206-15 1 Junction Box Assembly

A1206-10-PS Pendant Ass’y POWER (CL10-0)

A1206-10-PX 1 Pendant Ass’y POWER (CL10-2 or-3)

A1206-10-IS Pendant Ass’y IDLER (CL10-0)

A1206-10-IX 1 Pendant Ass’y IDLER (CL10-2 or-3)

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. Standard open end wrenches 7/16”, 1/2",

(2) 9/16”, (2) 11/16”, 3/4", 15/16”

f. 5/16” allen wrench

g. Needle nose pliers

h. Hammer drill with 3/4” diameter carbide

tipped bits

i. 2lb hammer

j. Torque wrench: 150 foot pounds minimum

with 1 1/8” socket

k. 12 ft. Step ladder

l. 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.

Note: the only difference between the Power and

Idler Column is the length of hose attached to the

cylinder (long hose in Idler Column). The Power

Unit may be mounted on the Power Column on

either side of the bay.

2) Assemble column extension to column using

3/8-16 x 3/4" lg Hex flange head bolt. Repeat

for opposite column and extension.

3) Erect both column assemblies (column with

short cylinder hose on side of bay with Power

Unit). Align the notches in column base, with

the installation lines.

CL10DPC-IOM-A.doc

Model CL10 with Dual Pendant Control

Installation, Operation, and Maintenance

Page 5

Rev. 4/22/11

LOCKING PAWL

4) Attach 1/2" O.D. Extension Spring to hole

located on bottom side of both supplied Lock

Pawls, Fig 2a. Install Lock Pawl and Lock

Release Clevis on both columns using 5/8”

diameter x 1 1/2” lg shoulder bolt and 1/2”-13

nylon lock nut. Attach 3/8” O.D. Extension

Spring to upper hole in locking pawl and

other end to hole in bracket welded to

column as shown in Fig 2a & 2b.

Fig 2a – Locking Pawl Assembly

Fig 2b – Locking Pawl Assembly

ANCHORING

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

from any crack, edge, or expansion joint.

6) 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.

7) 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.

Complete steps 8 thru 11 for the five (5)

exposed anchors around each column, then

raise the carriages. Repeat steps 8 thru 11 for

the two (2) anchors under each carriage.

8) Vacuum dust from the hole for proper holding

power.

9) Shim both columns to plumb using the shims

provided as shown in Fig 3. DO NOT shim

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

no less than 24” in length to plumb columns.

10) 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 3 – Column Shimming

11) Tighten power column anchors and recheck

column for plumb. Re-shim if necessary.

Torque to 150 foot-pounds to set anchors.

CL10DPC-IOM-A.doc

Model CL10 with Dual Pendant Control

Installation, Operation, and Maintenance

Page 6

Rev. 4/22/11

OVERHEAD

12) Before raising overhead into position install 4

each (2 per column) hex flange bolts and

nuts in middle hole of column extension (see

Fig 4 Installation Aid) for temporary support of

overhead. Lift overhead assembly up into

position and install with 8 each (4 per

column) 3/8-16 x 3/4” lg hex flange bolts and

hex flange nuts per side as shown in Fig 4.

Fig 4 – Overhead Assembly

13) Check idler column shimming. Use additional

shims (see Fig. 3) 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.

14) Assemble the sheaves and spacers onto the

sheave pin as shown in Fig 5. Set in cradle

with all assembly parts between the two

plates.

Fig 5 – Sheave Assembly

SYNCHRONIZER CABLES

15) Attach one end of synchronizing cable to

carriage with the supplied nut and jam nut.

See Fig 6a &6b for proper attachment.

16) 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. Use Fig 6a for proper

attachment.

17) At the top of each column extension

assemble a 3/8-16 x 3”Lg bolt with (2) 3/8-16

flange nut at each sheave location, Fig 5.

18) Repeat for opposite side.

19) Manually raise the carriages to a common

lock position, to gain access to the

cable-tie-off tabs located on the carriage

ladder.

Insure that the top of the hydraulic

cylinder is out of the way but still retained

in the opening of the top plate of the

carriage as shown in Fig 6a.

Failure to follow previous

step could result in

personal injury.

IMPORTANT:

4 1/2" lg STAND-OFF

FOR 11'- 6 1/2" WIDTH

SETTING ONLY

IMPORTANT:

4 1/2" lg STAND-OFF

FOR 11'- 6 1/2" WIDTH

SETTING ONLY

IMPORTANT:

4 1/2" lg STAND-OFF

FOR 11'- 6 1/2" WIDTH

SETTING ONLY

IMPORTANT:

4 1/2" lg STAND-OFF

FOR 11'- 6 1/2" WIDTH

SETTING ONLY

CA UT I ON

Fig 6a – Cable Assembly

IMPORTANT:

Stand-Offs to be used only on the 11’– 6 ½”

Overall Width Setting.

Fig 6b – Jam Nut

CL10DPC-IOM-A.doc

Model CL10 with Dual Pendant Control

Installation, Operation, and Maintenance

Page 7

Rev. 4/22/11

POWER UNIT &HYDRAULIC HOSES

Fig 7 – Power Unit Mounting

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 1/2 hex flats (90 deg.). Back the flared fitting off

one full turn. Again tighten flared fitting finger

tight, then rotate flared fitting 1 1/2 hex flats (90

deg.).

20) Mount Power Unit to column extension as

shown in Fig 7. Assemble the mounting

hardware, (4) 5/16”-18 x 1” bolts and (8)

5/16”-18 hex nuts with the bolt installed from

the inside of the column and one nut holding

it in place at all four locations as shown.

Hang the power unit from these studs and

secure with remaining (4) 5/16 nuts.

21) Uncoil Idler side hose and route through the

Idler Side column extension as shown in

Fig 8a, taking care to avoid the

synchronizing cables and hydraulic cylinder

path. Remove slack and tighten all 3 clamps.

Route hose across overhead avoiding the

synchronizing cables and down through the

Power Side column extension as seen in Fig

8b. Do Not Tighten Clamps at this time.

Fig 8a – Hose Routing,

Idler Side Column Ext.

Fig 8b – Hose Routing,

Power Side Column Ext.

22) Loosely attach power column hose and idler

column hose using the tee fitting (in hardware

box) Attach Power Unit Hose to power side

column extension as seen in Fig 9a.

Connect Power unit hose to tee from Fig 8b

and remove slack from power column hose.

Tighten loose fittings and clamps from

previous step. Serpentine any extra hose

length in overhead.

Fig 9a – Power Unit Hose

23) Thread 9/16-18 O-ring elbow (in hardware box)

into power unit. CAUTION do not damage

rubber O-ring. Attach free end of power unit

hose to elbow. See Fig 9b.

CL10DPC-IOM-A.doc

Model CL10 with Dual Pendant Control

Installation, Operation, and Maintenance

Page 8

Rev. 4/22/11

Fig 9b Power Unit Connection

24) 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.

LOCK RELEASE

DUAL LOCK RELEASE

(TWO LOCK RELEASE CABLES WILL BE ROUTED TOGETHER

THROUGH THE LIFT.ONE CABLE ATTACHES TO THE TOP OF THE

POWER COLUMN LOCK RELEASE CLEVIS AND THE BOTTOM OF

THE IDLER COLUMN LOCK PAWL.THE OTHER CABLE ATTACHES

TO THE TOP OF THE IDLER COLUMN LOCK RELEASE CLEVIS AND

THE BOTTOM OF THE POWER COLUMN LOCK PAWL)

25) Attach Mechanical Lock Release Cable

Assembly to Power Column Lock Pawl using

the 3/16” diameter x 1/2" long pin and (2) “C”

clip retainers found in hardware, Fig 10.

26) Insert threaded sleeve portion of cable

assembly in slot located on tab above locking

pawl, Fig 10. One jam nut should be located

on each side of tab. Position threaded sleeve

with ½” of thread below tab as indicated in

Fig 10 and tighten jam nuts.

27) Route opposite end of cable assembly up

Power Column and into column through

access slot in bottom of Column Extension.

Following the path of the hydraulic hose,

route cable assembly across overhead clear

of moving parts and back out through access

slot in bottom of idler side column extension.

Attach Cable Assembly to the hydraulic hose

with loosely fit wire ties.

NOTE: DO NOT kink cable assembly when

routing. Tighten and trim wire ties after final cable

adjustments have been made

Fig 10 – Power Column Lock Release Assembly

28) Attach Adhesive-Backed Tab to Idler Column

left of the lock assembly (Fig 11). Route

Lock Release Cable down left side of Idler

Column and secure with loosely fit wire tie to

Adhesive-Backed Tab. Attach Cable clevis to

1/2" O.D. Extension Spring.

Fig 11 – Idler Column Lock Release Assembly

29) Insert threaded sleeve portion of cable

assembly in slot located on tab below lock

pawl, Fig 11. With one jam nut located on

each side of tab, adjust the threaded sleeve

CL10DPC-IOM-A.doc

Model CL10 with Dual Pendant Control

Installation, Operation, and Maintenance

Page 9

Rev. 4/22/11

to begin to pull tension on the ½” O.D. spring.

Snug jam nuts by hand.

30) Repeat procedures 24 thru 28 with second

Lock Release Cable routing from top of Idler

Column Lock to bottom of Power Column

Lock, (Figs. 10 & 11).

THE LOCK RELEASE CABLE ADJUSTMENT IS NOT

COMPLETE UNTIL THE LIFT HAS BEEN LOWERED AND

“FINAL ADJUSTMENTS”HAVE BEEN MADE.

ARM INSTALLATION

31) 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.

32) Extend the foot pad to both extents and apply

“anti-seize” to the three retaining rings and

where the double screw makes contact with

the base of the foot pad.

ELECTRICAL

JUNCTION BOX

33) Install Junction Box Assembly to inside of

Power Column with (2) #10-32 x 1/2" lg.

phillips pan head screws and flange nuts,

Fig 12.

Fig 12 – Junction Box Assembly

34) Route junction box pigtail through “T-slot” in

back of Column Extension around to the front

of the Power Unit. Insert plug into mating

receptacle mounted to the bottom of the

motor wiring box. Twist plug collar to lock in

place, Fig 13.

Fig 13 – Junction Box Connection to Power Unit

CL10DPC-IOM-A.doc

Model CL10 with Dual Pendant Control

Installation, Operation, and Maintenance

Page 10

Rev. 4/22/11

OVERHEAD LIMIT SWITCH

IMPORTANT: There are two overall width

settings. Insure to place the limit switch and

shutoff bar in the proper pivot holes as shown in

Fig’s 14a & 14b.

35) Install Overhead Limit Switch to REAR of

Power Column using (1) 3/8” pivot pin, (1)

3/8” flat washer and (1) hairpin cotter pin as

shown below. Switch MUST pivot freely on

pin for proper function. NOTE switch tube

cord is to be oriented above pivot pin as

shown in Fig 14a.

Fig 14a – Overhead Limit Switch Sub-Assembly

PIVOT HOLE FOR

11'-11"

OVER ALL WIDTH

11'-6 1/2"

PIVOT HOLE FOR

(6) 3/8" FLAT WASHERS

HAIRPIN COTTER PIN

Fig 14b – Overhead Limit Switch Sub-Assembly

36) Insert shut-off bar in switch tube on power

column side and take other end to idler side.

Attach shut-off bar to idler column in same

manner as switch tube. Use extra washers

to take up extra pin length.

Insure that both switch tube and shut-off

assemblies pivot freely for proper

operation.

PENDANT SWITCHES

37) Locate the Pendant mounting hole on each

column just below the lock cover on the left

side. Tap hole on both columns 5/16-18NC.

Hang both pendant switches using supplied

1/2” Line Clamp, 5/16-18 x 3/8 Lg. Pan Head

Screw and 5/16” Split Lock Washer (Fig 15).

Position Line Clamp around pendant wire.

Insert screw thru lock washer, free end of

Cable Lanyard, and Line Clamp and secure

to column.

IMPORTANT: RISK OF EXPLOSION.THE PENDANT

CONTROLS HAVE INTERNAL ARCING OR

SPARKING PARTS THAT SHOULD NOT BE

EXPOSED TO FLAMMABLE VAPOR.THE PENDANT

CONTROLS SHOULD BE LOCATED AT LEAST 18

INCHES (460mm) ABOVE THE FLOOR.

Fig 15 – Pendant Switch Installation

38) Route both Pendant Switch cords up the

column and attach with another 1/2” Line

Clamp and a 3/8” bolt that connects the

Column Extension to the Column. Continue

the cord up following the path of the Lock

Release Cable clear of moving parts. Secure

with wire ties.

CL10DPC-IOM-A.doc

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