Challenger Lifts 4030SFX Manual de instrucciones

Rev. 5/22/19

Installation, Operation & Maintenance Manual

Four Post

Surface Mounted Lift

Model 4030

(30,000 lb Capacity)

2311 South Park Rd, Louisville, Kentucky 40219

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 4030

Installation, Operation and Maintenance

2 Rev. 5/22/2019

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GENERAL SPECIFICATIONS MODEL:4030[EOR X] [AOR F] [OOR X]

[LENGTH)][ALIGN OR FLAT DECK][OPEN OR CLOSED FRONT]

SPECIFICATIONS 4030SFX 4030EFX 4030XFX 4030SAX 4030EAX 4030XAX

ALength Overall 308” 344” 380” 308” 344” 380”

BWidth Overall 172.75”

CInside Columns 152”

DBetween Columns 246” 282.5” 318.5” 246.5” 282.5” 318.5”

EHeight of Columns 92.25”

FHeight of Runways 8.5”

GWidth of Runways 24"

HWidth Between Runways 46” & 52"

IMaximum Wheelbase * 244.5”281”317”244.5”281”317”

JRise Height 71.75"

KMax. 2 Wheel Alignment N/A N/A N/A 219.5" 256" 292

Lifting Capacity

(Hydraulic Pressure at Cap.) 30,000 lbs.

(2190 psi)

Air Supply Required 90-120 psi Clean & Dry

Motor 3HP

Voltage (Single Phase Std.) 230v

Rise Time 126 Seconds (approximate)

Min. Recommended Bay Size 28' x 17' 31' x 17' 34' x 17' 28' x 17' 31' x 17' 34' x 17'

* Maximum wheelbase is based on a tire diameter of 30”

383

' MIN. TO NEAREST

BSTRUCTION FOR

N-ALIGNMENT LIFTS

FRONT

REAR

DRIVE O

IDLER RUNWAY

POWER RUNWAY

13"

BASE PLAT

13"

DIAGONALS TO BE WITHIN 1/4"

EKI

23"101

POWER UNIT

OPTIONAL POWER UNIT LOCATION

SEE NOTE

NOTE: IF USING THIS LIFT IN CONJUNCTION WITH AN ALIGNMENT SYSTEM, CONSULT ALIGNER'S

MANUAL FOR MANUFACTURER'S MINIMUM RECOMMENDED DISTANCE TO FRONT TURN PLATE AND

ADJUST THIS DIMENSION ACCORDINGLY.

Fig 1 – General Specifications and Service Bay Layout

Model 4030

Installation, Operation and Maintenance

Rev. 5/22/2019

4030-IOM-A.doc

ERTICAL

LEARANCE

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.

LOORING

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. This lift is designed to accommodate a 3-

inch total variation in elevation at the base of the four

posts. Floor should be level within 1/2 inch from side-

to-side and 2 1/2 front-to-rear to avoid special

shimming. 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.

OCATION

This lift has been evaluated for indoor use only with

an operating ambient temp. range of 5 – 40°C

(41-104°F)

LECTRICAL

EQUIREMENTS

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.

EQUIREMENTS

This lift is equipped with an air operated lock release

system. The air supplied to the lift must be clean,

dry, lubricated, and regulated to 90-120 psi, FRL

(Filter/Regulator/Lubricator). The FRL must be within

30 feet of lift. Failure to provide clean, dry,

lubricated, and pressure regulated air will void

warranty on pneumatic components.

AFETY

OTICES AND

ECALS

For your safety, and the safety of others, read and

understand all of the safety notices and decals

included here.

EAD ENTIRE MANUAL BEFORE ASSEMBLING

INSTALLING

OPERATING

OR SERVICING THIS

EQUIPMENT

ROPER MAINTENANCE AND INSPECTION IS

NECESSARY FOR SAFE OPERATION

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 Power

Unit reservoir. 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 4030

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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

DAMAGEAFTERYOUHAVEGIVENTHECARRIER

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.

Fig 2 – Package Components

Component Packing List

ITEM # PART # QTY/LIFT DESCRIPTION

1 9430-2000 1 POWER COLUMN ASSEMBLY

2 9430-1000 3 IDLER COLUMN ASSEMBLY

3 9430-4000 1 REAR CROSSBEAM

4 9430-3000 1 FRONT CROSSBEAM

5 9430-0306 2 RAMP ASSEMBLY

6 7430-0367 2 FRONT WHEEL STOP

7 7430-0506 2 WHEEL CHOCK

8 AB-100157 1 POWER UNIT

9 9430-0308 1 POWER RUNWAY ASSEMBLY

10 8430-0334 1 IDLE RUNWAY ASSEMBLY

11 8430-0334 1 IDLE RUNWAY ASSEMBLY

INSTALLATION

SAFETY REQUIREMENTS FOR INSTALLATION AND

SERVICE

Refer to ANSI/ALI ALIS (current edition)

IMPORTANT:Always wear safety glasses while installing lift.

TOOLS (MINIMUM REQUIRED)

a. Tape measure, 50ft

b. Chalk line

c. 4ft level

d. 2 adjustable wrench to 1-5/8"

e. Standard open end wrenches 3/8”, 7/16”, 1/2",

9/16”, 5/8”, (2) 11/16”, 3/4", 15/16”, 1-5/16"

f. 3.5 hex key wrench

g. Box knife

h. Thread locking compound non-permanent

i. Thread tape sealant (for air line)

j. Needle nose pliers

k. Hammer drill with 3/4” diameter carbide tipped

bits

l. 2lb hammer

m. Torque wrench: 110 foot-pounds minimum with 1

1/8” socket

n. 8 ft. Step ladder

o. Blocking – (4) 4x4x30”

p. Transit for leveling alignment lift

q. 1 Vice grip

LAYOUT

1) Lay out the service bay according to the

architect’s plans or owners instructions (see Fig

1). Be certain that the proper conditions exist, see

page 3.

2) Unpack lift. Remove all packaging from Power

Runway (power runway has four cable sheaves

at rear end and two at front). Make sure the

cables are in the proper sheaves at both ends of

the runway, Figs 3 & 4.

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Fig 3 – Power Runway 4-Stack (rear view)

Fig 4 – Power Runway 2-Stack (front view)

3) Position runways on blocking, see Fig 5, per

layout lines established in step 1. Use four 30”

long 4x4’s spanning the width of the runway.

Cables #3 and #4 should be extending out from

the rear of the power runway and cables #1 and

#2 from the front of the power runway, Fig 5.

4) Position the front and rear cross beams, Fig 5.

5) Feed Cable #3 through the cross beam, Figs 5 &

6. Note: The Slack Cable Latch springs must be

removed, but the Cross Beam Sheaves do not.

Feed cable thru above air cylinder and then on to

the sheave, see Fig 6.

6) Repeat for remaining cables ensuring that cable

#4 is on top of cable #3 and #2 is on top of #1.

Fig 5 – Runway Layout

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Fig 6 - Cross Rail Assembly

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7) Attach both cross beams to the runways (Fig.

4) using 3/4"-16,2.5" Length Steel Hex Cap

Screws, ZC-PLTD, a 3/4" screw size washer

on the bolt head side, and nut side. secure

with a 3/4"-16 GRADE 8 STEEL NYLON-

INSERT LOCKNUT. Position the power

runway on top of the cross rail and align the

slots with the holes. The idler runway can be

installed using the outer or inner sets of cross

beam holes, see “Width Between Runways”

dimension in Fig. 1. Do not torque bolts yet.

8) Check the layout of the lift in the bay. (This is

the last opportunity to reposition the lift.)

Adjust the position of the runways so the

distance from power side jack rail to idler side

jack rail is the same at the front and the rear

and the diagonal measurements from the front

tip of one rail to rear tip of the opposite rail are

within 1/4”, Fig 7.

DIAGONALS TO BE WITHIN 1/4"

SIDE TO SIDE TO BE IDENTICAL

Fig 7 – Final Runway Positioning

9) Center cross beam bolts with slots in runway

and tighten. (Be careful not to move runways.)

10) Bolt the runways as shown in Figure I. Repeat

for all 8x places. and Bolt the Ramps as

shown on Figure J

COLUMNS

11) Stand up a column assembly near each

corner of the lift (column with power unit

bracket goes at the 2-sheave-stack corner)

{see page 2 Measure from the bottom of the

ladder, to the top of the column base plate,

Adjust the ladder so the bottom of the ladder,

to the top of the column base plate is 12

inches.

12) Slidepowersidecolumn onto cross beamuntil

the 1/2"-13 threaded holes in the side of the

beam are just exposed. Position slide blocks

as shown in Fig 8 and Fig 9 and attach with

1/2"-13, 0.75" Length steel cap screw, ZC-

PLTD, GR-8 bolts (apply thread

nonpermanent locking compound before

installing).

Fig 8 – Slide Block Installation

13) Push the column against the slide blocks, Fig

9. Measure from the column to the edge of the

rub block bracket. the dimension should be 4-

5/8".

Fig 9 – Column Positioning

14) Repeat for remaining three columns.

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ANCHORING

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

from any crack, edge, or expansion joint. Also,

at least 16” from any other lifts hole.

16) 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.

17) 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.

18) Vacuum dust from the hole for proper holding

power.

19) Shim columns to plumb using the shims

provided or steel washers. DO NOT shim

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

no less than 24” in length to vertically plumb

columns.

20) Assemble washer and nut to anchor with nut

just below impact section of bolt. Drive anchor

into hole until nut and washer contact base.

Tighten anchor bolts and recheck column for

plumb. Re-shim as required.

21) Torque to 110 foot-pounds to set anchors.

NOTE: Level bubble should not only be

between the lines; the bubble should be

centered between the lines. If the provided

shims do not allow sufficient centering of the

bubble, it is best to lean the rear columns in

the direction toward each other and the front

columns in the direction toward each other.

22) Install the four cable ends with one flat

washer, one load nut, and one jam nut. See

Item's 21, 22, & 23 on page 15. Pull the

cables, on until the tension of the cables

overpowers the springs on the cross beam

(disengages the locks). The Slack device

pulley mechanism should be vertical, as

shown on figure 5. The cables need to be

inserted on the top hole of the column. Ensure

the cable is aligned with the cross beam

sheaves. (Do not put tension on the slack

device if it is setting on the locks to avoid

damage).

23) Install the power unit and the air button valve

assembly on the power column, Fig 10.

Fig 10 – Air Button & Power Unit Mounting

24) Install O-Ring end of 90-degree hydraulic

elbow & pipe (6801-LL-06-06 ELBOW

{pressure port} & 4550K152 0.375 DIA X 1.50

SCH 80 PIPE MNPT X MNPT) (May need to

remove plug on the power unit return port to

install part 4550K152) to power unit. The

hydraulic hose is pre-installed to the hydraulic

cylinder and secured inside the runway. Pull

loose end out through the gap between

runway and cable retaining bar. (Figure G.)

Pull hoses through the hole on the cross

beams. Attach a 2500-06-06, 90 degree

fittings on each hose, then connect hose

1034-0003 on each of the 90-degree fitting

done previously. Connect the hose line

closest to the cylinder rod (The longest hose

{PRESSURE LINE}) to the 6801-LL-06-06

fitting on the power unit. Connect 2502-06-06

3/8 MJIC X 3/8 FNPT 90 ELL to the pipe on

the power unit 4550K162. Connect the hose

line closest to the cylinder clevis (shortest

hose {RETURN LINE}) to the elbow (2502-06-

06) previously connected to the pipe Do Not

Use Teflon Tape or Pipe Dope on fittings.

25) Have a certified electrician connect the power

unit to a suitable electrical power source as

shown in Fig 15.

Model 4030

Installation, Operation and Maintenance

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(Normally Open)

FOR SINGLE PHASE

FIELD

CONECTIONS

Wiring Diagram

Fig 15 – Electrical Wiring Diagram

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 6.3 gallons of clean 10wt anti-foam

anti-rust hydraulic oil or Dexron III ATF. DO

NOT USE OILS WITH DETERGENTS.

27) Energize the power unit and raise the lift

approximately 1-ft off the ground and look

underneath the power runway to verify that the

cable lugs are resting firmly against the cylinder

pull bar.

28) For flat deck style runways, level the runways

and crossbeams using a 4 ft. level. With the lift

resting in its locks, find the highest corner and

adjust the other three column ladder bars until

the runways are level front-to-rear and side-to-

side. Tighten jam nut against bottom side of

each column top plate. For alignment style

runways, use a transit for leveling runways

placing the target in the center of the turn plate

(with lift lowered into locks, adjusting the lock

ladders as needed). Refer to alignment

equipment for leveling tolerance.

29) Install 5/32” air line from air valve assembly thru

opening in runway to Tee. Fig 11 & F

30) Route power side front and rear cross beam air

lines through power runway (See Figure G) to

Tee with 5/32" airline provided. Use welded

rings inside the power runway to secure air

lines. Insert 5/32" air line through the tubing in

front of the crossbeams Fig 12

31) See Figure F. Connect 6534K46 to an air

supply. Air supply must be clean, dry,

lubricated, and regulated to 90-120 psi. The

FRL, must be within 30 feet of valve. Failure to

provide clean, dry, lubricated, and pressure

regulated air will void warranty on

pneumatic components.

32) While hanging on the cables energize air valve

assembly and insure that all air cylinders are

working properly.

33) Adjust cables until all four locks are

synchronized when lift is raised. Tighten cable

jam nuts against adjustment nuts.

Fig 11 – Lock Release Air Line Routing

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Fig 12 – 5/32 Air Line Connection

34) Clamp the airlines and hydraulic hoses with

bracket, as shown. See Figure H. Add

Abrasion-Resistant Sleeve. (55545K86) to

protect the hoses and airline.

35) Install Grease Fittings. 6 fittings in total. 2 on

each cross beam pins. and 2 fittings on the

runway pins. See figure C & D

36) Raise and lower lift several times to bleed

hydraulic cylinder. Hydraulic cylinder is self-

bleeding. Lower lift and check fluid level in

reservoir. Add fluid as needed.

37) Run lift to full rise and continue running motor

approximately 5 more seconds. Check

hydraulic hose and connections for leaks. Re-

tighten fitting if leaking.

38) Raise lift approximately half way. Slowly jog

power unit until you hear one of the locks

engage. Adjust locking ladder until it just barely

raises the crossbeam end. Back off 1/2 turn.

Repeat for each column.

COLUMN DECAL PLACEMENT

39) Center the decal on the front drivers side

column and rear passenger side column.

40) Apply decal 4” from top of columns, Fig 13.

Fig 13 – Decal Placement

ALIGNMENT RUNWAYS

41) Lower lift and raise to check for lock

engagement. The locks should engage

simultaneously (clicking noise). Re-adjust

cables as needed to synchronize locks.

42) Position Front Turn Plates (SOLD

SEPARATELY) and install TURN TABLE

STOPS (ITEM 1 PART NUMBER ALIG-430-

029-XX) to runway using (8, ITEM 2) #10-24 x

0.75” Socket Head Cap Screws. Ensure that the

Turn Plates will slide freely and tighten Guide

Bars. Reference Fig 14 and Fig L

Fig 14 – Alignment Turn Plate Installation

FINAL CHECKOUT PROCEDURE

43) Demonstrate the operation of the lift to the

owner/operator/employer using a typical

vehicle and review correct and safe lifting

procedures using the Lifting It Right booklet

as a guide.

44) Return all provided literature (including this

manual) to the literature pack envelope and

deliver the envelope to the

owner/operator/employer.

45) Complete the online warranty registration

(refer to the included warranty statement).

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