Challenger Lifts 4018XFX Installation, Operation & Maintenance Manual
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Challenger Lifts 4018XFX Installation, Operation & Maintenance Manual

Challenger Lifts 4018XFX Installation, Operation & Maintenance Manual

Four post surface mounted lift
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Installation, Operation & Maintenance Manual
Four Post
Surface Mounted Lift
 
Model 4018XFX
Closed Front
(18,000 lb Capacity)
2311 South Park Rd Louisville, Kentucky 40219
Email:
Web site:
sales@challengerlifts.com
www.challengerlifts.com
 
/
Office 800-648-5438
502-625-0700 Fax 502-587-1933
IMPORTANT:
READ THIS MANUAL COMPLETELY BEFORE 
INSTALLING or OPERATING LIFT 
Rev. 05/03/2021 

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  • Page 1   Installation, Operation & Maintenance Manual Four Post Surface Mounted Lift   Model 4018XFX Closed Front (18,000 lb Capacity) 2311 South Park Rd Louisville, Kentucky 40219 Email: Web site: sales@challengerlifts.com www.challengerlifts.com   Office 800-648-5438 502-625-0700 Fax 502-587-1933 IMPORTANT: READ THIS MANUAL COMPLETELY BEFORE  INSTALLING or OPERATING LIFT ...
  • Page 2 Owner / Employer Obligations 1. The Owner/Employer shall ensure 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;...

  • Page 3: Important Safety Instructions

    DO NOT ATTEMPT TO OPERATE THIS LIFT IF ANY PART IS NOT WORKING PROPERLY OR YOU HAVE NOT READ THE COMPLETE OPERATING INSTRUCTION MANUAL.   Important Safety Instructions When using this lift, basic safety precautions should always be followed, including the following: 2.
  • Page 4 10. Adequate ventilation should be provided when working on operating internal combustion engines. 11. Keep hair, loose clothing, fingers, and all parts of body away from moving parts. 12. To reduce the risk of electric shock, do not use on wet surfaces or expose to rain. 13.
  • Page 5 24. Always keep the lift area free of obstruction and debris. Grease and oil spills should always be cleaned up immediately. 25. Never raise vehicle with passengers inside. 26. Before lowering check area for any obstructions. 27. Before removing the vehicle from the lift area, position the arms to the drive-thru position to prevent damage to the lift and /or vehicle.

  • Page 6: Safety Warning Labels

    Safety Warning Labels 6   ...

  • Page 7: General Specifications

    SAVE THESE INSTRUCTIONS General Specifications Maximum Capacity 18,000 lb 8165 kg Maximum Wheelbase – General Service 220” 5588 mm Overall Length 303-3/8” 7706 mm Overall Width 152-1/8" 3864 mm Lowered Runway Height 9-1/2" 241 mm Maximum Lifting Height (to runway surface) 72”...
  • Page 8 Installation Requirements & Tools Foundation It is the user’s responsibility to provide a satisfactory installation area for the lift. Lifts should only be installed on level concrete floors with a minimum thickness of six inches (6") or 152 mm. Concrete must have a minimum strength of 4000 psi or 28 MPa and should be aged thirty (30) days prior to installation.
  • Page 9 Contents The lift is packaged to protect it from any damage that may occur during shipping. The two deck assemblies and crossmembers are packaged together with the accessory boxes strapped to them. Main Structural Components: 1 - Left Side Deck Assembly (complete with hydraulic cylinder, sheaves and cables) 1 - Right Side Deck Assembly 1 - Front Crossmember Assembly (with air cylinder release locks and sheaves) 1 - Rear Crossmember Assembly (with air cylinder release locks and sheaves)
  • Page 10 Bay Layout PLEASE TAKE THE TIME TO READ THESE INSTRUCTIONS COMPLETELY. A QUICK CHECK OF THE CONTENTS OF THE ACCESSORY BOX WOULD ALSO DECREASE THE INSTALLATION TIME. 1. Gather the tools and materials required for the installation. 2. Select the location best suited for your lift. NOTE: In determining lift area check for the following: ...
  • Page 11 Typical Bay Layout 11   ...
  • Page 12 Figure 3 – Typical Bay Layout Chalk Line Layout None of the anchors shall be closer than 4-3/4" to any edge of a concrete slab, expansion joint or crack in the garage floor. Review position of front towers, base plates and anchors, and relocate lines "1", "A", "D" if needed.
  • Page 13 Figure 4 – Chalk Line Layout 13   ...
  • Page 14 Identification of Components 1. Identify and unpack major lift components (Towers, Crossmembers & Runways) and place them where they belong according Figure 1. Figure 5. Component Identification 14   ...

  • Page 15: Installation Instructions

    2. Locate and identify the coiled cables as follows, place close to the rear of the left side of the chalk outlines. (Table 2): Cable P/N Location Length 2-1360 Front Left 407.5" Table 2: Cable  2-1361 Front Right 473.5" Identification  2-1362 Rear Left 162"...
  • Page 16 NOTE: THE CYLINDER ROD MUST BE FULLY EXTENDED IN ORDER TO ATTACH THE NON-THREADED ENDS (SLEEVES) OF THE CABLES TO THE CABLE FLANGE ON CYLINDER ROD. USE COMPRESSED AIR IN THE SHOP AND AN AIR NOZZLE AT THE BREATHER END TO EXTEND THE CYLINDER ROD. USE CAUTION AND PROTECTIVE EQUIPMENT WHEN WORKING WITH COMPRESSED AIR.
  • Page 17 9. Referring to Figure 8 and Figure 9, assemble the left side of the pulley stack, as shown, with cables 2-1363 & 2-1360 starting from the bottom of the stack and working to the top.  Assemble lower thrust washer and pulley and reinstall the pulley pin to hold these in place.
  • Page 18 10. Referring to Figure 8 and Figure 10, assemble the right side of the pulley stack, as shown, with cables 2-1362 & 2-1361.  Pass the rear left cable 2-1362 between the two pulleys on the left side (shown above). ...
  • Page 19 11. Use Figure 11 as reference during the front pulley stack and cable assembly. Figure 11. Front Pulley Stack Assembly 12. Remove the pulley pin and hardware from front of runway. 13. Referring to Figure 11 and Figure 12, assemble the pulley stack with cables as shown.
  • Page 20 Assembly of Front & Rear Crossmember 1. Move the front crossmember and rear crossmembers into position. Do not assemble yet. Refer to 2. Figure 5 to identify the front and rear crossmembers. 3. Starting at the front pulley stack assembly, route the front cables thru the window in the front crossmember and out past the safety locks on each side of the crossmember.
  • Page 21 Figure 14. Front Right and Left Cable Installed in Crossmember 6. Using a floor jack or engine hoist, raise the front crossmember up to the level of the decks and attach it using the ½”DIA x 4½”LG hex bolts, ½” flat washers, ½” lock washers and ½”...
  • Page 22 8. Using floor jack(s) and/or engine hoist(s), move the (4) jack stands from under the left side deck to each corner on the crossmember. Figure 16 Figure 16. Jack Stand setup on Crossmembers 9. Assemble right side deck assembly to front and rear crossmembers. 10.
  • Page 23 3. Insert the safety ladder into the top plate hole furthest to back of the column. Keep in place by assembling the 3/4" flat washer and two 5/8" nuts. 4. At the back of the tower, align the holes in safety ladder mounting blocks to the slots on the tower and assemble the 3/8"...
  • Page 24 4. Place the Glide Bearings (located in the accessory box) on the slider block weldments and bolt the slider block weldments back onto the crossmember using the 3/8”-16UNC x 1”LG Hex HD Bolts and 3/8” lock washers removed previously. 5. Pull the towers backwards (away from the decks) so that the slider blocks are contacting the inside of the tower.
  • Page 25 Power Pack Installation NOTE: When working with hydraulic lines and valves, it is important to keep all components clean and free of dirt. Figure 19. Power pack Install 25   ...
  • Page 26   1. Locate Power pack and Filter/Regulator/Lubricator (FRL) assembly inside the accessory box. Gather the 5/16" hardware located in "Polybag D" inside the hardware kit 2. Mount the power pack to the mounting bracket on the front face of the left front post using the 5/16"-18UNC ×...
  • Page 27 Figure 21. Powerpack Install Air Installations NOTE: When cutting polytube, be sure to cut the line at 90 degrees. Failure to do so may result in leaks in the air connections. 1. Locate the 1/4" polytube cross and tee fitting in polybag "C" in hardware kit. 2.
  • Page 28 Figure 22. Air Connections   4. Connect the 3/8” polytube from the hose guard to the 3/8” fitting at the front of the left deck assembly (jacking beam air bracket). Before this can be done, remove the plug and replace with 1/4" NPT - 3/8" polytube straight adapter located in polybag "C"...
  • Page 29 Figure 23. JB Air Connections Figure 24. Air Connections NOTE: For those units equipped with jacking beams, this is the appropriate time to install them. Consult the jacking beam instruction manual found in each jacking beam box. 6. Hook up an air supply to the inlet of the FRL. (Note: customer to supply this fitting) 29 ...
  • Page 30 Electrical Connections CAUTION: ALL ELECTRICAL CONNECTIONS SHOULD BE MADE BY A LICENCED ELECTRICIAN. Refer to Figure 24, Electrical Diagram for electrical connections. Electrical Breaker Size Recommendation: 20Amps Figure 24. Electrical diagram for 230V/1 ph 30   ...
  • Page 31 Filter/Regulator/Lubricator Commissioning   PROCEDURE FOR PREPARING FRL FOR USE WITH LIFT 1. Disconnect shop air from FRL inlet. Adding Oil to the lubricator cannot take place under a pressurized condition. 2. Using a slotted screwdriver or an Allen key, remove the filler cap from the top of the FRL.

  • Page 32: Pressure Adjustment

    5. With the output end of the FRL disconnected (remove the quick disconnect fitting), reconnect the air line to the FRL unit. Air will flow freely through the FRL. 6. Perform Drip Check / Adjustment: Drips to be set to 2-3 per minute. SMC Brand - DIAL VERSION Turn the dial on the top end of the oil reservoir to the 2 position.
  • Page 33 Deck Leveling Procedure   NOTE: MAKE CERTAIN THAT THE MECHANICAL SAFETY LOCKS AND CABLE ROLLERS ARE WORKING PROPERLY.   Note: Read the Operation Label on the powerpack for instructions. LEVELING ON FLOOR 1. Now that all the hydraulic and pneumatic connections are completed, push the up button on the powerpack to raise the lift off the jack stands.
  • Page 34 Leveling on Safety Ladders 1. Repeat the preceding steps until the lift is completely level when supported by the cables. 2. Raise the lift so that the deck is supported by the cables and is not resting on the safety ladders. 3.
  • Page 35 Anchor Installation Check all layout dimensions in the General Specifications in Figure 2 before continuing with anchor installation. 1. Refer to Figure 29 while reading through these instructions. Figure 29. Anchor installation 2. Ensure that the lift is fully supported by the cables and is at a level just above ground.
  • Page 36 NOTE: If anchors do not tighten to required torque, OR project more that 2-1/4" above the concrete surface due to floor slope, contact a foundation engineer to determine the best course of action. Figure 30: Embedment Figure 31: Leveling NOTE: The 3/4”  5 ½” lg. wedge anchor bolts supplied must have a minimum embedment of 3¼”...
  • Page 37 Accessory Installation 1. Install the front wheel stops using the 1/2"-13 UNC × 1"LG hex bolts, 1/2" lock washers and flat washers found in polybag “F” (Wheelstops/Ramps). Figure 32: Front Wheelstops 2. Install the (4) sheave covers over the sheaves in the crossmember assembly. These are found in the accessory box.
  • Page 38 4. Ensure the proper operation of the approach ramps. 5. Cycle the lift several times to check proper operation of the cables, safety locks, air locks, etc. with and without load. STOP IMMEDIATELY IF THE LIFT IS NOT OPERATING PROPERLY! 6.
  • Page 39 Operating Instructions To avoid personal injury and/or property damage, only trained personnel must operate the lift. After reviewing these instructions, get familiar with lift controls, by running the lift through a few cycles before loading vehicle on lift. Read and follow SAFETY and WARNING labels on the lift. 39 ...

  • Page 40: Lift Operation

    LIFT OPERATION Loading: Ensure the lift is fully lowered and all personnel are clear of th service bay while driving he vehicle onto the lift. If the lift is equipped with rolling jacks, jacks must be fully lowered and the rear jack pushed toward center of lift, to provide under-car clearance.
  • Page 41 Fully lower lift, remove the triangular wheel chocks and check to be sure area is clear before removing vehicle from lift. If lift is not operating properly, do not use until adjustment or repairs have been made by qualified lift service personnel. For Rolling Jack operating instructions, see Rolling Jack Installation, Operation and maintenance Instructions in the rolling jack shipping box.
  • Page 42 Safety and Operating Instructions 1. Inspect the lift daily. Do not operate if malfunctions occur or damaged parts have been found. 2. Never attempt to overload the lift. The manufacturer's rated capacity is shown on the serial number tag on the power post. 3.
  • Page 43 Recommended inspection and maintenance Lubrication Specifications Where hydraulic oil is required > ISO 32 10W - non detergent hydraulic oil Where grease is required > multi-purpose lithium grease Where multipurpose lube is required > multi-purpose SAE 30 lubricating oil Where pneumatic oil is required > Snap-On air motor oil IM1PT Where cable lube is required >...
  • Page 44 Chocks, Wheel Stops Anchor Bolts 8.11.2 Turn Tables and Rear Slip 8.13.1 8.13.2 8.13.3 8.13.5 Plates Bearing Cage / Rear Slip 8.13.1 8.13.2 8.13.4 8.13.5 Plates Edges of Cable Flange 8.2.6 Slots Runways 8.10.1 Columns 8.11.1 Air cylinders, Lines, Fittings Hydraulic Power Pack, Hose, Fittings...
  • Page 45 Maintenance Records Maintenance and Training Performed Date Notes 45   ...
  • Page 46 Wire Ropes Wire ropes are critical to safe and reliable performance of your lift. Cables are expendable items and should be replaced as a set. Wire Rope Conditions Guide Typical good cable  Cable with necking  Broken wires  Excessive wear of wires  Rust on sheave stack and ropes  Corrugated sheave groove  46   ...
  • Page 47 Wire Rope Replacement Criteria If any cable is found to be in need of replacement, the entire cable set, pulleys and safety rollers must be replaced immediately.See cable conditions guide. In the following table, "lay" means the distance measured along a line parallel to the axis of the rope in which the strand makes one complete turn about the axis of the rope, or the wires make a complete turn about the axis of the strand.
  • Page 48 Wire Rope Inspection Inspect wire rope cables for wear or damage. Wipe cables with a rag to detect hard to see small broken or frayed cable strands. See chapter 8.2, Fig.15 and ANSI/ALI ALOIM standard. Wire Rope Lubrication Lubricate wire ropes with lift in both lowered and raised position, by spraying them with wire rope lubricant (i.e.
  • Page 49 Fasteners Check all the attaching bolts and nuts for tightness. Note: Air cylinder bolts and nuts should allow movement of the cylinder. Sheaves & Pins   Sheaves and pins are expendable items. Sheaves and pins should be replaced when worn. Use of sheaves and pins with excessive wear will lead to reduced service life of the cables.
  • Page 50 Mechanical Safety Latch (Dog)    Watch and listen to safety latch operation during lift operation, to ensure that latches move as required, have not lost spring preload, and line up with slots in latch plates (safety ladders) in columns. ...
  • Page 51 Air Lubricator Oil Level  Refill oil reservoir using instructions above before the oil level reaches the MIN OIL line on the reservoir.  Recheck drip rate after refilling.  Check pressure is adjusted to 100 psi.  The FRL unit is autodraining. However, you can drain the water trap filter bowl by pressing valve at the bottom of the bowl until all water has drained.
  • Page 52 Runways Check Runways  Check level of runways on the floor, on the locks and on the cables: Refer to Section 6.10. Adjust as required.  Check runways for damage or abnormal deformation. If such conditions exist, contact Snap-on Equipment Technical Support. Inspect Jack beam Tracks ...
  • Page 53 Approach Ramps, Chocks, Front Wheel Stops  Inspect for excessive wear or damage. Repair or replace if required.  Inspect hinge pins. Replace if excessively worn. Lubricate if in good condition Front and Rear Turn/Slip Plates Visual Inspection  Check front turn tables and rear slip plates for unusual deflection, damage, fluid spills.
  • Page 54 Rolling Air Jacks  Lubricate roller bearings and roller guide springs.  Dismantle and clean lift arms.  Clean and lubricate rollers/sliders and hinge points.  Clean and lubricate safety mechanism.  Change hydraulic oil every two years Entire Lift ...

  • Page 55: Shutdown Procedure

    Effective hazardous energy control procedures will protect employees during machine and equipment servicing and maintenance where the unexpected energization, start up or release of stored energy could occur and cause injury, as well as while working on or near exposed de-energized electrical conductors and parts of electrical equipment. Hazards being guard against include being caught in, being crushed by, being struck by, being thrown from, or contacting live electrical circuits/parts.
  • Page 56 Isolation and Verification Procedure: Table 1: ISOLATION AND VERIFICATION PROCEDURES: LOCKOUT LOCATION ENERGY TYPE PROCEDURE FOR LOCING OUT AND OR VERIFY PROCEDURES (TO BE AND SOURCE RELEASING ENERGIES COMPLETED BY END USER) VERIFY THAT THE LIFT IS CONTACTING THE SUPPLEMENTARY JACK STANDS, THE BLOCKS ARE SECURLY PLACED AND THE COME ALONG IS SECURED BETWEEN THE SCISSORS.

  • Page 57: Returning To Service

    RETURNING TO SERVICE:  Check the lift and the immediate area around the lift to ensure that nonessential items,, tools and parts are removed and that the lift components are operationally intact.  Check the work area to ensure that all employees have been safely positioned or removed from the work area.
  • Page 58 IF THE MECHANICAL LOCKS ARE NOT ENGAGED: 1) If there is air pressure in the pneumatic system; have another person press and hold the mechanical safety release button to disengage the mechanical locks. Confirm that all mechanical locks have been disengaged and will allow the lift to lower.

  • Page 59: Parts List

    Parts List Lift Assembly 59   ...
  • Page 60 Parts List – Lift Assembly   REPLACE WORN, DAMAGED OR BROKEN PARTS WITH PARTS APPROVED BY THE ORIGINAL EQUIPMENT MANUFACTURER ONLY Item# Part # Description Qty. 4-1457 POWER TOWER (FL) ASSY 4-0657-3 FRONT CROSSMEMBER ASS'Y 4-0656-3GS GENERAL SERVICE DECK ASSEMBLY, LS 4-0659-3GS GENERAL SERVICE DECK ASSEMBLY, RS 4-0658-3...
  • Page 61 Tower Assembly 61   ...
  • Page 62 Parts List – Power Tower Assembly Item# Part # Description Qty. 4-1449 TOWER WELDM'T, POWER 4-1450 TOWER WELDM'T, SLAVE 2-3026 TOP PLATE - FLAMECUT 3-0581 SAFETY RACK WELDMENT 6-1401 FLAT WASHER 5/8" 6-0673 5/8" HEX NUT, GRADE 8 6-0625 3/8 ID WASHER REG PLT USS 6-0058 LOCK WASHER, 3/8"...
  • Page 63 Deck Assembly (Left Side) 63   ...
  • Page 64 Parts List – Deck Assembly (Left Side) Item# Part # Description Qty. 4-0629GS GENERAL SERVICE DECK WELDMENT LS 2-1355 DECK SHEAVE PIN 3-0681 HYDRAULIC CYLINDER ASSEMBLY 6-0248 Flat Washer, ½ID SAE 6-0044 Hex HD Bolt, 1/2" x 1/2" 1-1747 CYLINDER SLING 6-0058 LOCK WASHER, 3/8"...
  • Page 65 Crossmember Assembly 65   ...
  • Page 66 Parts List – Crossmember Assembly Item# Part # Description Qty. 4-0627 FRONT CROSSMEMBER WELDMENT 1-1744 LOCK SAFETY PIN WELDMENT 2-1424 SAFETY LOCK WELDMENT 6-0801 SHOULDER BOLT , 3/8x 1 ½LG. 6-0069 Shoulder Bolt, 3/8DIA. X 5/8LG. 1-0786 SHEAVE SPACER 1-1712 AIR CYLINDER BRACKET 6-0651 AIR CYLINDER...
  • Page 67 Cylinder Assembly 67   ...
  • Page 68 Parts List – Cylinder Assembly ITEM QTY. DESCRIPTION PART # CYLINDER TUBE WELDMENT 4” BORE 2-1345 PISTON ROD - MACHINED 2-1340 ORING, 4”OD x 1/8”C/S 6-1633 BACKUP RING 6-1634 GLAND 3-0673 ROD SEAL, 1½”ID x 1 7/8”OD x 1/4” 6-1892 ROD WIPER, 1½”ID x 1 7/8”OD x 3/16”...
  • Page 69 Hydraulic And Air Kit 69   ...
  • Page 70 Parts List – Hydraulic And Air Kit ITEM QTY. DESCRIPTION PART # 90° ELBOW, 1/8" NPT x 1/4" POLYTUBE 6-0709 AIR CYLINDER 6-0651 10FT 1/4" DIA. POLY TUBE 6-1396 ADAPTER, 3/8" POLY TUBE x 1/4" NPT 6-0710 TERMINAL BOLT, 3/4" 6-0713 1/4"...
  • Page 71 Filter / Regulator / Lubricator Assembly Complete Assembly: 2-3005 ITEM QTY DESCRIPTION PART # MOUNTING BRACKET, FRL 2-3022 DECAL, SAFETY RELEASE 6-3558 DECAL, OIL LEVER 6-3696 FRL ASSEMBLY W/ RELEASE BUTTON, contains: 2-3021 FILTER/REGULATOR/LUBRICATOR ASS'Y 6-4142_FM 90 DEG. ELBOW, 1/4"NPT M - 3/8" POLY 6-3010 AIR VALVE &...
  • Page 72 Cable Routing 72   ...
  • Page 73 Parts List – Cable Routing ITEM QTY. DESCRIPTION PART # CABLE ASSY. 407.5” - FRONT LEFT 2-1360 CABLE ASSY. 473.5” - FRONT RIGHT 2-1361 CABLE ASSY. 162” - REAR LEFT 2-1362 CABLE ASSY. 228” - REAR RIGHT 2-1363 HEX NUT, 7/8”-14UNF GR5 6-0724 CABLE SPACER, 2”LG 1-0800...
  • Page 74 Power Pack Assembly 74   ...
  • Page 75 Parts List – Power Pack ITEM QTY. DESCRIPTION PART # MICROSWITCH AND WIRING ASSEMBLY, 1PH 6-0881 MICROSWITCH BOOT 6-1084 MOTOR, 230V AC, 1 PHASE, 60 HERTZ 3HP 6-1959 MOTOR ADAPTER KIT 0-0197 SOCKET HD.CAP SCW. 1/4"-20UNC X 1 5/8"LG. 6-1085 LOCK WASHER, 1/4"I.D.

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