Challenger Lifts BT3300 Instruction manual

Rev 22-03-17

Installation, Operation & Maintenance Manual

Battery Lift

MODEL: BT3300

1500 KG / 3300 LBS. CAPACITY

IMPORTANT:

READ THIS MANUAL COMPLETELY

BEFORE

INSTALLING OR OPERATING LIFT

2311 South Park Road, Louisville, KY 40219

Email:

[email protected]

Website:

www.challengerlifts.com

Office 800-648-5438 / 502-625-0700

Fax 502-587-1933

Battery Lift

Installation, Operation and Maintenance

TABLE OF CONTENTS

1.0 OWNER / EMPLOYER OBLIGATIONS.............................................................................................. 2

2.0 IMPORTANT SAFETY INSTRUCTIONS ............................................................................................. 3

3.0 SAFETY WARNING DECALS ............................................................................................................ 5

4.0 GENERAL SPECIFICATIONS............................................................................................................. 6

5.0 TOOLS REQUIRED FOR INSTALLATION OF LIFT .............................................................................. 7

6.0 RECEIVING..................................................................................................................................... 8

7.0 INSTALLATION AND OPERATION INSTRUCTIONS........................................................................... 8

7.1 INSTALLATION INSTRUCTIONS......................................................................................................... 8

7.2 OPERATION INSTRUCTIONS .......................................................................................................... 12

7.2.1 PALLET JACK........................................................................................................................ 12

7.2.2 FLEXIBLE LIFTING PLATFORM ............................................................................................. 12

7.2.3 CONTROL SYSTEM DESCRIPTIONS...................................................................................... 15

7.2.4 CONTROL BUTTON DESCRIPTIONS..................................................................................... 16

7.2.5 CONSOLE RELATED DESCRIPTIONS..................................................................................... 16

7.2.6 HYDRAULIC PRINCIPLE ....................................................................................................... 17

7.3 OWNER/OPERATOR CHECKLIST..................................................................................................... 18

8.0 OPERATION PROCEDURE............................................................................................................. 19

8.1 SAFETY NOTICES AND DECALS ...................................................................................................... 19

8.2 OWNER/EMPLOYER RESPONSIBILITIES .........................................................................................19

8.3 IMPORTANT SAFETY INSTRUCTIONS ............................................................................................. 19

8.4 LIFTING A BATTERY........................................................................................................................ 20

8.5 LOWERING A BATTERY .................................................................................................................. 20

9.0 RECOMMENDED MAINTENANCE................................................................................................ 21

10.0 EMERGENCY OPERATION ............................................................................................................ 22

11.0 TROUBLESHOOTING.................................................................................................................... 23

12.0 ORD OF MAINTENANCE/TRAINING............................................................................................. 24

13.0 BATTERY LIFT ASSEMBLY ............................................................................................................. 25

13.1 LIFT ASSEMBLY ............................................................................................................................ 25

13.2 BASE FRAME ASSEMBLY .............................................................................................................. 27

13.3 SCISSOR ASSEMBLY ..................................................................................................................... 28

13.4 PLATFORM ASSEMBLY ................................................................................................................. 29

13.5 CONSOLE BOX ASSEMBLY............................................................................................................ 31

Battery Lift

Installation, Operation and Maintenance

1.0 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; ASME PASE-2019, Safety Standard for

Portable Automotive Service Equipment;National Standard for Automotive Lifts - Safety Requirements

for Operation, Inspection and Maintenance.

2. The Owner/Employer shall establish procedures to periodically inspect the lift in accordance with the lift

manufacturer’s instructions and ASME PASE-2019, Safety Standard for Portable Automotive Service

Equipment; National Standard for Automotive Lifts - Safety Requirements for Operation, Inspection and

Maintenance; and the Employer shall ensure that the lift inspectors are qualified and that they are adequately

trained in the inspection of the lift.

3. The Owner/Employer shall establish procedures to periodically maintain the lift in accordance with the lift

manufacturer’s instructions and ASME PASE-2019, Safety Standard for Portable Automotive Service

Equipment;National Standard for Automotive Lifts - Safety Requirements for Operation, Inspection and

Maintenance; and the Employer shall ensure that the lift maintenance personnel are qualified and that they are

adequately trained in the maintenance of the lift.

4. The Owner/Employer shall maintain the periodic inspection and maintenance records recommended by the lift

manufacturer’s instructions and ASME PASE-2019, Safety Standard for Portable Automotive Service

Equipment;National Standard for Automotive Lifts - Safety Requirements for Operation, Inspection and

Maintenance.

5. The Owner/Employer shall display the lift manufacturer’s operating instructions; ASME PASE-2019, Safety

Standard for Portable Automotive Service Equipment;National Standard for Automotive Lifts - Safety

Requirements for Operation, Inspection and Maintenance.

6. The Owner/Operator shall provide necessary lockout/tagout means for energy sources per ANSI Z244.1-1982

(R1993), Safety Requirements for the Lockout/Tagout of Energy Sources, before beginning any lift repairs

and maintenance.

Battery Lift

Installation, Operation and Maintenance

2.0 IMPORTANT SAFETY INSTRUCTIONS

1. When using this lift, basic safety precautions should always be followed, including the following (where

applicable).

2. Read all instructions in this manual and literature provided with lift thoroughly before installing, operating,

servicing or maintaining the lift.

3. Care must be taken as burns can occur from touching hot parts.

4. Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged – until it

has been examined by a qualified service person.

5. Do not let a cord hang over the edge of the table, bench, or counter or come in contact with hot manifolds or

moving fan blades.

6. If an extension cord is necessary, a cord with a current rating equal to or more than that of the equipment

should be used. Cords rated for less current than the equipment may overheat. Care should be taken to

arrange the cord so that it will not be tripped over or pulled.

7. Always unplug equipment from electrical outlets when not in use. Never use the cord to pull the plug from the

outlet. Grasp plug and pull to disconnect.

8. Let equipment cool completely before putting away. Loop cord loosely around equipment when storing.

9. To reduce the risk of fire, do not operate equipment in the vicinity of open containers of flammable liquids

(gasoline).

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 wet surfaces or exposure to rain.

13. Use only as described in this manual. Use only the manufacturer’s recommended attachments.

14. ALWAYS WEAR SAFETY GLASSES. Everyday eyeglasses only have impact-resistant lenses, they are not

safety glasses.

15. Inspect lift daily. Do not operate if it malfunctions or problems have been encountered.

16. Never attempt to overload the lift. Do not override the operating controls or the warranty will be void.

17. Only trained and authorized personnel should operate the lift. Do not allow customers or bystanders to operate

the lift or be in the lift area.

Battery Lift

Installation, Operation and Maintenance

18. Caution! Never work under the lift.

19. Always keep the lift area free of obstruction and debris. Grease and oil spills should always be cleaned up

immediately.

20. Before lowering check area for any obstructions.

21. Do not remove hydraulic fittings while under pressure.

For additional safety instructions regarding lifting, lift types, warning labels, preparing to lift, load spotting, load lifting,

maintaining load stability, emergency procedures, load lowering, lift limitations, lift maintenance, good shop practices,

installation, operator training and owner/employer responsibilities, please refer to “Lifting It Right” (PASE) and

“Safety Tips” (PASE).

For additional instruction on general requirements for lift operation, please refer to “Automotive Lift-Safety

Requirements for Operation, Inspection and Maintenance” (PASE).

Installation shall be performed in accordance with PASE, Safety Requirements for Installation and Service of

Automotive Lifts.

ATTENTION! This lift is intended for indoor use only. It is prohibited to use this

product outdoors. The operating environment temperature range should be 41

– 104 °F (5 – 40 °C). Failure to adhere will result in certification, loss of

warranty, and possible damage to the equipment.

SAVE THESE INSTRUCTIONS

Note: Some images in this manual are generic and may not reassemble the lift you have purchased.

Battery Lift

Installation, Operation and Maintenance

3.0

SAFETY

WARNING

DECALS

All safety warning labels are depicted on the lift to ensure that the operator is aware of and avoids the dangers of using the

lift incorrectly. The labels must be kept clean, and they have to be replaced if detached or damaged. Please read carefully

the meaning of each label and memorize them for future operation.

The instructions, cautions and warnings written above cannot cover all possible conditions and situations that may

occur. The common sense for safety must always be in the operator’s mind. The manufacturer or its distributors

are excluded from damage caused through willful misconduct or gross negligence.

Battery Lift

Installation, Operation and Maintenance

4.0 GENERAL SPECIFICATIONS

Lifting Capacity 1500kg (3300lbs)

Lift Height [C]

Rise Height 1950mm (76.77")

Collapsed Height 750mm (29.53")

Platform Adjust Height [S] 45mm (1.77")

Platform Length [A] 1741-2066mm (68.54“-81.34")

Platform Width [E] 800mm (31.50")

Platform Height [B] 229 ±45 mm (9.02" ±1.77")

Deck Length [D] 1500mm (59.06")

Base Height [F] 205mm (8.07")

Wheel Diameter [G] Ø200mm (7.87")

Overall length [H] 2956mm (116.38")

Overall, Weight 750kg (1654lbs)

Motor 1.5 kW

Power supply 110VAC-1Ph-60Hz

Control voltage 24VAC

Hydraulic Pressure 25MPa (3626psi)

Hydraulic Oil Capacity Tank size: 4L (1 gal)

Hydraulic Oil Type ISO 32 (3L) hydraulic oil

Full stoke time (Rated Load) 45s

Full decent time (Rated Load) 55s

Shipping Weight 850 kg (1900 lbs.)

Lift capacity ratings are based on loads equally distributed.

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

Battery Lift

Installation, Operation and Maintenance

Fig.4.1 General Specification

5.0

TOOLS

REQUIRED

FOR

INSTALLATION

LIFT

Self-Leveling Laser Level

SAE Wrenches and Sockets

10" Adjustable Wrench

2 lb. Hammer

Side Cutters

Screw Drivers

Funnel

Utility Knife

Needle Nose Pliers

A set of Allen wrenches (metric)

Recommended:

Impact Wrench

Engine Crane/Hoist

8’ Sling

Battery Lift

Installation, Operation and Maintenance

6.0

RECEIVING

The shipment should be thoroughly inspected as soon as it is received. The signed bill of lading is

acknowledged 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 protection.

7.0 INSTALLATION

AND

OPERATION

INSTRUCTIONS

When the lift arrives on-site, please read the owner’s installation and operation manual completely. Check

the contents to make sure no parts are missing before starting installation. Gather all of the tools listed and

make sure that the instructions are fully understood before starting the installation.

7.1

INSTALLATION

INSTRUCTIONS

After the preparations are done, please complete the simple installation according to the following steps:

A. Open the package and check if the accessories are complete.

The items in the shipping box include (Fig.7.1.1)

①

1 pc. Main structure

②

1 pc. Pallet Jack connecting bracket weldment

③

1 pc. Pallet Jack (includes bolts and nuts)

④

1 pc. Rear Handle (Including pins

）

⑤

1 pc. Power connection plug

⑥

1 pc. Control handle

⑦

4 pcs. Clamp bracket assembly

⑧

1 pc. Service manual

Fig.7.1.1 The Items in The Shipping Box

Battery Lift

Installation, Operation and Maintenance

B. Hoist the main structure of the machine onto the flat ground.

C. Remove the packing belts. (Fig.7.1.2).

Fig.7.1.2 Packing Belts Position

D. Remove the Wire Ties at the limit switch (Fig.7.1.3).

Fig.7.1.3 Wire Ties Position

E. Install the Pallet Jack and its Bracket Weldment

The Pallet Jack and its bracket weldment are installed to increase the mobility of this machine. It is best to install

them before operation. The installation steps are as follows:

a) As shown in Figure 7.1.4, assemble Part 2 with Part 1 through bolts and nuts A.

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