4 Post

INSTALLATION, OPERATION
& MAINTENANCE MANUAL

Four Post
Surface Mounted Lift
Model 40000
Closed Front
(12,000 lb Capacity)
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
Rev. 7/5/05
40010.doc
Model 40000 Closed Front
Installation, Operation and Maintenance
GENERAL SPECIFICATIONS MODEL: 40 [E OR X] [A OR F] [O OR X]

[LENGTH)] [ALIGN OR FLAT DECK] [OPEN OR CLOSED FRONT]
SPECIFICATIONS 40NFX 40SFX 40EFX 40XFX 40EAX 40XAX
A Length Overall 18' 3 1/2" 18' 3 1/2" 20' 4 1/2" 22' 8” 20' 4 1/2" 22' 8”
B Width Overall 10’ 3/4” 10’ 10 3/4”
C Inside Columns 106" 116"
D Between Columns 14’ 3” 14’ 3” 16’ 4” 18’ 7½” 16’ 4” 18’ 7½”
E Height of Columns 90 1/2"
F Height of Runways 7"
G Width of Runways 20"
H Width Between Runways 40 or 43"
I Maximum Wheelbase * 157 1/2" 157 1/2" 182 1/2" 210" 182 1/2" 210"
J Max. 2 Wheel Alignment N/A 166 1/2" 194"
K 4 Wheel Alignment N/A 88" - 158"
L Rise Height 78"
Lifting Capacity 12,000 lbs.
Air Supply Required 85-115 psi Clean & Dry
Motor 2HP
Voltage (Single Phase Std.) ** 208v-230v
Speed of Rise 70 Seconds (approximate)
Min. Recommended Bay Size 11' x 22' 12' x 22' 12' x 24' 12' x 26' 12' x 24' 12' x 26'
* Wheelbase is based on a tire diameter of 30”
** Optional 3 phase, 50/60Hz, 208, 230 or 460V available.
9" 1"
92
BASE PLATE
IDLER RUNWAY
H DIAGONALS TO BE WITHIN 1/4"

C
B
G POWER RUNWAY
33"
A
2' MIN.
TO NEAREST
OBSTRUCTION D
E
L
5 20"
68"
Fig 1 – General Specifications and Service Bay Layout

2 Rev. 7/5/05
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VERTICAL CLEARANCE Safety decals similar to those shown here are

found on a properly installed lift. Be sure that all
Check the height of the area where the lift is to be safety decals have been correctly installed on the
installed. Clearance should be calculated based on Power Unit reservoir. Verify that all authorized
the full raised height of the lift. operators know the location of these decals and
Failure by purchaser to fully understand their meaning. Replace worn,
WARNING provide adequate clearance faded, or damaged decals promptly.
could result in Do not attempt to raise a
unsatisfactory lift performance, property WARNING vehicle on the lift until the
damage, or personal injury. lift has been correctly
FLOORING installed and adjusted as described in this
manual.
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.
Failure by purchaser to
WARNING provide the recommended
mounting surface could
result in unsatisfactory lift performance,
property damage, or personal injury.
ELECTRICAL REQUIREMENTS
For lift installation and operation for single
phase units, it is necessary to have a dedicated
circuit with a double pole 25 amp circuit breaker
or time delay fuse.
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.
3 Rev. 7/5/05
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RECEIVING Component Packing List

The shipment should be thoroughly inspected as
ITEM QTY/
soon as it is received. The signed bill of lading is DESCRIPTION
# LIFT
acknowledgement by the carrier of receipt in good
condition of shipment covered by our invoice. 1 1 POWER RUNWAY ASS’Y.
If any of the goods called for on this bill of lading 2 1 IDLER RUNWAY ASS’Y
are shorted or damaged, do not accept them until 3 1 POWER COLUMN ASS’Y
the carrier makes a notation on the freight bill of 4 3 IDLER COLUMN ASS’Y
the shorted or damaged goods. Do this for your
own protection. 5 2 ENTRANCE RAMP WELD
NOTIFY Challenger Lifts AT ONCE if any hidden 6 2 CROSS BEAM ASS’Y
loss or damage is discovered after receipt. 7 1 POWER UNIT
IT IS DIFFICULT TO COLLECT FOR LOSS OR 8 1 HARDWARE BOX
DAMAGE AFTER YOU HAVE GIVEN THE 9 2 MOVABLE WHEEL CHOCK
CARRIER A CLEAR RECEIPT.
10 2 FRONT WHEEL STOP
File your claim with Challenger Lifts promptly.
Support your claim with copies of the bill of lading, 11 2 WORK STEP (alignment lifts only)
freight bill, and photographs, if available. 12 2 SHIPPING BRACKET WELD
13 8 ½” SHIPPING HARDWARE
INSTALLATION
IMPORTANT: Always wear safety glasses while installing lift.
TOOLS (MINIMUM REQUIRED)

a. Tape measure, 25ft
b. Chalk line
c. 4ft level
d. 10” & 12” adjustable wrench
e. Standard open end wrenches 3/8”, 7/16”, 1/2",
9/16”, 5/8”, (2) 11/16”, 3/4", 15/16”
f. Box knife
g. Thread locking compound
h. Thread tape sealant (for air line)
i. Needle nose pliers
j. Hammer drill with 3/4” diameter carbide tipped
bits
k. 2lb hammer
l. Torque wrench: 150 foot pounds minimum with
1 1/8” socket
m. 8 ft. Step ladder
n. Blocking – (4) 4x4x30”, (4) 1x4x12”
o. Transit for leveling alignment lift
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
Fig 2 – Package Components sheaves at rear end) and pull threaded cable
ends out. Make sure the cables are in the
proper sheaves at the 4-stack, Fig 3.
4 Rev. 7/5/05
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side of the runway. Cable #1, #3, & #4 should
be extending out from the rear of the power
runway and cable #2 from the front of the
power runway, Fig 4.
4) Position the front and rear cross beams,
Fig 4. (Both cross beams are identical.)
5) Reach in through either of the access holes in
the rear cross beam tube and pull out the roll
of 1/8” dia. plastic air line connected to the air
Fig 3 – Power Runway 4-Stack (rear view) cylinder at the end of the cross beam. Repeat
for opposite access hole and position the cross
3) Position runways on blocking (see Fig 4) per beam near the end of the runways as in Fig 4.
layout lines established in step 1. Use four 30”
long 4x4’s spanning the width of the runway
and four 12” long 1x4’s to shim up the jack-rail
Fig 4 – Runway Layout

6) Remove the four (4) cross beam sheaves (one spacer bushing on the bottom of idler rear
sheave from each end) and the two idler sheave only), Figs 5 & 6.
runway sheaves (also one sheave from each
end). The runway sheave pins do not need to
be removed, just lowered enough to remove
the sheaves.
7) Starting from the bottom of the stack, route
cable #4 through the access hole and up out
the left end of the rear beam. Repeat for cable
#3 out the right end of the rear beam. Route
cable #1 through the access hole, and back
out the idler side access hole. Look through Fig 5 – Rear Single-Stack (idler runway)
the idler end of the cross beam and ensure
that cable #1 and #3 have not crossed.
8) Route cable #1 through the idler runway, into
the front cross beam access hole, and out the
right end of the front beam. (Don’t forget to
route it up over the cross-braces in the bottom
of the runway.)
9) Route left front cable #2 through the access
hole and up out the left end of the front beam.
10) Reinstall the cross beam sheaves (one thin Fig 6 – Front Single-Stack (typical for idler and
plastic bearing on each side of each sheave) power runways)
and the idler runway sheaves (2 1/8” long
5 Rev. 7/5/05
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11) Attach both cross beams to the runways (Fig. 15) Slide power side column onto cross beam until
4) with ½” x 1 ¼” lg. flange head bolts (two at the 5/16-18NC threaded holes in the side of
each end of each runway) being careful not to the beam are just exposed. Position slide
pinch the air line. Leave the air lines hanging blocks as shown in Fig 9 and attach with
out the bottom of the cross beam access holes 5/16x3/4 bolts (apply thread locking compound
at this time, they will be fed in through the before installing).
runway after the lift is raised. The outermost
power runway slots should be in line with
the outermost holes in the top of the cross
beam, see Fig. 4. 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.
12) 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 ¼”, Fig 7.
Fig 9 – Slide Block Installation
16) Raise the locking ladder, push the column
against the slide blocks, and lower the ladder
SIDE TO SIDE TO BE IDENTICAL into the slide blocks, Fig 10.
DIAGONALS TO BE WITHIN 1/8"
LOCKING
COLUMN
LADDER
Fig 7 – Final Runway Positioning

13) Center cross beam bolts with slots in runway
and tighten. (Be careful not to move runways.)
COLUMNS SLIDE
14) Stand up a column assembly near each corner BLOCK
of the lift (column with power unit bracket goes
at the 4-sheave-stack corner, power rear) and
check the locking ladder bar orientation per
Fig 8. Note that the center of the threaded rod
is offset (away from the back of the column)
from the center of the ladder. Thread the
locking ladder jam nut (located under the Fig 10 – Locking Ladder Orientation
column top plate) down approximately 6” to 17) Repeat for remaining three columns.
allow the ladder to be lifted freely.
ANCHORING
18) The anchor bolts must be installed at least 8”
from any crack, edge, or expansion joint.
19) Use a concrete hammer drill with a 3/4 inch
carbide bit. Tip diameter should conform to
THREADED
ROD ANSI Standard B94.12-1977 (.775 to .787). Do
not use excessively worn bits or bits which
have been incorrectly sharpened. A core bit
LOCKING
LADDER may be necessary if an obstruction is
BAR encountered. Never substitute with shorter
anchor.
Fig 8 – Locking Ladder Orientation
6 Rev. 7/5/05
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20) Drill the anchor holes using the base plate as a 28) BE CERTAIN ALL FITTINGS AND CONNECTIONS
template. Drill through the floor if possible or to ARE TIGHT. IT IS THE INSTALLERS RESPONSIBILITY
a depth of 5 inches minimum. TO INSURE SYSTEM IS LEAK-FREE. Fill the Power
21) Vacuum dust from the hole for proper holding Unit with three gallons of clean 10wt anti-foam
power. anti-rust hydraulic oil or Dexron III ATF. DO
NOT USE OILS WITH DETERGENTS.
22) Shim columns to plumb using the shims
provided or steel washers. DO NOT shim 29) Energize the power unit and raise the lift
more than 1/2" at any given point. Use a level approximately 1 ft off the ground and look
no less than 24” in length to plumb columns. underneath the power runway to verify that the
cable lugs are resting firmly against the
23) Assemble washer and nut to anchor with nut
cylinder pull bar.
just below impact section of bolt. Drive anchor
into hole until nut and washer contact base. 30) For flat deck style runways, level the runways
Tighten anchor bolts and recheck column for and crossbeams using a 4 ft. level. With the lift
plumb. Re-shim as required. resting in its locks, find the highest corner and
adjust the other three column ladder bars until
NOTE: Level bubble should not only be
the runways are level front-to-rear and side-to-
between the lines, the bubble should be
side. Tighten jam nut against bottom side of
centered between the lines. If the provided
each column top plate. For alignment style
shims do not allow sufficient centering of the
runways, use a transit for leveling runways
bubble, it is best to lean the rear columns in the
placing the target in the center of the turn plate
direction toward each other and the front
and the center of the rear slip plate (with lift
columns in the direction toward each other.
lowered into locks, adjusting the lock ladders
24) Install the four cable ends with one flat washer, as needed). Refer to alignment equipment for
one load nut, and one jam nut. leveling tolerance.
25) Install the power unit and the air button valve 31) Adjust cables until all four locks are
assembly on the power column, Fig 11. synchronized when lift is raised. Tighten cable
jam nuts against adjustment nuts.
32) Install 1/8” air line from air valve assembly thru
opening in runway to Tee. Fig 12
1/8" TEE FACTORY
INSTALLED AT EACH
1/8" SPLICE
CROSS BEAM END
FRONT
REAR
1/8" TEE
POWER UNIT
w/ AIR VALVE
ASS'Y
Fig 11 – Air Button & Power Unit Mounting 1/8" AIR LINE
Fig 12 – Lock Release Air Line Routing

26) Install O-Ring end of 90 degree hydraulic
elbow (9/16-18 O-Ring x 37° Male JIC) to 33) Route power side front and rear cross beam
power unit output port. The hydraulic hose is air lines through power runway to Tee. Route
pre-installed to the hydraulic cylinder and idler side front and rear cross beam air lines
secured inside the runway. Pull loose end out through idler runway and connect together with
through 1 ½” x 4 ½” slot in the side of the 1/8” air line spice provided. Use provided
power runway near the power unit and attach adhesive tabs and plastic cable ties to secure
to the elbow fitting. air lines inside runways.
Do Not Use Teflon Tape or Pipe Dope on fittings. 34) Connect the button valve to a source of clean,
27) Have a certified electrician connect the power dry air (filter, regulator, lubricator) using the
unit to a suitable electrical power source. The hose barb and clamp provided. Failure to
standard power unit is 208/230 volt 60 Hz provide clean, dry air will void warranty on
single phase requiring a dedicated 25 amp pneumatic components.
double poll, double throw circuit breaker to Air pressure required 90/120 psi.
operate lift at full capacity.
7 Rev. 7/5/05
40010.doc
35) Energize air valve assembly and insure that all 41) Attach Work Step to each runway. (The Work
air cylinders are working properly. Step may be located in three different positions
36) Raise and lower lift several times to bleed on each runway.)
hydraulic cylinder. Hydraulic cylinder is self 42) Install Handle to Drop-In Spacer and position
bleeding. Lower lift and check fluid level in behind rear Guide Bar. The Drop-In Spacer is
reservoir. Add fluid as needed. provided for “Roll Back” alignment.
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.
ALIGNMENT RUNWAYS
39) Lower lift and raise to check for lock
engagement. The locks should engage
simultaneously (clicking noise). Re-adjust
cables as needed to synchronize locks.
40) Position Front Turn Plates (SOLD
SEPARATELY) and install Guide Bars to
runway using (3) #10-24 x 1” Socket Head Cap
Screws and lock nuts provided. Ensure that
the Turn Plates will slide freely and tighten
Guide Bars.
Fig 16 – Alignment Turn Plate Installation
8 Rev. 7/5/05
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Owner/Operator Checklist employer shall insure that the lift inspectors are
qualified and that they are adequately trained in
SAVE THESE INSTRUCTIONS deliver them to the inspection of the lift.
owner/user/employee along with other materials
furnished with this lift. The Owner/Employer shall establish procedures
to periodically maintain the lift in accordance with
Demonstrate the operation of the lift to the the lift manufacturer’s instructions or ANSI/ALIOIM-
owner/operator and review correct and safe lifting 2000, American National Standard for Automotive
procedures using the Lifting It Right booklet as a Lifts-Safety Requirements for Operation,
guide. Inspection and Maintenance; and the employer
shall insure that the lift maintenance personnel are
Complete the Installation Checklist/Warranty qualified and that they are adequately trained in
Validation questionnaire with the owner. Review the maintenance of the lift.
the terms of the warranty registration card, and
return the card and a copy of the questionnaires to: The Owner/Employer shall maintain the periodic
Challenger Lifts, Inc. inspection and maintenance records
200 Cabel Street recommended by the manufacturer or ANSI/ALI
Louisville, KY. 40206 ALOIM-2000, American National Standard for
Automotive Lifts-Safety Requirements for
Safety Notices and Decals Operation, Inspection and Maintenance.
This product is furnished with graphic safety The Owner/Employer shall display the lift
warning labels, which are reproduced on page 3 of manufacturer’s operating instructions; ALI/SM 93 -
these instructions. Do not remove or deface these 1, ALI Lifting it Right safety manual; ALI/ST-90 ALI
warning labels, or allow them to be removed or Safety Tips card; ANSI/ALI ALOIM-2000, American
defaced. For your safety, and the safety of others, National Standard for Automotive Lifts-Safety
read and understand all of the safety notices and Requirements for Operation, Inspection and
decals included. Maintenance; and in the case of frame engaging
lift, ALI/LP-GUIDE, Vehicle Lifting Points/Quick
Owner/Employer Responsibilities Reference Guide for Frame Engaging Lifts; in a
conspicuous location in the lift area convenient to
This lift has been designed and constructed the operator. Demonstrate the operation of the lift
according to ANSI/ALI ALCTV-1998 standard. The to the owner and review correct and safe lifting
standard applies to lift manufactures, as well as to procedure, using the “Lifting It Right “ booklet as a
owners and employers. The owner/employer’s guide.
responsibilities as prescribed by ANSI/ALI ALOIM-
2000, 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-2000, 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-2000, American National Standard for
Operation, Inspection and Maintenance; and the
9 Rev. 7/5/05
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Important Safety Instructions MAINTENANCE
When using your garage equipment, basic safety To avoid personal injury, permit only qualified
precautions should always be followed, including personnel to perform maintenance on this
the following: equipment.
1 Read all instructions. The following maintenance points are suggested
2 Care must be taken as burns can occur from as the basis of a preventive maintenance program.
touching hot parts. The actual maintenance program should be
3 To reduce the risk of fire, do not operate tailored to the installation. See ANSI/ALI ALOIM
equipment in the vicinity of open containers of booklet for periodic inspection checklist and
flammable liquids (gasoline). maintenance log sheet.
4 Adequate ventilation should be provided when • If lift stops short of full rise or chatters, check
working on operating internal combustion fluid level and bleed both cylinders per
engines. Installation Instructions.
5 Keep hair, loose clothing, fingers, and all parts • Replace all Safety, Warning or Caution Labels if
of body away from moving parts. missing or damaged.
6 To reduce the risk of electric shock, do not use
on wet surfaces or expose to rain. Daily
7 Use only as described in this manual. Use • Keep lift components clean. To keep
only manufacturer’s recommended alignment lifts with rear slip plates working
attachments. properly use compressed air to blow out any
Save These Instructions debris from the bearing area.
• Check for loose or broken parts.
LIFTING A VEHICLE
• Check hydraulic system for fluid leaks.
Drive vehicle onto lift. Set parking brake and/or use
wheel chocks that are provided with lift. • Check lock release activation.
When the vehicle has reached the desired working
height, release the power pack button, and lower Weekly
the vehicle until the safety locks are engaged. The • Check cables and sheaves for wear or damage.
vehicle should remain level when all locks are Replace as required with genuine Challenger
engaged. If one side engages and the other Lifts parts.
continues to descend, stop lowering the vehicle, • Inspect lock mechanism for proper function.
raise it several inches, and try again to engage
locks. Monthly
IMPORTANT, Before walking under the lift insure • Torque concrete anchor bolts to 80 ft-lbs.
that all locks are properly engaged.
• Clean and inspect cables and sheaves for wear
It is not safe to work under the vehicle unless all or damage. Lubricate cables and sheaves with
locks are engaged, and the vehicle is level. light oil.
LOWERING A VEHICLE
Insure that the area under the vehicle is clear of IMPORTANT ! Failure to keep lift free of
personnel and tools. corrosive agents and solvents will lead
Raise the vehicle until locks are free. to reduced service life, which could
result in property damage and/or
Disengage the locks by depressing the palm personal injury.
button and holding it.
Lower the vehicle by depressing the lowering valve If any problems are encountered,
handle. Watch lift to insure that the lift is lowering contact your local service
evenly. If not, raise lift and check all locks to insure representative
they are disengaged before trying to lower lift Maintenance
again.
Continue to lower the vehicle until the crossbeams
stop against the base plate. It is important to fully
lower the lift to release hydraulic pressure on the
system.
10 Rev. 7/5/05
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Parts Breakdown
IMPORTANT!!!
Replace all worn or broken parts with genuine Challenger Lifts

Inc. parts. Contact your local Challenger Lifts parts distributor
for pricing and availability. Call 502-625-0700 for the closet parts
distributor in your area.
11 Rev. 7/5/05
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Parts Breakdown
Fig A. General Layout
6 12
12 8
9
12
4
3
3
14
2
11
10
18 13
20
19
17
15
16
12 Rev. 7/5/05
40010.doc
ITEM # PART # QTY/LIFT DESCRIPTION

1 44011 1 HYDRAULIC CYLINDER
2 40082 1 CLEVIS PIN
3 40126 5 1/8 x 1 1/2" Lg. COTTER PIN
40391 FLAT DECK POWER RUNWAY (40XF)
40381 FLAT DECK POWER RUNWAY (40EF)
4 1
40396 ALIGNMENT POWER RUNWAY (40XA)
40386 ALIGNMENT POWER RUNWAY (40EA)
40393 FLAT DECK IDLER RUNWAY (40XF)
40383 FLAT DECK IDLER RUNWAY (40EF)
5 1
40398 ALIGNMENT IDLER RUNWAY (40XA)
40388 ALIGNMENT IDLER RUNWAY (40EA)
6 40266 2 WHEEL STOP
7 40083 8 1/2-13NC x 1 1/4" Lg. HEX.FLG.HD.CAP SCREW
40460 CROSS BEAM ASSEMBLY (Models 40X, 40E, & 40S)
8 1
40460N CROSS BEAM ASSEMBLY (Model 40N)
9 40265 2 WHEEL CHOCK
31368-19 POWER UNIT 1 PHASE, 60Hz, 208-230VAC
10 1
31355-19 POWER UNIT 3 PHASE, 230/460VAC
11 40449-P 1 POWER COLUMN ASSEMBLY
12 40449-I 3 IDLER COLUMN ASSEMBLY
13 40161 2 ENTRANCE RAMP
14 40165 2 RAMP HINGE PIN
15 40168 2 RAMP SLIDE
16 31062 6 1/4-20NC x 3/4" Lg. PAN HEAD SCREW
17 40085 6 1/4-20NC HEX FLANGE NUT
18 A1121 1 UNION ADAPTER #6 O-RING x #6 JIC 37 deg FLARE
19 16167 1 90 DEGREE ADAPTER ELBOW – MALE #6 O-RING x MALE #6 J.I.C.
20 40349 1 HYDRAULIC HOSE – FEMALE #6 J.I.C. BOTH ENDS
Replace all worn or broken parts with genuine Challenger Lifts Inc. parts.
Contact your local Challenger Lifts Parts Distributor for pricing and availability.
(Call Challenger Lifts Inc. (502) 625-0700 for the Parts Distributor in your area)
13 Rev. 7/5/05
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PARTS BREAKDOWN (continued)
Fig B. Cables
10
2 11
VIEW B
12
VIEW C
3 A
VIEW A
VIEW B

40372-X1 RIGHT FRONT CABLE #1 (40X)
1 40372-E1 1 RIGHT FRONT CABLE #1 (40E)
40372-S1 RIGHT FRONT CABLE #1 (40S & 40N)
40372-X2 LEFT FRONT CABLE #2 (40X)
2 40372-E2 1 LEFT FRONT CABLE #2 (40E)
40372-S2 LEFT FRONT CABLE #2 (40S & 40N)
3 40472-3 1 RIGHT REAR CABLE #3
4 40472-4 1 LEFT REAR CABLE #4
5 40147 4 7/8-9NC HEX NUT
6 40148 4 7/8-9NC HEX JAM NUT
7 40149 4 7/8 FLAT WASHER
8 40438-R 1 2 1/8” SPACER
9 40473 1 CABLE PULL BAR
10 40474 1 CABLE RETAINER WELD
11 44015 2 1 3/8-12NF JAM NUT
12 40186 4 Cable Spacer (40N only)
14 Rev. 7/5/05
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Fig C. Runway Sheaves

1 40050 10 SHEAVE
2 40053 11 1/8” THICK BEARING
3 40055 4 SHEAVE PIN WELD (RUNWAY)
4 31188 16 5/16-18NC x 3/4 Lg. HEX.HD.CAP SCREW
5 40438-R 1 RUNWAY SHEAVE SPACER
15 Rev. 7/5/05
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Fig D. Cross Beam
2 1 2
18
17 13 19
16
3
20 21
15
14
13
12
11
6
10
7
4
4

1 40050 10 SHEAVE
2 40054 8 1/16” THIN BEARING
3 40118 4 SLIDE BLOCK
5 40120 8 1/4-20NC x 1/2" Lg. SELF TAPPING SCREW
6 40122 2 RUBBER SHEAVE GUARD (REAR)
7 40116 4 SHEAVE PIN (CROSS BEAM)
8 40461 1 REAR CROSS BEAM WELD
9 40127 4 LOCK PIVOT PIN
10 40126 8 1/8” x 1 1/2" Lg. COTTER PIN
12 40141 4 AIR CYLINDER ASSEMBLY
13 40128 16-28 3/4" WASHER – (1.5 O.D. x .13 THICK NOMINAL)
14 40131 4 PRIMARY LOCK PAWL
15 40132 4 SPACER BUSHING
16 40137 2 RETAINING RING
17 40135 2 ROLLER
18 40134 2 SLACK CABLE LATCH
19 40139 8 EXTENSION SPRING
20 40124 4 HAIR PIN COTTER PIN
21 40125 4 1/4" DIA. x 3/4" Lg. SHOULDER BOLT
16 Rev. 7/5/05
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Fig F. Air Lock Release
11
12
FRONT
REAR
12
12
POWER UNIT
4
10
w/ AIR VALVE
ASS'Y
2 5
6
7
10 8

1 37015 1 BUTTON VALVE BRACKET
2 37016 1 AIR VALVE
3 40091 1 IN-LINE AIR FILTER
4 37021 1 HOSE BARB
5 37023 2 #8-32 HEX NUT
6 37024 2 #8 LOCK WASHER
7 37022 2 #8-32 x 1 1/4" Lg. PAN HD. SCREW
8 37020 1 1/8” NPT STREET ELBOW
9 37019 1 1/8” NPTM x 1/8” PUSH-LOCK 90 DEGREE ELBOW
10 00901 60 ft. 1/8” DIA. PLASTIC AIR LINE
11 40445 1 1/8” STRAIGHT UNION
12 37032 3 1/8” UNION TEE
17 Rev. 7/5/05
40010.doc
Fig G. Alignment Equipment

1 40291 4 GUIDE BAR
2 40299 12 #10-24 x 1” SOC.HD.CAP SCREW
3 055-127 12 #10-24 HEX LOCK NUT
4 40296 2 DROP-IN SPACER
5 40295 2 HANDLE
6 40506 2 WORK STEP
7 40530 2 REAR SLIP PLATE WELDMENT
8 40220 4 PIN ASSEMBLY
9 40211 196 3/4" DIA. BALL
10 40525 2 BALL RETAINER ASSEMBLY
40526 2 BALL RETAINER SHEET
40527 28 STAND-OFF PIN
40528 28 STAND-OFF SPACER (GROMMET)
40221 24 1/2" DIA. EXTENSION SPRING
40219 8 7/8” INTERNAL TOOTH LOCK WASHER
18 Rev. 7/5/05
40010.doc
MODEL 24006 Installation, Operation
6000 LB and Repair Parts
Rolling Air Jack Information
NOTICE -
AIR SUPPLY MUST HAVE IN-LINE FILTER/REGULATOR/LUBRICATOR
(NOT INCLUDED) TO VALIDATE THE ROLLING AIR JACK WARRANTY
Challenger Lifts, Inc. • 200 Cable Street • P.O. Box 3944 • Louisville, Kentucky 40201-3944
P/N: 81-0023
CAUTION
♦ Before using this product, read and fully understand the operating
instructions and all decals on the product. This is necessary to
prevent injury to the operator and damage to the product.
♦ Roll jack forward before moving vehicle on or off lift.
♦ Do not attempt to use this jack for anything other than it’s intended
purpose.
♦ If jack begins to tilt as the vehicle is raised, STOP! Lower the jack
and reposition the vehicle.
♦ Do not use this jack if it is visibly worn, distorted or damaged.
♦ Maximum air operating pressure not to exceed 120 p.s.i. Air supply
must have in-line filter/regulator/lubricator.
♦ Always wear appropriate eye protection.
WARNING
♦ Maximum lift capacity of this jack is 6000 lbs. (2722 kg)
Exceeding this could result in severe personal injury or death.
♦ Lift vehicle at manufacturer’s recommended pick-up points only.
Vehicle weight must be evenly distributed on each jack lift pad.
♦ Keep fingers and hands clear of all pinch points at all times.
SPECIFICATIONS
Lift Capacity....................................................... 6000 lbs. (2722 kg)

Maximum Air Pressure.......................................120 p.s.i. (8.25 bar)
Lift Height...........................................................10 inches (254 mm)
Lift Pad Spread.....Min........................................33 inches (838 mm)
Max.......................................50 inches (1270 mm)
Lift Pad
Lift Pad
Spacer
Air
Inlet
Control
Lever Lift Rack
Mounting
Lock Bracket
Release
INSTALLATION
1) Install a 1/4 NPT male quick-disconnect coupling (not included) in air inlet to match shop
fittings. Install an in-line filter/regulator/lubricator (not included) within 20 feet of jack.
Operating pressure 80-120 p.s.i.
2) Install lift rack mounting brackets per instructions included with brackets.
NOTE:
Check each jack Mounting Bracket application decal to be certain the Mounting Brackets and
the model lift rack on which it is installed are compatible.
3) Place jack assembly on lift rack rails.
OPERATION
NOTE:
Before lifting a vehicle, operate the jack through a couple of cycles to become familiar with
the controls.
WARNING
Keep fingers and hands clear of all
pinch points at all times.
1) Roll jack forward before moving vehicle on lift rack. Be sure vehicle is centered on rack,
apply parking brake and chock wheels.
2) Roll jack to the vehicle manufacturer’s recommended pick-up points. Extend Lift Pad
Arms to proper lift points. Use Lift Pad Spacers if necessary.
WARNING
Lift vehicle at manufacturer’s recommended pick-up points only.
Vehicle weight must be evenly distributed on each jack lift pad.
3) Raise jack by moving the Control Lever to the “RAISE” position.
CAUTION
If jack begins to tilt as the vehicle is raised, STOP! Lower the jack
and reposition the vehicle.
4) Raise vehicle to desired height.
5) To lower jack, hold the Lock Release Lever to the left while moving the Control Lever to
the “LOWER” position. If jack does not lower, raise it slightly while holding the Lock
Release Lever to the left until you feel the lock move past the detent, then continue to
lower jack.
6) Lower jack completely, slide Lift Pad Arms in and remove Lift Pad Spacers (if used). Roll
jack forward before moving vehicle off rack.
MAINTENANCE
DAILY - Inspect jack and it’s components for damage or excessive wear. Replace parts as
required (see repair parts).
DAILY - Inspect air/hydraulic system for leaks.

Check in-line lubricator oil level.
ANNUALLY - Check hydraulic pump fluid level (see below).
FLUID LEVEL CHECK & FILL PROCEDURE

1) Raise jack all the way up.
2) Locate the two 1/4” spring pins in the pivot

pin blocks. Using a 1/4” punch, drive the
spring pins into the pivot pins. Remove the
pivot pins and be sure to punch the spring
pins out and save for reassembly (Fig. 1).
3) Remove the two 1/2” allen head screws (Fig. 1).
4) Remove the top section of the jack.
5) Completely lower the jack lift arms. Fig. 1
6) Block up the “cylinder end” of jack about 6 inches.
7) Wipe area around filler plug to prevent contamination

of oil. Remove filler plug and check oil level (Fig. 2).
Oil level should be at the top of the filler plug hole.
8) Fill as required with ATF, Dextron II, or 5605 oil.

Take care to prevent contamination during fill.
9) Remove blocks and level jack. Top off fluid to the

top of filler plug hole. Reinstall plug, hand tighten only. Fig. 2
ROLLING AIR JACK REPAIR PARTS
ITEM PART NO QTY DESCRIPTION
1 50-0065 4 3/8-16 X 3/4 Serrated Hex Head Flange Screw
2 10-0017 2 Rubber Lift Pad
3 03-0131 2 Lift Pad
4 73-0349 2 Lift Pad Spacer
5 51-0016 4 1/4-20 Heavy Square Nut
6 028-132 5 1/4-20 X 1/2 Hex Head Cap Screw
7 50-0043 2 1/2-13 X 1/2 Hex Socket Head Cap Screw
8 061-091 4 1/4 X 7/8 Spring Pin
9 63-0005 1 Air/Hydraulic Pump
10 055-160 4 1/4-20 Nylon Hex Lock Nut
11 028-141 4 1/4-20 X 1 Hex Head Cap Screw
12 55-0012 1 Torsion Spring
13 03-0126 1 Linkage Bar
14 061-032 2 1/8 X 3/4 Spring Pin
15 03-0132 1 Latch
16 62-0002 1 Hydraulic Hose
17 50-0066 1 1/4-20 X 3/8 Set Screw
18 63-0004 1 Hydraulic Cylinder
19 73-0343 1 Retainer Tab
20 60-0023 1 90 Degree Male Elbow Fitting
21 73-0332 1 Latch Pivot Rod
22 03-0129 1 Linkage Rod
INSTRUCTIONAL DECALS
ITEM PART NO QTY DESCRIPTION
1 80-0078 1 Raise/Lower Decal
2 80-0079 1 Lock Release Decal
3 80-0080 1 Caution Decal
4 80-0083 2 Warning Decal
5 80-0084 1 Warning Decal
6 M00-003 128" Caution Stripe Tape
NOTES
Challenger Lifts, Inc.
Part Number 40230
AIR LINE ACCESSORY KIT

For Model 40000 Series
INSTALLATION, OPERATION & MAINTENANCE MANUAL
IMPORTANT !!!
READ THIS MANUAL COMPLETELY BEFORE INSTALLING OR
OPERATING THE LIFT
200 CABEL STREET, P.O. BOX 3944
LOUISVILLE, KENTUCKY 40201-3944
E-Mail - [email protected]
Web Site - www.challengerlifts.com
OFFICE (502) 625-0700 FAX (502) 587-1933

Rev. 5/17/04
40230-IOM.doc
Air Line Accessory Kit
Note: On current production lifts the holes for the Air Accessory Kit should be pre-drilled.
1) a. Raise lift to comfortable working height and rest in lock.
b. Drill (1) 13/16" diameter hole in the power runway.
c. Drill (2) 9/32" diameter holes in the crossbeam (one per side of the tube). Drill
both cross tubes as shown in FIG 1.
FIG 1
2) Assemble the brass fittings (provided) to the air valve bracket as shown in FIG 2.
FIG 2
Page 2 Rev. 5/17/04

40230-IOM.doc
3) a. Route the 3/8" hose through opening in runway. Route hose down side of
runway to end of hydraulic cylinder. See FIG 3.
b. Attach hose clamp and position to where it does not interfere with cables.
Drill 7/32" hole through runway and use 1/4-20 x 1/2" lg self tap screw
provided.
c. Route hose across inside of runway to opposite wall using caution that the
hose does not interfere with cables.
d. Attach hose clamp and position. Drill 7/32" hole through runway and use
1/4-20 x 1/2" lg self tap screw provided.
e. Assemble Anchor coupling in 13/16" hole previously drilled. Washer and
3/4-16 hex nut goes on inside of runway. Attach 1/4" NPT swivel elbow.
f. Cut excess hose and attach to swivel elbow.
3/8" Plastic Hose
3/8" Hose Clamp
1/4-20 x 1/2" Lg
Self Tap Screw
3/8" Plastic Hose
3/4-16 Hex Nut

& Washer
1/4" NPT Swivel 3/4-16 Anchor

to 3/8" Hose Coupling
FIG 3
Page 3 Rev. 5/17/04

40230-IOM.doc
4) a. Run one end of the 1/8" diameter cable through the 9/32" hole in the cross
beam and put washer and 1/4-20 lock nut on.
b. Run the other end of the 1/8" cable through the coil of the 3/8" air hose.
Insure that the swivel end of the air hose (longer straight piece) is facing towards
middle of the lift. If running two jacks insure that both swivel ends are facing
towards middle of lift. Run other end of 1/8" cable to opposite crossbeam and
put washer and lock nut on.
c. Adjust cable tension (do not over tighten). Important: Cut excess cable
stud length flush with edge of nut and deburr.
c. Attach 1/4" NPT Tee to anchor coupling. Attach swivel end of 3/8" air hose to
1/4" NPT Tee.
d. Install the 1/2-13 bolt using (3) lock washers per bolt with the head up in the
jack track holes closest to the center of the lift. Important, do not use more
than the (3) washers provided to avoid damage to the rollers on the jack.
1/2-13 x 1" Lg 1/2" Lock Washer

(3) each
1/2-13
Lock Nut
Tee
1/4" NPT
1/8" Dia.
Cable
3/8" Dia. Coiled

Air Hose
1/8" Cable
1/4" Flat Washer
1/4-20 Lock Nut
FIG 4
Page 4 Rev. 5/17/04

40230-IOM.doc
5) a. Position the jack(s) on the runway and lock the side members down after
positioning.
b. Hook-up the F.L.R.(Filter, Lubricator, Regulator) provided with jack.
c. Attach the 1/4 NPT to 1/4" hose fitting to the 1/4" NPT brass elbow provided
with F.L.R. kit. Insert the 1/4" plastic hose in the fitting and route around the
jack as shown in FIG 5 below.
d. Attach the 1/4" NPT to 1/4" hose fitting to the 3/8" coiled hose. Insert the 1/4"
hose. Attach the 3/8" hose clamp to the 3/8" coiled hose and position on the
side member away from the rollers. Drill 7/32" hole through and screw 1/4-20
x 1/2" lg self tap screw.
3/8" Coiled
Air Hose
3/8" Hose Clamp

1/4" NPT to
1/4" Hose
1/4-20 x 1/2" lg
Self Tap Screw 1/4" Plastic
Air Hose
1/4" Plastic
Air Hose
1/4" Hose to
1/4" NPT
FIG 5
Page 5 Rev. 5/17/04

40230-IOM.doc
INSTALLATION & OPERATION
MANUAL SUPPLEMENT
Bolt-On Alignment Kit
(P/N 40200-3D)
with 3-D Alignment Roll-Back
FOR MODEL 40000 4-POST LIFT

Office 800-648-5438 / 502-625-0700 Fax 502-587-1933

Rev. 1/30/04
40229.doc
Bolt-On Alignment Kit (3-D)
Installation & Operation Supplement
GENERAL SPECIFICATIONS AND LAYOUT
83" MIN. TO 150" MAX. WHEEL BASE

(71" TO 162" BY SHIFTING REAR HOUSING ON ADJUSTMENT PINS)
GUIDE BAR
DROP-IN SPACER
GUIDE BAR SLIP PLATE
ROLL-BACK
FRONT WHEEL PLATFORM
STOP
PLATFORM
FRONT OF
FRONT OF
FRONT OF
BRACKET
BRACKET
18
REAR LOCATOR
FRONT TURN PLATE BRACKET
* SOLD SEPERATELY *
94" 24"
Fig 1 – General Specifications and Layout
READ ENTIRE MANUAL BEFORE LAYOUT

ASSEMBLING, INSTALLING, 1) Raise the lift to a comfortable work height
OPERATING, OR SERVICING THIS and lay out the Bolt-On Alignment Kit
components on the lift runways, see Fig 1.
EQUIPMENT.
(Note: all left and right components are
PROPER MAINTENANCE AND identical except the Front Roll-Back
INSPECTION IS NECESSARY FOR SAFE Platforms)
IMPORTANT: Locations illustrated in Fig 1 are
OPERATION. only suggested and may be repositioned to better
DO NOT OPERATE A DAMAGED LIFT. suit specific needs. If Front Turn Plates are
positioned less than 18” from the front cross
beam, ensure the alignment equipment will clear
INSTALLATION the front wheel stop.
FOR NEW LIFT OR RETRO-FIT INSTALL FRONT TURN PLATE
2) Locate and drill three 7/32” holes in the
TOOLS (MINIMUM REQUIRED FOR RETRO-FIT) Power Runway 18” back from the Front
a. Standard open end wrenches 3/8”, 9/16" Cross Beam as indicated in Fig 2. Use the
b. 5/32” allen wrench front Guide Bar as a template and use a 2’
c. Drill with 7/32” & 13/32” bits carpenter’s square to ensure Guide Bar is
d. Carpenter’s square (2 ft.) square with runway.
e. Straight edge (8 ft.) IMPORTANT: Drill bit must not touch cables
located inside Power Runway.
FRONT WHEEL STOP

FRONT CROSSBEAM
18
(6) PLACES
1 9 9
POWER IDLER
RUNWAY RUNWAY
Fig 2 – Front Guide Bar Location
Page 2 1/30/04
40229.doc
3) Attach Guide Bar to runway using (3) REAR SLIP PLATE

#10-24NC Socket Head Cap Screws and
The following procedures are the same for the
lock nuts provided. Use square to check
Power and Idler Runway.
position.
7) Locate the front edge of the Rear Locator 94"
4) Locate front Guide Bar on Idler runway using
back from the front edge of the Roll-Back
a straight edge aligned with the Power
Platform, see Fig 1. Using the holes in the
runway Guide Bar and attach in the same
Rear Locator, drill (2) 13/32" holes through
manner.
the side of the runway. Bolt the rear locator
5) Position the Front Turn Plate (SOLD using the 3/8" flange bolts and nuts provided.
SEPERATELY) against the fixed front Guide
8) Measure 24" from the front edge of the rear
Bar and mount a second Guide Bar against
locator to the front edge of the second rear
the back of the Front Turn Plate.
locator and repeat the previous procedure
6) Position the Drop-In Spacer and the Position Rear Slip Plate Housing on locator
Roll-Back Platform, Fig 1. Using the holes in pins, Fig 3.
the side of the Roll-Back Platform as a
9) Attach Linch Pin chain strap to Slip Plate
template, drill (2) 13/32” holes for both
Housing, Fig 3.
runways. Mount platforms using 3/8” flange
Note: The Slip Plate Housing has (5) 9/16” holes
bolts and nuts provided.
spaced 12” apart to fit over the Rear Locator
Pins. The housing may be shifted (without the
use of any tools) forward or rearward 12” to
accommodate a wider range of wheelbases.
AFTER INSTALLING REAR LOCATOR PINS,

HOUSING MAY BE SHIFTED 12" FORWARD
OR REARWARD BY USING EXTRA LOCATOR HOLES
19 1 4
12
24 263 8
(4) PLACES
ATTACH LINCH PIN CHAIN TO 15 8

OUTSIDE EDGE OF HOUSING
765 8
Fig 3 – Rear Slip Plate Housing Locations
Page 3 1/30/04
40229.doc
PARTS BREAKDOWN
5
7 8
1
7 8
Fig A. Bolt-On Alignment Kit #40200-3D
PARTS BREAKDOWN
ITEM # PART # QTY/ LIFT DESCRIPTION
1 40290 2 SLIP PLATE HOUSING

2 40222 16 BALL RETAINER SUB-ASSEMBLY
3 40211 192 DELRIN BALL
4 40214 2 SLIP PLATE
5 40220 4 LINCH PIN
6 40216 4 REAR LOCATOR
7 A1153 12 3/8-16NC x 3/4Lg HEX.FLG.HD.CAP SCREW
8 A1154 12 3/8-16NC HEX.FLG.NUT
9 40292 2 ROLL-BACK PLATFORM
11 40295 2 HANDLE
12 40291 4 GUIDE BAR
13 40299 12 #10-24NC x 1”Lg SOC.HD.CAP SCREW
14 055-127 12 #10-24NC HEX.LOCK NUT
Page 4 1/30/04
40229.doc
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
Four Post
Surface Mounted Lift
Model 40000
Open Front
(12,000 lb Capacity)

Office 800-648-5438 / 502-625-0700 Fax 502-587-1933

Rev. 7/5/05
40404.doc
Model 40000 Open Front
GENERAL SPECIFICATIONS MODEL: 40 [E OR X] [A OR F] [O OR X]

[LENGTH)] [ALIGN OR FLAT DECK] [OPEN OR CLOSED FRONT]
SPECIFICATIONS 40EAO 40XAO 40EFO 40XFO
A Length Overall 20' 9" 23' 20' 9" 23'
B Width Overall 11' 10" front - 10’ 10 3/4” rear
C Inside Columns 120" front - 116" rear
D Between Columns 16’ 3” 18’ 6½” 16’ 3” 18’ 6½”
E Height of Columns 99 1/2" front - 90 1/2" rear
F Height of Runways 7"
G Width of Runways 20"
H Width Between Runways 43"
I Maximum Wheelbase * 182 1/2" 210" 182 1/2" 210"
J Max. 2 Wheel Alignment 166 1/2" 194" N/A
K 4 Wheel Alignment 88" - 158" N/A
L Rise Height 78"
Lifting Capacity 12,000 lbs.
Air Supply Required 85-115 psi Clean & Dry
Motor 2HP
Voltage (Single Phase Std.) ** 208v-230v
Speed of Rise 70 Seconds (approximate)
Min. Recommended Bay Size 12' x 24' 12' x 26' 12' x 24' 12' x 26'
* Wheelbase is based on a tire diameter of 30”
** Optional 3 phase, 50/60Hz, 208, 230 or 460V available.
18" 9"
1"
92
1"
162 BASE PLATE
IDLER RUNWAY
H DIAGONALS TO BE WITHIN 1/4"

C
B
G POWER RUNWAY
33"
A
2' MIN.
TO NEAREST
OBSTRUCTION
D
E
L
1"
82 19"
Fig 1 – General Specifications and Service Bay Layout

2 Rev. 7/5/05
40404.doc
VERTICAL CLEARANCE Safety decals similar to those shown here are

found on a properly installed lift. Be sure that all
Check the height of the area where the lift is to be safety decals have been correctly installed on the
installed. Clearance should be calculated based on Power Unit reservoir. Verify that all authorized
the full raised height of the lift. operators know the location of these decals and
Failure by purchaser to fully understand their meaning. Replace worn,
WARNING provide adequate clearance faded, or damaged decals promptly.
could result in Do not attempt to raise a
unsatisfactory lift performance, property WARNING vehicle on the lift until the
damage, or personal injury. lift has been correctly
FLOORING installed and adjusted as described in this
manual.
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.
Failure by purchaser to
WARNING provide the recommended
mounting surface could
result in unsatisfactory lift performance,
property damage, or personal injury.
ELECTRICAL REQUIREMENTS
For lift installation and operation for single
phase units, it is necessary to have a dedicated
circuit with a double pole 25 amp circuit breaker
or time delay fuse.
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.
3 Rev. 7/5/05
40404.doc
RECEIVING Component Packing List

The shipment should be thoroughly inspected as ITEM QTY/
DESCRIPTION
soon as it is received. The signed bill of lading is # LIFT
acknowledgement by the carrier of receipt in good 1 1 POWER RUNWAY ASS’Y.
condition of shipment covered by our invoice.
2 1 IDLER RUNWAY ASS’Y
If any of the goods called for on this bill of lading
3 2 FRONT COLUMN ASS’Y
are shorted or damaged, do not accept them until
the carrier makes a notation on the freight bill of 4 2 REAR COLUMN ASS’Y
the shorted or damaged goods. Do this for your 5 2 ENTRANCE RAMP WELD
own protection.
6 1 FRONT POWER CROSS BEAM
NOTIFY Challenger Lifts AT ONCE if any hidden
7 1 FRONT IDLER CROSS BEAM
loss or damage is discovered after receipt.
8 1 REAR CROSS BEAM ASS’Y
IT IS DIFFICULT TO COLLECT FOR LOSS OR
DAMAGE AFTER YOU HAVE GIVEN THE 9 1 POWER UNIT
CARRIER A CLEAR RECEIPT. 10 1 HARDWARE BOX
File your claim with Challenger Lifts promptly. 11 2 MOVABLE WHEEL CHOCK
Support your claim with copies of the bill of lading,
12 2 FRONT WHEEL STOP
freight bill, and photographs, if available.
13 2 WORK STEP (alignment lifts only)
14 2 SHIPPING BRACKET WELD
15 8 ½” SHIPPING HARDWARE
INSTALLATION
IMPORTANT: Always wear safety glasses while installing lift.
TOOLS (MINIMUM REQUIRED)

a. Tape measure, 25ft
b. Chalk line
c. 4ft level
d. 10” & 12” adjustable wrench
e. Standard open end wrenches 3/8”, 7/16”, 1/2",
9/16”, 5/8”, (2) 11/16”, 3/4", 15/16”
f. Box knife
g. Thread locking compound
h. Thread tape sealant (for air line)
i. Needle nose pliers
j. Hammer drill with 3/4” diameter carbide tipped
bits
k. 2lb hammer
l. Torque wrench: 150 foot pounds minimum with
1 1/8” socket
m. 8 ft. Step ladder
n. Blocking – (4) 4x4x30”, (4) 1x4x12”
o. Transit for leveling alignment lift
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 pull threaded cable
ends out. Make sure the cables are in the
proper sheaves at the 4-stack, Fig 3.
Fig 2 – Package Components
4 Rev. 7/5/05
40404.doc
long 4x4’s spanning the width of the runway
and four 12” long 1x4’s to shim up the jack-rail
side of the runway. Cable #1, #3, & #4 should
be extending out from the rear of the power
runway and cable #2 from the front of the
power runway, Fig 4.
4) Reach in through either of the access holes in
the rear cross beam tube and pull out the roll
of 1/8” dia. plastic air line connected to the air
cylinder at the end of the cross beam. Repeat
for opposite access hole and position the cross
Fig 3 – Power Runway 4-Stack (rear view) beam near the end of the runways as in Fig 4.
3) Position runways on blocking (see Fig 4) per
layout lines established in step 1. Use four 30”
Fig 4 – Runway Layout

5) Remove the two sheaves from the rear cross
beam and the two sheaves from the idler
runway. The runway sheave pins do not need
to be removed, just lowered enough to remove
the sheaves.
6) Starting from the bottom of the stack, route
cable #4 through the access hole and up out
the left end of the beam. Repeat for cable #3
out the right end of the beam. Route cable #1
through the access hole, and back out the idler
Fig 5 – Runway Single-Stack (typical for front of
side access hole. Look through the idler power runway and front & rear of idler)
end of the cross beam and ensure that
cable #1 and #3 have not crossed. Route 8) Attach the rear cross beam to the runways
cable #1 through the idler runway (don’t forget (Fig. 4) with ½” x 1 ¼” lg. flange head bolts
to route it up over the cross-braces in the being careful not to pinch the air line. Leave
bottom of the runway). the air lines hanging out the bottom of the
7) Reinstall the cross beam sheaves (one thin cross beam access holes at this time, they will
plastic bearing on each side of each sheave) be fed in through the runway after the lift is
and the idler runway sheaves (2 1/8” long raised. The outermost runway slots should
spacer bushing on the bottom then 1/8” thick be in line with the outermost holes in the
bearing, sheave, and 1/8” thick bearing, Fig 5). top of the cross beam, see Fig. 4. Do not
torque bolts yet.
5 Rev. 7/5/05
40404.doc
9) Check the layout of the lift in the bay. (This is
the last opportunity to reposition the lift. If
there is any question about where the front
column anchors or power unit are going to
end up, complete steps 21 - 24 first and
come back to this step). 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 ¼”, Fig 6.
SIDE TO SIDE TO BE IDENTICAL

DIAGONALS TO BE WITHIN 1/8"
Fig 8 – Slide Block Installation
13) Raise the locking ladder, push the column
against the slide blocks, and lower the ladder
into the slide blocks, Fig 9.
LOCKING
COLUMN
Fig 6 – Final Runway Positioning LADDER
10) Center rear cross beam bolts with slots in

runway and tighten. (Be careful not to move
runways.)
REAR COLUMNS
11) Stand up both rear (small) column assemblies
near the rear corners of the lift and check the SLIDE
locking ladder bar orientation per Fig 7. Note BLOCK
that the center of the threaded rod is offset
(away from the back of the column) from the
center of the ladder. Thread the locking ladder
jam nut (located under the column top plate)
down approximately 6” to allow the ladder to
be lifted freely.
Fig 9 – Locking Ladder Orientation
14) Repeat for idler side rear column.
ANCHORING (rear columns only at this time)
THREADED 15) The anchor bolts must be installed at least 8”
ROD from any crack, edge, or expansion joint.
16) Use a concrete hammer drill with a 3/4 inch
LOCKING carbide bit. Tip diameter should conform to
LADDER ANSI Standard B94.12-1977 (.775 to .787). Do
BAR
not use excessively worn bits or bits which
have been incorrectly sharpened. A core bit
Fig 7 – Locking Ladder Orientation may be necessary if an obstruction is
12) Slide power side column onto cross beam until encountered. Never substitute with shorter
the 5/16-18NC threaded holes in the side of anchor.
the beam are just exposed. Position slide 17) Drill the anchor holes using the base plate as a
blocks as shown in Fig 8 and attach with template. Drill through the floor if possible or to
5/16x3/4 bolts (apply thread locking compound a depth of 5 inches minimum.
before installing). 18) Vacuum dust from the hole for proper holding
power.
6 Rev. 7/5/05
40404.doc
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 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.
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 away from each other.
FRONT COLUMNS
21) Position the two front columns near the front
corners of the lift and insert the front cross Fig 11 – Front Cross Beam Installation
beams as shown in Fig 10. Notice that the
front columns are identical, but the cross 23) Attach the cross beam to the runway with ½” x
beams are not. 1 ¼” lg. flange head bolts being careful not to
pinch the air line. (Leave the air line hanging
FRONT CROSS BEAM out the bottom of the cross beam access holes
at this time, it will be fed in through the runway
after the lift is raised.) Center the cross beam
bolts with slots in runway while squaring the
cross tube with the runway (gap between the
front of the runway and cross tube should be
the same on both sides of the runway).
Torque runway bolts to 60-80 foot pounds.
24) Repeat for idler side cross beam.
25) Insert stack cable latch disengaging tool inside
power side front cross beam and engage the
groove at the top end of the tool with the latch
roller shaft as shown in Fig 12. Push the slack
lock latch back into the column while rotating
the bottom of the tool upward and engage the
bottom groove of the tool in the cross beam.
This will allow the column to be moved into
position without resistance from the slack lock.
Fig 10 – Front Cross Beam Installation
26) POWER COLUMN ONLY – Thread the front
22) Ensure that the power side front cross beam is power side locking ladder jam nut (located
touching the power column base plate and under the column top plate) down
stand the column up. Move the column into approximately ½”. Remove 1/2" x 3/4" lg. lock
position and remove the cross beam sheave. ladder securing bolt from bottom of column
Reach in through the access hole in the cross and rock the ladder to one side to allow access
beam tube and pull out the 6 ft. roll of 1/8” dia. to power unit mounting holes and insert two
plastic air line connected to the air cylinder at 5/16” x 1” flange head bolts from the inside out
the end of the cross beam. Feed cable #2 into and secure with 5/16” flange nut, Fig 13. Shift
the cross beam access hole and back out the ladder to opposite side and install remaining
top, Fig 11. two power unit bolts. Reinstall lower ladder
bolt.
7 Rev. 7/5/05
40404.doc
30) After properly shimming column plumb, loosen
anchors and add one shim to both of the two
inside anchors to lean the column outward
slightly. Make sure lower roller wheels are in
contact with column and torque anchor bolts to
150 foot pounds.
Fig 14 – Front Column Shimming

31) Repeat steps 25-30 (excluding step 26) for
idler side.
32) Install the four cable ends with one flat washer,
one load nut, and one jam nut.
33) Install the power unit and the air button valve
assembly on the power column, Figs 13 & 15.
Fig 12 – Slack Cable Latch Disengaging Tool
Fig 15 – Air Button & Power Unit Mounting

34) Install O-Ring end of 90 degree hydraulic
elbow (9/16-18 O-Ring x 37° Male JIC) to
power unit output port. The hydraulic hose is
Fig 13 – Power Unit Mounting Bolts pre-installed to the hydraulic cylinder and
secured inside the runway. Pull loose end out
27) Push the power column against the two roller through the opening and attach to the elbow
wheels located on the lower portion of the fitting.
cross beam. The upper roller wheels should
not be touching the column at this time. If they Do Not Use Teflon Tape or Pipe Dope on fittings.
are, roughly shim the column plumb, then shim 35) Have a certified electrician connect the power
up the blocking on the jack-rail side of the unit to a suitable electrical power source. The
runway. standard power unit is 208/230 volt 60 Hz
28) Recheck the four measurements from Fig 6. single phase requiring a dedicated 25 amp
double poll, double throw circuit breaker to
29) After ensuring column is touching lower wheels operate lift at full capacity.
and not the upper wheels, drill and install
anchors per steps 15-21.
8 Rev. 7/5/05
40404.doc
36) BE CERTAIN ALL FITTINGS AND CONNECTIONS 43) Energize air valve assembly and insure that all
ARE TIGHT. IT IS THE INSTALLERS RESPONSIBILITY air cylinders are working properly.
TO INSURE SYSTEM IS LEAK-FREE. Fill the Power 44) Raise and lower lift several times to bleed
Unit with three gallons of clean 10wt anti-foam hydraulic cylinder. Hydraulic cylinder is self
anti-rust hydraulic oil or Dexron III ATF. DO bleeding. Lower lift and check fluid level in
NOT USE OILS WITH DETERGENTS. reservoir. Add fluid as needed.
37) Energize the power unit and raise the lift 45) Run lift to full rise and continue running motor
approximately 1 ft off the ground and look approximately 5 more seconds. Check
underneath the power runway to verify that the hydraulic hose and connections for leaks. Re-
cable lugs are resting firmly against the tighten fitting if leaking.
cylinder pull bar.
46) Raise lift approximately half way. Slowly jog
38) For flat deck style runways, level the runways power unit until you hear one of the locks
and crossbeams using a 4 ft. level. With the lift engage. Adjust locking ladder until it just barely
resting in its locks, find the highest corner and raises the crossbeam end. Back off 1/2 turn.
adjust the other three column ladder bars until Repeat for each column.
the runways are level front-to-rear and side-to-
side. Tighten jam nut against bottom side of ALIGNMENT RUNWAYS
each column top plate. For alignment style 47) Lower lift and raise to check for lock
runways, use a transit for leveling runways engagement. The locks should engage
placing the target in the center of the turn plate simultaneously (clicking noise). Re-adjust
and the center of the rear slip plate (with lift locking ladders as needed.
lowered into locks). Refer to alignment
48) Position Front Turn Plates (SOLD
equipment for leveling tolerance.
SEPARATELY) and install Guide Bars to
39) Adjust cables until all four locks are runway using (3) #10-24 x 1” Socket Head Cap
synchronized when lift is raised. Tighten cable Screws and lock nuts provided. Ensure that
jam nuts against adjustment nuts. the Turn Plates will slide freely and tighten
40) Install 1/8” air line from air valve assembly thru Guide Bars.
opening in runway to Tee. Fig 16 49) Attach Work Step to each runway. (The Work
Step may be located in three different positions
1/8" TEE FACTORY on each runway.)
1/8" SPLICE AT EACH BOTH ENDS
50) Install Handle to Drop-In Spacer and position
behind rear Guide Bar. The Drop-In Spacer is
provided for “Roll Back” alignment.
FRONT
REAR
1/8" TEE
1/8" AIR LINE
POWER UNIT
AIR VALVE ASSEMBLY
Fig 16 – Lock Release Air Line Routing

41) Route power side front and rear cross beam
air lines through power runway to Tee. Route
idler side front and rear cross beam air lines
through idler runway and connect together with
1/8” air line spice provided. Use provided
adhesive tabs and plastic cable ties to secure
air lines inside runways.
42) Connect the button valve to a source of clean,
dry air (filter, regulator, lubricator) using the
hose barb and clamp provided. Failure to
provide clean, dry air will void warranty on
pneumatic components.
Air pressure required 90/120 psi. Fig 16 – Alignment Turn Plate Installation
9 Rev. 7/5/05
40404.doc
Owner/Operator Checklist employer shall insure that the lift inspectors are
qualified and that they are adequately trained in
SAVE THESE INSTRUCTIONS deliver them to the inspection of the lift.
owner/user/employee along with other materials
furnished with this lift. The Owner/Employer shall establish procedures
to periodically maintain the lift in accordance with
Demonstrate the operation of the lift to the the lift manufacturer’s instructions or ANSI/ALIOIM-
owner/operator and review correct and safe lifting 2000, American National Standard for Automotive
procedures using the Lifting It Right booklet as a Lifts-Safety Requirements for Operation,
guide. Inspection and Maintenance; and the employer
shall insure that the lift maintenance personnel are
Complete the Installation Checklist/Warranty qualified and that they are adequately trained in
Validation questionnaire with the owner. Review the maintenance of the lift.
the terms of the warranty registration card, and
return the card and a copy of the questionnaires to: The Owner/Employer shall maintain the periodic
Challenger Lifts, Inc. inspection and maintenance records
200 Cabel Street recommended by the manufacturer or ANSI/ALI
Louisville, KY. 40206 ALOIM-2000, American National Standard for
Safety Notices and Decals Operation, Inspection and Maintenance.
This product is furnished with graphic safety The Owner/Employer shall display the lift
warning labels, which are reproduced on page 3 of manufacturer’s operating instructions; ALI/SM 93 -
these instructions. Do not remove or deface these 1, ALI Lifting it Right safety manual; ALI/ST-90 ALI
warning labels, or allow them to be removed or Safety Tips card; ANSI/ALI ALOIM-2000, American
defaced. For your safety, and the safety of others, National Standard for Automotive Lifts-Safety
read and understand all of the safety notices and Requirements for Operation, Inspection and
decals included. Maintenance; and in the case of frame engaging
lift, ALI/LP-GUIDE, Vehicle Lifting Points/Quick
Owner/Employer Responsibilities Reference Guide for Frame Engaging Lifts; in a
conspicuous location in the lift area convenient to
This lift has been designed and constructed the operator. Demonstrate the operation of the lift
according to ANSI/ALI ALCTV-1998 standard. The to the owner and review correct and safe lifting
standard applies to lift manufactures, as well as to procedure, using the “Lifting It Right “ booklet as a
owners and employers. The owner/employer’s guide.
responsibilities as prescribed by ANSI/ALI ALOIM-
2000, 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-2000, 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-2000, American National Standard for
Operation, Inspection and Maintenance; and the
10 Rev. 7/5/05
40404.doc
Important Safety Instructions MAINTENANCE
When using your garage equipment, basic safety To avoid personal injury, permit only qualified
precautions should always be followed, including personnel to perform maintenance on this
the following: equipment.
1 Read all instructions. The following maintenance points are suggested
2 Care must be taken as burns can occur from as the basis of a preventive maintenance program.
touching hot parts. The actual maintenance program should be
3 To reduce the risk of fire, do not operate tailored to the installation. See ANSI/ALI ALOIM
equipment in the vicinity of open containers of booklet for periodic inspection checklist and
flammable liquids (gasoline). maintenance log sheet.
4 Adequate ventilation should be provided when • If lift stops short of full rise or chatters, check
working on operating internal combustion fluid level and bleed both cylinders per
engines. Installation Instructions.
5 Keep hair, loose clothing, fingers, and all parts • Replace all Safety, Warning or Caution Labels if
of body away from moving parts. missing or damaged.
6 To reduce the risk of electric shock, do not use
on wet surfaces or expose to rain. Daily
7 Use only as described in this manual. Use • Keep lift components clean. To keep
only manufacturer’s recommended alignment lifts with rear slip plates working
attachments. properly use compressed air to blow out any
Save These Instructions debris from the bearing area.
• Check for loose or broken parts.
LIFTING A VEHICLE
• Check hydraulic system for fluid leaks.
Drive vehicle onto lift. Set parking brake and/or use
wheel chocks that are provided with lift. • Check lock release activation.
When the vehicle has reached the desired working
height, release the power pack button, and lower Weekly
the vehicle until the safety locks are engaged. The • Check cables and sheaves for wear or damage.
vehicle should remain level when all locks are Replace as required with genuine Challenger
engaged. If one side engages and the other Lifts parts.
continues to descend, stop lowering the vehicle, • Inspect lock mechanism for proper function.
raise it several inches, and try again to engage
locks. Monthly
IMPORTANT, Before walking under the lift insure • Torque concrete anchor bolts to 80 ft-lbs.
that all locks are properly engaged.
• Clean and inspect cables and sheaves for wear
It is not safe to work under the vehicle unless all or damage. Lubricate cables and sheaves with
locks are engaged, and the vehicle is level. light oil.
LOWERING A VEHICLE
Insure that the area under the vehicle is clear of IMPORTANT ! Failure to keep lift free of
personnel and tools. corrosive agents and solvents will lead
Raise the vehicle until locks are free. to reduced service life, which could
result in property damage and/or
Disengage the locks by depressing the palm personal injury.
button and holding it.
Lower the vehicle by depressing the lowering valve If any problems are encountered,
handle. Watch lift to insure that the lift is lowering contact your local service
evenly. If not, raise lift and check all locks to insure representative
they are disengaged before trying to lower lift Maintenance
again.
Continue to lower the vehicle until the crossbeams
stop against the base plate. It is important to fully
lower the lift to release hydraulic pressure on the
system.
11 Rev. 7/5/05
40404.doc
Parts Breakdown
Fig A. General Layout
11
7
8
5
18
12
4
10
19
2
3
20
22 9
21
12 16
14
13
15
17
12 Rev. 7/5/05
40404.doc

1 44011 1 HYDRAULIC CYLINDER
3 40126 5 1/8 x 1 1/2" Lg. COTTER PIN
40391 FLAT DECK POWER RUNWAY (40XFO)
40381 FLAT DECK POWER RUNWAY (40EFO)
4 1
40396 ALIGNMENT POWER RUNWAY (40XAO)
40386 ALIGNMENT POWER RUNWAY (40EAO)
40393 FLAT DECK IDLER RUNWAY (40XFO)
40383 FLAT DECK IDLER RUNWAY (40EFO)
5 1
40398 ALIGNMENT IDLER RUNWAY (40XAO)
40388 ALIGNMENT IDLER RUNWAY (40EAO)
6 40266 2 WHEEL STOP
7 40083 8 1/2-13NC x 1 1/4" Lg. HEX.FLG.HD.CAP SCREW
40408-P 1 FRONT POWER CROSS BEAM ASSEMBLY
8
40408-I 1 FRONT IDLER CROSS BEAM ASSEMBLY
9 40460 1 REAR CROSS BEAM ASSEMBLY
10 31368-19 1 POWER UNIT 1 PHASE, 60Hz, 208-230VAC
11 40409 2 FRONT COLUMN ASSEMBLY
12 40449-I 2 REAR COLUMN ASSEMBLY
13 40161 2 ENTRANCE RAMP
14 40165 2 RAMP HINGE PIN
15 40168 2 RAMP SLIDE
16 31062 6 1/4-20NC x 3/4" Lg. PAN HEAD SCREW
17 40085 6 1/4-20NC HEX FLANGE NUT
18 40265 2 WHEEL CHOCK
19 16167 1 90 DEGREE ADAPTER ELBOW – MALE #6 O-RING x MALE #6 J.I.C.
40349 1 HYDRAULIC HOSE – FEMALE #6 J.I.C. BOTH ENDS
39101-024 HYDRAULIC HOSE EXTENSION – 2 ft (Model 40E)
21 1
39101-048 HYDRAULIC HOSE EXTENSION – 4 ft (Model 40X)
22 A1121 1 UNION ADAPTER #6 O-RING x #6 JIC 37 deg FLARE
13 Rev. 7/5/05
40404.doc
Fig B. Cables
2 VIEW B
9
10
11
VIEW C
3 A
VIEW A
VIEW B

40472-X1 RIGHT FRONT CABLE #1 (40X)
1 1
40472-E1 RIGHT FRONT CABLE #1 (40E)
40472-X2 LEFT FRONT CABLE #2 (40X)
2 1
40472-E2 LEFT FRONT CABLE #2 (40E)
3 40472-3 1 RIGHT REAR CABLE #3
4 40472-4 1 LEFT REAR CABLE #4
5 40147 4 7/8-9NC HEX NUT
6 40148 4 7/8-9NC HEX JAM NUT
7 40149 4 7/8 FLAT WASHER
8 40438-R 1 2 1/8” SPACER
9 40473 1 CABLE PULL BAR
10 40474 1 CABLE RETAINER WELD
11 44015 2 1 3/8-12NF JAM NUT
14 Rev. 7/5/05
40404.doc
Fig C. Runway Sheaves

1 40050 10 SHEAVE
3 40055 4 SHEAVE PIN WELD (RUNWAY)
5 40438-R 3 RUNWAY SHEAVE SPACER
15 Rev. 7/5/05
40404.doc
Fig D. Rear Cross Beam
2 1 2
18
17 13 19
16
3
20 21
15
14
13
12
11
6
10
7
4
4

1 40050 10 SHEAVE
2 40054 4 1/16” THIN BEARING
3 40118 4 SLIDE BLOCK
6 40122 2 RUBBER SHEAVE GUARD (REAR)
8 40461 1 REAR CROSS BEAM WELD
10 40126 8 1/8” x 1 1/2" Lg. COTTER PIN
16 40137 2 RETAINING RING
17 40135 2 ROLLER
18 40134 2 SLACK CABLE LATCH
16 Rev. 7/5/05
40404.doc
Fig E. Front Cross Beam
40408-P
SHOWN 40420-P

40420-P 1 CROSS BEAM WELD (POWER SIDE)
1
40420-I 1 CROSS BEAM WELD (IDLER SIDE)
2 40126 8 1/8” x 1 1/2" Lg. COTTER PIN
4 40440 2 SLACK LOCK ASSEMBLY
12 40050 10 SHEAVE
14 40438-X 4 SHEAVE SPACER BUSHING (CROSS BEAM)
17 40425 8 WEAR BUTTON
18 40426 16 THRUST BEARING
19 40430 8 ROLLER WHEEL ASSEMBLY
20 40433 4 3/4-10NC x 1” Lg. HEX.HD.CAP SCREW
21 40434 4 3/4" PLAIN WASHER (13/16” I.D. x 2” O.D.)
22 40435 4 ROLLER COVER
24 40443 2 METAL SHEAVE GUARD (FRONT)
17 Rev. 7/5/05
40404.doc
Fig F. Air Lock Release
11
FRONT 12
REAR
12
12
10
4
POWER UNIT 5
AIR VALVE ASSEMBLY 2
7
6
10

1 37015 1 BUTTON VALVE BRACKET
2 37016 1 AIR VALVE
3 40091 1 IN-LINE AIR FILTER
4 37021 1 HOSE BARB
5 37023 2 #8-32 HEX NUT
6 37024 2 #8 LOCK WASHER
7 37022 2 #8-32 x 1 1/4" Lg. PAN HD. SCREW
8 37020 1 1/8” NPT STREET ELBOW
9 37019 1 1/8” NPTM x 1/8” PUSH-LOCK 90 DEGREE ELBOW
10 00901 60 ft. 1/8” DIA. PLASTIC AIR LINE
11 40445 1 1/8” STRAIGHT UNION
12 37032 3 1/8” UNION TEE
18 Rev. 7/5/05
40404.doc
Fig G. Alignment Equipment

1 40291 4 GUIDE BAR
2 40299 12 #10-24 x 1” SOC.HD.CAP SCREW
3 055-127 12 #10-24 HEX LOCK NUT
5 40295 2 HANDLE
6 40506 2 WORK STEP
7 40530 2 REAR SLIP PLATE WELDMENT
8 40220 4 PIN ASSEMBLY
9 40211 196 3/4" DIA. BALL
10 40525 2 BALL RETAINER ASSEMBLY
40526 2 BALL RETAINER SHEET
40527 28 STAND-OFF PIN
40528 28 STAND-OFF SPACER (GROMMET)
40221 24 1/2" DIA. EXTENSION SPRING
40219 8 7/8” INTERNAL TOOTH LOCK WASHER
19 Rev. 7/5/05
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INSTALLATION, OPERATION

& MAINTENANCE MANUAL

200 Cabel Street, P.O. Box 3944 Louisville, Kentucky 40201-3944

Office 800-648-5438 / 502-625-0700 Fax 502-587-1933

GENERAL SPECIFICATIONS MODEL: 40 [E OR X] [A OR F] [O OR X]

H DIAGONALS TO BE WITHIN 1/4"

Fig 1 – General Specifications and Service Bay Layout

VERTICAL CLEARANCE Safety decals similar to those shown here are

PROPER MAINTENANCE AND

DO NOT OPERATE A DAMAGED LIFT.

RECEIVING Component Packing List

TOOLS (MINIMUM REQUIRED)

Fig 4 – Runway Layout

Fig 7 – Final Runway Positioning

Fig 12 – Lock Release Air Line Routing

Fig 16 – Alignment Turn Plate Installation

The Owner/Employer shall insure that lift

The Owner/Employer shall establish procedures

Replace all worn or broken parts with genuine Challenger Lifts

ITEM # PART # QTY/LIFT DESCRIPTION

ITEM # PART # QTY/LIFT DESCRIPTION

ITEM # PART # QTY/LIFT DESCRIPTION

ITEM # PART # QTY/LIFT DESCRIPTION

ITEM # PART # QTY/LIFT DESCRIPTION

ITEM # PART # QTY/LIFT DESCRIPTION

Lift Capacity....................................................... 6000 lbs. (2722 kg)

3) Place jack assembly on lift rack rails.

3) Raise jack by moving the Control Lever to the “RAISE” position.

DAILY - Inspect air/hydraulic system for leaks.

ANNUALLY - Check hydraulic pump fluid level (see below).

FLUID LEVEL CHECK & FILL PROCEDURE

2) Locate the two 1/4” spring pins in the pivot

3) Remove the two 1/2” allen head screws (Fig. 1).

4) Remove the top section of the jack.

5) Completely lower the jack lift arms. Fig. 1

6) Block up the “cylinder end” of jack about 6 inches.

7) Wipe area around filler plug to prevent contamination

8) Fill as required with ATF, Dextron II, or 5605 oil.

9) Remove blocks and level jack. Top off fluid to the

AIR LINE ACCESSORY KIT

INSTALLATION, OPERATION & MAINTENANCE MANUAL

OFFICE (502) 625-0700 FAX (502) 587-1933

Page 2 Rev. 5/17/04

3/8" Plastic Hose

3/8" Hose Clamp

3/8" Plastic Hose

3/4-16 Hex Nut

1/4" NPT Swivel 3/4-16 Anchor

Page 3 Rev. 5/17/04

1/2-13 x 1" Lg 1/2" Lock Washer

3/8" Dia. Coiled

Page 4 Rev. 5/17/04

3/8" Hose Clamp

Page 5 Rev. 5/17/04

200 Cabel Street, P.O. Box 3944 Louisville, Kentucky 40201-3944

Office 800-648-5438 / 502-625-0700 Fax 502-587-1933

IMPORTANT: READ THIS MANUAL COMPLETELY BEFORE

GENERAL SPECIFICATIONS AND LAYOUT

83" MIN. TO 150" MAX. WHEEL BASE