Challenger Lifts CLHM-140 Wireless Portable Lift System Installation Guide
- June 1, 2024
- Challenger Lifts
Table of Contents
- Challenger Lifts CLHM-140 Wireless Portable Lift System
- Product Specifications
- Product Usage Instructions
- Frequently Asked Questions (FAQ)
- CLHM-140 Assembly
- Front Caster Arm Subassembly & Hydraulic Handle Subassembly
- Hydraulic Power Unit
- Electrical Components
- Placards
- References
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
Challenger Lifts CLHM-140 Wireless Portable Lift System
Product Specifications
- Product Name: CLHM-140 Wireless Portable Lift System
- Manufacturer: Challenger Lifts
- Contact Information:
- Email: sales@challengerlifts.com,
- Web: www.challengerlifts.com
- Phone: 800-648-5438 / 502-625-0700,
- Fax: 502-587-1933
Product Usage Instructions
Assembly:
Follow the assembly instructions provided in the manual for proper setup of
the CLHM-140.
Front Caster Arm Subassembly & Hydraulic Handle Subassembly:
- Grease bore of Item 7 using EP-1 yellow grease.
- Apply Loctite C5-A copper antiseize or equivalent to Item 2.
Hydraulic Power Unit:
- Ensure proper torque ranges are maintained for cartridge and solenoid coil nuts.
- Apply EP-1 yellow grease as specified in the manual.
- Apply removable thread locker to Item 18 and torque to 15-19 ft-lb.
Electrical Components:
- Torque nuts on Item 42 to 72-90 in-lb after installing Item 43.
- Torque 10-32 nuts on Item 38 to 15-30 in-lb. Torque M8X1.25 nuts on Item 38 to 80-100 in-lb.
- Torque motor nuts on Item 35 to 96-120 in-lb after installing motor cables.
Frequently Asked Questions (FAQ)
-
What is the torque range for the solenoid coil nut?
The torque range for the solenoid coil nut is 5-7 ft-lb. -
How many items are required for the Front Caster Arm Subassembly?
The Front Caster Arm Subassembly requires a total of 10 items as listed in the manual.
CLHM-140 Assembly
| ITEM | QTY | PART NUMBER | DESCRIPTION |
|---|---|---|---|
| 1 | 2 | 957-01020 | Front Caster Arm Subassembly (See Page 4) |
| 2 | 2 | 200-31718 | Capscrew, Hex Hd,3/4-10 UNC, Stl,Gr 5,Pl, 4″ Lg |
| 3 | 2 | 203-01710 | Nut, Hex, 3/4-10UNC, Grade 5, Steel, Plated, Self Locking |
Insert
4| 2| 957-04046| Spacer, Bottom
5| 2| 480-01021| Roller Wheel
6| 1| 353-45026| Cylinder, Hydraulic
7| 1| 274-12020| Adapter, Straight, -6 SAE O-Ring Male X 1/4 NPT Female
8| 1| 275-01044| Nipple, 1/4 NPT, 4″ Long, Schedule 80, Steel
9| 1| 275-11011| Elbow, 1/4 NPT Female X 1/4 NPT Female, Steel
10| 1| 274-12017| Adapter, Straight, -6 SAE O-Ring Female X 1/4 NPT Male
11| 1| 353-60002| Flow Limiter, -6 SAE O-Ring X -6 ORS, 1.2 GPM
12| 1| 390-90005| Grommet, Rubber, 13/16 ID, 1-3/8 OD, 3/4 Th, 1.000 Panel
Hole
13| 1| 936-04094| Hydraulic Handle Assembly (See Page 4)
14| 4| 200-31409| Capscrew, Hex Hd, 1/2-13 UNC, Stl,Gr 5,Pl,1-3/4″ Lg
15| 4| 203-01403| Nut, Hex, 1/2-13, Steel, Plated, Grade 5, Nylon Self Locking
16| 1| 271-24013| Hose Assembly, 3/8″ X 86.000″ Long
17| 2| 400-50000| Grease Fitting, 3/16 Drive
18| 6| 200-31607| Capscrew, Hex Head, 5/8 – 11UNC, Steel, Grade 5, Plated,
1-1/4″ Long
19| 2| 441-59028| Bearing, Plain, Linear Slide Block, UHMW
20| 1| 204-02201| Washer, 1-7/8 O.D. X 1-3/8 I.D. X 1/16, Steel, Plated
21| 1| 230-14002| Retaining Ring, External, 1-1/4″ Dia.
22| 1| 957-04154| Position Transducer Cable Mount Bracket
23| 1| 232-10021| Rod End, Clevis, 10-32 Female Thread, Plastic
24| 1| 202-00829| Screw, Pan Head, 10-32UNF, 3/8″ Long, w/ Ext Lock Washer,
Stl, Black
25| 4| 200-31409| Capscrew, Hex Hd, 1/2-13 UNC, Stl,Gr 5,Pl,1-3/4″ Lg
26| 1| 204-01403| Washer, Flat, 1/2, Type A, Wide, Steel, Plated
27| 2| 201-41401| Capscrew, Socket Hd, 1/2-13 UNC, Stl, Pl, 1.500″ Long
28| 2| 203-01400| Nut, Hex, 1/2-13 UNC, Reg. Steel, Plated
29| 2| 204-11400| Washer, Lock, 1/2,Split Type, Steel, Plated
30| 2| 441-59030| Bearing, Plain, Linear Slide Pad, UHMW, Ø1.500 OD X .530 ID
31| 4| 201-00702| Capscrew, Socket Hd, #8-32 UNC, Stl, Pl, 1/2″ Long
32| 8| 204-20701| Washer, Lock, #8 Internal Tooth,Type A, Stl, Pl
33| 2| 957-04105| Downstop Linkage
34| 4| 202-81000| Shoulder Bolt, 1/4-20, 5/16 Shoulder X 3/8 Lg, Stl
35| 1| 235-20002| Roll Pin, 1/8 Dia. X 1″ Long
36| 1| 957-04177| Downstop
37| 1| 957-04179| Solenoid/Downstop Connecting Link
38| 1| 233-19004| Spring, Compression, Conical, .840 X 1.125 O.D.
39| 1| 957-04079| Down Stop Solenoid Bracket
40| 4| 203-61101| Threaded Insert, Rivet Nut, 5/16-18 UNC, .615 Lg, Steel
41| 4| 202-01106| Capscrew, Hex Hd, Flange Lock, 5/16-18 UNC, Gr 5, Plt, 5/8
Lg
42| 1| 591-00110| Solenoid, Encapsulated, 24 VDC, w/ Custom Plunger
43| 4| 201-00700| Capscrew, Socket Hd, #8-32 UNC, Stl, Pl, 1/4″ Long
44| 1| 593-20177| Wire Assembly, Down Stop Switch
45| 1| 936-04172| Down Stop Switch Plunger
46| 2| 201-00408| Capscrew, Socket Hd, #4-40 UNC, Stl, Pl, 1.500″ Long
47| 2| 203-00501| Nut, Hex, #4-40 UNC, Self Locking
48| 1| 936-04175| Down Stop Switch Mounting Block
49| 1| 591-00100| Position Transducer, String Potentiometer
50| 1| 957-04153| Position Transducer Bracket, Upward Cable Feed
Front Caster Arm Subassembly & Hydraulic Handle Subassembly
| ITEM | QTY | PART NUMBER | DESCRIPTION |
|---|---|---|---|
| 1 | 1 | 233-15008 | Spring, Compression, 1.937 O.D., 4″ Free Length |
| 2 | 1 | 936-04089 | Spring Guide Pin |
| 3 | 1 | 957-02013 | Caster Pivot Arm Weldment |
| 4 | 1 | 202-80002 | Bolt, Shoulder, 3/8-16 UNC X 1/2 Dia X 2 1/4 Lg Shoulder, |
Stl, Pl
5| 4| 203-01202| Nut, Hex, 3/8 – 16UNC, Steel, Plated, Self Locking
6| 1| 204-01414| Washer, Flat, 1/2″, Type A, Narrow, Extra Thick
7| 1| 480-00035| Wheel, 3 1/2 O.D. X 1/2 Bore
8| 1| 936-02007| Handle Bracket Weldment
9| 1| 936-04094| Hydraulic Handle
10| 1| 936-04235| Chain Cover
11
| ****
2
| ****
202-00826
| Screw, Pan Head, 10-32UNF, 5/8″ Long, w/ Ext Lock Washer, Stl, Black Ox
12| 2| 203-60802| Threaded Insert, Rivet Nut, 10-32 UNF, .475 Lg, Steel
13| 3| 200-31207| Capscrew, Hex Head, 3/8-16UNC, Steel, Grade 5, Plated, 1
1/4″ Long
14| 1| 200-31106| Capscrew, Hex Head, 5/16 – 18UNC, Steel, Grade 5, Plated, 1″
Long
15| 1| 203-01101| Nut, Hex, 5/16 – 18UNC, Regular, Steel, Plated
16| 1| 203-00805| Nut, Hex #10-24UNC, Steel, Plated, Nylon Insert (Locknut)
17| 1| 936-04236| Plunger Cap
18| 1| 936-04234| Handle Release Cable Extension
Hydraulic Power Unit
| Item | QTY | PART NUMBER | DESCRIPTION |
|---|---|---|---|
| 1 | 1 | 591-00068 | 24 VDC Motor |
| 2 | 1 | 353-49387 | Hydraulic Pump Block |
| 3 | 1 | 353-60012 | Reservoir, Poly, 9 X 10 X 16 |
| 4 | 1 | 231-06001 | Clamp, Hose, Screw Adjustable, 3.750 – 4.625 Dia. |
| 5 | 1 | 353-60013 | Breather, 3/4″ NPT |
| 6 | 1 | 274-06001 | Adapter, 90 Deg, -6 SAE O-Ring Male X -6 ORS Male |
| 7 | 1 | 274-22003 | Adapter, Tee, -6 SAE O-Ring Male X Female X Female |
| 8 | 4 | 201-01002 | Capscrew, Socket Head, 1/4-20UNC, Steel, 5/8″ Long |
| 9 | 4 | 204-01005 | Washer, Flat, 1/4 Narrow Rim, Steel, Plated |
| 10 | 1 | 353-50021 | Dump Valve, 24 VDC |
| 11 | 1 | 353-50009 | Check Valve |
| 12 | 1 | 353-49406 | 3/8 NPT Pipe Nipple, SCH 80, PVC, 12″ Lg |
| 13 | 1 | 275-23001 | Bushing, Reducing, 1/2 NPT X 3/8 NPT |
| 14 | 1 | 275-13001 | Elbow, Street, 1/2 NPT |
| 15 | 1 | 353-60014 | Tank Mount Strainer, 1/2″ NPT X 1″ NPT |
| 16 | 1 | 353-49407 | 3/8 NPT Pipe Nipple, SCH 80, PVC, 10″ Lg |
| 17 | 1 | 353-10001 | Hydraulic Gear Pump, 2.1 cc/rev |
| 18 | 2 | 201-01116 | Capscrew, Socket Head, 5/16-18UNC, Steel, 3″ Long |
| 19 | 1 | 353-50005 | Relief Valve |
| 20 | 1 | 353-50008 | Needle Valve |
| 21 | 1 | 353-50022 | Holding Valve, 24 VDC |
| 22 | 1 | 353-60008 | 24V Coupler |
| 23 | 1 | 353-60007 | Motor Coupler Sleeve |
| 24 | 1 | 353-60006 | Pressure Transducer, 0-3500 psi |
| 25 | 1 | 353-50020 | Proportional Valve, 24 VDC |
Electrical Components
| ITEM | QTY | PART NUMBER | DESCRIPTION |
|---|---|---|---|
| 1 | 1 | 957-02027 | Cabinet Weldment, 10.1″ Screen |
| 2 | 1 | 593-10062 | RF Antenna, 2.4GHz, RP-SMA Male |
| 3 | 5 | 591-00053 | Plug, Enclosure Ø.750 |
| 4 | 1 | 957-04101 | Hinge, Top Cover |
| 5 | 17 | 202-00829 | Screw, Pan Head, 10-32UNF, 3/8″ Long, w/ Ext Lock Washer, |
Stl, Black
6| 18| 203-10802| Nut, Hex, w/ External Lock Washer, 10-32, Stl, Pl
7| 1| 591-00127| Switch, Battery, Single Circuit
8| 1| 957-04159| Battery Switch Conversion Plate, Blue Sea – Cole Hersee
9| 20| 202-00826| Screw, Pan Head, 10-32UNF, 5/8″ Long, w/ Ext Lock Washer,
Stl, Black
10| 1| 591-00111| Charger Inlet w/ Cord
11| 9| 202-00824| Screw, Pan Head, 10-32UNF, 3/4″ Long w/Ext Lock Washer, Stl,
Blk
12| 1| 591-00142| Switch, E-Stop, Push-Pull, 22 mm
13| 2| 591-00143| Contact Block, Normally Closed
14| 1| 957-04169| Lower Cover, 10.1″ Screen
15| 4| 203-60804| Threaded Insert, Rivet Nut, 10-32 UNF, .585 Lg, Steel
16| 1| 957-04167| Cabinet, Door, 10.1″ Screen
17| 1| 593-30095| Control Box Assembly, Metal
18| 1| 957-04170| Mounting Bracket, Lester to NOCO Charger
19| 1| 591-00105| Battery Charger, Dual Bank, NOCO, 4A/Bank
20| 4| 202-00602| Screw, Pan Head, #6-32 UNC, Stl, Pl, 1.000 Lg
21| 4| 203-00601| Nut, Hex, 6-32 UNC, Steel, Plated, Nylon Locknut
22| 1| 957-04168| Cabinet, Top, 10.1″ Screen
23| 1| 593-30073| LED Subassembly, 24 VDC, Green
24| 1| 591-00013| Push Button Switch
25| 1| 957-04080| Switch Bracket
26| 4| 202-00819| Screw, Pan Head, 10-32UNF, Steel, 1/2″ Long w/ External Lock
Washer
27| 1| 591-00012| Toggle Switch
28| 3| 591-00085| Terminal Insulator Cap, 8-2 AWG, Red
29| 2| 680-00188| Cap Plug, 9X, Red
30| 2| 237-00006| Strap Assembly
31| 2| 591-00069| Battery, Group 31, Wet Cell
32| 4| 204-01109| Washer, Flat, 5/16″ Dia., Type B, Narrow Rim, Stainless
33| 4| 204-11104| Washer, Lock, Split Type, 5/16″, Stainless
34| 1| 957-04145| Latch, Draw, Lockable
35| 1| 353-40146| Power Unit Assembly, 24 VDC Valves
36| 2| 202-01235| Capscrew, Hex Head, Flange Lock, 3/8 – 16UNC, Plated, 3/4″
Long
37| 1| 593-30074| LED Subassembly, 24 VDC, Yellow
38| 1| 591-00109| Series Contactor, 24 DC Coil
39| 26| 203-60802| Threaded Insert, Rivet Nut, 10-32 UNF, .475 Lg, Steel
40| 2| 202-00818| Screw, Pan Head, 10-32UNF, Steel, 1″ Long with External Lock
Washer
41| 1| 957-04074| Components Mounting Bracket
42| 1| 591-00065| Fuse Block, High Amp, UL Listed
43| 1| 591-00049| 200 Amp Fuse
44| 1| 591-00108| Relay, SPDT, 24 VDC Coil
45| 1| 593-10132| Terminal Block, Carrier, 2+1 Pos, 22-12 AWG, WAGO
46| 1| 593-10133| Terminal Block, Component Plug, WAGO
47| 1| 593-02147| Diode, Schottky, 60 V, 1.0 A, Thru Hole
48| 9| 593-10128| Terminal Block, Feed Thru, 2 Conductor, 22-14 AWG, WAGO
49| 3| 593-10131| End Retainer, Screwless, 35mm DIN Rail, WAGO
50| 1| 593-10129| Jumper, Terminal Block, 5 Pole, WAGO
51| 4| 593-10134| Terminal Block, Fuse, 2 Conductor, 22-12 AWG, WAGO
52| 1| 593-10135| Jumper, Terminal Block, 2 Pole, WAGO
53| 1| 040-00021| DIN Rail, 35mm X 7.5mm, 5.746″ Long
54| 2| 591-00144| Fuse, Blade, 3A, Mini/ATM Size
55| 2| 591-00137| Fuse, Blade, 7.5A, Mini/ATM Size
56| 2| 593-10130| Jumper, Terminal Block, 2 Pole, WAGO
Placards
| Item | QTY | PART NUMBER | DESCRIPTION |
|---|---|---|---|
| 1 | 1 | 670-00030 | Identification Placard, “G” |
| 2 | 1 | 670-00309 | ID Placard, Master ON/OFF Switch |
| 3 | 1 | 670-00310 | Identification Placard, Battery Charger Cord Socket |
| 4 | 1 | 670-00583 | Identification Placard |
| 5 | 1 | 670-10518 | Information Placard, Original Wireless |
| 6 | 1 | 670-10655 | Information Placard, Emergency Procedures, 10.1″ Screen |
| 7 | 1 | 670-10437 | Information Placard, Warning Decal |
| 8 | 1 | 670-10474 | Information Placard, Warning, Arcing Parts |
| 9 | 1 | 670-10505 | Information Placard, ALI Member |
| 10 | 1 | 670-10567 | Information Placard, Maintenance Instructions |
| 11 | 2 | 670-10561 | Safety Tape, Vinyl, 2″ Wide, Yellow/Black, 12″ Long |
| 12 | 2 | 670-10359 | Information Placard, Warning |
| 13 | 1 | 670-10636 | Placard Kit, ALI/WL 400, French |
| 14 | 1 | 670-10472 | Information Placard, Caution, Fuse Replacement |
| 15 | 1 | 670-10491 | Placard Kit, ALI/WL 400 |
| 16 | 1 | 670-10569 | Info Placard, Warning, Tire Engagement |
| 17 | 1 | 670-10473 | Information Placard, Caution, Control Box |
| 18 | 1 | 670-10630 | Information Placard, Control Box Plugs |
| 19 | 1 | 670-10469 | Information Placard, Low Amp Fuse Replacement |
| 20 | 1 | 670-10568 | Information Placard, Manual Raise/Lower Switch |
| 21 | 1 | 670-10471 | Information Placard, 200 Amp Fuse Replacement |