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Harmar Mobility AL003 Installation & Service Manual Download Page 17

Outside Vehicle Lifts:

  Installation & Service Manual

06DEC19  |  P/N: 630-00106 REV A

17

OUTSIDE VEHICLE LIFTS:

 

SECTION 4

INSTALLATION

Swing-Away Adjustment Screw

If the model was purchased with a swing-away 
option, read the following installation instructions. 
Not needed for AL105L. 

1. 

With the swing-away closed, loosen the nut.

2. 

Tighten the bolt so the ramp touches the pin in 
the closed position.

3. 

Tighten the nut. Open and close the swing-
away. See Figure 4-15.

Figure 4-15

4. 

Verify the T-handle opens freely.  
NOTE: There should be slight tension when pulling 
the T-handle.

5. 

Verify the upper arm is locked and does not 
move. See Figure 4-16.

Figure 4-16

AL030 POWER TOTE 

INSTALLATION WITH BALL 

MOUNT HITCH ADAPTOR 

1. 

Install bumper mount of flat bar. See Figure 4-17. 

Figure 4-17

2. 

Install hitch post assembly. See Figure 4-18.

Figure 4-18

Bolt

Nut

Pin

Ramp

FOR AL030 ONLY

Ball Mount Hitch Adaptor

Bumper Mount

Be sure to comply with 

vehicle’s bumper rating

Flat Bar Style

Be sure to comply with 

vehicle’s bumper rating

OR

OR

Flip Over

Omit 

Stabilizer

Do not use ball mount adaptor with swing-away.

WARNING

!

Summary of Contents for AL003

Page 1: ...0106 Rev A INSTALLATION SERVICE MANUAL AL001 AL003 AL010 AL015 AL030 AL050 AL100 AL100HD AL160 AL300 AL300HD AL300RV AL301XLHD AL301XL AL500 AL500HD AL560XL AL560 AL570 AL570XL AL580 AL580 HDX AL580XL OUTSIDE LIFTS ...

Page 2: ......

Page 3: ...ontents 7 Vehicle Hitch 8 Hitch Adapters 9 Hitch Adapter Size Chart 10 INSTALLATION 12 Wiring the Vehicle 12 Hitch Adapter Installation 15 Swing Away or Hitch Post Installation 16 AL030 Power Tote Installation with Ball Mount Hitch Adapter 17 CHAIR PREPARATION 19 Anchor Plate 19 U Bolt Hardware Kit 20 LIFT ADJUSTMENTS 21 Hold Down Foot Height Setting 21 AL100 AL160 AL300 Wheel Cradle Adjustments 2...

Page 4: ...D AND UNDERSTAND Read and understand this manual prior to installation or operation Having an overall understanding of the lift and proper installation techniques will help you save time energy and avoid possible injury This manual provides instructions for proper installation of Outside Vehicle Lifts Please refer to the Owner s Manual for operating instructions Be sure to provide the Owner s Manu...

Page 5: ...ement weather conditions that jeopardize the technician s safety or ability to complete the installation in a safe manner Tents canopies or other outdoor provisions that help protect the work area from weather or other safety concerns are recommended when conditions warrant Do not proceed IF upon visual inspection the vehicle or hitch has severe rust structural damage a possible suspension issue o...

Page 6: ...r Crimping Tool Work Lights Wired or Wireless Soldering Gun Iron Labeler for Wiring First Aid Kit Box Cutter Torque Wrench REQUIRED TOOLS Socket Set 3 8 7 16 1 2 9 16 3 4 Wrench Set 7 16 1 2 9 16 3 4 15 16 Allen Wrench 1 8 3 16 5 16 Wire Cutters Needle Nose Pliers No 2 Flat Head Screwdriver No 2 Phillips Head Screwdriver Marking Implement Tape Measure Multimeter UNPACKING THE LIFT Never attempt to...

Page 7: ...ew each part against the packaging checklist to ensure that all parts have been included If any parts are missing or damaged immediately contact the dealer who sold the lift DO NOT attempt to install or use a lift that has missing or damaged parts DO NOT LIFT FROM MOTOR COVER LIFT BODY HITCH ADAPTER HARDWARE PACK SWING AWAY HITCH POST NOT INCLUDED IF AL105 SWING AWAY IS PURCHASED ...

Page 8: ... 4 The receiver tube of the hitch must be installed parallel to the ground This is a requirement and not a recommendation as an improperly installed hitch affects the operation of the lift Note that some vehicles require the rear suspension to be supplemented If the vehicle has suspension requirements the installer should contact a suspension specialist for additional technical support Figure 3 1 ...

Page 9: ...he hitch class by measuring the inside of the receiver on the trailer hitch See Figure 3 2 Figure 3 2 NOTE Some shallow hitches for example hitches blocked by spare tires may call for a short hitch adapter See Figure 3 3 Figure 3 3 The effective range of the hitch adapter varies slightly if the lift is equipped with the standard AL107 hitch post See Figure 3 4 Figure 3 4 If the lift is equipped wi...

Page 10: ...18 7 5 2 6 16 0 7 5 2 AL1262 STANDARD 2 DROP 18 20 7 5 2 16 18 0 7 5 2 AL1265 STANDARD 4 25 DROP 20 22 7 5 2 18 20 0 7 5 2 AL127 EXTRA LONG 6 18 7 5 10 5 2 6 16 7 5 10 5 2 AL1272 EXTRA LONG 2 DROP 18 20 7 5 10 5 2 16 18 7 5 10 5 2 AL1275 EXTRA LONG 5 DROP 20 23 7 5 10 5 2 18 21 7 5 10 5 2 AL128 SHORT 6 18 5 1 5 6 16 0 5 1 5 AL1285 SHORT 4 25 DROP 20 22 5 1 5 18 20 0 5 1 5 AL111 STANDARD FOR AL001 ...

Page 11: ... SHORT 6 DROP 20 24 4 3 5 18 22 0 4 3 5 AL125HD HEAVY DUTY EXTRA LONG STANDARD 6 18 7 5 13 5 5 6 16 7 5 13 5 5 AL1252 EXTRA LONG 2 DROP 18 20 7 5 13 5 5 16 18 7 5 13 5 5 AL1252HD HEAVY DUTY EXTRA LONG 2 DROP 18 20 7 5 13 5 5 16 18 7 5 13 5 5 AL1255HD HEAVY DUTY EXTRA LONG 5 DROP 20 23 7 5 13 5 5 18 21 7 5 13 5 5 AL1256 EXTRA LONG 6 DROP 20 24 7 5 13 5 5 18 22 7 5 13 5 5 AL1256HD HEAVY DUTY EXTRA L...

Page 12: ... black connector This black connector goes to the trailer hitch area where the lift will mount See Figure 4 1 Figure 4 1 2 Start routing the wiring harness at the vehicle s battery Join the black wire to the negative terminal on the battery DO NOT attach the red wire until the very end of the installation process See Figure 4 2 Figure 4 2 NEVER attempt to connect the harness to a secondary power s...

Page 13: ...t operate correctly See Figure 4 6 Figure 4 6 Letters are molded into plastic Seals B l a c k W i r e R e d W i r e B A B Black A Red Hinged Retainer CORRECT Adjust by prying out slightly IF NEEDED Protective tubing If the installation process requires the wiring harness to run on the underside of the vehicle direct the harness away from the exhaust system brake lines fuel lines and gas tank Avoid...

Page 14: ...sting NOTE Troubleshooting with a test light or voltage meter may lead to a false reading When you probe for 12 volts the reading may indicate a connection even though the connection may not necessarily be sufficient The lift s motor can draw up to 20 amps at some points requiring all of the available wire to flow proper current Poor connections are the main problem associated with a slow intermit...

Page 15: ...ge 10 HITCH ADAPTOR INSTALLATION 1 Attach the hitch adaptor to the hitch post ensuring that the adaptor is properly oriented with the post according to the application s hitch height See Figure 4 09 Figure 4 09 2 Attach the hitch post to the lift but DO NOT overtighten it 3 Insert the hitch adaptor into the receiver on the vehicle s hitch Secure the adaptor according to the hitch class See Figure ...

Page 16: ... away or hitch post to the hitch adaptor See Figure 4 12 Figure 4 12 3 Position the open box hehind the vehicle and connect the wiring harness together See Figure 4 13 Figure 4 13 4 Stand the lift up use the switch to line up the hitch post or swing away with the lift and fasten in place See Figure 4 14 Figure 4 14 Connect Power to the li Vehicle Harness Li Harness OR Swing Away Hitch Post Only cl...

Page 17: ...ure 4 15 Figure 4 15 4 Verify the T handle opens freely NOTE There should be slight tension when pulling the T handle 5 Verify the upper arm is locked and does not move See Figure 4 16 Figure 4 16 AL030 POWER TOTE INSTALLATION WITH BALL MOUNT HITCH ADAPTOR 1 Install bumper mount of flat bar See Figure 4 17 Figure 4 17 2 Install hitch post assembly See Figure 4 18 Figure 4 18 Bolt Nut Pin Ramp FOR ...

Page 18: ...IFTS SECTION 4 INSTALLATION 3 Adjust for bumper height See Figure 4 19 Figure 4 19 OR X X Do not attempt to mount up from under Flat Bar WARNING Ball Mount Hitch Adaptor and Stabilizer Standard equipment shipped with AL030 Power Tote AL030 can also be upgraded with Class 3 and Class 2 hitch adaptors ...

Page 19: ...scooter that has a center seat post See Figure 5 1 Figure 5 1 The anchor plate should extend about 11 2 out from the side of the cushion To secure the chair to the lift the user can attach the strap hooks to the anchor plate See Figure 5 2 Anchor Plate Installation 1 Remove the seat from the chair 2 Loosen the screws that attach the plate to the bottom of the seat Allow enough room to slide the an...

Page 20: ...re that the loop extends to the outside of the chair so the user can attach the strap hooks Each chair is slightly different so the U bolt placement will differ among models and manufacturers Place the U bolts toward the center of the seat if possible If your seat type requires you to install the U bolts more toward the front or rear of the seat aim to install them as close as possible to the cent...

Page 21: ...s of the platform See Figure 6 1 Figure 6 1 2 For AL160 be sure that the frame of the scooter is in contact with the platform The front wheel may have to be rotated CAUTION 2 Raise the platform until you hear the motor clutch which indicates the top of travel The hold down foot should be above the scooter s deck See Figure 6 2 CLICK CLICK CLICK CLICK CLICK CLICK SCOOTER DECK Figure 6 2 3 Raise bot...

Page 22: ...r lift CAUTION Figure 6 4 5 Lower the platform about 5 to relieve pressure from the scooter s deck While holding the stationary nut in place run the bottom nut up to the hold down arm and tighten See Figure 6 5 Figure 6 5 Do not rotate the stationary nut otherwise it will change the pressure that was previously set CAUTION AL100 AL160 AL300 WHEEL CRADLE ADJUSTMENTS Add or replace a rear wheel crad...

Page 23: ...uts Figure 6 8 1 Estimate the chair s center position depending on the entry preference driver s side or passenger s side Locate the drive wheel s position See Figure 6 7 Adjust the two main cradle positions to match Capture the smaller wheels on the two larger platform skins 2 Position the chair onto the platform Verify that the chair is secure and does not move in any direction once positioned b...

Page 24: ...1 3 Loosen the two bolts and nuts in the back of the vertical tube See Figure 6 12 Allow the arm assembly to lower until the arm contacts the seat Figure 6 12 4 Lower the platform approximately 2 to 3 and allow the arm to drop along with the seat Retighten the two bolts and nuts Figure 6 13 Figure 6 13 5 Run the lift up until the top of travel and when you hear the clutch Re tighten the 2 bolts an...

Page 25: ...ions can change the overall ground clearance and some options change the center of gravity Every installation must be checked and validated to ensure that as much of the wheel is captured before the wheelchair frame makes contact with the platform The AL580 HDX platform will capture the mid drive wheels in adjustable gaps and will rest the chair s battery tray on the platform pad See Figure 6 16 F...

Page 26: ...o far too the driver s side of the vehicle move the passenger side wheel chock away to create a bigger opening See Figure 6 20 Figure 6 20 Using a 3 16 hex drive and 7 16 wrench remove the bolt and nut from each side of the platform See Figure 6 21 Figure 6 21 Adjust platform as required Use bolt to hold platform in place Test platform with chair Once satisfied fasten platform in place with nyloc ...

Page 27: ...place the entry ramps See Figure 6 25 Start by laying both angled portions of the ramps on the angles of the wheel chocks and rest on top of the stationary ramps as indicated With the ramps laying on top of the wheel chocks find PEMS pressed in the stationary ramps See Figure 6 26 Figure 6 26 Find the closest alignment with the multiple holes of the upper ramps and PEMS while the upper ramp is pre...

Page 28: ...e 6 28 Figure 6 28 7 Test the positioning by running multiple cycles loading and unloading the power chair Be sure the end user is informed and comfortable with positioning the chair on the platform References for AL580 HDX Range of setup Adjustable in 1 2 increments Smallest Platform Gaps Largest Platform Gaps 5 75ˈˈ 4 00ˈˈ PEAK TO PEAK EDGE TO EDGE 10 75ˈˈ 9 00ˈˈ PEAK TO PEAK EDGE TO EDGE ...

Page 29: ...lift wiring using the process of elimination with a known good fully charged 12V automotive battery or a known good fully charged power chair scooter battery 3 Inspect the full length of the wiring harness to ensure the insulation is not torn The lift s vehicle power harness running through or under the vehicle is subject to a possible short from road debris rubbing against the vehicle s frame 4 V...

Page 30: ...ER AUTOMOTIVE TEST LIGHT Figure 7 2 The license plate light does not work The four prong connector is not wired The license plate light runs from the four prong trailer plug located on the vehicle harness that powers the lift Most hitch installers will install this type of wiring when the hitch is installed If no such plug exists it may be wired directly to a tail light or the license plate light ...

Page 31: ...daptor to the hitch post on the back of the lift See Hitch Adaptor Installation on page 15 The normal range of lift operation is 5 to 16 to the bottom of the hitch receiver of the vehicle Any higher vehicles will require a different hitch adaptor MANUAL OVERRIDE In the event of a power failure for example if your car battery dies you can still operate the lift using the manual override system Alwa...

Page 32: ...C19 P N 630 00106 REV A 32 OUTSIDE VEHICLE LIFTS SECTION 8 MOTOR COVER WIRING SCHEMATIC Section 8 Motor Cover Wiring Schematic CIRCUIT BREAKER BATTERY VEHICLE HARNESS KEY SWITCH LIFT LIGHT TRAILER PLUG MOTOR COVER LIGHT ACTUATOR POLE REVERSING SWITCH 12 V ...

Page 33: ...Outside Vehicle Lifts Installation Service Manual 06DEC19 P N 630 00106 REV A 33 NOTES ...

Page 34: ...Outside Vehicle Lifts Installation Service Manual 06DEC19 P N 630 00106 REV A 34 NOTES ...

Page 35: ...Outside Vehicle Lifts Installation Service Manual 06DEC19 P N 630 00106 REV A 35 NOTES ...

Page 36: ...2075 47th Street Sarasota FL 34234 800 833 0478 harmar com ...

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