Harmar Mobility AL600 Pioneer Installation And Owner's Manual

Hybrid Lifts

Installation and Owner’s Manual

AL600

Universal Hybrid Lift

Capacity: 350 lbs.

AL690

Side-Door Hybrid Lift

Capacity: 275 lbs.

Read and understand this manual thoroughly before attempting to install or operate the lift. If you have any questions, please contact your Authorized Harmar Dealer or

Harmar’s Technical Service Department.

Dealer Name & Contact Information:

Serial # of Your Lift:

Install Date:

2

Table of Contents

SECTION 1: OWNER

OPERATING YOUR LIFT 3-4

AL600 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3

AL690 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY & MAINTENANCE

SECTION 2: INSTALLER

PREPARATION

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Unpacking the Lift . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation Overview . . . . . . . . . . . . . . . . . . . . . . 10

Single Person Installation . . . . . . . . . . . . . . . . . . 11

5

INSTALLATION

Wiring the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

AL600 Installation w/removable 3rd row . . 14

AL600 Installation w/folding 3rd row . . . . . 18

AL690 Installation . . . . . . . . . . . . . . . . . . . . . . . 22

CHAIR / SCOOTER PREPARATION

TROUBLESHOOTING

27

29

EXPLODED VIEWS & PARTS LISTS

AL600 & AL690

Base Stage Assembly . . . . . . . . . . . . . . . . . . . 32-33

AL600 & AL690

Middle Stage Assembly . . . . . . . . . . . . . . . . . 34-35

AL600 &AL690

Horizontal Assembly . . . . . . . . . . . . . . . . . . . 36-37

AL600 & AL690

Stop Rod and Micro Switch Assembly . . . . 38-39

AL600 & AL690

Drive Tower Assembly . . . . . . . . . . . . . . . . . . 40-41

AL600 & AL690

Tower Assembly . . . . . . . . . . . . . . . . . . . . . . . . 42-43

AL600 Platform Assembly . . . . . . . . . . . . . . . 44-45

AL690 Platform Assembly . . . . . . . . . . . . . . . 46-47

WIRING DIAGRAMS 48-49

SERVICE NOTES 48

SECTION 3: WARRANTY

WARRANTY 51

Read & Understand this Manual Prior to Installation or Operation. Please read, follow, and fully understand the installation section of this manual before beginning. Knowing the lift’s adjustments and the tips on proper installation and operation techniques will save time, energy and avoid possible injury. If you do not understand any portion of installation or operation, please consult our technical service department or authorized mobility dealer.

NOTE

: The following symbols indicate areas where you should take special care to avoid danger to individuals or property.

WARNING

Hazardous situation. If not avoided, could result in serious injury to installer or user.

CAUTION

Hazardous situation. If not avoided, could result in serious damage to property.

© 2014 Harmar Mobility, LLC • All Rights Reserved

SECTION 1 : OWNER

AL600 Operation

LOADING & SECURING YOUR CHAIR

Lower the Lift Platform.

Using your remote control, lower the lift platform until it reaches the ground and becomes level.

Do

NOT

over-lower to the point where the vehicle begins to rise or the platform rises with the "DOWN" button pressed. This will damage the lift or cause the lifting system to back drive.

1. Drive Chair/Scooter onto Platform.

Set your chair or scooter’s speed control to slow speed to maneuver easily onto the platform. [Figure 3-1] You can drive onto the platform from either side.

2. Secure the Chair.

Each corner of the AL600 platform has a restraint attached, with a hook on the end. Place each hook in either the anchor plate slot or in each U-bolt. [Figure 3-2]

Pull the loose end of each restraint tight. To release, simply press the release tab and remove the hooks. [Figure 3-3]

3. Fold Seat Backs.

If your chair has a folding seat back, you may want to place it in the down position for easier clearance when loading the chair into the vehicle.

Depending on the size of your chair, you may need to remove the headrest as well.

4. Raise the Chair.

Double-check that the chair is secured properly on the platform. While holding the hand control, stand to the side and away from the lift. Press the "UP" button.

[Figure 3-4]

The platform will rise and retract into the vehicle. When the platform stops retracting release the button. The platform will automatically lock itself into travel position. Close the door slowly, making sure that no part of the chair or other objects in the cargo area contact the door.

SLOW

Figure 3-2

Figure 3-4

Figure 3-1

PUSH to

RELEASE

PULL to

TIGHTEN

Figure 3-3

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4

AL690 Operation

SECTION 1 : OWNER

LOADING & SECURING YOUR CHAIR

1. Lower the Lift Platform.

Using your remote control, lower the lift platform until it reaches the ground and becomes level.

Do

NOT

over-lower to the point where the vehicle begins to rise or the platform rises with the "DOWN" button pressed. This will damage the lift or cause the lifting system to back drive.

2. Drive Chair/Scooter onto Platform.

Set your chair or scooter’s speed control to slow speed to maneuver easily onto the platform. [Figure 4-1]

3. Secure the Chair.

Each corner of the AL690 platform has a restraint attached, with a hook on the end. Place each hook in either the anchor plate slot or in each U-bolt.

[Figure 4-2]

Pull the loose end of each restraint tight. To release, simply press the release tab and remove the hooks.

[Figure 4-3]

4. Fold Seat Backs.

If your chair has a folding seat back, you may want to place it in the down position for easier clearance when loading the chair into the vehicle. Depending on the size of your chair, you may need to remove the headrest as well.

5. Raise the Chair.

Double-check that the chair is secured properly on the platform. While holding the hand control, stand to the side and away from the lift. Press the "UP" button.

[Figure 4-4]

The platform will rise and retract into the vehicle. When the platform stops retracting, release the button. The platform will automatically lock itself into travel position. Close the door slowly, making sure that no part of the chair or other objects in the cargo area contact the door.

Figure 4-1

Figure 4-2

Figure 4-3

PUSH to

RELEASE

PULL to

TIGHTEN

Figure 4-4

© 2014 Harmar Mobility, LLC • All Rights Reserved

SECTION 1 : OWNER

Safety & Maintenance

WARNING

This lift is NOT meant for human transport. The chair or scooter MUST be unoccupied before operating the lift. Each lift is designed to transport a speciic chair only. DO NOT attempt to move any mobility devices, objects, people, or materials other than those for which the lift was intended.

CAUTION

Do not allow anyone to use this lift unless they are properly instructed on operational and safety procedures.

When using the lift, keep your hands and feet from under the platform.

WARNING

IMPORTANT

Your Hybrid Lift has been engineered for years of trouble-free use, but as with any mechanical system, daily use may result in some parts becoming loose or worn.

Check regularly for any worn, lose, or damaged parts of your lift. If you note any issues, do NOT use the lift.

Contact your dealer or installer of the lift for repairs. Failure to act may cause severe injury or damage to property.

Use your Hybrid Lift only for loading and unloading the scooters and power chairs for which it is intended. If your combination of vehicle and scooter/chair changes, for example if you buy a diferent vehicle or upgrade your mobility device, please consult your installer or dealer. The original equipment may not conigure the same. Do not add to or modify any part of the lift system without irst consulting the lift manufacturer. Any modiications may void warranties, as well as, hinder the structural integrity of the lift.

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AL600 & AL690 Hybrid Installation & Owner's Manual 2014

5

Safety & Maintenance

SECTION 1 : OWNER

MAINTENANCE

This Hybrid Lift is designed to be as trouble-free as possible, but as with any mechanical device, regular maintenance will help ensure that it continues to ofer reliable and safe use for years to come.

Schedule a maintenance inspection.

We recommend that you schedule a preventative maintenance inspection with your dealer at least once a year on motors, lift frame, wiring harnesses, and all moving parts of the lift.

Check for paint chips and touch up bare metal.

Use a good gloss black enamel or lacquer to inhibit rust. You may need to do this more frequently if your lift is subject to salt air or road salt.

6

© 2014 Harmar Mobility, LLC • All Rights Reserved

SECTION 2 : INSTALLER

Preparation

PROFESSIONAL INSTALLATION RECOMMENDED

NOTE:

The following section is designed for the professional installer. We strongly recommend that a certiied dealer install the lift and instruct the user on correct operation and establish a safety and maintenance schedule.

If you do not understand any portion of installation or operation, please consult our technical service department or authorized mobility dealer. Do not attempt to install or use this lift with any hesitation or question. Serious injury or damage can result if proper procedures are not followed.

READ & 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.

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AL600 & AL690 Hybrid Installation & Owner's Manual 2014

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8

Preparation

SECTION 2 : INSTALLER

TOOLS REQUIRED

Installations may vary to some degree, but below are the basic tools to have on hand for an Hybrid Lift installation.

SOCKET SET

Speciically

9/16”

7/16”

3/4”

3/8"

#2 FLAT HEAD

SCREWDRIVER

WRENCH SET

Speciically

9/16”

7/16”

3/4”

#2 PHILLIPS HEAD

SCREWDRIVER

ALLEN WRENCH SET

Speciically

1/8”

3/16”

5/16”

MARKING

IMPLEMENT

WIRE CUTTERS

NEEDLE NOSE

PLIERS

TAPE MEASURE

HAND

CONTROL

PLUG

POWER "IN"

(from vehicle harness)

© 2014 Harmar Mobility, LLC • All Rights Reserved

SECTION 2 : INSTALLER

Preparation

UNPACKING THE LIFT

Check the box contents.

Review 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.

Lift

Assembly

2x

Hardware Pack

ALA680

INSTALLATION WASHERS

VEHICLE HARNESS

2 - 3/8-16 4.00" FULL THREAD HHCS

2 - 3/8-16 HEX NYLOC NUTS

2 - 3/8 FLAT WASHERS

10 - 15" CABLE TIES

OWNERS MANUAL WITH WARRANTY

1 - T-HANDLE HEX KEY ( 1/8" x 6" )

( Manual Over-Ride Tool )

+

2 BUTT

ON

HAND

CONTROL

AL600

J-HOOKS

HHCS 1/2-13 x 4”

FULLY THREADED

1/2-13 HEX NUT

1/2” SPLIT LOCK WASHER

3/8-16 HEX NUT

3/8 SPLIT LOCK WASHER

MOUNTING WASHER

AL600

OR

AL690

J-HOOKS

3/8-16 HEX NUT

3/8 SPLIT LOCK WASHER

HHCS 1/2-13 x 4”

FULLY THREADED

1/2-13 HEX NUT

1/2” SPLIT LOCK WASHER

MOUNTING WASHER

MOUNTING U-BRACKET

AL690

+

MOUNTING U-BRACKET

LEVELING PADS

MOUNTING

HARDWARE

600

PLA

TFORM

LEG

AL

617

FOO

T PLA

TE

OPTIONAL

Scooter plate

U-BOLT

HARDWARE

PACK

ALA 580

4 - U-Bolts 1/4-20 Thread

8 - 1/4-20 Nuts

8 - 1/4 Split Lock Washers

8 - Backing Plates

ANCHO

R PLA

TE

TEC0020 17Sep14 P/N: 630-00025 revA

690

PLA

TFORM

REAR LEG

FRONT LEG

U-BOLT

HARDWARE

PACK

ALA 580

4 - U-Bolts 1/4-20 Thread

8 - 1/4-20 Nuts

8 - 1/4 Split Lock Washers

8 - Backing Plates

PLA

TE

ANCHOR

AL600 & AL690 Hybrid Installation & Owner's Manual 2014

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10

Preparation

SECTION 2 : INSTALLER

WARNING

Never attempt to pick up the lift from the box, ground or on/of a vehicle alone. Two people should work together to place this lift inside a vehicle.

If only one person is available, please follow the short disassembly procedure on next page.

Overview – Installation Procedure

1. Install Wiring Harness.

See page12. Installing the wiring harness irst will ensure you have power to the lift during installation. This allows access to platform assembly outside the vehicle and at waist level. (If you skip this step, use a 12V shop battery.)

2. Remove Seating & Determine Lift Placement.

Remove seating. For AL600 (page 14) this is usually the third row; for AL690 (page 22), second row. Determine mounting range by climbing inside cargo area and closing access door. Measure from inside the door threshold to determine the lift’s fully-stowed placement. For the AL600, measure to 43”; for AL690, measure to

55.” [Figure 10-1 ]

Look at the loor in the mounting area. If seat removal reveals seat attachment points, or “dog bones,” you will not need to drill.

If no attachment points exist in the area, you will need to drill two 3/8” holes approximately

1” to 10” from your measurement point. (See installation section for details.)

10"

AL600

55"

Figure 10-1

10"

AL690

43"

© 2014 Harmar Mobility, LLC • All Rights Reserved

SECTION 2 : INSTALLER

Preparation

Single Person Installation Option

• We recommend two people install the lift together. If only one person is available, a few extra steps make the lift lighter and more manageable to permit installation.

• Remove connections at limit switch and remove power connections at 4-way plug. [Figure 11-1]

• Remove 4 nuts at tower base . [Figure 11-2]

• Lift tower straight up to remove from base.

[Figure 11-3 ]

• Install base as instructed later in manual.

• Re-attach tower once the base is mounted in the vehicle. Re-connect 4-way and limit switches connectors.

Figure 11-1

9/16”

REMOVE 4 NUTS

AT TOWER BASE

Figure 11-2

TEC0020 17Sep14 P/N: 630-00025 revA

LIFT TOWER

STRAIGHT UP

TO REMOVE

FROM BASE

INSTALL BASE AS

INSTRUCTED LATER IN MANUAL.

RE-ATTACH TOWER ONCE BASE IS

MOUNTED IN VEHICLE. RE-CONNECT

4 WAY & LIMIT SWITCH CONNECTORS.

Figure 11-3

AL600 & AL690 Hybrid Installation & Owner's Manual 2014

11

Wiring the Vehicle

SECTION 2 : INSTALLER

12

Improper Wiring is the #1 Cause of

Problems in the Operation of a Vehicle

Lift. Follow the Wiring Instructions

Carefully

The vehicle wiring harness is located in the hardware pack. The harness is manufactured to comply with

SAE J1128 requirements. It is approximately 23 feet long and will accommodate most vehicles.

Instructions

1. Unwind the wiring harness and lay it lat.

One end of the harness has 2 covered pins. This is the lift end and goes to the rear cargo area where the lift will mount.

The wiring harness is unassembled for easier installation. The end connector is included separately from the harness to enable the installer to run the wire under and through the vehicle with the smallest clearance possible.

Figure 12-1

CAUTION

Never attempt to connect the harness to a secondary power source. Always connect both leads directly to the battery.

IMPORTANT

If the installation requires the wiring harness to run on the underside of the vehicle, route it away from exhaust system, brake lines, fuel lines, gas tank and any moving parts. Avoid pinch points and sharp edges. Avoid locating the harness where it can be snagged by road debris.

2. Route the wire harness beginning at the battery.

Attach the black wire to the negative terminal on the battery. [Figure 12-1]

Do NOT connect the red wire to the battery until the very end.

3. Run the vehicle harness under and, when possible, through the vehicle back to the rear cargo area/trunk

, gaining entry into the vehicle through the irewall.

[Figure 12-2]

If you want to run the harness under the vehicle, you will most likely need to drill a hole to get the wire into the rear cargo area/trunk. Use the supplied 3/8 grommet in the hole to protect the wire.

Figure 12-2

CAUTION

Do NOT run wiring where it can be snagged by road debris.

Do NOT run wiring near the gas tank.

© 2014 Harmar Mobility, LLC • All Rights Reserved

SECTION 2 : INSTALLER

Wiring the Vehicle

CAUTION

If the harness is too long for the vehicle, coil the excess wire and secure it to the vehicle frame with the supplied tie wraps.

5. Inspect the pin’s retaining langes.

The langes may have been deformed while being run through the vehicle. These are critical to secure the pins inside the connector. Adjust as needed.

[Figure 13-2]

Do NOT cut or shorten the harness

4. When harness is through the vehicle

the pin’s protective tubing. [Figure 13-1]

, remove

6.

Flip open end connector’s hinged retainer.

• Insert pins as shown.

[Figure 13-3]

• Verify the wires cannot be pulled out by moderately pulling on the wires. Be sure rubber seals are inside the back of the connector.

• Close the hinged retainer.

• Plug connector into lift.

7.

Last, attach red wire to the positive terminal on the battery. [ Figure 13-4]

Figure 13-1

NOTE: Troubleshooting with a test light or voltage meter may give a false indication.

When you probe for 12 volts, the reading may indicate a connection, even if the connection is not necessarily suicient. The lift’s motor can draw up to 20 Amps at some points, requiring all of the available wire to low proper current. Poor connections are the #1 problem associated with a slow, intermittent, warm, poorly performing motor which will also deteriorate prematurely.

If a single strand of a multi-strand wire is making contact, 12V will appear on a meter or test light, but it will not allow the motor to operate. It is always best to test both current and voltage, or run the motor with known good shop battery or power source when troubleshooting.

AUTOMOTIVE

TEST LIGHT

VOLTAGE

METER

Figure 13-2

Figure 13-3

TEC0020 17Sep14 P/N: 630-00025 revA

Figure 13-4

AL600 & AL690 Hybrid Installation & Owner's Manual 2014

13

Installation - AL600

SECTION 2 : INSTALLER

With Removable 3rd Row Seating

1. Remove 3rd Row Seating.

[Figure 14-1]

2. The AL600 Leg must be mounted

between 32” and 42” from the internal surface of the closed back door of the vehicle.

[Figure 14-2]

2nd ROW SEATING

CENTER

32”

42”

3.

Examine the Floor for Additional Seat

Attachment Points.

These must be recessed into the loor. [Figure 14-3]

IMPORTANT:

Attachment Points MUST be FLUSH or LOWER than the loor.

Figure 14-2

Figure 14-1

2nd ROW SEATING

32”

42”

14

Figure 14-3

© 2014 Harmar Mobility, LLC • All Rights Reserved

4 A.

If Seat Attachment Points ARE

Available:

See Figure 15-1 for mounting diagram.

SECTION 2 : INSTALLER

Installation - AL600

With Removable 3rd Row Seating

Mounting

Bracket

3/8 -16 Nyloc Nuts

3/8 Flat Washer

Mounting Bracket

3/8 - 16

J-HOOK

Hex Head Bolt,

1/2-13 x 4.00"L

Fully Threaded

Figure 15-1

4 B. If Seat Attachment Points are NOT

Available:

Look under vehicle in approximate area where Leg will need to be mounted. See

Figure 15-2 for mounting diagram.

Drill a pilot hole irst, up from under the vehicle to ensure nothing will be damaged.

Find hole from inside vehicle and drill 3/8” hole down through vehicle’s loor.

CAUTION

USE EXTREME CAUTION

Avoid Gas Tank, Fuel / Brake / Electrical

Lines

PILOT

HOLE

3/8"

Hex Head Bolt,

3/8 - 16 x 4.00"L

Fully Threaded

Mounting Bracket

3/8"

3/8 Flat

Washer

Mounting

Bracket

Hex Head Bolt,

1/2-13 x 4.00"L

Fully Threaded

Figure 15-2

Installation

Washers

PILOT

HOLE

3/8 - 16

Nyloc Nuts

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AL600 & AL690 Hybrid Installation & Owner's Manual 2014

15

Installation - AL600

SECTION 2 : INSTALLER

With Removable 3rd Row Seating

7.

Place mounting washers on bolts

, on top of mounting lange on lift. Place ½” lock washers onto bolts. Thread ½-13 nuts onto bolts.

5. Thread ½-13 nuts onto ½-13 x 4.00”

L bolts.

Place ½” lock washers onto bolts.

Place mounting washers onto bolts.

1/2-13

Hex Nut

1/2 Split Lock

Washer

Mounting

Washer

6.

Use an assistant

to place lift onto bolts through mounting lange on lift as shown.

Mounting

Washer

1/2 Split Lock

Washer

1/2-13

Hex Nut

(LEVELING NUT)

Mounting

Flange

1/2-13 x 4.00"L bolts

Leveling

Pad w/

Jam Nut

Foot Plate

16

WARNING

If no assistant is available, follow instructions on page 11 to avoid injury.

8. Lift front end of lift and install leveling pads as shown.

Place foot plate under leveling pads. Lower lift and check with a level. Adjust by threading nut on leveling pads and threading bottom nut under mounting lange.

© 2014 Harmar Mobility, LLC • All Rights Reserved

8. Plug hand controller into lift.

[Figure 17-1]

Connect to vehicle harness.

[Figure 17-2]

SECTION 2 : INSTALLER

Installation - AL600

With Removable 3rd Row Seating

Figure 17-1

From vehicle harness

( installed on page 12)

10. Attach platform

by placing platform’s upright pins into u-shaped bracket on tower. [Figure

17-4]

FROM LIFT

BLACK

RED

BLACK

RED

FROM VEHICLE HARNESS

( FROM BATTERY )

Figure 17-2

Figure 17-4

11. Thread ½-13 x 1-3/4” L Hex head Bolts and

9. Press the DOWN button

until the lift’s tower has

½” washers into threaded holes as shown.

[Figure moved out of the vehicle.

[Figure 17-3]

17-5] Test full motion of lift into and out of the vehicle.

Be sure lift is level and no obstructions interfere with platform travel.

Tighten all fasteners from all steps at this time.

Figure 17-5

Figure 17-3

TEC0020 17Sep14 P/N: 630-00025 revA

AL600 & AL690 Hybrid Installation & Owner's Manual 2014

17

Installation - AL600

SECTION 2 : INSTALLER

With Folding 3rd Row Seating

NOTE:

A BA-02 Kit is needed for this installation.

More detailed instructions on BA-02 installation will be provided with the BA-02 Kit.

4.

Attach brackets together supplied hardware.

and fasten using

[Figure 18-4]

BHCS

1/4-20 x 3/4"

Figure 18-4

1/4-20

Nylock Nut

1. Fold 3rd Row seating up,

exposing the storage well. [Figure 18-1]

5. Position assembled parts around third row seat(s)

then fold into well. [Figure 18-5]

18

Figure 18-1 folded seat storage well

Figure 18-5

2. Measure the height of the well.

[Figure 18-2]

6. Install set screws (leave loose) as shown.

Slide foot plate assembly onto legs.

[Figure 18-6]

Figure 18-6

Figure 18-2

3. Position brackets as shown.

Slide up or down until you achieve the measured well height. (Holes are arranged for ¼” increments) [Figure 18-3]

X

Figure 18-3

X

7. Attach rails to brackets.

[Figure 18-7]

1/4-20 Acorn Nuts

1/4" Split Lock Washers

Figure 18-7

© 2014 Harmar Mobility, LLC • All Rights Reserved

SECTION 2 : INSTALLER

Installation - AL600

With Folding 3rd Row Seating

8.

With BA-02 installed in rear cargo area,

examine loor for area to install leg assembly. [Figure 19-1]

10 A. If Seat Attachment Points ARE Available:

See

Figure 19-3

for mounting diagram.

Figure 19-1

9.

The AL600’s leg will need to be mounted

between 32” and 42” from the internal surface of the closed back door of the vehicle.

Examine the loor for additional seat attachment points recessed into the loor. [Figure 19-2]

IMPORTANT:

Attachment Points MUST be FLUSH or LOWER than the loor.

2nd ROW SEATING

3/8 - 16 Nyloc Nuts

3/8 Flat Washer

Mounting Bracket

Mounting

Bracket

3/8 - 16

J-HOOK

Hex Head Bolt,

1/2-13 x 4.00"L

Fully Threaded

Figure 19-3

10 B. If Seat Attachment Points are NOT Available:

Look under vehicle in approximate area where Leg will need to be mounted.

Drill a pilot hole irst, up from under the vehicle to ensure nothing will be damaged. [Figure 19-3]

Find hole from inside vehicle and drill 3/8” hole down through vehicle’s loor. [Figure 19-4]

3/8"

2nd ROW SEATING

CENTER

32”

42”

32”

42”

3/8" Hex Head Bolt,

3/8-16 x 4.00"L

Fully Threaded

Mounting Bracket

3/8 Flat

Washer

Figure 19-2

CAUTION

USE EXTREME CAUTION

Avoid Gas Tank, Fuel / Brake /

Electrical Lines

TEC0020 17Sep14 P/N: 630-00025 revA

PILOT

HOLE

Mounting

Bracket

Hex Head Bolt,

1/2-13 x 4.00"L

Fully Threaded

Installation

Washers

PILOT

HOLE

3/8 - 16

Nyloc Nuts

Figure 19-4

AL600 & AL690 Hybrid Installation & Owner's Manual 2014

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20

Installation - AL600

SECTION 2 : INSTALLER

With Folding 3rd Row Seating

13. Place mounting washers on bolts,

on top of mounting lange on lift. Place ½” lock washers onto bolts. Thread ½-13 nuts onto bolts.

11. Thread ½-13 nuts onto

½-13 x 4.00” L bolts.

Place ½” lock washers onto bolts. Place mounting washers onto bolts.

1/2-13

Hex Nut

1/2 Split

Lock Washer

Mounting

Washer

Mounting

Washer

1/2 Split

Lock Washer

1/2-13

Hex Nut

( Leveling Nut )

Mounting

Flange

1/2-13 x 4.00"L bolts

Leveling

Pad w/

Jam Nut

12. Use an assistant to place lift onto bolts

through mounting lange on lift as shown.

WARNING

If no assistant is available, follow instructions on page11 to avoid injury.

14. Lift front end of lift and install leveling pads as shown.

Place pads into circular cups of BA-02 as shown. Lower lift and check with a level.

Adjust by threading nuts on leveling pads and threading bottom nut under mounting lange.

© 2014 Harmar Mobility, LLC • All Rights Reserved

15. Plug hand controller into lift.

[Figure 21-1]

Connect to vehicle harness.

[Figure 21-2]

SECTION 2 : INSTALLER

Installation - AL600

With Folding 3rd Row Seating

Figure 21-1

FROM LIFT

BLACK

RED

From vehicle harness

( installed on page 12)

BLACK

RED

FROM VEHICLE HARNESS

( FROM BATTERY )

17. Attach platform

by placing platform’s upright pins into u-shaped bracket on tower. [Figure 21-4]

Figure 21-2

16. Press the DOWN button

moved out of the vehicle. until the lift’s tower has

[Figure 21-3]

Figure 21-4

18. Thread ½-13 x 1-3/4” L Hex head Bolts and

½” washers into threaded holes as shown.

[Figure

21-5] Test full motion of lift into and out of the vehicle.

Be sure lift is level and no obstructions interfere with platform travel.

Tighten all fasteners from ALL steps at this time.

Figure 21-3

Figure 21-5

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Installation - AL690

SECTION 2 : INSTALLER

1.

Remove 2nd Row Seating.

[Figure 22-1]

3. Front Leg Attachment

Figure 22-1

2. Installing the Front Leg.

The AL690’s front leg must be mounted between 42” and 52” from the internal surface of the closed side door of the vehicle.

22

Examine loor area for remaining seat attachment points that are recessed into the loor.

[Figure 22-2]

IMPORTANT:

Attachment Points MUST be FLUSH or LOWER than the loor.

Figure 22-3

3A. If Seat Attachment Points ARE Available:

See

Figure 22-3 for mounting diagram.

3/8 - 16

Nyloc Nut

3/8 Flat Washer

Mounting Bracket

42"

52"

Inner

Door

Surface

Figure 22-2

3/8 - 16

J-HOOK

Mounting

Bracket

Hex Head Bolt,

1/2-13 x 4.00"L

Fully Threaded

© 2014 Harmar Mobility, LLC • All Rights Reserved

SECTION 2 : INSTALLER

Installation - AL690

3B. If Seat Attachment Points are NOT Available:

Look under vehicle in approximate area where Leg will need to be mounted.

[Figure 23-1]

3/8 Flat

Washer

Hex Head Bolt,

3/8-16 x 4.00"L

Fully Threaded

24"

36"

VEHICLE

FLOOR

Installation

Washer

Mounting

Bracket

Hex Head Bolt,

1/2-13 x 4.00"L

Fully Threaded

3/8-16

Nyloc Nut

Figure 23-1

Look under vehicle in approximate area where leg will need to be mounted.

Drill a pilot hole irst, up from under the vehicle to ensure nothing will be damaged.

Find hole from inside vehicle and drill

3/8” hole down through vehicle’s loor.

Figure 23-2

4. Installing the Rear Leg.

The AL690’s rear leg will be installed approximately 24” to 36” from the front leg.

[Figure 23-2]

The uprights on both legs must be in line and square.

Verify by measuring corner to corner. Distance should be identical. [Figure 23-3]

REAR LEG

FRONT

LEG

IN-LINE

BE SURE

" X "

CAUTION

USE EXTREME CAUTION

Avoid Gas Tank, Fuel / Brake /

Electrical Lines

REAR LEG

=

24-36"

False loor support available when applicable for vehicles with Stow & Go seating. (2nd row seats must be removed)

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FRONT LEG

" X "

Figure 23-3

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Installation - AL690

SECTION 2 : INSTALLER

Rear Leg Attachment (con't) 4B. If Seat Attachment Points are NOT Available:

Look under vehicle in approximate area where leg will need to be mounted.

[Figure 24-2]

Hex Head Bolt,

3/8-16 x 4.00"L

Fully Threaded

Mounting

Bracket

3/8 Flat

Washer

Pan Head

1/4-20 x 1.50"L

Machine Screw

VEHICLE

FLOOR

Installation

Washer

3/8-16

Nyloc

Nut

Figure 24-1

4A. If Seat Attachment Points ARE Available:

See

Figure 24-1 for mounting diagram.

3/8-16

Nyloc

Nut

3/8 Flat

Washer

Mounting

Bracket

Pan Head

1/4-20 x 1.50"L

Machine Screw

Drill a pilot hole irst, up from under the vehicle to ensure nothing will be damaged.

Find hole from inside vehicle and drill

3/8” hole down through vehicle’s loor.

Figure 24-2

3/8-16

J-Hook

CAUTION

USE EXTREME CAUTION

Avoid Gas Tank, Fuel / Brake /

Electrical Lines

© 2014 Harmar Mobility, LLC • All Rights Reserved

5. Thread ½-13 nuts onto ½-13 4.00”L bolts installed previously.

Place ½” lock washer onto bolts.

Place mounting washers onto bolts

Using an assistant, place lift onto bolts through mounting lange on lift as shown. [Figure 25-1]

SECTION 2 : INSTALLER

Installation - AL690

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1/2-13

Hex Nut

1/2 Split

Lock Washer

Mounting

Washer

Figure 25-1

1/2-13 x

4.00"L bolts

Mounting

Washer

1/2 Split

Lock Washer

1/2-13

Hex Nut

( leveling nut )

Place mounting washers on bolts, on top of mounting flange on lift.

Place 1/2" split lock washers onto bolts.

Thread 1/2-13 nuts onto bolts.

WARNING

If no assistant is available, follow instructions on page 11 to avoid injury.

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Installation - AL690

SECTION 2 : INSTALLER

6. Plug Hand

Controller into lift.

[Figure 26-1]

26

Figure 26-1

7. Connect to vehicle harness.

[Figure 26-2]

FROM LIFT

BLACK

RED

Figure 26-2

From vehicle harness

( installed on page 12)

BLACK

RED

FROM VEHICLE HARNESS

( FROM BATTERY )

8. Press the DOWN button

until the lift’s tower has moved out of the vehicle. [Figure 26-3]

Figure 26-3

The platform components may be reassembled to match the opening of the vehicle’s side door.

[Figure 26-4]

9. Attach platform

by placing platform’s upright pins into u-shaped bracket on tower. [Figure 26-5]

Figure 26-5

10. Install ½-13 x 1-3/4”

Hex head Bolts and ½” lat washers into threaded holes as shown.

[Figure 26-6]

Test full motion of lift into and out of the vehicle. Be sure lift is level and that no obstructions interfere with the travel of the platform.

Tighten ALL fasteners from ALL steps.

WIDTH OF

VEHICLE

OPENING

Figure 26-4 Figure 26-6

© 2014 Harmar Mobility, LLC • All Rights Reserved

SECTION 2 : INSTALLER

Chair / Scooter Preparation

The strap hooks included with lift can be attached by means of an Anchor Plate (for chairs or scooters with a center seat post)

[Figure 27-1]

or Anchor U-Bolts (for those without a center post.)

3. Make sure the anchor plate will extend about

1-1/2” on each side of the cushion.

This provides space for the user to secure the strap hooks to the chair.

4. Attach the Anchor Plate

in the center of the seat plate evenly, with the holes on each end. [Figure 27-3]

Figure 27-3

Figure 27-1

ANCHOR PLATE INSTALLATION

Use Anchor Plate for chairs or scooters with a center seat post.

The Anchor Plate is a lat plate with a slot in each end.

This plate attaches to the bottom of the seat and works with any chair or scooter that has a center seat post.

1. Remove the chair seat

.

2. Loosen the screws that attach the plate to the seat.

Allow enough room to slide the anchor plate between the seat and the seat plate. [Figure 27-2]

5. Re-tighten the screws

that hold the seat plate to the bottom of the seat.

6. Replace the seat on the chair.

[Figure 27-4]

Figure 27-4

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Figure 27-2

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Chair / Scooter Preparation

SECTION 2 : INSTALLER

ANCHOR U-BOLTS

Use U-Bolts with Power Chairs or Scooter that do not have a center seat post.

For power chairs or scooters without a center seat post, the seat is normally attached to a tubular frame.

Install the U-bolts, two on each side, to the frame as shown.

[Figure 28-1]

ALA580

U-BOLT HARDWARE KIT

SEAT

POST

SEAT

POST

4 - 1/4-20 x 3-1/4” U-BOLTS

8 - U-BOLT BACKING PLATES

16 - SPLIT LOCK WASHERS

16 - 1/4-20 NUTS

SEAT

POST

SEAT

POST

Figure 28-1

Ensure that the loop extends to the outside of the chair so the user can attach the strap hooks.

[Figure 28-2]

U-bolt placement will difer among models and manufacturers. Place the U-bolts towards the center of the seat if possible. Due to diferent seat types, you may be forced to install the U-bolts more towards the front or rear of the seat, but we recommend attaching as close as possible to the center of the seat.

Figure 28-2

28

© 2014 Harmar Mobility, LLC • All Rights Reserved

SECTION 2 : INSTALLER

Troubleshooting

DEALER/INSTALLER ONLY SECTION

The following procedures are reserved for the approved installer/dealer. They should not be attempted by anyone without proper knowledge of automotive electrical circuitry.

CAUTION

Be careful when troubleshooting with a test light or voltage meter.

They may give false indications.

AUTOMOTIVE

TEST LIGHT

VOLTAGE

METER

The instruments will detect voltage, but may not indicate a tear or poor connection in the wiring.

It is strongly recommended that you examine both voltage and current, or isolate sections of the lift wiring using process of elimination with a known good/fully charged 12V automotive battery or known good/fully charged power chair/ scooter battery.

B ATTER

Y

12 V

LIGHTS UP

12 V READING

MOTOR

RUNS

INSULATION

REMOVED FOR

CLARITY

NO LIGHT

0 V READING

MOTOR

DEAD

BATTER

12 V

Y

SHORT

INSULATION

REMOVED FOR

CLARITY

OPEN

BA TTER

Y

12 V

LIGHTS UP

( )

12 V READING

( )

BUT

MOTOR

DEAD

EXAGGERATED

TEAR OR CHAFF

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Troubleshooting

SECTION 2 : INSTALLER

PROBLEM

Lift does not operate or lift operates slowly or intermittently

CAUSE

Bad electrical connection(s) / Circuit breaker

SOLUTION

Check / clean all connections that might be loose or dirty. This is the #1 cause of a poorly performing lift. The lifting motor requires quality electrical connections to operate at full capacity; any break in the wiring will slow down the motor and it will deteriorate prematurely.

Inspect the full length of the wire harness to ensure the insulation is not torn. The lift’s vehicle power harness running through or under the vehicle is subject to road debris and rubbing against the vehicle’s frame which can cause a short.

Verify the circuit breaker. The circuit breaker is located about 6” from the connections to the vehicle’s battery. The breaker will self-reset if overloaded; however, verify (with Ohm meter or test light) that the breaker is functioning.

Or replace it with a new/known-good circuit breaker and perform the following tests.

APPLY KNOWN GOOD POWER

DIRECT TO MOTOR

SHO

P BA

TTERY

BATTERY

12 V

DID

MOTOR

RUN

?

NO

REPLACE

MOTOR

YES

SHO P

BATTER

Y

12 V

WIRING

IN LIFT

APPLY KNOWN GOOD

POWER DIRECT

TO PLUG ON LIFT

OPERATE HAND

CONTROLLER

INSPECT /

REPLACE

LIFT WIRING

RED

RED

NO

DID

MOTOR

RUN

?

YES

SHOP

BATTERY

BATTERY

12 V

WIRIN

G IN

LIFT

APPLY KNOWN GOOD

POWER DIRECT

THRU VEHICLE HARNESS

OPERATE HAND

CONTROLLER

INSPECT or

REPLACE

VEHICLE

HARNESS

NO

DID

MOTOR

RUN

?

YES REPLACE

VEHICLE

BATTERY

20 A

SELF

RESETTING

CIRCUIT

BREAKER

© 2014 Harmar Mobility, LLC • All Rights Reserved

SECTION 2 : INSTALLER

Troubleshooting

PROBLEM

Scooter/ chair tips to the front or back while being lifted.

CAUSE

Platform is leaning to one side more than the other.

SOLUTION

Adjust position of chair or scooter on platform.

In some cases, a scooter plate can be added to the platform to allow more ofset.

PROBLEM

Lifting tower operates in reverse.

Cause

Button was held too long and unwound the lifting strap.

Like a yo-yo, the lifting strap wound in reverse.

SOLUTION

Press whichever button extends strap and continue to hold until strap returns to proper direction.

PROBLEM

Lift rattles while driving.

CAUSE

Platform is not ‘docked.’

SOLUTION

Be sure to press ‘IN’ button until platform is fully engaged in its locking mechanism.

Check rear limit switch. Be sure lift is backing all the way into the vehicle.

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© 2014 Harmar Mobility, LLC • All Rights Reserved

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© 2014 Harmar Mobility, LLC • All Rights Reserved

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