Harmar Mobility AL650 User Manual

AL690

Side-Door Hybrid Lift

09-16-09

AL650

Hybrid Powerchair Lift

w/ Docking Station

AL600

Universal Hybrid Lift

UNPACKING THE LIFT

Lift Assembly

AL600

Hardware Pack

ALA680

4x2x

690 only

INSTALLATION

WASHERS

2 - 5/16-18 x 4.00" HHCS 2 - 5/16-18 HEX NYLOC NUTS 2 - 5/16 FLAT WASHERS 10 - 15" WIRE TIES 1 - 6" STRIP of VELCRO ( for hand controller ) OWNERS MANUAL WITH WARRANTY 1 - T-HANDLE HEX KEY ( 1/8" x 6" ) ( Manual Over-Ride Tool )

VEHICLE

HARNESS

AL650

2 BUTTON HAND CONTROLLER

AL600

J-HOOKS

MOUNTING WASHER

MOUNTING U-BRACKET

AL650

5/16 -18 HEX NUT 5/16 SPLIT LOC WASHER

HHCS 1/2-13 x 4” FULLY THREADED

1/2-13 HEX NUT

1/2” SPLIT LOCK WASHER

MOUNTING HARDWARE

4 - Leveling Pads

AL690

J-HOOKS

HHCS 1/2-13 x 4” FULLY THREADED

1/2-13 HEX NUT

1/2” SPLIT LOCK WASHER

MOUNTING WASHER

MOUNTING U-BRACKET

AL690

5/16 -18 HEX NUT 5/16 SPLIT LOC WASHER

600 PLATFORM

617

ANCHOR PLATE

LEG

FOOT PLATE

Front Wheel Craddle ( option for scooters )

U-BOLT

HARDWARE

PACK

4 - U-Bolts 1/4-20 Thread 8 - 1/4-20 Nuts 8 - 1/4 Split Lock Washers 8 - Backing Plates

650 PLATFORM

LEG

FOOT PLATE

650

Hardware

Pack

DOCKING

PLATE

ASSY

4 - 1/4-20 x 2.25" Flat Head Ph 4 - 1/4-20 x 3.00" Flat Head Ph 8 - 1" Tall Spacer 4 - 1/2" Tall Spacer 4 - 1/4" Tall Spacer

690 PLATFORM

REAR LEG

FRONT LEG

U-BOLT

HARDWARE

PACK

4 - U-Bolts 1/4-20 Thread 8 - 1/4-20 Nuts 8 - 1/4 Split Lock Washers 8 - Backing Plates

ANCHOR PLATE

Be sure to check the contents of the box agaisnt the package checklist assuring that all parts are present. If any parts are missing, or damage is noted, contact your dealer immediately. DO NOT attempt to install or operate a lift with missing or damaged parts.

WIRING THE VEHICLE

IMPORTANT NOTE:

IMPROPER WIRING IS THE #1 CAUSE OF PROBLEMS IN THE OPERATION OF A VEHICLE LIFT.

FOLLOW THE WIRING INSTRUCTIONS CAREFULLY

LOCATED IN THE HARDWARE PACK IS THE VEHICLE WIRING HARNESS. THE HARNESS IS MANUFACTURED TO, AND COMPLIES WITH, THE SAE J1128 REQUIREMENTS. THE WIRE HARNESS IS APPROXIMATELY 23 ft LONG AND WILL ACCOMMODATE MOST VEHICLES.

YOUR HEAVY DUTY HARNESS HAS BEEN LEFT UN-ASSEMBLED FOR EASE OF INSTALLATION. THE END CONNECTOR HAS BEEN INCLUDED SEPARATELY FROM THE HARNESS TO ALLOW THE INSTALLER TO THE RUN THE WIRE UNDER AND THROUGH THE VEHICLE WITH THE SMALLEST HOLE POSSIBLE. FOLLOW THESE INSTRUCTIONS TO ASSURE PROPER INSTALLATION.

UNWIND THE HARNESS AND LAY IT FLAT. ONE END OF THE HARNESS HAS 2 COVERED PINS. THIS IS THE LIFT END OF THE HARNESS AND GOES TO THE MIDDLE OF THE VEHICLE AND INSIDE TO THE REAR CARGO AREA.

20 AMP SELF RESETTING CIRCUIT BREAKER

TO BATTERY

BLACK

CONNECTOR

END

WIRE

BEGIN ROUTING THE WIRING HARNESS AT THE VEHICLE BATTERY. ATTACH THE BLACK WIRE TO THE NEGATIVE TERMINAL ON THE BATTERY. DO NOT ATTACH THE RED WIRE UNTIL THE END.

RUN THE WIRING HARNESS UNDER OR WHEN POSSIBLE THROUGH THE VEHICLE, BACK TO THE REAR CARGO AREA. ALWAYS LOCATE THE WIRING WHERE IT CAN NOT BE SNAGGED BY ROAD DEBRIS AND AWAY FROM THE GAS TANK. THROUGH THE VEHICLE IS BEST FOR THE AL-600 SERIES, GAINING ENTRY INTO THE VEHICLE THROUGH THE FIREWALL. HOWEVER IF YOU WISH TO RUN THE HARNESS UNDER THE VEHICLE, A HOLE WILL MOST LIKELY NEED TO BE DRILLED TO GET THE WIRE INTO THE REAR CARGO AREA. IF THE HARNESS IS TOO LONG FOR THE VEHICLE, COIL THE EXCESS WIRE AND SECURE IT TO THE VEHICLE FRAME WITH SUPPLIED TIE WRAPS.

DO NOT CUT OR SHORTEN THE HARNESS.

Protectiv

ONCE THE HARNESS IS RUN INTO THE VEHICLE, REMOVE PIN’S PROTECTIVE TUBING.

INSPECT THE PIN’S RETAINING FLANGES. THE MAY HAVE BECOME DEFORMED WHILE RUNNING THEM THROUGH THE VEHICLE. THESE ARE CRITICAL TO SECURE THE PINS INSIDE THE END CONNECTOR. ADJUST AS NEEDED.

FLIP OPEN END CONNECTOR’S HINGED RETAINER. INSERT PINS AS SHOWN:

VERIFY THE WIRES CAN NOT BE PULLED OUT BY MODERATELY PULLING ON WIRE.

BE SURE WIRE SEALS ARE INSIDE CONNECTOR, AND CLOSE THE END CONNECTOR’S HINGED RETAINER.

tubing

CORRECT

UNDERSIDE OF THE VEHICLE,

FROM THE EXHAUST SYSTEM,

BRAKE LINES, FUEL LINES< GAS

TANK, PINCH POINTS, AND SHARP

HARNESS WHERE IT CAN NOT

BE SNAGGED BY ROAD DEBRIS

LETTERS ARE MOLDED INTO PLASTIC

PLUG CONNECTOR INTO LIFT

LAST: ATTACH RED WIRE TO THE POSITIVE TERMINAL ON THE BATTERY

BLACK WIRE

RED WIRE

BLACK WIRE

SIDE MOUNT

WHEN THE INSTALLATION

REQUIRES THE WIRING

HARNESS BE RUN ON THE

ROUTE THE HARNESS AWAY

EDGES. LOCATE THE WIRING

IF NEEDED

ADJUST BY PRYING OUT SLIGHTLY

SEALS

HINGED RETAINER

RED WIRE

SIDE MOUNT

NEVER ATTEMPT TO CONNECT THE HARNESS TO A SECONDARY POWER SOURCE.

ALWAYS CONNECT BOTH LEADS DIRECTLY TO THE BATTERY

TOP MOUNT

PROBING FOR 12 VOLTS MAY INDICATE

A CONNECTION, BUT NOT NECESSARILY

A SUFFICIENT CONNECTION.

THE LIFT’S MOTOR CAN DRAW UP TO 30 AMPS AT SOME POINTS, REQUIRING ALL OF THE AVAILABLE TO FLOW

PROPER CURRENT. POOR CONNECTIONS ARE THE #1 PROBLEM ASSOCIATED WITH

A SLOW, WARM, POORLY PERFORMING MOTOR.

NOT ONLY WILL THE MOTOR PERFORM POORLY,

BUT WILL PREMATURELY DETERIORATE.

IF A SINGLE STRAND OF A MULTI-

STRAND WIRE IS MAKING CONTACT,

12V WILL APPEAR ON THE METER, OR TEST LIGHT,

BUT 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.

WIRE

RED WIRE

LAST

TOP MOUNT

Docking Station

Docking Station Height

Height

PRIOR TO MOUNTING

DOCKING PLATE TO CHAIR

GROUND CLEARANCE

MUST BE GREATER

THAN OR EQUAL TO

1.75 INCHES

AL 650 - SETTING DOCK STATION HEIGHT

ONLY

IF GROUND CLEARANCE =

THEN USE:

AL650

HARDWARE USED: ( from hardware pack )

MEASURE DISTANCE OF

MOUNTING SURFACE TO

GROUND

1.75" - 2"

2.25"

2.5"

2.75"

3.25"

3.5"

3.75"

No Spacers

.25" spacers

0.25" 0.25"

.5" spacers

.75" spacers

0.25"

0.50"

1" spacers

1.00" 1.00"

1" + .25" spacers

0.25" 0.25"

1.00" 1.00"

1" + .5" spacers

0.50" 0.50"

1.00" 1.00"

1"+ .5" + .25" spacers

0.25" 0.25"

0.50" 0.50"

1.00" 1.00"

MOUNTED ON LIFT FROM FACTORY

1.25"

0.50"0.50"

0.25"

0.50"

2.25"

DETERMINE NUMBER

OF SPACERS AND

SCREW LENGTH REQUIRED FOR YOUR GROUND CLEARANCE

1"+ 1" spacers

1.00" 1.00"

3.00"

1"+ 1" + .25" spacers

0.25" 0.25"

1.00" 1.00"

4.25"

1.00" 1.00"

AL 650 - SETTING DOCK STATION HEIGHT

AL650

ONLY

REMOVE LOCKING STATION AND INSERT APPROPRIATE NUMBER OF SPACERS. RE-ATTACH TO PLATFORM. CHANGE TO LONGER SCREWS IF NECESSARY.

( CHART ON PREVIOUS PAGE )

Docking Station

Height

CHANGE TO LONGER

SCREWS AS REQUIRED

ADD SPACERS AS REQUIRED

ACCORDING TO CHAIR’S GROUND

CLEARANCE

( CHART ON PREVIOUS PAGE )

DO NOT ADD SPACERS TO CHAIR

DOCKING STATION CAN BE ORIENTATED

FOR DRIVER’S SIDE ENTRY

BY ROTATING STATION 180 DEGREES, AND

USING SECOND SET OF HOLES

NUMBER & TYPE OF SPACERS DEPENDS ON CHAIR’S GROUND CLEARANCE. SEE CHART ON PREVIOUS PAGE

VERIFY THE HEAD OF THE SHOULDER BOLT IS BELOW THE UNDERSIDE OF THE LOCKING DEVICE UP TO A 1/4” OF SPACE IS ACCEPTABLE

DRIVE CHAIR

ONTO PLATFORM

LOOK DOWN ENTRY

OF STATION

SHOULDER BOLT HEAD

PERFORM LOCKING TEST

BY ATTEMPTING TO BACK OFF

CHAIR, WHILE IN STATION IS IN

LOCKED POSITION

UNDERSIDE OF

LOCKING DEVICE

Power Chair Preparation

AL 650 - MOUNTING CHAIR PLATE

ONLY

AL650

MOUNTING THE DOCKING DEVICE PLATE

DO NOT ATTEMPT TO USE THIS AUTOMATIC LOCK DOWN DEVICE ON ANY FOLDING, OR TAKE APART CHAIRS UNLESS RECOMMENDED BY HARMAR.

FIND APPROXIMATE

CENTER OF THE CHAIR

Drive wheel

CHOOSING A LOCATION and

DOCKING

DEVICE

PLATE

THE CLOSER THE PLATE IS POSITIONED TO THE DRIVE WHEELS, THE EASIER THE CHAIR WILL BE TO ENGAGE THE DOCKING STATION

( CENTER )

USE EXISTING HOLES WHEREVER POSSIBLE

IF TOO LITTLE OR NO HOLES EXIST, HOLES WILL NEED TO BE DRILLED. REMOVE BATTERIES, AND USE PLATE AS TEMPLATE. DRILL AS REQUIRED.

ATTACH TO CHAIR USING SUPPLIED HARDWARE:

4 - 1/4-20 x 1.00” HHCS 4 - 1/4-20 NYLOC NUT

( ATTACHED TO PLATE )

+ 14 hidden pages

Harmar Mobility AL650 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

UNPACKING THE LIFT

INSTALLATION

WIRING THE VEHICLE