Forward this manual to all operators. Failure to operate this equipment as directed may cause injury. INSTALLATION AND OPERATION MANUAL SURFACE MOUNTED FOUR-POST LIFTS Models: FL-18 BP-18 BP-27/ BP-27A BP-35 / BP-35A BP-35X / BP-35XA BP-40 / BP-40A BP-40X / BP-40XA Keep this operation manual near the machine at all times. Make sure that ALL USERS read this manual. SHIPPING DAMAGE CLAIMS When this equipment is shipped, title passes to the purchaser upon receipt from the carrier. Consequently, claims for the material damaged in shipment must be made by the purchaser against the transportation company at the time shipment is received. BE SAFE Your new lift was designed and built with safety in mind. However, your overall safety can be increased by proper training and thoughtful operation on the part of the operator. DO NOT operate or repair this equipment without reading this manual and the important safety instructions shown inside. 1645 Lemonwood Dr. Santa Paula, CA. 93060, USA Tel: 1-805-933-9970 Fax: 1-805-933-9160
FOUR POST SURFACE MOUNTED TRUCK LIFT This instruction manual has been prepared especially for you. Your new lift is the product of over 25 years of continuous research, testing and development and is the most technically advanced lift on the market today. READ THIS ENTIRE MANUAL BEFORE OPERATION BEGINS. RECORD HERE THE FOLLOWING INFORMATION WHICH IS LOCATED ON THE SERIAL NUMBER DATA PLATE Serial No. Model No. Manufacturing date WARRANTY Your new lift is warranted for five years on equipment structure; one year on all operating components to the original purchaser, to be free of defects in material and workmanship. The manufacturer shall repair or replace at their option for this period those parts returned to the factory freight prepaid which prove upon inspection to be defective. The manufacturer will pay labor costs for the first 12 months only on parts returned as previously described. This warranty does not extend to defects caused by ordinary wear, abuse, misuse, shipping damage, or lack of required maintenance. This warranty is exclusive and in lieu of all other warranties expressed or implied. In no event shall the manufacturer be liable for special, consequential or incidental damages for the breach or delay in performance of the warranty. The manufacturer reserves the right to make design changes or add improvements to its product line without incurring any obligation to make such changes on product sold previously. Warranty adjustments within the above stated policies are based on the model and serial number of the equipment. This data must be furnished with all warranty claims. WARRANTY IS NOT VALID UNLESS WARRANTY CARD IS RETURNED 2
PARTS INVENTORY QTY. PART(S) DESCRIPTION WHERE USED CHECK PARTS BOX 16 3/4" x 4-3/4" Anchor Bolts Concrete Anchors 1 Lot Shims To Shim / Level Lift 8 1/2"-13 x 2" Bolts Bolts That Secure Power Beam 8 1/2"-13 Nuts For Bolts That Secure Power Beam 8 1/2" Lock Washers Washers That Secure Power Beam 4 3/4"-10 x 2" Bolts Secures Drive-Up Ramps 4 3/4"-10 Nuts For Bolts That Secure Drive-Up Ramps 4 3/4" Lock Washers Washers That Secure Drive-Up Ramps 4 1/2""-13 x 2" Bolts Secures Front Tire Stops 4 1/2"-13 Nuts For Bolts That Secure Front Tire Stops 4 1/2" Lock Washers Washers That Secure Front Tire Stops 4 5/16"-18 x 3/4" Bolt Secures Power Unit To Column 4 5/16"-18 Nuts For Bolts That Secure Power Unit 8 5/16 x 2 Hardened Dowel Pins Secures Chain To Chain Connectors 2 646 Chain Connecting Links Can Be Used To Level Lift 4 Air Safety Cylinders Releases Safety Locks 1 Roll Air Line Hose For Air Safety System 1 Brass Bulkhead Coupler Installs In Runway / For Air Safety System 1 Male Branch Tee Fitting Installs In Runway / For Air Safety System 2 Union Tee Fittings Installs In Runway / For Air Safety System 1 Flow Control Valve With Fitting Installs At Cylinder Power Port 1 90 Degree Hydraulic Fitting Installs At Cylinder Return Port 2 45 Degree Hydraulic Fittings Installs At Power Unit 2 Front Tire Stops Front Tire Stops 8 Hairpin Clips To Secure Air Safety Cylinders 2 Hoses From Power Unit To Cylinder 1 Can Spray Paint Touch Up Paint 1 Instruction Manual Instruction Manual 1 ALI Safety Instructions Safety Instructions SHIPMENT PARTS 2 Tire Stops Tire Stops 2 Drive-Up Ramps Drive-Up Ramps 1 Left Ramp Left Ramp 1 Right Ramp Right Ramp 1 Power Unit Electric / Hydraulic Power Source 1 Power Beam Assembly Overhead Power Beam Assembly 1 Front Cross-Tube Assembly Front Cross-Tube Assembly 1 Rear Cross-Tube Assembly Rear Cross-Tube Assembly 2 Offside Columns Offside Columns 1 Powerside Column / With Mtg. Plate Powerside Column 1 Powerside Column / No Mtg. Plate Powerside Column 3
1. Carefully remove the crating and packing materials. CAUTION! Be careful when cutting steel banding material as items may become loose and fall causing personal harm or injury. 2. Inspect the lift for any signs of concealed shipment damage or shortages. Remember to INTRODUCTION report any shipping damage to the carrier and make a notation on the delivery receipt. 3. Check the voltage, phase and proper amperage requirements for the motor shown on the motor plate. Wiring should be performed by a certified electrician only. IMPORTANT SAFETY INSTRUCTIONS Read these safety instructions entirely! 1. READ AND UNDERSTAND all safety warning procedures before operating lift. 2. KEEP HANDS AND FEET CLEAR. Remove hands and feet from any moving parts. Keep feet clear of lift when lowering. Avoid pinch points. 3. KEEP WORK AREA CLEAN. Cluttered work areas invite injuries. 4. Consider work area environment. Do not expose equipment to rain. DO NOT use in damp or wet locations. Keep area well lighted. 5. ONLY TRAINED OPERATORS should operate this lift. All non-trained personnel should be kept away from work area. Never let non-trained personnel come in contact with, or operate lift. 6. USE LIFT CORRECTLY. Use lift in the proper manner. Never use lifting adapters other than what is approved by the manufacturer. 7. DO NOT override self-closing lift controls. 8. REMAIN CLEAR of lift when raising or lowering vehicle. 9. CLEAR AREA if vehicle is on danger of falling. 10. ALWAYS INSURE that the safeties are engaged before any attempt is made to work on or near vehicle. 11. DRESS PROPERLY. Non-skid steel -toe footwear is recommended when operating lift. 12. GUARD AGAINST ELECTRIC SHOCK. This lift must be grounded while in use to protect the operator from electric shock. Never connect the green power cord wire to a live terminal. This is for ground only. 13. DANGER! The power unit used on this lift contains high voltage. Disconnect power at the receptacle before performing any electrical repairs. Secure plug so that it cannot be accidentally plugged in during service. 14. WARNING! RISK OF EXPLOSION. This equipment has internal arcing or sparking parts which should not be exposed to flammable vapors. This machine should not be located in a recessed area or below floor level. 15. MAINTAIN WITH CARE. Keep lift clean for better and safe performance. Follow manual for proper lubrication and maintenance instructions. Keep control handles and/or buttons dry, clean and free from grease and oil. 16. STAY ALERT. Watch what you are doing. Use common sense. Be aware. 17. CHECK FOR DAMAGED PARTS. Check for alignment of moving parts, breakage of parts or any condition that may affect its operation. Do not use lift if any component is broken or damaged. 18. NEVER remove safety related components from the lift. Do not use lift if safety related components are damaged or missing. THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS AND CAN CAUSE PERSONAL INJURY OR DEATH. READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE THIS MACHINE. 4
Rotary Hammer Drill Or Similar 3/4" Masonry Bit Hammer 4 Foot Level Open-End Wrench Set: 7/16" - 1-1/8" Socket And Ratchet Set: 7/16" - 1-1/8" Hex-Key / Allen Wrench Set TOOLS REQUIRED Medium Crescent Wrench Medium Pipe Wrench Crow Bar For Shim Installation Chalk Line Medium Flat Screwdriver Tape Measure: 25 Foot Minimum Needle Nose Pliers IMPORTANT NOTICE These instructions must be followed to insure proper installation and operation of your lift. Failure to comply with these instructions can result in serious bodily harm and void product warranty. Manufacturer will assume no liability for loss or damage of any kind, expressed or implied resulting from improper installation or use of this product. PLEASE READ ENTIRE MANUAL PRIOR TO INSTALLATION. STEP 1 ( Selecting Site ) Before installing your new lift, check the following. 1. LIFT LOCATION: Always use architects plans when available. Check layout dimension against floorplan requirements making sure that adequate space is available. 2. OVERHEAD OBSTRUCTIONS: The area where the lift will be located should be free of overhead obstructions such as heaters, building supports, electrical lines etc. 3. DEFECTIVE CONCRETE: Visually inspect the site where the lift is to be installed and check for cracked or defective concrete. STEP 2 ( Floor Requirements ) "DO NOT install this lift on any asphalt surface or any surface other than concrete. "DO NOT install this lift on expansion seams or on cracked or defective concrete. "DO NOT install this lift on a second / elevated floor without first consulting building architect. "DO NOT install this lift outdoors unless special consideration has been made to protect the power unit from inclimate weather conditions. CONCRETE SPECIFICATIONS LIFT MODEL CONCRETE REQUIREMENT 18,000 Pound Models 4-1/2 Min. Thickness 27,000 Pound Models 5 Min. Thickness Specifications of concrete must be adhered to. Failure to do so could cause lift failure resulting in personal injury or death. 35,000 Pound Models 6 Min. Thickness 40,000 Pound Models 6 Min. Thickness A level floor is suggested for proper installation and level lifting. Small differences in floor slopes may be compensated for by proper shimming. If a floor is of questionable slope, consider a survey of the site and/or the possibility of pouring a new level concrete slab. 5 NOTE All models MUST be installed on 2500 PSI concrete only conforming to the minimum requirements shown above. New concrete must be adequately cured by at least 28 days minimum.
FLOORPLAN X POWER BEAM B C APPROACH X A DIMENSIONS MODEL A B C FL-18 187 123 223 BP-18 197 144 244 BP-27 / BP-27A 257 144 294-1/2 BP-27X / BP-27XA 317 144 348-1/4 BP-35 / BP-35A 257 144 294-1/2 BP-35X / BP-35XA 317 144 348-1/4 BP-40 / BP-35A 257 144 294-1/2 BP-40X / BP-35XA 317 144 348-1/4 NOTE The power unit can be located in either X locations shown above. For right-side power unit location the power beam must be installed on the right side and for leftside power unit location the power beam must be installed on the left side. STEP 3 ( Site Layout ) 1. Determine which end of the lift will be the approach side. Remember, the drive-on ramps will overhang this side of the lift by 30 ( 48 on FL-18 model. ) 2. Now determine which side you prefer the power unit to be located on. Remember, the POWER-BEAM must be installed on the same side as the power unit. ALIGNMENT MODELS - For these models, the POWER BEAM and POWER UNIT must be installed on the DRIVER SIDE / LEFT SIDE only. 3. Once a location is determined, use a carpenters chalk line to layout a grid for the post locations. 6 Remember to keep all dimensions and squareness within 1/8 or malfunctioning of the lift will occur. 4. After the post locations are properly marked, use a chalk or crayon to make an outline of the posts on the floor at each location using the post baseplates as a template. 5. Double check all dimensions and make sure that the diagonal measurements are equal from all corners. 6. Before continuing with the installation it is helpful to stand the posts up at their respective locations and get a visual of the shop, aisles and other clearances. Also, this is a good time to drive a vehicle into position and check for adequate clearance.
STEP 4 ( Routing the chains through the CROSS-TUBES ) 1. Before starting, prepare the two CROSS-TUBES by routing the two cross-tube chains through the center of each cross-tube. ( See Fig. 1 ) 2. Pay careful attention making sure that the chains are not twisted. Once the chains are routed properly, tape / tie the ends of each chain to the ends of the CROSS-TUBES to hold in position during the installation process. Fig. 1 STEP 5 ( Preparing the POWER-BEAM ) 1. Before starting, prepare the POWER-BEAM by routing the four power-beam chains as shown below. Pay careful attention making sure that the chains are not twisted and are routed over the rollers at each end. ( See Fig. 2 ) Fig. 2 2. Connect the end of each chain to the CYLINDER CHAIN CONNECTOR using four of the 5/16 x 2 hardened dowel pins. ( See Fig. 3 ) Fig. 3 3. Once the chains are routed and connected properly, drop the ends of each chain through the openings at the bottom of the power beam. 7
ASSEMBLY DRAWING STEP 6 ( Mounting the POWERSIDE columns. ) Fig. 5 1. Locate the two POWERSIDE columns. ( The top of these columns will have square cutouts. ) 2. One of the POWERSIDE columns will have a power-unit mounting plate attached. Position this column at the designated chalk location for the power unit. Place the remaining POWERSIDE column at the other available POWERSIDE chalk location. 3. Before proceeding, double check measurements and make certain that the bases of each column are square and aligned with the chalk line. 4. Using the baseplate on each POWERSIDE column as a guide, drill each anchor hole in the concrete approximately 4-1/2 deep using a rotary hammer drill and 3/4 concrete drill-bit. To assure full holding power, do not ream the hole or allow the drill to wobble. ( See Fig. 4 & 5 ) 5. After drilling, remove dust thoroughly from each hole using compressed air and/or wire brush. Make certain that the column remains aligned with the chalk line during this process. 6. Assemble the washers and nuts on the anchors then tap into each hole with a hammer until the washer rests against the baseplate. Be sure that if shimming is required that enough threads are left exposed. ( See Fig. 6 ) Fig. 6 Fig. 4 8 NOTE: DO NOT tighten the anchor bolts until the POWER-BEAM is positioned and bolted firmly to the top of the powerside columns.
7. If shimming is required, insert the shims as necessary under the baseplate so that when the anchor bolts are tightened, the columns will be plumb. ( See Fig. 7 ) Fig. 8 Fig. 7 Fig. 9 STEP 7 ( Mounting the POWER-BEAM. ) 1. Once the POWERSIDE columns are secure, mount the power beam to the top of the POWER- SIDE columns using the 1/2"-13 x 2" Bolts and nuts then drop the chains through the openings. ( See Fig. 8 & 9 ) STEP 9 ( Positioning the CROSS-TUBES. ) NOTE: Make sure that the tail end of the cylinder where the hydraulic ports are located is located closest to the POWER UNIT. ( See ASSEMBLY DRAWING ) STEP 8 ( Mounting the OFFSIDE columns. ) 1. Position the OFFSIDE columns at the designated chalk locations and secure to the floor following the same procedures as outlined in STEP FIVE. 1. After the columns and POWERBEAM have been installed, position the CROSS-TUBES on the bottom safety lock position making sure the POWERSIDE ramp position blocks and Safety Cylinder brackets are positioned correctly. ( See Fig. 10 ) 9 Fig. 10
STEP 10 ( Connecting The POWERSIDE Chains ) 1. It is necessary to extend the TOP CYLINDER prior to connecting the POWERSIDE chains. To do this, first remove the plastic shipping plugs from the end of the cylinder. With the shipping plugs removed, extend the cylinder using a cable puller or air gun. STEP 11 ( Connecting The CROSS-TUBE Chains ) Connect the two CROSS-TUBE chains to the chain connectors located at the BOTTOM OF EACH POWERSIDE column using the master links supplied. Next route the CROSS-TUBE chains through the top of the OFFSIDE columns making sure that the threaded end extends at least 1/4 beyond the end of the nylock nut. (See Fig. 14 & 15) If using air pressure to extend the cylinder, DO NOT EXCEED 75 P.S.I. Be very cautious as cylinder may jump erratically. 2. After the cylinder has been extended, connect the four POWERSIDE chains to the CROSS-TUBE chain connectors using the 5/16 hardened dowel pins. ( See Fig. 12 & 13 ) Fig. 14 Fig. 12 Fig. 15 Fig. 13 PAY CAREFUL ATTENTION WHEN CON- NECTING CHAINS. Make sure that the connecting pins pass through all leafs in the chain and through all sections of the chain connectors. YOU MUST install center and outside leafs of chain when connecting CROSS-TUBE chains to POWER- SIDE columns. Failure to do so could cause lift failure resulting in personal injury or death. 10 USE ONLY FACTORY SUPPLIED CONNECTING PINS AND/OR CHAIN CONNECTING LINKS.
STEP 12 ( Preparing The POWERSIDE Runway ) 1. First locate the POWERSIDE runway. The POWERSIDE runway will have a hole on one end where the BULKHEAD FITTING for the air safety system will be installed. ( See Fig. 16 ) Fig. 16 STEP 14 ( Installing The Air Safety System ) 1. Install the air safety cylinders as shown below. The air fitting for each cylinder MUST be positioned on the top. It is recommended to lubricate each cylinder with spray lubricant such as WD-40 or similar. ( See Fig 18 ) 2. Install the BULKHEAD fitting and secure. Now install the MALE BRANCH TEE inside the runway and connect the airline until it exits at each end of the runway. Make sure that the airline is connected properly and the threaded connectors are tight. STEP 13 ( Positioning The Runways ) 1. After the bulkhead fitting and airline is installed position the POWERSIDE runway within the ramp locating blocks at the top of each CROSS-TUBE. Make sure the airline is not pinched or damaged when positioning the POWERSIDE runway. Next, position the OFFSIDE runway adjacent the POWERSIDE runway. ( See Fig. 17 ) Fig. 18 2. Install the airline as shown on the following page. It may be necessary to elevate the POWERSIDE runway to gain access to the airline at each end of the runway. Make sure that the tubing is clear of all pinch points and the fittings are tightened securely. 3. Install the power unit, push-button air valve and coiled air hose as shown below. Fig. 17 11
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STEP 15 ( Hydraulic Hose Connections ) 1. Connect the two 90 degree hydraulic fittings and flow-control valve to the main cylinder. ( See Fig. 19 ) STEP 16 ( Electrical Connections ) NOTE: Have a certified electrician run 208-230 volt single phase 60 HZ power supply to motor. ( If you ordered optional three phase power refer to the data plate found on the motor for proper power supply. ) Be sure to size wire for a 25 amp circuit. IMPORTANT NOTE: DO NOT USE 110 VOLT POWER SUPPLY FOR THIS POWER UNIT. DAMAGE TO MOTOR WILL OCCUR WHICH IS NOT COVERED UNDER WARRANTY. You must use a separate circuit breaker for each lift. Fig. 19 2. Install the two 90 degree hydraulic fittings to the POWER PORT and RETURN PORT of the power unit and connect the hoses as described below. It will be necessary to remove shipping plugs from both ports prior to installing fittings. After the hoses are connected, fill the power unit with 18 QTS. 10 WT. HYDRAULIC FLUID OR DEXRON II ATF. RISK OF EXPLOSION! This equipment has internal arcing or parts that may spark and should not be exposed to flammable vapors. Motor should not be located in a recessed area or below floor level. NEVER expose motor to rain or other damp environments. DAMAGE TO MOTOR CAUSED BY WATER IS NOT COVERED UNDER WARRANTY. STEP 17 ( Power Unit Start-Up ) 1. Test power unit by depressing button. If motor sounds like it is operating properly, raise lift to full height and check all hose connections for leaks. IF MOTOR GETS HOT OR SOUNDS PECULIAR, STOP IMMEDIATELY AND RE-CHECK ELEC- TRICAL CONNECTIONS. STEP 18 ( Installing Front Tire Stops ) 13
STEP 19 ( Installing Front Drive-Up Ramps ) 2. Raise the lift until the safety lock on the POWER UNIT column comes within 1/4 of the first safety lock ladder. 3. Tighten / loosen the adjusting nut on top of the OFFSIDE column directly across from the POWER UNIT column until the safety lock for that column comes within 1/4 of the safety lock ladder. 4. Repeat this step for the remaining columns until all safeties comes within 1/4 of the safety lock ladders. NOTE: Adjustments for the POWERSIDE chains should be made by using the extra chain connecting links supplied with your lift. STEP 21 ( Leveling Alignment Runways ) 1. Using a level or transit, adjust the runways so that they are level in all directions while resting on the BOTTOM safety lock. Adjustment bolts are located at the bottom of each column. ( See Fig. 20 ) Fig. 20 STEP 20 ( Final Adjustments ) 1. Load the lift with a vehicle such as light-duty truck or van. STEP 22 ( Installing The Optional Ramp Extensions ) 14
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