Reprinted with permission of Fleet Equipment, February 1995

It should come as no surprise to read that your job is becoming more and more complicated. Vehicle models and types are proliferating. Operational requirements are changing. Component technology is growing in sophistication. Occupational Safety and Health Administration (OSHA) rules combine with federal, state and local environmental regulations to generate concerns.

It’s in this environment that continuing competitive pressures require renewed efforts to increase shop productivity and cut costs. This includes the selection of the right shop tools and equipment – in particular, the size and type vehicle lifts. The right one can improve productivity and reduce costs. The wrong one can hinder even the best mechanics on their repair jobs and take up an excessive amount of valuable space.

Indeed, when building a new shop, you may even decide that a service pit might be suitable for your maintenance facility. Except for transit bus industry, however, the trend is away from the use of pits due to high initial cost, local zoning restrictions and OSHA regulations. In addition, technicians cannot work on tires while a vehicle is over a pit.

On the other hand, some fleets still opt for pits in new or remodeled facilities. Miami-based Ryder Commercial Leasing and Services is one. While they do install lifts in many of the new facilities, pits are built more often than not. The company offers two reasons:

1. With the variety of different sizes of vehicles in its fleet, a service pit is often more suitable than a lift.
2. Within reason, Ryder provides its technicians with the type of facilities they request. Company surveys indicate that technicians have a preference for service pits. Lift manufacturers suggest that this preference is a result of heavy-duty technicians being unaware of the benefits offered by lifts since there are not nearly as many heavy-duty lifts in service as there are light-duty designs.

Mike Mele, of San Diego-based Mele Amantes Architects, estimates the cost of constructing a typical concrete service pit, 60 ft. long with a concrete stair at one end, 4 ft. deep, with a 4 ft. wide opening to be approximately $62,231.

ROI on lifts

Steve Perlstein, sales manager at Mohawk Resources Ltd., offers a return-on-investment (ROI) analysis done for the Department of Defense to anyone who doubts the value of lifts. The analysis compares a two-post lift to hand-operated jacks and jack stands for light-duty applications.

Using the latter, a mechanic needs 40 minutes to setup, lift and secure a vehicle before he can start repairs. He can do the same job in only four minutes with a twin-post lift. Perlstein points out that a similar time savings would occur by using a four-post, 25,000-lb.-capacity lift for a heavy-duty vehicle.

Cost estimates based upon current market conditions for different types of lifting systems are outlined below. These costs are greatly influenced by government regulation and local soil conditions.

INSTALLATION COSTS

Type of lift — Lift Capacity — Lift Cost — Installation Cost

In-Ground Two-Post — 43,000 lbs. — $15,000 — $15,000

Above-Ground Two-Post — 25,000 lbs. — $9,000 — $1,000

Above-Ground Four-Post — 50,000 lbs. — $35,000 — $5,000

Mobile Column — 50,000 lbs. — $25,000 — none

Parallelogram — 50,000 lbs. — $45,000 — $5,000

These costs can be greatly influenced by government regulation and local soil conditions.

Lift designs

The three major players in the heavy-truck lift field are Mohawk Resources Ltd. of Amsterdam, NY; Advantage Lift Systems based in San Diego, CA; and Rotary Lift, Madison, IN. Mohawk offers above-ground, two-post, four-post and no-post scissor lifts. Advantage markets above-ground parallelogram and in-ground non-hydraulic designs. Rotary has both above-ground and in-ground designs.

All types have advantages as well as disadvantages.

Four-Post Above-Ground Lifts

Advantages: These are easy to load and can be used for both PM’s and service. Portable designs generally have little side obstructions. Platform lifts can service all vehicles. Adjustable runways can lift forklifts with narrow tire width. Rolling jacks provide “wheel freeing” capability for tire and brake service.

Disadvantages: Somewhat wide. Corner posts can get in the way. Tire work is sometimes hard to do. Cross beams can inhibit front-end work.

Parallelogram Above-Ground Lifts

Advantages: These can accommodate most fleet vehicles. They can be portable and have no outside posts to hinder tire work. Relatively small space requirement, they can be flush mounted and have lights in the platform.

Disadvantages: The platform can get in a technician’s way and some designs have a continuous base that can be a trip hazard or inhibit some work. They need additional space fore and aft due to movement of the superstructure when raising and lowering the lift.

Mobile Column Above-Ground Lifts

Advantages: These offer multiple lift application. They’re portable and generally good for repairs that would tie up bays. The use of jack stands allows one lifting unit to be used in multiple bays both indoor and outdoor.

Disadvantages: They’re relatively slow to set up, many moving parts and leave electric cables on the floor. Tire work can be difficult.

In-Ground Lifts

Advantages: These require minimum floor space and offer a clear floor when the lift is not in use. Wheels are free as soon as the vehicle is lifted. There are no posts or legs to inhibit side access.

Disadvantages: Poor for steam cleaning and offer no lights. They are often slow to set up and may not lift all vehicles. Pistons get in the way of work for some jobs.

Mohawk’s Perlstein says fleets generally favor four-post lifts because they’re based on known technology, offer good under-vehicle access, and allow entry from the front or side. His company offers scissor lifts for those fleets that do not have the shop space – about 12 to 14 feet for a four-post lift – or that want to flush mount the lift in a shop. Another alternative in these cases is the two-post, side-by-side frame contact lift.

Selection factors

There is no single lift design that will fill all needs. Here are some factors to be considered:

• Type of vehicles to be lifted and the amount of time it will be used.
• Initial cost.
• Is the facility, owned or leased? Does it require layout changes? What are the soil and water conditions?
• Space available in the facility for the lift, including ceiling limitations, and the amount of work area that will be fully or partially restricted. Vehicle turning radius in and out of the building could be a factor.
• Maintenance and repair of lift.
• Noise levels produced.
• Warranty.
• Service availability.
• Will work be performed outside?

All major lift suppliers have developed programs, including computer-aided designs, to assist fleet managers in making the correct selection.

Tom Phillips, vice-president of Marketing at Rotary Lift, suggests that the consideration of the personal preferences of owners, managers and technicians be added to the list above.

Replacing an in-ground lift

While there are no accurate production statistics for the industry, it is estimated that there are 2,000 or more heavy-duty lifts sold each year. Clayton N. Carley, chairman of Advantage, says that in the heavy-duty truck fleet maintenance market the mix on new purchases between in-ground and above-ground lifts currently is about 50/50. In light-duty applications, up to 8,000 lbs., the ratio is about 85 percent above-ground and 15 percent in-ground.

However, for the previous two decades in-ground lifts were the designs of choice. Because of their age, many now are in questionable condition, which brings up the decision for replacement.

Rotary Lift’s Phillips says among the benefits of replacing a malfunctioning in-ground lift with a new one include the facts that extensive digging should not be required, that electrical and/or air supply lines are already available in the bay area and can be reused and they normally offer desirable service warranties – some as long as 15 years.

On the other hand, if the decision is to go to an above-ground model, the hole must be filled with clean soil and concrete repoured over the area with a minimum thickness of six inches, using 3500 psi concrete.

The benefits of going to an above-ground lift include the facts that installation can be completed typically in less than a day once the concrete has cured; surface lifts can be relocated relatively easily and a 230-volt phase power supply is all that is needed in each bay area.

Non-hydraulic in-ground

Advantage Lift’s Carley says his firm has developed a solution to the problems of oil leakage associated with in-ground lifts. Although at present there are only prototypes undergoing life-cycle tests, plans call for market availability this spring.

The new lift’s electromechanical design requires no hydraulic fluid, thereby eliminating environmental risks caused by fluid leakage. The system is suspended from the shop floor and does not require a foundation under its lifting mechanism. Since the entire lift mechanism can be removed, repairs or relocation require no jack hammer, concrete work or extensive downtime.

TEN SAFETY TIPS

1. Operating controls are designed to close when released. Do not block or override them.
2. Never overload a lift. The manufacturer’s rated capacity is shown on the nameplate affixed to lift.
3. Positioning of vehicle and operation of lift should be done only by trained personnel.
4. Never raise a vehicle with anyone in it.
5. Keep the lift area free of obstructions, grease/oil and other debris.
6. Before driving a vehicle over a lift, position its arms and supports to provide an unobstructed clearance.
7. Load the vehicle on a lift carefully. Position lifts supports to contact at recommended lifting points. Raise the lift until supports contact the vehicle. Check supports for secure contact. Raise the lift to desired working height. CAUTION: If work will be done under the vehicle, the lift should be raised high enough for its locking device to be engaged.
8. Note that with some vehicles, the removal or installation of components may cause a critical shift in the center of gravity and result in instability. Refer to the lift manufacturer’s recommendation.
9. Before lowering a lift, be sure tool trays, stands etc. are removed from under the vehicle. Release any locking devices before attempting to lower lift.
10. Before removing a vehicle from the lift area, position arms and supports to provide unobstructed exit.

Reprinted with permission of PTEN, May 1994

There is no doubt, a lift will improve productivity. Shop owners have reported productivity increases of up to 30-percent from stalls with lifts compared to stalls without lifts. Correctly selecting, installing and maintaining a lift will ensure years of trouble free service; ensuring consistent productivity from the repair stall.

Selecting the right lift for your shop involves more than looking at just capacity and price. Different designs and product features can make a lift easier or safer to use, more durable, or more appropriate for certain types of repair tasks.

Lifts can be in-ground or above ground, and, for the above-ground types, stationary or portable. They can be frame-engaging, axle-engaging, rocker-panel (pad) lifts, or runway lifts.

Lifts can be operated using hydraulic, mechanical, electric, compressed air, or some combination of these power sources. In-ground units are often either all-hydraulic or a combination of air and hydraulic power. Above-ground lifts are typically powered by a combination of electric and hydraulic power.

Today’s lift technology is relatively simple. There are no significant differences on lifting speed or energy use between in-ground and above-ground versions having the same capacity.

In-ground versus above-ground

A shop 101-ft long can comfortably fit nine in-ground lifts in a bay area that would permit only eight above-ground units. In addition to the space bonus, in-ground lifts have fewer moving parts, and for that reason are said to require less service.

In-ground lifts are more costly to install because you must dig an excavation pit. If anything does go wrong, in-ground lifts are also more costly and time-consuming to service, if you must cut the concrete floor and dig to get to the working parts. To cut service and repair cost, newer systems put many connections and working parts near the surface and under access covers that make it unnecessary to break up the concrete floor.

Potential ground and ground water contamination has caused some environmental concern about possible leakage of hydraulic fluid into the soil around in-ground lifts. Lifts do not fall under the Underground Storage Tank (UST) regulations however, as they contain less than 110 gallons of fluid. This would preclude the need for a UST permit. However, soil and water clean-up costs can be enormous, requiring that the potential for any soil or water contamination be addressed.

New fiberglass linings provide cathodic protection to reduce the possibility of electrolysis or bacteriological corrosion causing leaks in the system. At least one major manufacturer is also enclosing its in-ground lift in a polyethylene secondary containment system that prevents any leakage from reaching surrounding soil. Additionally, there is now available a new, biodegradable hydraulic fluid that is environmentally safe, so even if leaks do occur, it is not harmful.

Above-ground lifts can easily be moved. That makes them preferred for facilities in which the shop layout may need to be rearranged for future growth, or where equipment may need to be relocated if the shop lease is not renewed.

According to several manufacturers, about 75- to 90-percent of all lifts sold are of two-post, above-ground configuration.

Low-rise, portable lifts

All of the machinery of a portable or low-rise lift is typically under the car, so technicians have full access all around the vehicle with no obstructions from posts.

Low-rise lifts raise the vehicle only a couple of feet off the ground, making them perfect for collision repair shops, tire stores, and brake shops. Height can be set just where the technician needs it in order to work on wheels or brakes without having to stoop or kneel, and for the painter or metal man to easily reach lower body panels. The productivity gains and work quality benefits are obvious.

Several of these lifts are equipped with wheels and can be moved around the shop and even outdoors in nice weather, offering an “extra bay” when needed. Some models can by used to carry a vehicle from one step to the next in the repair process.

Units are available that can be operated by shop air, with no electricity or hydraulic fluid required. They are ideal for use near or inside the paint booth, where you don’t want potential spark sources such as an electric lift motor.

With air lifts there is no hydraulic oil leakage to get in the paint finish and cause fisheye or other defects, or to spill on the floor and cause slips and falls.

Capacity

Determination of lifting capacity needs is very important and should be thoroughly thought out before a purchase is made. Here’s one example to consider:

A utility truck with an 8,000-lb loaded weight needs a lift with an 11,000-lb capacity. Here’s why: Each lift arm can handle only one-fourth of the lift’s maximum capacity. If the truck has its weight distributed with 2,500 lbs. in the front and 5,500 lbs. in the rear, the heavier load on the two rear arms will determine the proper lift capacity. Each arm must be able to hand one-half of the 5,500 lbs., or 2,750 lbs. Since each arm is designed to handle an equal amount of weight, the needed lift capacity is 2,750 multiplied by four, or 11,000 lbs. total weight.

Take the time to determine your shops present and future work load before you place the order.

Floor, ceiling space

Most two-post lifts sold are “clear-floor” lifts. There is no base plate under which hydraulic lines, chains, or cables run to connect the two posts. The benefit is no floor obstructions – the technician has free movement of equipment, jacks, and tool chests while working under the car.

With clear floor lifts, any chains, cables or hydraulic lines are run overhead to connect the two columns. Make sure that the height of the overhead lines does not exceed the ceiling clearance in that part of your building where the lift will be placed. Some lifts have adjustable height overhead lines, so you can get the height you need for fully raising tall vehicles without bumping the lift’s overhead lines.

The advent of an asymmetrical two-post surface lift design is probably one of two major design incorporations considered by purchasers and users of lifts today. The second is “clear-floor” mentioned above.

An asymmetrical design allows technicians to open passenger car doors fully without banging them on the lift columns, increasing interior access and reducing vehicle damage. The lift columns are rotated 30-degrees, allowing the short and long off-center arms to position the car far enough back from the columns that the doors cannot hit them.

But the asymmetrical lift that is perfect for passenger cars may not be right for other vehicle types. For example, some full-size vans may be so long that technicians cannot position the van doors away from the columns and still place the vehicle’s center of gravity properly on the lift. On a symmetrical lift, technicians can position full-size vans so the doors are ahead of the columns, preventing the doors from hitting when opened.

Carriages and columns

The carriage raises or lowers the lift arms. Depending on design, it rides up and down inside the column on steel roller bearings, or plastic slide blocks.

Metal roller bearings create less friction than do sliding plastic or teflon-type blocks. Low friction creates less strain on the pump and motor, offering longer life. As a rule, in order to use metal rollers and bearings, lifts tend to be designed with stronger columns.

Greater steel thickness gives greater column strength. Heavier actual weight – not shipping weight – of the lift gives an indication of the amount of steel in the columns.

Equalization

Because the weight of a car or truck many times is not balanced from side-to-side, the load on each side of the lift is not equal. Lifts are designed to equalize, or synchronize, the lifting speed of one side to the other to prevent falls. Manufacturers use three primary methods to equalize lifting rates.

One method uses cables to connect the two cylinders so that mechanical and hydraulic pressure combine to raise the two sides at the same rate. Another method uses a “hydraulic fluid displacement system” that regulates hydraulic pressure between the two different sized cylinders to equalize lifting speed. A third combines a single, higher-capacity cylinder on one side with stronger, elevator-style cable to pull the slave side arms up along with the power side cylinder. Each system requires some routine inspections and maintenance to keep the proper balance from side to side.

Some cables are made thicker and nylon-coated, to reduce potential for stretching or fraying. Hydraulic systems must be checked periodically for leaks. A chain or direct-drive system, more prevalent among lifts rated over 9,000 lbs., is designed to handle heavier loads with less likelihood of the problems that cable and hydraulic systems may suffer.

Regardless of the design, all require routine inspection and service, and occasionally some repair.

Safety systems

All lifts should have mechanical safety locks to prevent the vehicle from coming down unexpectedly. Hydraulic safety backup systems lock up when they sense any imbalance in pressure between the two sides of the lift. Some lifts also have safeties that lock when any slack or break is detected in a chain or cable.

Most major lift makers have some sort of locking device on their swing arms, as well. Locks prevent the arms from shifting out of position when the vehicle is in the air. Many arm restraints lock automatically as the lift rises. Locks that must be manually engaged and released increase the chance that technicians who find them inconvenient will ignore or disable them.

Some lifts have carriage release points on each side of the lift, making the technician walk around or under the lift to unlock it before lowering. Others have single point release, so the technician can lower the lift while standing in one position.

Adapters

Three different vehicle contact pad styles are available: flip-up, screw-in, and stackable pads. Screw-in adapters are infinitely adjustable. Flip-up pads adjust easily to several fixed heights, but have less surface area in contact with the vehicle. Stackable pads allow the lowest possible drive-over arm clearance, and can be stacked as high as needed to reach contact points on high-frame vehicles.

Any shop that works on high-frame vehicles such as 4X4’s, Bronco II’s, Ford Explorers, mini-vans, and Toyota 4-Runners should have the full set of adapters.

Installation

In some installations additional electrical service capacity may be needed. Most regions will require a permit and that a licensed electrical contractor install the service from the main circuit box to the lift.

Some companies prefer to install 230v 3-phase power to the lifts as power costs will be less over time. This involves installing the electrical service from the pole if not presently installed. In any event, an inspection of the electrical system will be required.

At times, some concrete work may be required, and occasionally some repositioning of overhead lights, exhaust systems or air and hydraulic dispensing systems is needed to make room for the columns and overhead connections.

Warranty; purchase price

How long is the warranty period: Does it cover everything, including the cylinder and power unit? Does the manufacturer and, more importantly, the selling distributor have a good reputation for reliability? Check the length of time it takes to get back in service if there is an equipment problem.

Look for a company that provides a good level of training for equipment it sells. You can get this information by talking to other shops who have purchased the model you are interested in. Ask if the training was adequate, and whether there have been problems, either with the equipment or the service from the seller.

When it comes to price, most suppliers of lifts generally agree: a larger quantity of lifts purchased at one time will, in some cases, benefit the purchaser. All agree that lift pricing is very competitive. In most cases it’s the installation difficulties that will be encountered, and the purchase terms, i.e. cash, lease, open-account, that effect the ultimate price.

Reprinted with permission of Public Works, April 1994

Lifts. The necessary inclusion of vehicle lifts in public works garages often requires municipalities to choose between in-ground and above-ground units. Service pits and in-ground lifts require excavations and consequently fall under the jurisdiction of Federal and state regulatory agencies, such as OSHA and the EPA. OSHA requires that the pit be shored so it will be safe to work around; EPA has become increasingly involved with in-ground installations because of the lift’s susceptibility to leakage. Also, once a pit system is installed, OSHA requires an extensive ventilation system be installed. Explosion-proof wiring must be used on any lighting or electrical equipment. A drainage system of raised flooring is needed if any water is present in the excavation. The pit must be covered or surrounded by a guard rail when not being used. Maintenance in an in-ground system can require substantial downtime.

With above-ground lifts, however, a complete system can be set up and operational in hours. Servicing can continue with no downtime, and vehicles are quickly and easily loaded onto the system, which requires less precise positioning than in-ground systems. Also, with no in ground posts to get in the way, above ground lifts feature unrestricted access to the undercarriage.

The Automotive Lift Institute’s (ALI) Lift Certification Program promotes safety in manufacture and design of lifts. The ALI has contracted with ETL Testing Laboratories, a nationally recognized testing lab, to test and verify that lifts meet ANSI standards. Lifts that meet the ANSI standards will receive the ALI/ETL Lift Certification Label, testifying to their safety.

Reprinted with permission of Public Works Magazine, November 1993

Whether it is the city, county, or state level, government agencies are always trying to find cost-effective solutions to equipment needs. Before investing tens of thousands of dollars in a new product, purchasing decisions have to be carefully researched, and each product’s advantages and disadvantages carefully weighed.

For government motor pools, an important purchasing decision is choosing a vehicle lift. This device represents a substantial investment – a decision the motor pool will live with for 20, 30 or 40 years. There are three basic systems for under-vehicle maintenance: service pits, in-ground lifts, and above ground lifts.

Service pits. A service pit is not a lift system, but simply a way of accessing the vehicle’s underside from a pit beneath it. Requiring an excavation 6 to 8 feet deep, the pit requires minimal maintenance. However, special care must be taken during construction to meet OHSA regulations. With the combination of fuels and sparks in a restricted area, OSHA requires an extensive ventilation system and explosion-proof wiring on electrical equipment to minimize any fire threat. Water encountered during excavation or during the pit’s use means requiring a drainage system. The service pit must have three means of escape. Also, a service pit does not permit tire removal.

In-ground lifts. Among true lift systems, the in-ground lift has been the industry standard for years. This system usually has one, two, or three posts that raise the vehicle either by one its wheels or chassis. A fully hydraulic or combination hydraulic/air compression system provides lift power.

Like the service pit, an in-ground lift needs an excavated area – usually a 4 ft square 6 to 8 ft. deep. Digging an installation site is costly, especially in areas of shallow bedrock. Although below-ground lifts are normally less expensive than their above-ground counterparts, excavation costs can result in cost parity. Being underground though, in-ground lifts are subject to damage by electrolysis, corrosion, and high water tables. While fiberglass insulation can prevent some problems, an in-ground lift repair often begins with a backhoe clearing an access to the piston. Because of its hard-to-reach under ground location, maintenance can be costly and time consuming.

An in-ground lift with one lifting cylinder also creates a significant obstruction under the car. Since the cylinder is directly beneath the vehicle, movement around the vehicle is hampered and under-car-access is restricted. A one-post system usually leaves a 1-in. clearance between the lift and the car. As a result, some repairs, especially exhaust and transmission work, are difficult, if not impossible to perform.

Because in-ground lifts require excavation, they fall under the jurisdiction of state and Federal regulatory agencies. The EPA is increasingly concerned with underground leakage of oil and other pollutants. They recently announced a plan to check in-ground lifts for leakage and to require a “soak-up” area surrounding leaking sites.

Above-ground lifts. Working to overcome some shortcomings of other systems, above-ground lifts have become more popular with constant refinement. As a result, they now compare favorably with other systems, and depending on the situation, can be the better choice, both in practical and economical terms. An above ground system does not require excavation work, only a concrete floor 4 in. deep rated at 4,000 psi. Because the posts are located on either side of the vehicle, there is little to obstruct the working area beneath the vehicle. There is also room for transmission jacks, engine hoists, and large tool boxes. Floor space is better used; and when a repair on a particular vehicle is delayed, it can be raised overhead, clearing the way for another vehicle underneath.

Several design changes eliminated many problems associated with above-ground lifts. For example, the twin posts of automotive lifts were originally located near the vehicle’s centerline. This prevented opening the doors an made switching from under-the-car to under-the-dash servicing impossible without removing the vehicle from the lift. The introduction of asymmetric design solved this problem. The posts can now be set away from the vehicle’s center, offset arms supporting the vehicle safely and securely. For heavier fleet vehicles, the posts are set far apart for easy door access. Another former problem was vehicle clearance. Some above-ground lifts now have only a 3-1/2″ arm height, which can accommodate almost any vehicle.

Until recently, a twin-post design, whether above-or in-ground, had to equalize hydraulic pressure between the two beams by using protrusive floor plates and overhead chains or cables. Floor plates obstruct the space beneath the vehicle, while fixed overhead chains or cable restrict the height of vehicles to be lifted. By using adjustable hydraulic tubes to equalize the posts’ hydraulics, the garage ceiling is the only factor limiting the vehicle height. On some lifts, adjustable hydraulic tubes can be lowered to 10 ft. 6 in., allowing them to fit almost any garage ceiling. If ceiling height is still a problem, several above-ground lift manufacturers offer an underground hydraulic line option.

An above-ground system should include several safety features. A direct drive or chain-driven system provides maximum safety since chains are stronger than cables, which fray, stretch, and require periodic adjustments. A chain’s longevity also required by cable or mechanical screw type lifts. An “all-heights” mechanical locking system with hydraulic back ups is another important safety feature. Twin-post, above-ground lifts are designed to lift different weights from 6,000 to 30,000 lbs. For motor pools that service large vehicles weighing more than 15 tons, such as fire engines, salt trucks, and earth moving equipment, ramp-style above-ground lifts have the advantages over their twin-post counterpart. The biggest lifts can handle up to 120,000 lbs., and if necessary, can be made to fit any wheelbase and track width.

Government motor pools can find many advantages to using an above-ground lift system. With free under car access, installation ease, low maintenance, clear-floor design, and ability to accommodate low vehicle clearance the above-ground lift is increasing in popularity.