P/N: 300588

HYDRAULIC TOOL LIFTMANUAL

2P/N: 300588

3P/N: 300588

INTRODUCTION

The Boss hydraulic powered tool lift utilizes the truck engines 12VDC-power source to operatethe self contained hydraulic power unit and lift assembly. Once installed the lifting function ofthe tools in and out of your truck or van is accomplished by simply using the raise / lowerelectrical rocker switch. The fixed speed of this unit allows the workforce a safe and effectivemeans for removing the heavy and cumbersome air tools at the start and end of your jobs.

SAFETY

WARNING

ALL UNITS ARE SHIPPED WITH A DETAILED OPERATOR’S, INSTALLATION ANDPARTS MANUAL. THIS MANUAL CONTAINS VITAL INFORMATION FOR THE SAFE USE

AND EFFICIENT OPERATION OF THIS UNIT. CAREFULLY READ THE OPERATOR’SMANUAL BEFORE STARTING THE UNIT. FAILURE TO ADHERE TO THE

INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR PROPERTYDAMAGE.

BOSS HYDRAULIC TOOL LIFT SAFETY PRECAUTIONS

Safety is basically common sense. There are standard safety rules but each situation has itsown peculiarities, which cannot always be covered by rules. Therefore with your experienceand common sense, you are in a position to do something about safety. Lack of attention tosafety can result in accidents, personal injury, reduction of efficiency and worst of all – loss oflife. Watch for safety hazards. Correct promptly. Use the following safety precautions as ageneral guide to safe operation:

• Do not attempt to service any part while the machine is operating.

• Do not remove any hose without first securing the lift mechanism from falling (safetylatch to tool platform).

• Hose removal should be done by first breaking loose the hose end by 1/8 turn torelieve any pressure in the system.

• Periodically check all safety devices for proper operation.

• Do not disconnect or bypass the safety circuit system.

• Do not operate lift with workers in its operational path.

4P/N: 300588

DANGER

DO NOT USE BOSS INDUSTRIES, INC. LIFT FOR ANY OTHER PURPOSE OTHER THANTHOSE SPECIFIED.

BOSS INDUSTRIES, INC. DISCLAIMS ANY AND ALL LIABILITIES FOR DAMAGE ORLOSS DUE TO PERSONAL INJURIES, INCLUDING DEATH, AND/OR PROPERTY

DAMAGE INCLUDING CONSEQUENTIAL DAMAGES ARISING OUT OF ANY BOSS LIFTNOT USED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS.

SPECIFICATIONS

• Height 54.5 inches

• Width 19.0 inches

• Length 19.5 inches

• Weight 200 pounds

• Recommended fluid: Dexron II ATF or equal

• Operating Pressure 1500 PSI

DESCRIPTION OF COMPONENTS

Boss Hydraulic Tool Lifts are shipped as an assembled unit for field installation (see figure 2).These assembled units include:

• Mechanical Lift Assembly: Mechanical arm with tool platform.

• Your choice of hex posts for tool mounting, 7/8", 1", 1 1/8" and 1 ¼” hex posts available.

• Hydraulic cylinder mounted to mechanical lift assembly.

• Self contained hydraulic power unit mounted to base of the mechanical lift assembly(power unit can be remote mounted).

• Hoses and fitting pre-plumbed.

• All necessary safety and information decals.

• Power up/down switch with wire harness.

• Safety circuit switches.

• Safety chains for mounted tools.

• Safety latch for tool platform.

• Parts, service, installation, and maintenance manual.

5P/N: 300588

Boss Industries offers factory installation by qualified technicians, as well as a nationwidenetwork of authorized distributors for field installations, parts, and service.

MAINTENANCE AND OPERATION

Periodic maintenance procedures should be understood that the intervals of inspection,lubrication and maintenance specified are maximum intervals. More frequent inspectionsshould be made if the unit is operating in a dusty environment, in high ambient temperatures orin other unusual conditions. A planned program of periodic inspection and maintenance willhelp to avoid premature failure and costly repairs. Daily visual inspections should becomeroutine.

DANGER

DO NOT INSPECT, LUBRICATE, OR MAINTENANCE THE POWER LIFT WHILEOPERATING.

• Lubricate the four (4) grease fittings located on the lift are pivot pin assemblies every sixmonths.

• Inspect reservoir oil level every six months; fill with ATF Dexron II or equivalent.

• Inspect cotter pins and pivot pins for wear or damage.

BLEEDING POWER UNIT

If power unit reservoir has been run low on fluid, air can be trapped in system and foam anyremaining fluid. If this occurs, you must drain the fluid from the system and refill with new fluid(automatic transmission fluid – Dexron II or equivalent).

1. Lower power unit to ground. Remove all tools from lift. Remove hose from rod end ofcylinder and place in a bucket.

2. Remove hose from mounting end of cylinder and place in bucket.3. With both hose ends secured in bucket, operate raise/lower switch in both positions to

remove fluid from power unit.4. Fill power unit reservoir with new, clean ATF. Attach hose to rod end of cylinder. Leave

the hose from the mounting end of the cylinder in the bucket.5. With hose from the mounting end of the cylinder secured in bucket, operate the raise

movement of the lift until it bottoms out on base.6. Attach hose from mounting end of cylinder. Top off oil reservoir. Operate lift to its

complete up and own position several times to remove any air trapped in the system.

6P/N: 300588

LIFT OPERATION

WARNING

CAREFULLY READ THE OPERATING INSTRUCTIONS BELOW. FAILURE TO ADHERETO THE FOLLOWING RAISE AND LOWER INSTRUCTIONS COULD RESULT IN

SERIOUS INJURY.

NOTE

POWER UNIT HAS A 4-MINUTE ON/OFF CYCLE TIME, (IE.. FOR EVERY 4CONTINUOUS MINUTES OF OPERATION, 4 MINUTES OF IDLE/NO OPERATION, MUST

TAKE PLACE OR MOTOR OVERHEATING CAN OCCUR).

LOWER OPERATION

1. Check and verify that the operational path of tool lift is clear.

2. Move safety latch out of tool platform and into latch hole on base. NOTE: Lift will notoperate until safety latch is placed in the hole on the base.

3. Verify that tools are locked onto the respected posts.

4. Lower tools by pushing the lower side of rocker switch until the lift makes contact withground or is at the end of its stroke.

5. Remove safety chains and unlock tools from their posts.

RAISE OPERATION

1 Place tools back on hex posts. Lock tools onto hex posts. Attach safety chains.

2 Check and verify that operational path of tool lift is clear.

3 Raise tools by pushing the rise side of the rocker switch. Raise tool lift until metal tometal contact securely locks lift in place.

4 Move safety latch from hole in base to bottom of tool platform.

7P/N: 300588

INSTALLATION

Only those who have been trained and delegated to do so, and who have read and understandthe operator, installation, and parts manual should install the Boss hydraulic tool lift. Failure tofollow the instructions in this manual may result in accident and/or injury.

GENERAL

The installation of the tool lift should be done in the following sequence:

1. Mounting the mechanical lift unit: (See Figure 1.)

The lift unit assembly measures 54.5" high X 19.0" wide X 19.5" long when in the upposition. When the lift is lowered, it is cantilevered over the edge of the truck bodycreating considerable torque on the mounting surface. The surface of the truck wherethe lift is bolted to must be rigid enough to support the 300-pound maximum tool weightextended the 27" out beyond the truck. This can be accomplished by increasing thefloor thickness or gusseting the floor from the bottom. The position of the lift in relationto the drop edge should not exceed the dimensions in Figure 1. This insures properclearance of the back edge of the tool platform when lowering tools to the ground.

2. Wiring for the power unit: (See Figure 3.)

A detailed wiring diagram is enclosed in this manual. Power from the hot side of thetruck’s starter solenoid is the electrical source for the Boss hydraulic tool lift. Twentyfive feet of six gauge wire is supplied and should be run from the hot side of the truck’sstarter solenoid to the power unit’s solenoid bracket to the truck’s frame.

The remainder of the wiring comes in a harness with the raise/lower switch and the doorsafety switch pre-wired. These two components require mounting.

The safety switch needs to be mounted so that the roll-up door on vans are in the upposition in order to get power to the raise/lower switch. In cases where some other typeof door is used, a normally open switch should be used to insure accidental operationdoes not occur when doors are closed on the vehicle.

The raise/lower operator switch should be mounted inside the vehicle and several feetaway from the operational path of the lift (this switch is not waterproof).

When testing unit, if unit raises when it is supposed to lower, switch the position of thetop and bottom feed wires at the raise/lower switch.

8P/N: 300588

Parts&

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9P/N: 300588

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10P/N: 300588

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SHEET

600304 2 OF

REV9

OPT, HYD TOOL LIFT HL300 (12V)

BOSS INDUSTRIES1761 GENESIS DR.LA PORTE, IN 46350

N/APATH

MATERIAL

G:\Inventor Files\60k\60030.dwg

11/16/2006JPCDRAWN

CHECKED

1=4D

DESCRIPTION

DWG NO

R

SCALESIZE

UNMACHINED SURFACES

FRACTIONAL ` 1/16

DECIMAL ` .03

ANGULAR ̀1°

DO NOT SCALETOLERANCES

UNLESS NOTED

MACHINED SURFACES NOMINAL DIM.

0.000 TO 1.000 ` .010

1.001 TO 5.000 ` .015

5.001 TO 10.000 `.020

10.001 & OVER `.025

THIS DRAWING AND ALL ITS CONTENTS ARE PROPERTY OF BOSS INDUSTRIES, INC. AND MUST NOT BE COPIED OR MADE PUBLIC. IT IS LOANED AND IS SUBJECT TO RETURN UPON DEMAND. THEINFORMATION CONTAINED IN THIS DRAWING IS CONFIDENTIAL AND MUST NOT BE USED, DIRECTLY OR INDIRECTLY, IN ANY WAY DETRIMENTAL TO THE INTEREST OF BOSS INDUSTRIES, INC.

PROPRIETARY INFORMATION

53 7/8 in[1369.9 mm]

19 1/2 in[495.6 mm]

11 in[278.1 mm]

1 in[25.4 mm]

13 in[330.2 mm]

3 in[76.2 mm]

9 in[228.6 mm]

2 1/4 in[58.7 mm]

6 1/2 in[164.6 mm]

5 1/2 in[139.7 mm]

11 1/4 in[284.9 mm]

15 in[381.0 mm]

n1/2 in THRU

MOUNTING HOLE6-PLACES

2 1/4 in[57.2 mm]19 1/2 in

[495.3 mm]

6 in[152.4 mm]

1/4 in[6.4 mm]

WEIGHT: APPROX 325lbs LIFT CAPACITY: 300lbs

9 UPDATED 300657 TO REV 2. 9/19/2008 MCM8 UPDATED 305779 TO REV 2. 7/15/2008 MCM7 ADDED (2) 970407-056. 2/19/2008 MCM

REVISION HISTORYREV DESCRIPTION DATE ENG

11P/N: 300588

1

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SHEET

600304 3 OF

REV9

OPT, HYD TOOL LIFT HL300 (12V)

BOSS INDUSTRIES1761 GENESIS DR.LA PORTE, IN 46350

N/APATH

MATERIAL

G:\Inventor Files\60k\60030.dwg

11/16/2006JPCDRAWN

CHECKED

1=4D

DESCRIPTION

DWG NO

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SCALESIZE

UNMACHINED SURFACES

FRACTIONAL ` 1/16

DECIMAL ` .03

ANGULAR ̀1°

DO NOT SCALETOLERANCES

UNLESS NOTED

MACHINED SURFACES NOMINAL DIM.

0.000 TO 1.000 ` .010

1.001 TO 5.000 ` .015

5.001 TO 10.000 `.020

10.001 & OVER `.025

THIS DRAWING AND ALL ITS CONTENTS ARE PROPERTY OF BOSS INDUSTRIES, INC. AND MUST NOT BE COPIED OR MADE PUBLIC. IT IS LOANED AND IS SUBJECT TO RETURN UPON DEMAND. THEINFORMATION CONTAINED IN THIS DRAWING IS CONFIDENTIAL AND MUST NOT BE USED, DIRECTLY OR INDIRECTLY, IN ANY WAY DETRIMENTAL TO THE INTEREST OF BOSS INDUSTRIES, INC.

PROPRIETARY INFORMATION

53 7/8 in[1369.9 mm]

19 1/2 in[495.6 mm] 17 in

[431.8 mm] *

27 5/8 in[702.0 mm]

37 1/4`1 in946.2`25.4 mm[ ]

DROP EDGE

MOUNTING SURFACE

FRONT EDGE

* DO NOT MOUNT THE FRONT EDGE

OF THE UNIT MORE THAN 17.00" AWAY FROM THE DROP EDGE. INTERFERENCE BETWEEN LIFT ARM AND MOUNTING SURFACE WILL OCCUR IF THIS DIMENSION IS EXCEEDED.

9 in[228.6 mm]

9 UPDATED 300657 TO REV 2. 9/19/2008 MCM8 UPDATED 305779 TO REV 2. 7/15/2008 MCM7 ADDED (2) 970407-056. 2/19/2008 MCM

REVISION HISTORYREV DESCRIPTION DATE ENG

12P/N: 300588

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