Unsafe bolts on BendPak XPR series two-post vehicle lift

Health and Safety Executive - Safety notice

Department Name: Field Operations Division

Bulletin No: FOD02-2023

Issue Date: August 2023

Target Audience: Users and suppliers of BendPak XPR series two-post vehicle lifts, motor vehicle repair and associated industries.

Issue

BendPak XPR series two-post vehicle lifts have a half-moon-shaped arm restraint gear on each arm which is either welded or bolted. On some of the lifts with the arm restraint gear attached with bolts, the bolts do not meet the required strength standard increasing the risk of a major incident.

Outline of the problem

Evidence from an investigation of a fatal incident revealed concerns with an aspect of the manufacture and supply of the BendPak XPR series two-post lifts.

The bolts should be 8.8 class bolts. If the lift's arm restraint gear is attached using bolts marked '4.8' or unmarked bolts, then there is an increased risk of a major incident, including a vehicle falling from the lift.

BendPak XPR series lifts use a teeth-meshing mechanism to lock the arm gears. Many of these lifts use a bolted connection to attach the arm restraint gear (as is in the diagram): 

Arm restraint gear ring and pin assembly diagram

BendPak require the use of a minimum class of 8.8 bolts tightened to an appropriate torque for the lift to meet the strength standards for two-post vehicle lifts set out in the British Standard; BS EN 1493. An understrength lift is at risk of not being able to support or withstand the forces it is subjected to, and is at risk of collapse. 

Action required:

Users of BendPak two-post lifts should:

Check

Check the bolts. If the arm restraint gear has a bolted connection check if any 4.8 class, or unmarked, bolts are in use. The class should be clearly stamped on the bolt head. If there is no marking, then you should assume that it is not the correct class bolt.

Check that bolts are tightened. If you have 8.8 class bolts you must ensure that they are tightened to the correct torque of 33 ft/lb (or 45 NM).

A previous HSE safety alert covered the need to install a redesigned arm restraint gear. Check that your lift has the newer arm restraint gear type. The newer gear rings sit flush to the pin, have circular rather than slotted or elongated holes, and have the appearance of being machined rather than cast. More information is available from the previous Safety Bulletin.

Replace

Contact the lift supplier to get replacement parts. If the lift does not have a minimum class of 8.8 bolts for all arm gear bolted connections (or it does not have the redesigned arm restraint gear) take immediate action to replace those bolts or the gear.

Do not use the lift until the necessary replacements have been made by a competent person. A manufacturer's video demonstrating how replacement can be carried out is available.

Thorough examination by a competent person

Users must make sure that the lift undergoes thorough examination as required by the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER).

Maintain

Users of two-post vehicle lifts should inspect and maintain them in accordance with the manufacturer's instructions. This includes regular checks (at least monthly, according to the manual) on the tightness of all bolted connections to ensure they are correctly torqued. See the manual for further information on required maintenance checks.