AussieCarHoists YL-240 Installation And Operation Manual Download

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YL-240 4500KG BASE PLATE CAR HOIST

Installation and operation manual

CONTENTS

Important notice

Introduction 6

Check parts before assembly

Machine parameters

Tools required

Specifications of concrete

Installation 13

Important power unit installation notes

Test run

Lift start up/final adjustments

Optional and standard accessories

Owner/operator responsibilities & lift operation safety

Wire rope inspection and maintenance

Safe lift operation

Troubleshooting guide

Drawing details

PH 1300 232 153

HIGHLIFT

Summary of Contents for YL-240

Page 1: ... FORWARD THIS MANUAL TO ALL OPERATORS FAILURE TO OPERATE THIS EQUIPMENT AS DIRECTED MAY CAUSE INJURY OR DEATH KEEP THIS OPERATION MANUAL NEAR THE MACHINE AT ALL TIMES ENSURE ALL USERS READ THIS MANUAL RECEIVING Ensure shipment is thoroughly inspected as soon as received The signed Bill of Lading is acknowledgement by the shipping carrier as receipt that this product as listed on invoice is in good...

Page 2: ...stalling or operating lift under conditions not in accordance with installation and operation guidelines or damaged by contact with tools or surroundings f Motor or pump failure caused by rain excessive humidity corrosive environments or other contaminants g Rusted components due to improper maintenance or corrosive environments h Cosmetic defects that do not interfere with product functionality i...

Page 3: ...d 12 Specifications of concrete 13 Installation 13 Important power unit installation notes 24 Test run 25 Lift start up final adjustments 26 Optional and standard accessories 27 Owner operator responsibilities lift operation safety 28 Wire rope inspection and maintenance 33 Safe lift operation 34 Troubleshooting guide 35 Drawing details 37 P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 4: ...rators Make certain all operators are properly trained know how to safely and correctly operate the unit and are properly supervised Allow unit operation only with all parts in place and operating safely Carefully inspect the unit on a regular basis and perform all maintenance as required Service and maintain the unit only with authorized or approved replacement parts Keep all instructions permane...

Page 5: ...to follow installation instructions may lead to serious personal injury or death to operator or bystander or damage to property or lift Failure to follow danger warning and caution instructions may lead to serious personal injury or death to operator or bystander or damage to property Please read entire manual prior to installation Do not operate this machine until you read and understand all the ...

Page 6: ...identally plugged in during service or mark circuit breaker switch so that it cannot be accidentally switched on during service 12 Use only as described in this manual Use only manufacturer s recommended attachments 13 ALWAYS WEAR SAFETY GLASSES Everyday eyeglasses only have impact resistant lenses they are not safety glasses 14 Consider work environment Keep work area clean Cluttered work areas i...

Page 7: ...or the possibility of pouring a new level concrete slab DO NOT install or use this lift on any asphalt surface or any surface other than concrete DO NOT install or use this lift on expansion seams or on cracked or defective concrete DO NOT install or use this lift on a second elevated floor without first consulting a building architect When removing the lift from shipping angles pay close attentio...

Page 8: ...pper and inside the column take out the parts box check the parts according to the shipment parts list 3 Loosen the screws of the upper package stand take off the upper column and remove the package stand 4 Move aside the parts and check the parts according to the shipment parts list motor CHECK THE PARTS BEFORE ASSEMBLY Motor Floor Cover Off side post assembly Parts boxarts box P H 1 3 0 0 2 3 2 ...

Page 9: ...9 5 Parts in the parts box outer arm machine NOTE view according to order type 6 Parts in the parts box inner arm machine NOTE view according to order type NOTE Accurate view by actual purchase order photo above for reference only P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 10: ...olyethylene slidrs and bronze bushings Single point security release and dual security design Standard super symmetric arms can be used as symmetric or asymmetric SPECIFICATIONS Style Lifting capacity Lifting time Lifting height Overall width Width between columns Minimum pad Hheight Gross weight Motor Floor plate chaindriven 4500kg 9000lbs 45S 70 87 1800mm 136 89 3477mm 115 75 2940mm 3 94 100mm O...

Page 11: ...ER 1 OUTER ARM 2 long and 2 short Lift arm a b 29 92 47 24 760 1200mm c d 27 95 41 34 710 1050mm 2 INNER ARM 2 long and 2 short Lift arm a b 35 43 55 12 900 1400mm c d 29 5 3 45 28 750 1150mm 3 INNER ARM 2 long and 3 short Lift arm a b 35 43 57 09 900 1450mm c d 26 38 44 88 670 1140mm P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 12: ...otary Hammer Drill 3 4in 19mm Hammer Level Bar Crescent Wrench 12 Ratchet Spanner With Socket 28 Wrench set 10 13 14 15 17 19 24 27 Carpenter s Chalk Screw Drivers Tape Measure 25ft Pliers Allen Head Wrench 6 Vise Grips TOOLS REQUIRED P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 13: ...Installation Check the installation location concrete layout space size etc so it is suitable for lift installation LIFT HEIGHT CLEARANCE NOTE There must be 70 plus the height of typical vehicle MIN distance from top of lift to nearest obstruction 2 Use a carpenter s chalk line to establish installation layout of base plate Check the installation location concrete layout space size etc so it is su...

Page 14: ...Check the columns are plumb with level bar and adjusting with the shims if the columns are not vertical Power side column Offside column Car in direction 115 75 2940mm 136 89 3477mm Work Smart not Hard No need to measure Use the base plate as a distance gauge Before drilling the anchor holes position the columns up to each end of the base plate Double check that the columns are positioned on the c...

Page 15: ...tap into each hole with a hammer until the washer rests against the base plate If shimming is required be sure that enough threads are left exposed 4 With the foot guards shims and anchor bolts in place tighten by securing the nut to the base then turning 3 5 full turns clockwise DO NOT use an impact wrench for this procedure INSTALL CABLE 1 Lift the carriages up by hand and locked them at the sam...

Page 16: ...lance cable 1 The balance cable passes through the carriages along the top pulley 3 Through the carriages and secure at the top of the carriages One end of the balance cable has been installed prior to shipment 2 Bypass two rows of bottom pulleys P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 17: ... NPT fittings Do not use Teflon tape on the hydraulic hose JIC threads Tighten all the hydraulic fittings and fill the reservoir with approximately 2 6 gallons of hydraulic oil Note In consideration of hydraulic power unit s durability and keeping the equipment running in good condition please use Hydraulic Oil 46 P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 18: ...ty 2 Install safety cable oil hose and protective cover NOTE The protective cover welded on the extension column only need to install the protective cover on the column 3 Install shelves to place height adapters Balance cable Balance cable Oil hose Oil hose Protective cove Safety cable Safety cable Height adapters shelves P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 19: ... installed on the column before shipment 2 Safety lock on the power side column and offside column component connect safety cables 3 Install cover the safety lock protection box Install power side column lock safety cables Install offside column lock safety cables Install Lock Box Install Lock Box P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 20: ... operation manual 20 INSTALL LIMIT SWITCH ASSEMBLE FLOOR COVER AND PROTECTIVE RUBBER SETS Install limit switch with power unit Note The security switch is on the main column side Protective rubber sets Floor Cover P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 21: ...n of the arm restraint pin Pivot the arms back and forth and test the operation of the arm restraint pin in various positions 6 Ensure that the arms do not move when a force of approximately 100 pounds or less is applied laterally to the fully extended arms Lift head pins Lift head pins Lift head pins Lift head pins NOTE Arm gears rings have left and right orientations DANGER DANGER THE ARM RESTRA...

Page 22: ...the arms Each arm and arm restraint gear must be positioned in the proper location in the lift head 4 Install Arm Lock assembly in to the lift 5 Install Arm lock pins in to the lift 6 Pull up arm lock rod to ensure it is fully unlocked adjust in this state Adjust nut as shown 7 Adjust the arm lock Follow the arrow direction Lift head pins Lift head pins Lift head pins Lift head pins Arm lock Arm r...

Page 23: ... test the operation of the arm restraint pin in various positions 10 Ensure that the arms do not move when a force of approximately 100 pounds or less is applied laterally to the fully extended arms Locking the nuts after the moon gear and arm lock engaged well Pull up Pull up Lift head pins Arm lock DANGER NOTE EACH ARM RESTRAINT ASSEMBLY MUST BE INSPECTED BEFORE EVERY TIME THE LIFT IS OPERATED D...

Page 24: ...e vehicle until a thorough operation check has been completed ALL WIRING MUST BE PERFORMED BY A CERTIFIED ELECTRICIAN ONLY POWER UNIT CONNECTION Have a certified electrician run the power supply to motor Refer to the data plate found on the motor for proper power supply and wire size RISK OF EXPLOSION This equipment has internal arcing or parts that may spark and should not be exposed to flammable...

Page 25: ...he lift and the side with the carriage in the lower position will remain locked in the same place and the other side higher side is unlocked Continue to lower down the lift until the higher carriage is at the same level as the lower carriage c Loosen the jam nut on the higher carriage synchronizing cable and tighten the tension nut until the synchronizing cable has the same tension as the other sy...

Page 26: ...feet from any moving parts Keep feet clear of lift when lowering Avoid pinch points 7 Check all MAIN SAFETY LOCKS to make sure they move freely 8 Cycle the lift up and down a few times to ensure that the safety locks are engaging uniformly and that the safety release mechanisms are functioning Re adjust if necessary POST INSTALLATION CHECK LIST 1 Columns properly shimmed and stable 2 Anchor Bolts ...

Page 27: ...spiral tray Double spiral tray OR 2 long 2 short Lift arm 2 long 2 short Lift arm 2 long 3 short Lift arm Outer arm inner arm Iron motor plastic oil tank or iron oil tank Aluminum motor iron oil tank or plastic oil tank Aluminum motor iron oil tank or plastic oil tank only electrolytic locks optional Tool tray curtain prevent dust only mechanical dual point release optional P H 1 3 0 0 2 3 2 1 5 3...

Page 28: ...repairs Shall not modify the lift in any manner without the prior written consent of the manufacturer LIFT OPERATION SAFETY DAILY inspect your lift Never operate if it malfunctions or if it has broken or damaged parts Use only qualified lift service personnel and genuine parts to make repairs THOROUGHLY train all employees in use and care of lift using manufacturer s instructions and lifting it ri...

Page 29: ...d pawl to mesh DO NOT hammer arm restraint pin down as this will damage the restraint gear teeth Raise vehicle until tires clear the floor Stop and check adapters for secure contact at vehicle manufacturer s recommended lift points Continue to raise to desired height only if vehicle is secure on lift DO NOT go near or under a raised vehicle if all four adapters are not in secure contact with vehic...

Page 30: ...ERING valve handles must be held down simultaneously to lower lift Do not override self closing lift controls 5 Remain clear of lift when lowering vehicle Observe pinch point warning decal instructions 6 Remove adapters from under vehicle and swing arms to full drive thru position before moving vehicle 7 If lift is not operating properly DO NOT use until adjustment or repairs are made by qualified...

Page 31: ...s and sheaves for wear Replace worn parts as required with genuine parts Daily Inspect adapters for damage or excessive wear Replace as required with genuine parts Weekly Lubricate all sheaves and rollers with general purpose oil Weekly Check all cable connections bolts and pins to ensure proper mounting Monthly Check equalizer cable tension Adjust per lift installation instructions Monthly Lubric...

Page 32: ...orts to provide an unobstructed exit NEVER drive over lift arms REQUIRED MONTHLY MAINTENANCE Check all arm adjusting locks for proper operation Check all cables connections bolts and pins to ensure proper mounting and torque Visually inspect safeties for proper operation Lubricate posts with grease Inspect all anchors bolts and retighten if necessary Check all posts for squareness and plumb Inspec...

Page 33: ... or similar heavy lubricant applied by any method including pump spray dispensing brush hand and or swabbing HOW OFTEN TO INSPECT Lifting cables should be visually inspected at least once each day when in use as suggested by American Petroleum Institute API RP54 guidelines Any lifting cables that have met the criteria for removal must be immediately replaced WHEN TO REPLACE LIFTING CABLES DUE TO B...

Page 34: ...aised observe the chocks Put pads or adapters in the right position under the contact points that have been recommended The lift should be raised just until the vehicle s wheels are about one foot off the ground If contact with the vehicle is uneven or it appears that the vehicle is not sitting secure carefully lower the lift and readjust Always consider potential problems that might cause a vehic...

Page 35: ... Compare wiring of motor to electrical diagram on power unit drawing 7 Oil seal damaged or cocked Replace oil seal around pump shaft 8 See Installation Manual Contact Factory 9 Replace with new part Replace with new part 10 Return unit for repair Return unit for repair 11 Check pump mounting bolts Bolts should be 15 to 18 ft lbs 12 Inlet screen clogged Clean inlet screen or replace 13 Check wall o...

Page 36: ...cal diagram on power unit drawing 10 Inlet screen clogged Clean inlet screen or replace 11 Check wall outlet voltage and wiring Make sure unit and wall outlet is wired properly IMPORTANT If after observing that all mechanical locks are released and the lift still fails after following all standard operating procedures immediately stop using the lift and contact factory or factory approved service ...

Page 37: ...YL 240 4500KG BASE PLATE CAR HOIST Installation and operation manual 37 DRAWING DETAILS LIMITED SWITCH ELECTRICAL CONNECTION DIAGRAM 220V MOTOR P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 38: ...YL 240 4500KG BASE PLATE CAR HOIST Installation and operation manual 38 LIMITED SWITCH ELECTRICAL CONNECTION DIAGRAM 380V MOTOR P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 39: ...ON ANALYSIS Start button Check valve Release valve Handle for release valve Throttle valve Oil outlet Overflow valve Check valve Prevent reverse flow of oil Overflow Overflow valve Adjusting oil pressure Throttle valve Adjusting the descent rate P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 40: ...1 3 Valve block blockage 1 4 Overflow valve 1 5 Valve body 1 6 O ring 1 7 Valve body bolt 4 8 Gear pump 1 9 Gear pump bolt 2 10 Oil inlet pipe 1 11 Filter 1 12 Socket bolt 4 13 Oil storage tank 1 14 Oil retum pipe 1 15 Buffer valve 1 16 Throttle valve 1 17 Release valve 1 18 Handle for release valve 1 19 Check valve 1 P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

Page 41: ... for chain pulley 2 2 YL DBSZ 00 17 00 Equalizing cable assy ø8X8050 thread head M16 2 14 SF 3550 Bronze bush for chain pulley SF3550 2 3 HN001600 Hex nut M16 8 15 YL DBSZ 00 20 Inner pulley 4 4 LH1244 121joints Chain LH1244 121joints 2 16 YL DBSZ 00 21 Chain fixing pole 2 5 ø8X2940 Both ends are Z curved fitting M16X1 5 oil tube assy ø8X350 Both ends are Z curved fitting M16X15 1 17 HN002400 Hex ...

Page 42: ...Head bolt M5x30 2 25 YL DBSZ 00 11 Main lock plate 1 8 H000820 Hex bolt M8x20 4 26 SL001000 Self lock nut M10 4 9 IH001012 Inside Hex bolt M10X12 2 27 UH000510 Umbrella Head bolt M5x10 5 10 YL DBSZ 00 03 Pump bracket 1 28 YL DBSZ 00 12 Limit switch bracket 1 11 HN000800 Hex nut M8 4 29 8108 Limit switch 1 12 YL DBSZ 00 04 Handle ball 1 30 YL DBSZ 00 13 Rope wheel Interval sleeve 2 13 YL DBSZ 00 05...

Page 43: ...pin 2 4 S000630 Expansion pin ø6X32 2 5 YL DBSZ 00 25 Arm fix shaft 2 6 YL DBSZ 00 26 Protective rubber 1 7 SH000825 Sunk bolt M8x25 2 8 YL DBSZ 00 27 Arm lock 2 9 YL DBSZ 00 28 Arm lock spring ø26x140xø2 2 10 W001000 Washer ø10 2 11 YL DBSZ 00 29 Lock rod spring 2 12 SP000330 Circlip B shape 2 13 YL DBSZ 00 30 Locked teeth block 2 14 YL DBSZ 00 31 Unlock lever 2 15 YL DBSZ 00 32 Handle ball 2 Out...

Page 44: ...rm of two stage arms 4 3 IH000810 Inside Hex bott M8x10 4 4 RE005000 Retaining ring extemal ø50 4 5 YL DBSZ 00 33 Sleeve of one stage screwed pad 4 6 YL DBSZ 00 34 Steel wire circlip 4 7 YL DBSZ 00 35 Extension 4 8 YL DBSZ 00 36 Steel wire circlip 4 9 YL DBSZ 00 37 Screwed pad 4 10 YL DBSZ 00 38 Rubber cover 4 11 IH001020 Inside Hex bolt M10X20 4 P H 1 3 0 0 2 3 2 1 5 3 H I G H L I F T ...

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AussieCarHoists YL-240, Installation And Operation Manual

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