AussieCarHoists YL-250 Page 40 Installation And Operation Manual Download | Manualshive

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YL-250 5000KG 2 BASE PLATE CAR HOIST

Installation and operation manual

MOTOR FUNCTION ANALYSIS - MECHANICAL RELEASE

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

NOTE: Accurate view by actual purchase order. Photo above for reference only

HIGH-LIFT

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Summary of Contents for YL-250

Page 1: ... OF THIS MANUAL 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 inv...

Page 2: ...aused by installing 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 func...

Page 3: ...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 permanently with the unit and a...

Page 4: ...eters 11 Tools required 13 Specifications of concrete 14 Installation 14 Important power unit installation notes 25 Test run 26 Lift start up final adjustments 27 Optional and standard accessories 28 Owner operator responsibilities lift operation safety 29 Wire rope inspection and maintenance 34 Safe lift operation 35 Troubleshooting guide 36 Drawing details 38 H I G H L I F T ...

Page 5: ...only Failure 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 unders...

Page 6: ...cannot be accidentally 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...

Page 7: ...the site and 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 c...

Page 8: ...s from upper 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 Mechanical Release Motor Floor cover Off side post assembly Parts box...

Page 9: ...Release 1 Packaged lift and hydraulic power unit 2 Move the lift aside with fork lift or hoist and open the outer packing carefully take off the parts from upper and inside the column take out the parts box check the parts according to the shipment parts list NOTE Accurate view by actual purchase order photo above for reference only Motor Electric control box Floor cover Off side post assembly Par...

Page 10: ...ve aside the parts and check the parts according to the shipment parts list motor 5 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 6 Electric control box NOTE view according to order type NOTE Accurate view by actual purchase order photo above for reference only H I G H L I F T ...

Page 11: ...I standards Self lubricating UHMW polyethylene sliders and bronze bushings Double Point Release with dual safety design Standard super symmetric 4 sets of 3 stage arms SPECIFICATIONS Style Lifting capacity Lifting time Lifting height Overall width Width between columns Minimum pad height Gross weight Motor Floor plate Chain driven 5000kg 11000lbs 60 65S 70 87 1800mm 155 15 3950mm 133 86 3400mm 3 3...

Page 12: ...YL 250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 12 ACCURATE VIEW BY ACTUAL PURCHASE ORDER H I G H L I F T ...

Page 13: ...n manual 13 Rotary 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 H I G H L I F T ...

Page 14: ...al wire must be a minimum of 10 gauge INSTALLATION 1 Location of 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 3 Using t...

Page 15: ...vironment POSITION COLUMNS Check the columns are plumb with level bar and adjusting with the shims if the columns are not vertical 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 chalk line Power side column Offside column Car in d...

Page 16: ... on the anchors then 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 Lift the carriages up by hand and unt...

Page 17: ...STALL BALANCE CABLE 3 Thread through the carriages and secure at the top of the carriages 1 The balance cable passes through the carriages along the top pulley 2 Bypass two rows of bottom pulleys One end of the balance cable has been installed prior to shipment H I G H L I F T ...

Page 18: ...flon tape on all tapered NPT fittings Do not use Teflon tape on the hydraulic hose JIC threads Tighten all the hydraulic fittings and fill the reservoir with approximately 10 litres of hydraulic oil Note In consideration of hydraulic power unit s durability and maintaining good running condition use Hydraulic Oil 46 H I G H L I F T ...

Page 19: ...oil hose and safety 2 Install safety cable oil hose and protective cover Note The protective cover welded on the extension Colum only need to install the protective cover on the column 3 Install shelves to place height adapters Balance cable Balance cable Safety cable Safety cable Oil hose Oil hose Oil hose height adapters shelves H I G H L I F T ...

Page 20: ...re 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 Mechanical Release Install Power side column lock safety cables Install Lock Box Install Lock Box H I G H L I F T ...

Page 21: ... column component connect safety cables 3 Install cover the safety lock protection box INSTALLATION OF ELECTRICAL CONTROL BOX ELECTRIC RELEASE 22 21 20 19 18 17 16 23 24 25 26 36 37 13 12 14 15 Install Lock Box Has been installed prior to shipment Installation of electrical control box accessories are all in the electronic control box packaging Power indicator Power switch Up switch Unlock switch ...

Page 22: ...lation and operation manual INSTALL LIMIT SWITCH ASSEMBLE FLOOR COVER AND PROTECTIVE RUBBER SETS MECHANICAL RELEASE Install limit switch with power unit Note The security switch is on the main column side Floor cover Power indicator H I G H L I F T ...

Page 23: ... CAR HOIST Installation and operation manual ASSEMBLE FLOOR COVER AND PROTECTIVE RUBBER SETS ELECTRIC RELEASE Floor cover Power indicator NOTE Accurate view by actual purchase order driagram above for reference only H I G H L I F T ...

Page 24: ... pulling up on 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 T...

Page 25: ...olt three phase use a 20 amp fuse For 415 volt three phase use a 15 amp fuse INSTALLATION AND ADJUSTMENT DO NOT attempt to raise 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 an...

Page 26: ... Then lower the 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...

Page 27: ...ve hands and 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 ...

Page 28: ... INCLUDED OPTIONAL 85mm height adaptor 40mm Height adaptor Single spiral tray Double spiral tray Inner arm 4 sets of 3 stage 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 H I G H L I F T ...

Page 29: ...ing any lift 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 ...

Page 30: ...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 vehicle at vehicle manufacturer s ...

Page 31: ...lease and LOWERING 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...

Page 32: ...y Check cables 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 M...

Page 33: ... and supports 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 plu...

Page 34: ...mmends 90 WT gear oil 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 LI...

Page 35: ...the lift is raised 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 ...

Page 36: ...ck if motor is wired correctly Wired correctly explain 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 outlet voltages...

Page 37: ...or to electrical 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 appr...

Page 38: ...YL 250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 38 DRAWING DETAILS LIMITED SWITCH ELECTRICAL CONNECTION DIAGRAM 240V MOTOR H I G H L I F T ...

Page 39: ...39 YL 250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual LIMIT SWITCH ELECTRICAL CONNECTION DIAGRAM 415V MOTOR H I G H L I F T ...

Page 40: ...rt 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 NOTE Accurate view by actual purchase order Photo above for reference only H I G H L I F T ...

Page 41: ...CTRICAL RELEASE Check valve 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 NOTE Accurate view by actual purchase order Photo above for reference only H I G H L I F T ...

Page 42: ...otor connecting shaft 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 H I G H L I F T ...

Page 43: ...ron motor 1 2 Motor connecting shaft 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 Check valve 1 H I G H L I F T ...

Page 44: ...001000 Self lock nut M10 4 8 H000820 Hex bolt M8X20 4 27 UH000510 Umbrella Head bolt M5X10 5 9 IH001012 Inside Hex bolt M10X12 2 28 YL DJSSZ5 00 12 Limit switch bracket 1 10 YL DJSSZ5 00 03 Pump bracket 1 29 8108 Limit switch 1 11 HN000800 Hex nut M8 4 30 YL DJSSZ5 00 13 Rope wheel Interval sleeve 2 12 YL DJSSZ5 00 04 Handle ball 1 31 YL DJSSZ5 00 14 Rope wheel shaft 2 13 YL DJSSZ5 00 05 Lock rele...

Page 45: ...45 YL 250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 001 A POWER SIDE COLUMN Mechanical unlocking does not have 13 and 23 item number H I G H L I F T ...

Page 46: ...Name Qty 1 YL DJSSZ5 0 03 01 00 Section 1 Arm welding 4 2 YL DJSSZ5 0 03 02 00 Section 2 Arm welding 4 3 YL DJSSZ5 0 03 03 00 Section 3 Arm welding 4 4 YL DJSSZ5 0 03 04 00 Single helix tray 4 5 IH001020 Inside hex bolt M10X20 14 6 YL DJSSZ5 0 00 34 Moon gear 4 7 IH000810 Inside hex bolt M8X10 8 H I G H L I F T ...

Page 47: ...1 00 Carraige weldment 1 2 YL DJSSZ5 00 23 UHMW polyethylene Slider block 8 3 YL DJSSZ5 00 24 Arm lock pin 2 4 S000630 Expansion pinø6X32 2 5 YL DJSSZ5 00 25 Arm fix shaft 2 6 YL DJSSZ5 00 26 Protective rubber 1 7 SH000825 Sunk bolt M8X25 2 8 YL DJSSZ5 00 27 Arm lock 2 9 YL DJSSZ5 00 28 Arm lock spring ø26X140Xø2 2 H I G H L I F T ...

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