AussieCarHoists YL-250 User manual

This instruction manual has been prepared especially for the operator of this equipment. Your new lift is the product of over
15 years of continuous research, testing and development, it is the most technically advanced lift on the market today.
READ THIS ENTIRE MANUAL BEFORE INSTALLATION &
OPERATION COMMENCES
YL-250
5000KG 5 TON BASE PLATE CAR HOIST
Installation and operation manual
READ FIRST
Do not operate this machine
until you have read and
understood all dangers, warnings
and cautions in this manual
YOUR
SAFETY
OUR
STANDARDS
IMPORTANT SAFETY INSTRUCTIONS
KEEP THESE INSTRUCTIONS ON HAND. PLEASE READ THE ENTIRE CONTENTS OF THIS MANUAL PRIOR TO INSTALLATION AND
OPERATION. BY PROCEEDING WITH LIFT INSTALLATION AND OPERATION YOU AGREE THAT YOU FULLY UNDERSTAND THE FULL
CONTENT 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 invoice is in good
condition for shipment. For your protection: If any goods listed on
this Bill of Lading are missing or damaged, do not accept goods
until the shipping carrier makes a notation on the freight bill of
the missing or damaged goods.
BE SAFE
Your hoist was designed and built with safety in mind. To
increase your overall safety operate with proper training
and thoughtful operation. DO NOT operate or repair this
equipment without reading this manual and the important
safety instructions included throughout. Ensure ALL USERS
read and understand this manual.
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 2
READ THIS ENTIRE MANUAL BEFORE INSTALLATION &
OPERATION COMMENCES
This instruction manual has been prepared especially for the operator of this equipment. Your new lift is the product of over
15 years of continuous research, testing and development, it is the most technically advanced lift on the market today.
PRODUCT WARRANTY
What is not covered under this warranty:
a. Any failure that results from purchaser’s abuse, neglect or failure to operate, maintain or service product in accordance with
instructions provided in the owner’s manual(s) supplied.
b. Any damage caused by overloading lift beyond rated capacity.
c. Items or service normally required to maintain the product, i.e. lubricants, oil, etc.
d. Items considered general wear parts such as rubber pads, lifting cables, etc. unless wear or failure is a direct result of manufacturer
defect due to material and/or workmanship.
e. Any component damaged in shipment or any failure caused 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 functionality.
i. Damage due to incorrect voltage or improper wiring.
j. Any incidental, indirect, or consequential loss, damage or
expense that may result from any defect, failure or malfunction of the product.
k. All electrical components (excluding power unit) are guaranteed for one year
NOTE
Every effort has been taken to ensure complete and accurate instructions have been included in this manual, however possible product
updates, revisions and/or changes may occur post publication. We reserve the right to change specications without incurring any
obligation for equipment previously or subsequently sold. No responsibilty taken for typographical errors.
YL-340 4500KG 2 POST CLEAR FLOOR HOIST
Installation and operation manual
READ THIS ENTIRE MANUAL BEFORE INSTALLATION & OPERATION BEGINS
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual
Do not attempt to install this lift if you have not been trained on
basic automotive lift installation procedures. Never attempt to lift
components without proper lifting tools such as forklift or cranes.
Stay clear of any moving parts that can fall and cause injury. These
instructions must be followed to ensure proper installation and
operation of your lift. Failure to comply with these instructions
can result in serious bodily harm and void product warranty.
Manufacturer will assume no liability for loss or damage of any
kind, expressed or implied resulting from improper installation or
use of this product.
DEFINITIONS OF HAZARD LEVELS
Identify the hazard levels used in this manual with the following
denitions and signal words:
Watch for this symbol:
It Means: Immediate hazards which will result in severe personal
injury or death.
Watch for this symbol:
It Means: Hazards or unsafe practices which could result in severe
personal injury or death.
Watch for this symbol:
It Means: Hazards or unsafe practices which may result in minor
personal injury, product or property damage.
OWNER’S RESPONSIBILITY
• Follow all installation and operation instructions.
• Make sure installation conforms to all applicable Local, State, and
Federal Codes, Rules, and Regulations; such as State and Federal
OSHA Regulations and Electrical Codes.
• Carefully check the lift for correct initial function.
• Read and follow the safety instructions. Keep them readily
available for machine operators.
• 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 permanently with the unit and all decals on
the unit clean and visible.
BEFORE YOU BEGIN
Receiving: The shipment should be thoroughly inspected as soon
as it is received. The signed bill of lading is acknowledgement by
the carrier that the shipment has been delivered in good condition.
If any of the goods called for on this bill of lading are shorted or
damaged, do not accept them until the carrier makes a notation on
the freight bill of the shorted or damaged goods. Do this for your
own protection.
NOTIFY THE CARRIER AT ONCE if any hidden loss or damage
is discovered after receipt and request the carrier to make an
inspection. If the carrier will not do so, prepare a signed statement
to the effect that you have notied the carrier (on specic date) and
that the carrier has failed to comply with your request.
IT IS DIFFICULT TO COLLECT FOR LOSS OR DAMAGE AFTER YOU
HAVE GIVEN THE CARRIER A CLEAR RECEIPT. File your claim with
the carrier promptly. Support your claim with copies of the bill
of lading, freight bill, invoice, and photographs, if available. Our
willingness to assist in helping you process your claim does not
make responsible for collection of claims or replacement of lost or
damaged materials.
CAUTION
WARNING
DANGER
READ FIRST
Do not operate this machine
until you have read and
understood all dangers, warnings
and cautions in this manual
IMPORTANT NOTICE
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 4
CONTENTS
Important notice 3
Important hints 5
Introduction 6
Check parts before assembly 8
Machine parameters 11
Tools required 13
Specications of concrete 14
Installation 14
Important power unit installation notes 25
Test run 26
Lift start up/nal 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
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 5
INSTALLER/OPERATOR -
PLEASE READ AND ENSURE FULL
UNDERSTANDING OF CONTENT.
BY PROCEEDING YOU AGREE TO THE FOLLOWING:
• I have visually inspected the site where the lift is to be installed
and veried the concrete to be in good condition and free of cracks
or other defects. I understand that installing a lift on cracked or
defective concrete could cause lift failure resulting in personal
injury or death.
• I understand that a level oor is required for proper installation
and level lifting.
• I understand that I am responsible if my oor is of questionable
slope and that I will be responsible for all charges related to
pouring a new level concrete slab if required and any charges.
• I understand that the lifts are supplied with concrete fasteners
meeting the criteria of the American National Standard
“Automotive Lifts - Safety Requirements for Construction,
Testing, and Validation” ANSI/ALI ALCTV- 2011 and that I will
be responsible for all charges related to any special regional
structural and/or seismic anchoring requirements specied by any
other agencies and/or codes such as the Uniform Building Code
(UBC) and/or International Building Code (IBC).
• I will assume full responsibility for the concrete oor and condition
thereof, now or later, where the above equipment model(s) are
to be installed. Failure to follow danger, warning, and caution
instructions may lead to serious personal injury or death to
operator or bystander or damage to property.
• I understand that lifts are designed to be installed in indoor
locations 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 understand all the dangers, warnings
and cautions in this manual.
INSTALLER / OPERATOR
PROTECTIVE EQUIPMENT
Personal protective equipment helps makes installation and
operation safer, however, it does not take the place of safe operating
practices. Always wear durable work clothing during any installation
and/or service activity. Shop aprons or shop coats may also be
worn, however, loose tting clothing should be avoided. Tight tting
leather gloves are recommended to protect technician hands when
handling parts. Sturdy leather work shoes with steel toes and oil
resistant soles should be used by all service personnel to help
prevent injury during typical installation and operation activities.
Eye protection is essential during installation and operation
activities. Safety glasses with side shields, goggles, or face shields
are acceptable. Back belts provide support during lifting activities
and are also helpful inproviding worker protection. Consideration
should also be given to the use of hearing protection if service
activity is performed in an enclosed area or if noise levels are high.
CAUTION
THE SAFE OPERATING TEMPERATURE RANGE FOR
THIS PRODUCT IS 41ºF - 104ºF OR 5ºC - 40ºC
WARNING
DANGER
THIS SYMBOL HIGHLIGHTS IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED COULD ENDANGER THE
PERSONAL SAFETY AND/OR PROPERTY OR YOURSELF AND OTHERS AND CAN CAUSE PERSONAL INJURY OR DEATH.
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 6
1. Carefully remove the crating and packing materials. CAUTION! Be
careful when cutting steelbanding material as items may become
loose and fall causing personal harm or injury.
2. Check the voltage, phase and proper amperage requirements for
the motor shown on the motor plate. Wiring should be performed
only by a certied electrician.
1. Read and understand all instructions and all safety warnings
before operating lift.
2. Care must be taken as burns can occur from touching hot parts.
3. Do not operate equipment with a damaged cord or if the equipment
has been dropped or damaged until it has been examined by a
qualied service person.
4. Do not let a cord hang over the edge of the table, bench, or counter
or come in contact with hot manifolds or moving fan blades.
5. If an extension cord is necessary, a cord with a current rating equal
to or more than that of the equipment should be used. Cords rated
for less current than the equipment may overheat. Care should
be taken to arrange the cord so that it will not be tripped over or
pulled.
6. Always unplug equipment from electrical outlet when not in use.
Never use the cord to pull the plug from the outlet. Grasp plug and
pull to disconnect.
7. Let equipment cool completely before putting away. Loop cord
loosely around equipment when storing.
8. T o reduce the risk of re, do not operate equipment in the vicinity
of open containers of ammable liquids (gasoline).
9. Adequate ventilation should be provided when working on
operating internal combustion engines.
10. Keep hair, loose clothing, ngers, and all parts of body away
from moving parts. Keep feet clear of lift when lowering.
Avoid pinch points.
11. DANGER! To reduce the risk of electric shock, do not use on
wet surfaces or expose to rain. The power unit used on this lift
contains high voltage. Disconnect power at the receptacle or
at the circuit breaker switch before performing any electrical
repairs. Secure plug so that it 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
work areas invite injuries. Keep areas well lit.
15. Guard against electric shock. This lift must be grounded while in
use to protect operator from electric shock. Never connect the
green power cord wire to a live terminal. This is for ground only.
16. Only trained operators should operate this lift. All non-trained
personnel should be kept away from the work area. Never let
non-trained personnel come in contact with or operate lift.
17. DO NOT override self-closing lift controls.
18. Clear area if vehicle is in danger of falling.
19. ALWAYS make sure the safeties are engaged before attempting to
work on or near a vehicle.
21. WARNING! RISK OF EXPLOSION. This equipment has internal
arcing or sparking parts which should not be exposed to
ammable vapors. This machine should not be located in a
recessed area or below oor level.
22. MAINTAIN WITH CARE. Keep lift clean for better and safer
performance. Follow manual for proper lubrication and
maintenance instructions. Keep control handles and/or buttons
dry, clean and free from grease and oil.
23. Check for damaged parts. Check for alignment of moving parts,
breakage of parts or any condition that may affect operation of
lift. Do not use lift if any component is broken or damaged.
24. NEVER remove safety related components from the lift. Do not
use lift if safety related components are missing or damaged.
23. STAY ALERT. Use common sense and watch what you are doing.
Remember, SAFETY FIRST.
INTRODUCTION
IMPORTANT SAFETY INSTRUCTIONS
Read these safety instructions entirely
Do not attempt to install this lift if you have never been trained on basic automotive lift installation procedures. Never attempt to lift
components without proper lifting tools such as forklift or cranes. Stay clear of any moving parts that can fall and cause injury.
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 7
SELECTING SITE
Before installing your new lift, check the following.
1. LIFT LOCATION: Always use architect’s plans when available.
Check layout dimension against oor plan requirements making
sure that adequate space is available.
2. OVERHEAD OBSTRUCTIONS: The area where the lift will be
located should be free of overhead obstructions such as heaters,
building supports, electrical lines etc.
3. DEFECTIVE FLOOR: Visually inspect the site where the lift is to be
installed and check for cracked or defective concrete.
4. Lift is designed for INDOOR INSTALLATION ONLY.
Outdoor use permitted only if covered and dry. Always follow
warnings illustrated on equipment labels.
FLOOR REQUIREMENTS
This lift must be installed on a solid level concrete oor with no
more than 3°s of slope. Failure to do so could cause personal injury
or death.A level oor is suggested for proper use and installation
and level lifting. If a oor is of questionable slope, consider a survey
of 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 oor without
rst consulting a building architect.
When removing the lift from shipping angles, pay close attention as
the posts can slide and can cause injury. Prior to removing the bolts
make sure the posts are held securely by a fork lift or some other
heavy lifting device
SAVE THESE INSTRUCTIONS
IMPORTANT NOTICE
THESE INSTRUCTIONS MUST BE FOLLOWED TO ENSURE PROPER INSTALLATION AND OPERATION OF YOUR LIFT. FAILURE TO COMPLY
WITH THESE INSTRUCTIONS CAN RESULT IN SERIOUS BODILY HARM AND VOID PRODUCT WARRANTY. MANUFACTURER WILL ASSUME NO
LIABILITY FOR LOSS OR DAMAGE OF ANY KIND, EXPRESSED OR IMPLIED, RESULTING FROM IMPROPER INSTALLATION OR USE OF THIS
PRODUCT. PLEASE READ ENTIRE MANUAL PRIOR TO INSTALLATION.
CAUTION
DANGER
DANGER
DANGER
WARNING
ALL MODELS MUST BE INSTALLED ON 3000 PSI
CONCRETE ONLY CONFORMING TO THE MINIMUM
REQUIREMENTS SHOWN ABOVE. NEW CONCRETE MUST
BE ADEQUATELY CURED FOR A MINIMUM OF 28 DAYS.
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 8
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.
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
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 9
Electric
control box
Motor
5. Parts in the parts box —inner arm machine
NOTE: view according to order type
CHECK THE PARTS BEFORE ASSEMBLY
(Electrical 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 Parts box
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 10
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
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)
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 11
MACHINE PARAMETERS
FLOORPLATE CHAIN-DRIVE MODEL FEATURES
• Compact design, minimizes the lift wear parts and breakdown ratio
• Dual hydraulic cylinders, designed and made on ANSI 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
3.33”
110mm
831kg
1832lbs 2.0/3.0HP
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 12
ACCURATE VIEW BY ACTUAL PURCHASE ORDER
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation 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
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 14
SPECIFICATIONS OF CONCRETE
IMPORTANT NOTICE
Concrete must be in compliance to the specifications below.
Failure To Do So May Result In Personal Injury or Property Damage.
1. Concrete must have a thickness of 6.3 inches minimum and without reinforcing steel bars, and must be completely cured before lift installation.
2. Concrete must be in good condition and must have a test strength 3,000 psi (210kg/cm²) minimum.
3. Floors must be level and no cracks
POWER SUPPLY
The capacity of power must be 3HP minimum. The electrical 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 the base plate on the POWER SIDE post as a guide, drill each anchor hole in the concrete approximately 4.72” deep using a rotary
hammer drill and 0.79” concrete drill-bit. To ensure full holding power, do not ream the hole or allow the drill to wobble.
4. After drilling, remove dust thoroughly from each holemaking certain that the posts remain aligned with the chalk line.
DANGER
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 15
POSITION POWER SIDE COLUMNS
Lay down two posts on the installation site parallel, position the Power side post according to the actual installation environment.
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 columnCar- in direction
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 16
FIX ANCHOR BOLTS
1. Prepare anchor bolts
2. If shimming is required, insert the shims as necessary under the base plate so that when the anchor bolts are tightened,
the posts will be plumb
3. Assemble the washers and nuts 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 until they lock at the same level, you will hear a click.
Washer
Nut
Lock washer
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual
INSTALL 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
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 18
INSTALL HYDRAULIC POWER UNIT AND OIL HOSE ASSEMBLY
Use Teon tape on all tapered (NPT) ttings.
Do not use Teon tape on the hydraulic hose (JIC) threads.
Tighten all the hydraulic ttings and ll 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#
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 19
OIL HOSE AND PROTECTIVE COVERS
1.Install oil Hose
Note: Don’t cross thee 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 cableBalance cable
Safety cable
Safety cable
Oil hose Oil hose
Oil hose
height adapters
shelves
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YL-250 5000KG 2 BASE PLATE CAR HOIST Installation and operation manual 20
INSTALL SAFETY WELDMENTS
1. The safety lock component has been pre-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
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