installation manual - capris · 2016. 3. 19. · taper plunger chip hammer 1.5 kg (3 lb) crescent...

LAUNCH TLT830WA INSTALLATION MANUAL

1

INSTALLATION MANUAL

Contents 1 Precautions…………………………………………………2

2 Structure and Working Principle……………………….3

2.1 Structure …………………………………………………..3

2.2 Electrical Diagram………………………………………..4

2.3 Hydraulic Diagram………………………………………..5

2.4 Hydraulic Components in the Control Desk……………5

2.5 Pneumatic Diagram ……………………………………..6

3 Tools for Installation and Adjustment…………………7

4 Unpacking………………………………………………….7

5 Installation of the Lift…………………………………….7

5.1 Overall Position……………………………………………7

5.2 Installation on Floor Surface……………………………..8

5.3 Installation on Ditch……………………………………....9

5.4 Control Desk Installation………………………………...10

5.5 Power Connection………………………………………..10

5.6 Hydraulic Hoses Connection…………………………….11

5.7 Anchoring………………………………………………….12

5.8 Air Hose connection……………………………………...13

6 Lift Adjustment ……………………………………………13

6.1 Preparation………………………………………………..13

6.2 Adjustment Procedure…………………………………...13

7 Parts List …………………………………………………...14


2

1 Precautions

Warnings

This manual is a substantial part of this product

and please read it carefully.

Keep this manual properly so that it can be used

during maintenance or repair the equipment.

Do not use the product for any other purposes.

The manufacturer is not responsible for any

damage caused by improper use or uses other

than the designed purpose.

Precautions for Installation and

Adjustment

Please read this manual and operation manual in

full before installation and adjustment. Any

changes to the components or use for other

purpose without the consent of the manufacturer

may lead to direct or indirect damage to the

product.

Installation and adjustment personnel must have

certain hydraulic and electrical knowledge。

The operator must be given special training and be

qualified。

Allow sufficient space for the lift so that operation

should not be hindered.

Do not install the lift in an environment with

extreme temperature and humidity conditions.

Keep it away from heating device, faucet,

humidifier or furnace.

Do not install the lift outdoors or expose it to rain.

If it is really necessary to do so, a special order

should be made from the manufacturer.

Check the components against parts list before

installation. In case of any questions, please

contact your dealer or Launch Tech.

For the sake of technical improvements, Launch

(Shanghai) Machinery Co., Ltd reserves the right

to change the specifications without prior notice


3

2 Structure and Working

Principle

2.1 Structure

1680mm(66.1″)

Drive-on Ramp340mm-1900mm(13.4″-74.8″)

Control Desk安全齿啮合

侧滑板锁紧

注意事项

一次举升上升

一次举升下降

二次举升上升

二次举升下降

紧急停止

电源指示灯

550mm(21.7″)

880mm(34.6″)

Big Scissor Cylinder

Safety Ratchet

280mm(11″)

1400mm(55.1″)

4000mm(157.5″)

340mm-450mm(13.4″-17.7″)

Small Scissor Cylinder

Small Scissors Platform

Sideslip PlateTurn Table

550mm(21.7″)

Limit Switch 1

Limit Switch 2

Fig.1


4

2.2 Electrical Diagram

Fig.2

Press the big scissors UP button SB1, the contactor KM

closes, gear pump driven by the motor supplies the oil

through the actuated solenoid valve YA1 to supply oil to the

big scissors cylinders which in turn drives the platforms

rising by getting the oil; Release the UP button SB1, the

contactor KM disconnected, the motor is out of power, and

the platforms stop rising. If keep on pressing SB1, the

platforms will reach a certain height and touch the height

limit switch SQ1, then the contactor KM will be cut out of

power, and the platforms stop rising to protect the lift.

When the big scissors reach a desired height, release the

button SB1. Press the SAFETY LOCK button SB5, the

solenoid valve YA1 and YA3 will get the power to lower the

platforms. Since the safety air valve YA4 is not active at this

time, and the safety ratchet will be engaged to prevent the

platforms from lowering, so that vehicle servicing can be

carried out.

After servicing the vehicle, press the big scissors DOWN

button SB2, the solenoid valve YA1, relay KA and time relay

KT will be actuated to supply oil to big scissor cylinders

which in turn drives the platforms rising, while the actuated

air cylinder (valve YA4) will push the safety ratchet away

from locking position. After a few seconds of rising, the time

FU2-3:AC380V

WU V

M

3~

V21U21 W21

QC

KM

PEL1 L2 L3

24V~

T

AC220V/380V 3PH

V11U11 W11

FU1

FU2/(0.5A）

FU3 (4A）

U V

M

1~

V21U21

QC

KM

PEL1 L2

AC220V 1PH

V11U11

FU1

FU2

2

3

FU2

3

FU2-2:AC220V

FU2

2

KT—时间继电器（Time relay）

YV1—大剪上升电磁阀（Big scissor lifting electromagnet valve)

YV2—小剪上升电磁阀（Small scissor lifting electromagnet valve)

YV3—下降电磁阀（Lowering valve)

YV4—小气动电磁阀（Small air valve)

KA—继电器（Relay）

KM—接触器（Contactor）

YV5—大气动电磁阀（Big air valve)

H—蜂鸣器（Buzzer）


2

relay KT will disconnect relay KA to stop the platforms rising,

and connect the lowering valve YA3 to lower the platforms.

Press the small scissors UP button SB3, the contactor KM

closes, gear pump driven by the motor supplies the oil

through the actuated solenoid valve YA2 to the small

scissors cylinders which in turn drives the small scissors

rising. Release the button SB3, the contactor KM and

solenoid valve YA2 will be disconnected, the motor is out of

the power and the small scissors stop rising. If keep on

pressing SB3, the small platforms will reach to a certain

height and touch the height limit switch SQ2, and the small

scissors stop rising to protect the lift. Press the small

scissors DOWN button SB4, the solenoid valve YA2 and

YA3 get the power and the small scissors will lower down.

If an emergent stop is needed, press Button SB6.


5

2.3 Hydraulic Diagram

3、Filter

4、Gear Pump

2、Oil Gauge/Air Blowhole

1、Oil Tank

11、Solenoid Valve/Manual Control

10、Solenoid Valve/Manual Control

6、Relief Valve

7、Check Valve

8、Lowering Solenoid Valve/Manual Control

9、Lowering Speed Control Valve

12、High Pressure Stop Valve

5、Motor

17、Small Scissor Slave Cylinder

14、Big Scissor Master Cylinder

13、High Pressure Stop Valve

15、Big Scissor Slave Cylinder

16、Small Scissor Master Cylinder

Z1、Big Scissors Master Cylinder Oil Hose

F1、Big Scissors Slave Cylinder Oil Hose

Z2、Small Scissor Master Cylinder Oil Hose

F2、Small Scissors Slave Cylinder Oil Hose

Fig.3

2.4 Hydraulic Components in the Control Desk

1

2

3

7

NO1(Z1)

NO2(F1)

NO3(Z2)

NO4(F2)

15 14

18 4

9 6

8

10

13

16

511

12

17

Fig.4


6

In normal working state, big scissors master cylinder

stop valve (Z1) is open, while slave cylinder stop valve

(F1) is closed. For small scissors, master cylinder stop

valve (Z2) is open while slave cylinder stop valve (F2) is

closed.

To level the two platforms, close the stop valve to

master cylinder (Z1/Z2) while open the stop valve to

slave cylinder (F1/F2) and then press UP button to

charge oil to slave cylinder. If two much oil charged,

press DOWN button to discharge the oil from slave

cylinder to keep the two platforms at equal height. After

level adjustment, change all stop valves back to normal

working state.

2.5 Pneumatic Diagram

Fig.5

Air cylinder

Solenoid valve

Air pressure

regulator and

filter

Pump


7

3 Tools for Installation

and Adjustment

Tools Model

Level Bar L=400（15.7″）

Chalk Line 10mm （0.4″）

Taper Plunger Chip

Hammer 1.5 kg (3 lb)

Crescent Wrench 40mm（1.6″）

Open end Wrench Set 11mm-23mm

（0.43″-0.9″）

Allen Wrench Set 2mm～12mm

Screwdriver 150mm（5.9″）

Rotary Hammer Drill 20mm（0.8″）

Hard Alloy Drill Bit Φ19mm（0.75″）

Frame Level（JB3239-83） 300X40X300(11

.8″×0.16″×11.8″)

4 Unpacking This machine consists of four parts: master platform

with hydraulic hoses, slave platform with hydraulic

hoses, one electrical control desk, and drive-on ramp

with hanging plate(this part is unavailable if the lift is

installed under the ground).

Unpack according to the instructions on the packages.

Remove the packing materials and check for damage

and loss of components.

To avoid accidents from occurring, keep the packing

material away from children. The packing materials

need to be disposed of properly if they may

contaminate the environment.

5 Installation of the Lift

5.1 Overall Position

select lift installation site by the procedure listed below：

The lift can only be installed on the concrete slab, the

minimum thickness of the concrete slab is 200mm

（7.9″）, and the minimum solidification time is 7

days.

The basic intensity of the concrete slab should reach

3000PSI（2.1kgf/mm2）.

The tolerance of the concrete floor levelness should

not exceed 5mm (0.2”). Slight slope can be

corrected with shims. Excessive slope on the

ground will greatly affect the performance of the lift.

In this case, new concrete slab should be made.

Inspect for possible hindrance such as low ceiling,

overhead pipelines in the work area, passageways

and escapes. The working area of the lift should be

4m high to give enough space.

Allow enough space at the front and back of the lift so

that operation should not be hindered (Fig. 6).


8

550mm(21.7″)

Drive-On Ramp

Drive-On Ramp

1680mm(66.1″) 4290mm（168.9″） min2000mm(78.7″)

Slave unit

Master unit

Drive in direction

Control desk

800mm(31.5″)

300mm(11.8″)

min 1200mm(47.2″

)

max 1800mm(70.9″

)

Wheel alignment

880mm(34.6″)

550mm(21.7″)

Fig.6

5.2 Installation on Floor surface

Seeing as Fig. 7: On a basis of overall width 2030

（79.9″）, two chalk lines of parallel are drawn on

concrete slab (#1 and #2 ), the error should be within

3mm（0.1″）

Then draw four lines（a、b、c、d）parallel to each other，

and perpendicular to line 1# and 2#。

Put both the master and slave units in the line frame

(Fig. 7).

Fig.7

Master unit

Slave unit

Drive in direction

2235mm(88″)

3200mm(126″)

2030

mm(79.9″

)

560m

m(22″)

600m

m(23.6″)

12-? 20m

m(0.8″

)

20mm(0.8″) 650mm(25.6″)

830m

m(32.7″)

1000mm(39.4″)

175mm(6.9″)

Diagnol3790mm(149.2″

)

300mm(11.8″)


9

Notice：

All the dimensions take the external boundary of

the floor plate as the datum.

Ensure that the overall errors shall be controlled

within 6mm（0.24″）.

The line layout is very important. If not correct,

problems will happen during the final assembly

and operation.

5.3 Installation on Ditch

The layout for ditch installation is similar as for ground

installation, but it is more difficult. The dimension of the ditch

channel can be seen in Fig. 8.

Notice：

The thickness of the concrete slab is not less than

200mm. The basic intensity of the concrete slab

should reach above 3000PSI（2.1kgf/mm2）.

Lifting jack should be used to place the master

and slave units in to the ditches.

Fig.8

5.4 Control Desk Installation

Select the installation site for the control desk

according to the layout.( Fig. 6)

Install the cover plate for the hoses and cables if the lift

is installed on the ground.

Fill the hydraulic oil to the oil tank with a proper quantity.

Do it carefully to prevent the dust or other pollution get

to the oil.

5.5 Power connection

Open the door at the back of control desk. Connect the

limit switch 1 cables on terminal 5, 7 and limit switch 2

on terminal 6, 7. Then connect power input cable to

terminal L1, L2, L3, PE (see Fig.9). The power indicator

on the operation panel should light on when the power

is on.

Fill hydraulic oil N32 or N46 into the oil tank (using oil

gauge to check the level). Pay special attention to

avoid dust and contaminants into the oil.

Note: High Voltage inside the control desk! Wiring

should be performed carefull

Slave Unit

Drive-On

Master Unit

min 2000mm(78.7″)

Floor

max 1800mm(70.9″

)

min

1200

mm(47.2″

)

630m

m(24.8″

)800m

m(31.5″

)

800mm(31.5″)

Control Desk

630m

m(24.8″

)

Wheel Alignment

Pre-buried Pipe 100mm(3.9″)

4080mm(160.6″)

320mm(12.6″)

340mm(13.4″)

150mm(5.9″) 100m

m(3.9″

)


1

VD

VD

Power Input

To Motor

Limit Switch1,2

Big Air Valve

Lowering Valve

Big Scissor Lifting

Indicator

Small Scissor Lifting

Emergency Stop

Small Air Valve

Com

4x1.5mm 2

4x2.5mm 2

Com

3x1.5mm2

3x2.5mm2

Power Input

To Motor

Emergency Stop

Limit Switch1,2

IndicatorBig Scissor Lifting

Lowering Valve

Small Air Valve

Small Scissor Lifting

Big Air Valve

Fig.9


11

5.6 Hydraulic Hose Connection Hydraulic Hoses Connection

TLT830WA hydraulic hoses connection is

illustrated in Fig. 10. First connect the big scissor

main cylinder hose NO1 to stop valve Z1 and

tighten the fitting. Open stop valve Z1 and close all

other stop valves.

Press the big scissor UP button to test the power

equipment: if the motor doesn’t work, with the

abnormal noise, or the motor is running but the

platform doesn’t rise, or heating, stop the machine

immediately and check the wire connection.

Press the big scissor UP button to raise the big

scissors master platform to 1.5m（59″） high.

Press SAFETY LOCK to engage the safety

ratchet.

Connect other oil hoses according to the Fig.10,

and tighten all fittings to prevent the oil leaking.

Open the big scissor slave cylinder stop valve (F1),

and close other stop valves. Press the big scissors

UP button to raise the platform of the slave

platform to 1.5m（59″） high. Press SAFETY

LOCK to engage the safety ratchet. The two

platforms must be locked on position of ratchet for

fine final level adjustment later. Change two stop

valves (Z1,F1) back to normal states.

The oil hoses below the platforms should be fixed

properly to prevent the damage by the machine

during the lowering down.

Power Unit

NO1(Z1)

NO2(F1)

NO3(Z2)

NO4(F2)

Small ScissorStop Valve

Big Scissor Stop Valve

Small Scissor Master Cylinder

Small Scissor Slave Cylinder

T Fitting

T Fitting

Big Scissor Master CylinderBig Scissor

Slave Cylinder

Fitting

Fitting

FittingOil Return Hose

Fig.10


12

5.7 Anchoring Anchoring

Wrap the oil fittings, cable connections and joints of the

lift to prevent dusts from getting in.

Guided by the hole on the base plate of the lift, drill the

holes into the concrete slab and use concrete anchor

bolts to fix it into the ground. During the process of

drilling, ensure that no movement occurs to the base

plate form the chalk line (see Fig.11 as installation). Fix

the lift on the ground with 12 M18X160 (M0.7″X6.3″)

anchor bolts.

Turn screws on the base plate to adjust the platform to

the level position, and the difference height between

the two platforms should be less than 3mm. Select the

steel plates with proper thickness as the shims and

insert them under the base plate. Insert the shims into

both sides of the anchor bolts.

Tighten the nuts of the anchor bolts to fix the base

plate.

Cautions: To ensure safety and performance, follow

the installation procedures step by step.

Wearing the safety goggles.

Use the solid and hard alloy drill bit with Φ19mm

（0.75″） in diameter. Don’t use the drill bit which is

worn more than the tolerance.

The drill bit is vertical to the drilled surface.

Let the drill work by itself; don’t impose any extra

pressure and don’t ream.

The depth of the drilled hole is dependent upon the

length of the anchor bolt; the distance of the bolt head

away from the concrete floor shall be around 30mm

(1.2″).

Blow out the dust in the hole.

Tap the anchor bolt into the hole, and insert the

expansion steel core. Tap the head of the steel core to

make the anchor bolts expanding.

.Screw the bolts tightly using the torque wrench. The

torque of the wrench should be more than 80 N.M

Fig.11

150

φ22

2

130

M18×120


13

5.8 Air Hose Connection

Connect air hoses according to the Fig. 5.

Adjust the air pressure regulator to supply 5 kgf/cm2 of

compressed air to the lift.

Press the DOWN button of the big scissor to see if the

cover of safety ratchet can be pushed away by air

cylinder

6 Lift Adjustment

6.1 Preparation

Add 2# lithium lubricating grease on the moving surface.

Lubricate the interface evenly from left to right.

Add 2# lithium lubricating grease on each joints of the

machine.

Fill up the hydraulic oil tank with the hydraulic oil N32 or

mechanical oil N46.

6.2 Adjustment Procedure

Check if all the connection bolts are tightly fastened.

If there is air in hydraulic system due to new installation,

air bleeding performance is needed. The air in the

master cylinder can be bled after the platform goes up

and down several times. The air in the slave cylinder

can be bled by following steps:1) lift Master Platform

close to the maximal height; 2) close stop valve Z1/Z2

and open stop valve F1/F2; 3) press the UP button to

raise the Slave Platform reaches near the maximal

height, 4)press the DOWN button to lower Slave

Platform to the bottom. All the air in the slave cylinder

can be bled after the operation is repeated three times.

Level the two platforms by charging or discharging oil

and change the stop valve Z1/Z2, F1/F2 back to normal

lifting state.

Press the big scissor UP button to raise the platforms;

release the button to stop the platforms rising. Press

the big scissor DOWN button, the platforms rise a little

automatically to release from the safety ratchet, while

the air cylinders push the safety covers away, and the

big scissor platforms will lower down.

Press the small scissor UP button to raise the small

scissors platforms, release the button to stop the small

platforms rising. Press the small scissor DOWN button

to lower the small scissors.

Adjust the bracket of the limit switch to let the platforms

stop at appropriate height. This will cut off the oil

supply to the cylinder and protect the lift.

For the machine installation on the ground, install the

cover plate after the hoses are connected

The adjustment is completed.

Notice:

Attention should be paid to the position of oil pipes and

hydraulic hose when the platforms move to the minimal

height for the first time. Make sure they don not get stuck

with platforms moving downwards.

When bleeding the air in the slave cylinder, do not lift

Master Platform to the maximal height. Otherwise, the

limit switch is triggered, the power will be cut off and Slave

Platform can not move.

When bleeding the air in the slave cylinder or leveling the

two platforms, lift Slave Platform to 1.5m, and then insert

cardboard under the safety ratchet near the air cylinder to

keep the safety ratchet from becoming effective.

Otherwise the Slave Platform can not be lowered even

when the DOWN button is pushed. Remove the

cardboard after bleeding or leveling.


14

7 Parts List This list is only used as the information for the maintenance

and repair. Our company will not be liable for the use in

other applications.

In case of damages to the components, purchase can be

made from the LAUNCH and its sales agents based on the

material code No in the list.

LAUNCH TLT830WA INSTALLATION

MANUAL

15

No ERP Code Name

1 201020400 Base Frame

2 201011074 Big scissor Outer Arm

3 201020396 Big scissor Inner Arm

4 103260132 Big Scissor Master Cylinder

103260134 Big Scissor Slave Cylinder

5 201020397 Safety Cover Assembly

6 103020123 Anchor Bolt M18*160

7 103260106 Bushing 2525

8 103201006 Upper Cover Of Bearing

9 103200864 Bearing

10 103200859 AxleⅡ

11 103050035 Returning Ring 25

12 103200857 Cylinder Support Axle


14 103020127 Bolt M12*55

15 103040110 Flat Washer 12

16 103200876 Left Auxiliary Arm

17 103260108 Bushing 3025

18 103260104 Bushing 3040

19 103200876 Right Auxiliary Arm

20 103200855 Cylinder Pushing Axle

21 103200860 AxleⅢ

22 103260109 Bushing 3030

23 103200861 AxleⅤ

24 103040170 Flat Washer 24

25 103040163 Spring Washer 24

26 103030135 Round Nut M24*1.5

27 103200858 AxleⅠ

28 103200866 RollerⅠ

29 103200862 Axle Ⅵ

30 103260107 Bushing 2530

31 103200867 RollerⅡ

32 103010477 Screw M6*15

33 103201010 Stop Plate

34 103110065 Buffer Spring

35 103220056 Master Cylinder Pressing Board

103230125 Slave Cylinder Pressing Board

36 103010478 Screw M8×35

37 103200878 Mat Plate

38 103010493 Screw M8×25



MANUAL

16


MANUAL

17


MANUAL

18

No ERP Code Name

101 201011075 Platform

102 201020409 Small Scissor Inner Arm

103 201020410 Small Scissor Outer Arm

104 201020411 Small Scissor Platform

105 X201020402 Sideslip Assembly

106 103260165 Small Scissor Master Cylinder

103260166 Small Scissor Slave Cylinder

107 103200858 AxleⅠ

108 103200865 Roller

109 103260106 Bushing 2525

110 103200853 Roller Axle


112 103200873 Central Axle

113 103200856 Cylinder Pushing Axle

114 103010356 Screw M8*15


116 103260104 Bushing 3040

117 103260108 Bushing 3025

118 103040170 Flat Washer 24


120 103030135 Round Nut M24*1.5

121 103260107 Bushing 2530

122 103200870 Cylinder Supporting Axle

123 103200865 Main Platform Roller

124 103010470 Screw M6*20

125 103200874 Roller Board

126 103201038 Bearing Groove

127 103201480 Sideslip Spring

128 103260116 Air Cylinder

129 103010493 Screw M8*25

130 103030134 Nut M18*1.5

131 103201480 Spring

132 103201037 Drive-on Ramp

133 103200986 Support Plate

134 103200869 Bushing


136 103010471 Screw M8×40

137 103200875 Cover Plate

138 103201480 Spring

139 103070012 Bearing 6203



MANUAL

19

201

214

202

209

208

215

222204

210

213

211

217

219

221205

220

206207225

Z1

F2

224209

212

203

223

F1

Z2

225

214

203

218

214

203

216

226

227

228

216

228226

226

203

229

230


MANUAL

20

No ERP Code Name

201

103990107 Power Pack (380V50Hz3ph)





202 103100159 Straight Fitting

203 103100162 Fitting

204 103100161 Burst Protection Valve

205 104990085 Hydraulic Hose 6II-3500

206 104130194 Rubber Seal

207 103160043 Burst Protection Valve

208 103100219 T Connector

209 103100218 Right Angel Fitting


211 103260117 Small Scissor Master Cylinder


213 103260120 Big Scissor Master Cylinder

214 103040157 Seal Gasket 14


216 103100189 Fitting ￠8/M8

217 103260118 Small Scissor Slave Cylinder

218 103260119 Big Scissor Slave Cylinder

219 103100164 Fitting


221 103990055 T Fitting


223

224 103030139 Nut M14x1.5

225 103040158 Seal Gasket 16

226 104990124 Oil Return Hose ￠12

227 103100190 Fast Fitting ￠12*￠12*￠12

228 103200206 Hose Hoop ￠14

229 103160063 High Pressure Stop Valve

230 107021380 Oil Gauge


MANUAL

21

301

302

303

304

302

305

307

306

308

309

311

310

302

304

302

No ERP Code Name

301 102160383 Air Pressure Regulator and Filter

302 102990071 Air Connector APL6-02

303 102160380 T Air Connector APE6

304 102990066 Muffler

305 103200654 Plug 1/8″

306 103160033 Solenoid Air Valve 4V210-08-DC24V

307 103100073 Plug 1/4″

308 104990092 Air Hose PU0604

310 102990070 Air Connector APL6-01

311 201011076 Small Air Cylinder


MANUAL

22

401

402

406

407

408

409

403

404405

410

411

412

413

414

416

415

No ERP Code Name

401 102100083 Button LA39-22/g

402 102100085 Button LA39-22/r

403 102110059 Contactor s-p11 AC24V

404 102110066 Thermo Relay TH-P12

405 102130034 Transformer JCY5-100 220V,380V/27V

406 102100084 Button LA39-11/K

407 102100090 Emergency Stop Button LA39-11/r

408 102990065 Power Indicator DC24V

410 102110051 Relay MY4NJ DC24V

411 102110067 Time Relay H3Y-2 DC24V 0-10S

412 102150042 Circuit Breaker DZ47-3

413 102270004 Bridge Rectifier KBPC25-10

414 102160379 Wiring Terminal TD15-24

415 102100087 Power Switch LW39B-16

416 102100075 Limit Switch ME-9101

installation manual - capris · 2016. 3. 19. · taper plunger chip hammer 1.5 kg (3 lb) crescent...

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