INSTALLATION MANUAL. Contents

Transcription

1 INSTALLATION MANUAL Contents 1 Precautions 2 2 Structure and Working Principle Structure Electrical Diagram Hydraulic Diagram Hydraulic Components in the Control Desk Pneumatic Diagram..6 3 Tools for Installation and Adjustment 7 4 Unpacking.7 5 Installation of the Lift Overall Position Installation on Floor Surface Installation on Ditch Control Desk Installation Power Connection Hydraulic Hoses Connection Anchoring Air Hose connection Lift Adjustment Preparation Adjustment Procedure Parts List

2 1 Precautions 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 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. 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 2

3 550mm(21.7 ) 880mm(34.6 ) 550mm(21.7 ) 一次举升上升 一次举升下降 二次举升上升 二次举升下降 注意事项 安全齿啮合 侧滑板锁紧 紧急停止 电源指示灯 340mm-450mm( ) 340mm-1900mm( ) 280mm(11 ) LAUNCH 2 Structure and Working Principle 2.1 Structure 1400mm(55.1 ) Small Scissors Platform Turn Table Small Scissor Cylinder Sideslip Plate 4000mm(157.5 ) Limit Switch 2 Safety Ratchet Big Scissor Cylinder Limit Switch 1 Drive-on Ramp 1680mm(66.1 ) Control Desk Fig.1 3

4 2.2 Electrical Diagram T FU3 (4A) FU2 2 FU2/(0.5A) 24V~ 3 FU2-3:AC380V FU2-2:AC220V KM 接触器 (Contactor) AC220V/380V 3PH L1 L2 L3 PE QC U11 V11 W11 FU1 U21 V21 W21 FU2 3 AC220V 1PH L1 L2 PE QC U11 V11 FU1 U21 V21 FU2 2 H 蜂鸣器 ( Buzzer) KA 继电器 (Relay) 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) KM KM YV3 下降电磁阀 ( Lowering valve) U V W U V YV4 小气动电磁阀 ( Small air valve) M 3~ M 1~ YV5 大气动电磁阀 ( Big air valve) 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 4

5 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. 2

6 2.3 Hydraulic Diagram F2 Small Scissors Slave Cylinder Oil Hose F1 Big Scissors Slave Cylinder Oil Hose Z2 Small Scissor Master Cylinder Oil Hose Z1 Big Scissors Master Cylinder Oil Hose 17 Small Scissor Slave Cylinder 16 Small Scissor Master Cylinder 15 Big Scissor Slave Cylinder 14 Big Scissor Master Cylinder 13 High Pressure Stop Valve 12 High Pressure Stop Valve 11 Solenoid Valve/Manual Control 10 Solenoid Valve/Manual Control 9 Lowering Speed Control Valve 8 Lowering Solenoid Valve/Manual Control 7 Check Valve 6 Relief Valve 5 Motor 4 Gear Pump 3 Filter 2 Oil Gauge/Air Blowhole 1 Oil Tank Fig Hydraulic Components in the Control Desk NO1(Z1) NO2(F1) NO3(Z2) NO4(F2) Fig.4 5

7 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 Air cylinder Solenoid valve Air pressure regulator and filter Pump Fig.5 6

8 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 ( ) Allen Wrench Set 2mm~12mm Screwdriver 150mm(5.9 ) Rotary Hammer Drill 20mm(0.8 ) Hard Alloy Drill Bit Φ19mm(0.75 ) Frame Level(JB ) 300X40X300( ) 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). 7

9 20mm(0.8 ) 600mm(23.6 ) 560mm(22 ) 2030mm(79.9 ) 830mm(32.7 ) 550mm(21.7 ) 880mm(34.6 ) Wheel alignment 550mm(21.7 ) min 1200mm(47.2 ) LAUNCH 300mm(11.8 ) Control desk max 1800mm(70.9 ) 800mm(31.5 ) Drive-On Ramp Master unit Drive in direction Drive-On Ramp Slave unit 1680mm(66.1 ) 4290mm(168.9 ) min2000mm(78.7 ) Fig 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). Master unit Drive in direction Diagnol3790mm(149.2 ) 1000mm(39.4 ) 300mm(11.8 ) 12-? 20mm(0.8 ) Slave unit 650mm(25.6 ) 2235mm(88 ) 3200mm(126 ) 175mm(6.9 ) Fig.7 8

10 100mm(3.9 ) 630mm(24.8 ) 800mm(31.5 ) Wheel Alignment 630mm(24.8 ) min 1200mm(47.2 ) LAUNCH 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/mm 2 ). Lifting jack should be used to place the master and slave units in to the ditches. Control Desk max 1800mm(70.9 ) 800mm(31.5 ) Master Unit Drive-On Pre-buried Pipe 100mm(3.9 ) Slave Unit min 2000mm(78.7 ) 150mm(5.9 ) 4080mm(160.6 ) 320mm(12.6 ) Floor 340mm(13.4 ) Fig 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 9

11 4x1.5mm 2 4x2.5mm 2 LAUNCH VD Power Input To Motor Emergency Stop Limit Switch 1,2 Indicator Big Scissor Lifting Lowering Small Valve Scissor Lifting Small Air Valve Com Big Air Valve VD 3x2.5mm 2 Power Input 3x1.5mm 2 To Motor Emergency Stop Limit Switch 1,2 Indicator Lowering Small Valve Scissor Lifting Big Scissor Small Lifting Air Valve Com Big Air Valve Fig.9 1

12 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. Small Scissor Slave Cylinder Small Scissor Master Cylinder Fitting Big Scissor Slave Cylinder Big Scissor Master Cylinder Power Unit Oil Return Hose Fitting Big Scissor Stop Valve Small Scissor Stop Valve Fitting T Fitting T Fitting NO1(Z1) NO2(F1) NO3(Z2) NO4(F2) Fig.10 11

13 LAUNCH 5.7 Anchoring Anchoring Wearing the safety goggles. Wrap the oil fittings, cable connections and joints of the Use the solid and hard alloy drill bit with Φ19mm lift to prevent dusts from getting in. (0.75 ) in diameter. Don t use the drill bit which is Guided by the hole on the base plate of the lift, drill the worn more than the tolerance. holes into the concrete slab and use concrete anchor The drill bit is vertical to the drilled surface. bolts to fix it into the ground. During the process of Let the drill work by itself; don t impose any extra drilling, ensure that no movement occurs to the base pressure and don t ream. plate form the chalk line (see Fig.11 as installation). Fix The depth of the drilled hole is dependent upon the the lift on the ground with 12 M18X160 (M0.7 X6.3 ) length of the anchor bolt; the distance of the bolt head anchor bolts. away from the concrete floor shall be around 30mm Turn screws on the base plate to adjust the platform to (1.2 ). the level position, and the difference height between Blow out the dust in the hole. the two platforms should be less than 3mm. Select the Tap the anchor bolt into the hole, and insert the steel plates with proper thickness as the shims and expansion steel core. Tap the head of the steel core to insert them under the base plate. Insert the shims into make the anchor bolts expanding. both sides of the anchor bolts..screw the bolts tightly using the torque wrench. The Tighten the nuts of the anchor bolts to fix the base torque of the wrench should be more than 80 N.M plate. Cautions: To ensure safety and performance, follow the installation procedures step by step. M φ22 Fig.11 12

14 5.8 Air Hose Connection Connect air hoses according to the Fig. 5. Adjust the air pressure regulator to supply 5 kgf/cm 2 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 N 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. 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. Press the big scissor UP button to raise the platforms; 13

15 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. 14

16 TLT830WA INSTALLATION MANUAL No ERP Code Name Base Frame Big scissor Outer Arm Big scissor Inner Arm Big Scissor Master Cylinder Big Scissor Slave Cylinder Safety Cover Assembly Anchor Bolt M18* Bushing Upper Cover Of Bearing Bearing AxleⅡ Returning Ring Cylinder Support Axle Returning Ring Bolt M12* Flat Washer Left Auxiliary Arm Bushing Bushing Right Auxiliary Arm Cylinder Pushing Axle AxleⅢ Bushing AxleⅤ Flat Washer Spring Washer Round Nut M24* AxleⅠ RollerⅠ Axle Ⅵ Bushing RollerⅡ Screw M6* Stop Plate Buffer Spring Master Cylinder Pressing Board Slave Cylinder Pressing Board Screw M Mat Plate Screw M Spring Washer 8 15

17 MANUAL TLT830WA INSTALLATION 16

18 MANUAL TLT830WA INSTALLATION 17

19 TLT830WA INSTALLATION MANUAL No ERP Code Name Platform Small Scissor Inner Arm Small Scissor Outer Arm Small Scissor Platform 105 X Sideslip Assembly Small Scissor Master Cylinder Small Scissor Slave Cylinder AxleⅠ Roller Bushing Roller Axle Returning Ring Central Axle Cylinder Pushing Axle Screw M8* Returning Ring Bushing Bushing Flat Washer Spring Washer Round Nut M24* Bushing Cylinder Supporting Axle Main Platform Roller Screw M6* Roller Board Bearing Groove Sideslip Spring Air Cylinder Screw M8* Nut M18* Spring Drive-on Ramp Support Plate Bushing Returning Ring Screw M Cover Plate Spring Bearing Returning Ring 17 18

20 TLT830WA INSTALLATION MANUAL Z1 F F1 Z

21 TLT830WA INSTALLATION MANUAL No ERP Code Name Power Pack (380V50Hz3ph) Power Pack (220V50Hz1ph) Power Pack (220V60Hz3ph) Power Pack (220V60Hz1ph) Power Pack (200V60Hz3ph) Straight Fitting Fitting Burst Protection Valve Hydraulic Hose 6II Rubber Seal Burst Protection Valve T Connector Right Angel Fitting Hydraulic Hose 6II Small Scissor Master Cylinder Hydraulic Hose 6II Big Scissor Master Cylinder Seal Gasket Hydraulic Hose 6II Fitting 8/M Small Scissor Slave Cylinder Big Scissor Slave Cylinder Fitting Hydraulic Hose 6II T Fitting Hydraulic Hose 6II Nut M14x Seal Gasket Oil Return Hose Fast Fitting 12* 12* Hose Hoop High Pressure Stop Valve Oil Gauge 20

22 MANUAL TLT830WA INSTALLATION No ERP Code Name Air Pressure Regulator and Filter Air Connector APL T Air Connector APE Muffler Plug 1/ Solenoid Air Valve 4V DC24V Plug 1/ Air Hose PU Air Connector APL Small Air Cylinder 21

23 MANUAL TLT830WA INSTALLATION No ERP Code Name Button LA39-22/g Button LA39-22/r Contactor s-p11 AC24V Thermo Relay TH-P Transformer JCY V,380V/27V Button LA39-11/K Emergency Stop Button LA39-11/r Power Indicator DC24V Relay MY4NJ DC24V Time Relay H3Y-2 DC24V 0-10S Circuit Breaker DZ Bridge Rectifier KBPC Wiring Terminal TD Power Switch LW39B Limit Switch ME