Trademark Information. Copyright Information. General Notice

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1 Trademark Information LAUNCH is a registered trademark of LAUNCH TECH. CO., LTD. (LAUNCH for short) in China and other countries. All other LAUNCH trademarks, service marks, domain names, logos, and company names referred to in this manual are either trademarks, registered trademarks, service marks, domain names, logos, company names of or are otherwise the property of LAUNCH or its affiliates. In countries where any of the LAUNCH trademarks, service marks, domain names, logos and company names are not registered, LAUNCH claims other rights associated with unregistered trademarks, service marks, domain names, logos, and company names. Other products or company names referred to in this manual may be trademarks of their respective owners. You may not use any trademark, service mark, domain name, logo, or company name of LAUNCH or any third party without permission from the owner of the applicable trademark, service mark, domain name, logo, or company name. You may contact LAUNCH by visiting Launch at or writing to LAUNCH Industrial Park, North Wuhe Avenue, Banxuegang Industrial Park, Longgang Dist., Shenzhen, P.R. China, to request written permission to use Materials on this manual for purposes or for all other questions relating to this manual. purposes only and may be trademarks of their respective owners. LAUNCH disclaims any and all rights in those marks. Copyright Information Copyright 2000 by LAUNCH TECH. CO., LTD. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of LAUNCH. The information contained herein is designed only for the use of this unit. LAUNCH is not responsible for any use of this information as applied to other units. Neither LAUNCH nor its affiliates shall be liable to the purchaser of this unit or third parties for damages, losses, costs, or expenses incurred by purchaser or third parties as a result of: accident, misuse, or abuse of this unit, or unauthorized modifications, repairs, or alterations to this unit, or failure to strictly comply with LAUNCH operating and maintenance instructions. LAUNCH shall not be liable for any damages or problems arising from the use of any options or any consumable products other than those designated as Original LAUNCH Products or LAUNCH Approved Products by LAUNCH. General Notice Other product names used herein are for identification i

2 The equipment is for specialist or qualified technician use only. Disclaimer All information, illustrations, and specifications contained in this manual are based on the latest information available at the time of publication. Launch reserves all the right to make changes at any time without notice. Safety Precautions the selected ATF must conform to the direction as specified in the manual of the auto to be operated. Otherwise, LAUNCH shall not be liable for any direct or consequential damages. Note: specifying operations that require attention when operating the equipment. Warning: Specifying a possible hazard that could result in damage to the machine or personal injury. Read all service procedures and precautions, installation instructions and equipment operating manuals thoroughly. Failure to observe these precautions, or the improper use of equipment, could result in property damage, serious injury or death. Never allow improperly trained personnel to perform these procedures or operate equipment. Read and understand the User s Manual before attempting to operate the CAT 402. Do not smoke in proximity to the machine while it is in operation. Do not use the machine in proximity to sources of heat and fire. Do not expose to direct sunlight or rain, use in wellventilated work area only. Turn off the power after the operation is completed. When it is in operation, keep the hoses away from rotating elements and hot parts such as cooling fans, radiators, etc. Vehicle exhaust includes various poisonous and harmful gases (such as carbon monoxide, hydrocarbon, nitrogen oxygen complex, etc.). Keep the unit in a well ventilated work area when performing operation and wear safety goggles, respirator and clothes. The operator should keep away from the heat parts such as exhaust hoses and radiator to avoid the personal injury. When disconnecting any connector of the pressurized fuel pipe, wrap the connector with towel to prevent the fuel from spurting out. The children and mental retardation personnel should keep away from the unit when performing. The operator should be quite familiar with the shift of automatic transmission to avoid the damage to transmission caused by improper operation. Always make the drive wheels hanging when cleaning the transmission or exchanging fluid. The unit should be placed vertically and should not be placed upside down. When changing the ATF, the operation should be performed by properly trained personnel. The quality of Content ii

3 Introduction... 2 Features... 2 Working Conditions...2 Specifications...2 Structure Outline Overall structure Pipeline diagram Circuit connection diagram Control panel... 4 Operations Preparation Jack vehicle Connecting hose Power cables connection Check up Filling liquid Circulating cleaning ATF exchange Adjusting fluid level Increase fluid amount Decrease fluid amount Empty new fluid tank Empty used fluid tank System parameter setting... 7 Warning... 8 Maintenance...9 Troubleshooting... 9 Main adapters Optional adaptors

4 Introduction The transmission fluid inside transmission will go bad for a period of usage of automatic transmission. If the transmission fluid can not be changed completely in time, it may cause the abnormality to the transmission. General auto transmission fluid changer can not control the filling quantity of the ATF as required, the excessive or shortage filling will cause the damage to auto transmission. CAT 402 auto transmission changer can complete the flush and fluid exchange in 20 minutes for transmission, torque converter and radiator. The fluid exchange rate is nearly 100% and the equivalent precision could be controlled within 100ml. Features LED display and personal operation making easy operation. Circulating cleaning: together with the automatic transmission detergent, to perform the circulating cleaning for automatic transmission. New and used fluid equivalent exchange: with the electronic weight and automatic control technology, to ensure equivalent exchange during the period of new and used fluid exchanging. Fluid level adjusting: when the fluid level is incorrect, the ATF amount can be increased or decreased to meet the desired requirement. Visual display the fluid pressure of transmission radiator. Various special adapters are applicable to vehicles types made in Europe, America and Asia. Effectively resolve the incomplete fluid exchange of manual operation. It improves the working performance of auto transmission. It prolongs the work life of transmission. Noise: <70db Net weight: 40Kg Gross weight: 45Kg Size: mm Structure 1.Outline As shown in Fig.01, CAT 402 is designed with a fine cabinet. There is a handle at the top of cabinet and two pairs of casters at the bottom of the cabinet, which makes it easy to move the unit. Fluid hoses are equipped with proper connectors for fast connection. The intelligible control panel helps you operate the machine easily. Fig.1 1 Casing; 2 Sight indicator; 3 Fluid pressure gauge; 4 Control panel; 5 Boat switch; 6 Outlet hose; 7 Inlet hose; 8 Power cable clamp. Working Conditions Ambient temperature: 10~+40 C Relative humidity: <85% Specifications Power supply: DC 12V Maximum power: 150W Pressure gauge: 0~150psi Fluid outlet hose: 2 m Fluid return hose: 2 m Fluid tank: 15L 2 Equivalent exchange error: ±100ml Max exchange speed: 2L/MIN 2

5 2.Overall structure Fig.2 No Code Name No Code Name 1 X Casing Solenoid valve DC12V Boat switch (size:22*30, 16A,250V,20A,125V, AC) 13 X Clapboard 3 Z Control board Socket for fuse, JEF 703C 4 X Control panel Line button Film 16 X Rear board Pressure gauge Expanding conversion connector Sight indicator Plastic tank 8 X Covering board 19 X Hook Driving pump 20 X Tray Socket for solenoid valve Weight sensor SUP 1.30KG 11 X Handle Pad for electronic scale plate 3.Pipeline diagram The pipeline diagram is shown as in Fig.3. 3

6 Fig.3. 1,2 Quick connector; 3 Pressure gauge for fluid return; 4 Sight indicator for new fluid; 5 Sight indicator for used fluid; 6 Twoposition three way solenoid valve; 7 Solenoid valve; 8 Used fluid tank; 9 New fluid tank; 10 Fuel pump; 11 Check valve 4.Circuit connection diagram The circuit connection diagram is shown as in Fig.4 5.Control panel Control panel is shown as in Fig.5. Fig.4 4

7 Control panel description: Name or mark NEW USED RETURN PRESSURE Run Stop Select Standby Exchange Adjust Drain new fluid Fig.5 Description Observe the flow rate and compare the color of new and used fluid. Display the fluid pressure of AT radiator Move cursor to increase the value and its unit is Liter when the unit is in standby mode. Move cursor to decrease the value and its unit is Quart when the unit is in standby mode. Confirm and run the function. To stop function. To select the function to be operated. Display the standby state, the unit will return to the standby state after each operation. Exchange the ATF. Adjust the fluid amount inside automatic transmission. Empty the residual new fluid inside new tank. Operations 1.Preparation 1.1Jack vehicle Jack the vehicle to get the drive wheel off the ground at least 200mm, draw the brake handle and add stop wheel ware before and after carrying wheel. and inlet hose: Start the engine for a short while, the one with the fluid spraying is outlet hose, and the other is return hose. 1.2 Connecting hose 1) Locate a fluid hose that is connected to the radiator and transmission at the most convenient location and then disconnect the adaptor. Locate a matched connector inside box and connect it to the disconnected adapter. 2) Connect the hose marked OUT of CAT 402 to the disconnected end of the fluid return hose of automatic transmission and the hose marked RETURN of CAT 402 to the end of the fluid outlet hose of automatic transmission. The way for identifying the return hose 5

8 Fig Power cables connection Connect the power cables clamps of the unit to the two poles of the auto battery (DC 12V), the red clamp to positive pole and the black clamp to the negative pole. Note: The quick charger cannot be as the power of the unit, which will result in the abnormal work of the unit. 1.4 Check up 1) Start the engine, and ensure that the pipeline is well connected and there is no leakage in pipeline. 2) Open the CAT 402 power switch and ensure that the power of the unit is normal. 2.Filling liquid (The cover that is not inserted with the hose indicating the tank is the new tank) 2.1 Fill detergent (the chosen detergent type must have no effect on the inner parts of auto transmission) When you are ready to perform the circulating cleaning for auto transmission, fill proper detergent from the new fluid tank or oil dipstick of transmission under the circumstance that there is no new fluid. 2.2 Adding new oil When you are ready to perform the exchange operation, fill new fluid to be replaced from the new tank. 3 Circulating cleaning CAT 402 is on circulating cleaning under the standby mode, the item for circulating cleaning is not set in main menu of CAT 402. When the pipeline connection is completed, enter the circulating cleaning process automatically after starting engine. 3.1 Fill detergent to auto transmission 1) Select the Adjust function in function menu and set the adjusted amount (When the - is displayed before the value, it indicates that the fluid inside transmission is drained.) The filled amount is selected in this operation and the adjusted amount is 0.1L when displaying ) Press key to adjust filled amount. The original value of the unit is 0.1L. The maximum adjusted value is the oil amount inside new tank. Press Run key after the fill amount is confirmed. 3) Press Run key, the detergent inside new transmission will be filled into transmission. 3.2 Circulating cleaning After the detergent is filled, with the state that the engine is running, the fluid will perform circulating in CAT 402. In order to speed the circulating speed, it can be considerable to engage a gear. (The time of each shift should stay about 1 minute, which depends on actual situation. When the auto is running at high speed gear, the speed should reach more than 60 km/h to ensure the quality of cleaning.) 3.3 Finish circulating cleaning After cleaning for 20 minutes, turn off the engine to end 6

9 the circulating cleaning. 4. ATF exchange 1) Start the vehicle to make the transmission to normal fluid temperature and fill desired new transmission fluid into it. 2) Make sure that there is no leakage in pipelines. 3) Set the fluid exchange amount: what the unit displayed is the total quantity of the fluid in new tank. You can also press key to adjust according to the amount to be exchanged. 4) Press Run key to enter exchange operation. 10

10 Note: Switch each gear when exchanging. The time of each shift should stay about 1 minute, which depends on actual situation. When the auto is running at high speed gear and accelerate the speed to more than 60 km/h, the ATF inside fuel control pipeline can be exchanged. To ensure the exchange quality, the quantity of new fluid inside the unit should be 2L~3L more than that of the fluid required by auto transmission (refer to the original data of the manufacturer for the amount of fluid in transmission). Do not add new fluid from the new tank during the running period of exchange. Otherwise, the operation will result in inequality amount. If there must be added the new fluid, fill after this exchange is completed! 5. Adjusting fluid level 5.1 Increase fluid amount When the fluid level is too low and there is need to increase the fluid level, select this operation. 1) Enter the menu of Adjust fluid level, press key to adjust and the level will increase. The minimum set amount is 0.1L and the maximum of the adjustment is the fluid amount inside new tank. After the filled amount is confirmed, press Run key. 2) After filling is completed, the unit will display End. 5.2 Decrease fluid amount If the quantity of ATF is more than the standard amount and there is need to decrease the fluid amount inside transmission (Lower the fluid level). 1) Start the engine. 2) Enter the menu of Adjust fluid level, press key to adjust (When the - is displayed before the value, it indicates that the fluid inside transmission is drained.). After the decreased amount is confirmed and press Run key, the unit will drain the set amount into the used tank automatically. 3) After the adjusting is completed, the unit will display End. 6. Empty new fluid tank 1) Be sure that the two hoses marked OUT and IN are not connected to vehicle. 2) Connect the quick female connector on the OUT hose to a male connector and place it into container. 3) The unit will enter the function for draining new fluid. Press Run key to run. The unit will finish draining until there is no fluid drained from the OUT hose or press the Stop key to end. Note: Do not connect the hose to the vehicle when draining new fluid. 7. Empty used fluid tank 1) Take the return hose (transparent PU hose) on the used tank out. 2) Loose fixed belt. 3) Take the used tank from the tray for electronic scale (Note that the used tank should be taken with care, do not take it out forcibly, otherwise the precision will be affected.) 4) Dispose the used fluid properly. 5) Place the used tank to the tray for electronic scale again and tighten the fixed belt and insert the return hose well. 8. System parameter setting The system parameter setting function has seven items, they are: No1: Calibrating the electronic scale for new fluid tank No2: Calibrating the electronic scale for used fluid tank No3: Viewing the sequence number of the unit No4: Viewing the date of manufacture No5: Viewing total work hours No6: Viewing software version number No7: Viewing hardware version number Description for each key: Key name The first usage The second usage Select Run Stop Increasing parameter value Decreasing parameter value Selecting number digit when adjusting Enter the selected menu item Exit the current menu item and return to the prior menu Moving menu item forward Moving menu backward Function and parameter confirmation 8.1Calibrating electronic scale for new fluid tank 1) Press and hold the Run key under the unit is in the standby mode. After the buzzer beeps once, press Select key. At this time, the LED will display No1, and then loose the key. 2) When the LED displays No 1, press Run key to enter. 3) The first step for calibration: Set the weight of poise. At this time, what the LED default set weight of the poise is 10.00kg. If there is no standard 10kg poise, you can press key or key to select the 7

11 proper poise (weight range:10~15kg). Press Run key to enter the next step. 4) The second step for calibration: Take the new tank away from the plate. At this time, the LED will display the weight of the empty plate. After the value is stable, press Run key to enter the next step. The weight of empty plate is about between 500 and 900. During the period of calibrating, the standby indicator illuminates using for indicating that this step is the calibrated to avoid mistake. 5) The third step for calibration: Place the poise to the plate for new tank. At this time, the LED displays the weight of poise and empty plate. When the value is stable, press Run key to enter next step. During the period of calibrating, the exchange indicator illuminates, the usage is same as the prior step. 6) The four step for calibration: At this time, the LED displays the linearity parameter of sensor, when the value is stable, press Run key to enter the next step, the value should be between 1300~1500. Otherwise, this calibration is invalid. During the period of calibrating, the adjust indicator illuminates and the usage is same as the prior step. 7) The fifth step for calibration: Check the linearity again. At this time, the LED will display the linearity parameter of the sensor, press Run key to save this calibrated value, the value must be between 1300~1500. Otherwise, this calibration is invalid. The adjust indicator illuminates; the usage is same as the prior step. If the above calibrations are successful, the buzzer beeps three times indicating the calibration is successful and the LED will display End. 8) Press Stop key to return to previous menu. 8.2 Calibrating electronic scale for used fluid tank 1) Press and hold the Run key under the unit is in the standby mode. After the buzzer beeps once, press Select key. At this time, the LED will display No1, and then loose the key. 2) When the LED displays No 1, press key to select the function for calibrating electronic scale for used tank. At this time, the LED will display No 2, press Run key to enter. 3) The following steps are same as the step 3) ~8). 8.3 Viewing sequence number 1) When the unit is in standby mode, press and hold the Run key. After the buzzer beeps once, press Select key. At this time, the LED will display No 1, and then loose the Run key. 2) When the LED displays No 1, press key two times and select the function for Viewing sequence number. At this time, the LED displays No 3, press Run key to enter. 3) The LED will display the sequence number of the unit. 4) Press Stop key to return to previous menu. 8.4 Viewing the date of manufacture 8 1) When the unit is in standby mode, press and hold the Run key. After the buzzer beeps once, press Select key. At this time, the LED will display No 1, and then loose the Run key. 2) When the LED displays No 1, press key three times and select the function for Viewing the date of manufacture. At this time, the LED displays No 4, press Run key to enter. 3) The LED will display date of manufacture, the format is: YY MM DD. 4) Press Stop key to return to previous menu. 8.5 Viewing total work hours 1) When the unit is in standby mode, press and hold the Run key. After the buzzer beeps once, press Select key. At this time, the LED will display No 1, and then loose the Run key. 2) When the LED displays No 1, press key four times and select the function for Viewing total work hours. At this time, the LED displays No 5, press Run key to enter. The LED will display the total work hours, its unit: hour. 3) Press Stop key to return to previous menu. 8.6 Viewing software version number 1) When the unit is in standby mode, press and hold the Run key. After the buzzer beeps once, press Select key. At this time, the LED will display software revision number, the format is V[1 9].[1 9]. 2) When the LED displays No1, press key five times and select the function for Viewing software version number. At this time, the LED displays No 6, press Run key to enter. The LED will display the software version number. The format is: V [1 9].[1 9]. 3) Press Stop key to return to previous menu. 8.7 Viewing hardware version number 1) When the unit is in standby mode, press and hold the Run key. After the buzzer beeps once, press Select key. At this time, the LED will display No 1, and then loose the Run key. 2) When the LED displays No1, press key six times and select the function for Viewing hardware version number. At this time, the LED displays No 7, press Run key to enter. 3) The LED will display the hardware version number. The format is: V [1 9].[1 9]. 4) Press Stop key to return to previous menu. Warning Warning sound: When there is no fluid in the new tank or the operation is completed, the unit enters the standby state.

12 Maintenance Pay attention to each connection to check if there is any leakage during fluid exchange. When any leak is found, stop the CAT 402 immediately and check for the unit. Start to exchange fluid again after reconnection is made. Before cleaning up the unit, the used fluid should be drained out from the used tank and the new fluid should be drained out from new tank and stored in container after every usage to protect the electronic scale is on the no load state at non work condition. Keep the new fluid tank clean. Troubleshooting 1)There is no display on LED and the unit does not be switched on. Cause 1: Power cable is poorly connected or not connected. Solution: Firmly connect the power cable. Cause 2: Fuse is broken. Solution: Replace the fuse. 2) The display of quantity of new fluid is incorrect. Cause 1: The calibration of electronic scale is incorrect. Solution: Calibrating the electronic scale well. Cause 2: The electronic cables are fallen. Solution: Firmly connect the electronic cables. 3)The exchange is not equivalent. Cause 1: The electronic scales of new and used fluid tank are calibrated incorrectly. Solution: Calibrating the electronic scales correctly. Main adapters 9

13 No. Parts Number Picture Size Applicable Car Type A Φ8, Φ10, Φ5 General type (TOYATA, MITSUBISHI SPACE WAGON GLXI) LEXUS ES300, HONDA and NISSAN car type Φ8 Hose Φ8 General type (TOYATA, Φ10 Hose Φ10 MITSUBISHI SPACE WAGON Φ12 HONDA and NISSAN GLXI) Φ12 Hose LEXUS ES300 A03A A03B A05A M M M One group CADILLAC, BMW 750 AT type 4HP 22 4HP 24 A421,MITSUBISHI V6,3000 One group CADILLAC, BMW 750 AT type 4HP 22 4HP 24 A42 EUROPEAN Eg: New VECTRA, PASAT A05B M EUROPEAN New VECTRA, PASAT A06A A06B A07A G1/4 CHRYSLER GRAND VOYAGER, CHRYSLER 300 G1/4 CHRYSLER mm GRAND VOYAGER, CHRYSLER 300 M EUROPEAN New VECTRA A07B A08A A08B A10A A10B A11A M UNF1/2 20 UNF1/2 20 UNF1/2 20 UNF1/2 20 Z1/4 * EUROPEAN New VECTRA GENERAL MOTORS LINCOLN, CADILLAC GENERAL MOTORS LINCOLN, CADILLAC FORD, eg: VOLVO, FORD CHRYSLER: DAIMLER BENZ FORD, eg: VOLVO, FORD CHRYSLER: DAIMLER BENZ FORD LINCOLN, VOLVO 11

14 No. Parts Number Picture Size Applicable Car Type Z1/4 FORD A11B LINCOLN, VOLVO A12A UNF5/8 18 FORD A12B UNF5/8 18 FORD CADILLAC A13A UNF5/8 18 (Outside) GENERAL CHRYSLER MOTORS A13B UNF5/8 18 (Inside) CHRYSLER GENERAL MOTORS A14A A14B A15A A15B A16A A16B A17A A17B A20A A20B A A UNF5/8 18 (Outside) UNF5/8 18 (Inside) UNF5/8 18 UNF5/8 18 M M Φ14.85 Φ14.95 UNF1/2 20 UNF1/2 20 M M12 FORD, VOLVO FORD, VOLVO CHRYSLER Benxc200,s325i GENERAL MOTORS CHRYSLER Benxc200,s325i GENERAL MOTORS EUROPEAN EUROPEAN EUROPEAN FORD FORD 12

15 Optional adaptors No. Parts Number Picture Size Applicable Car Type A A04A Φ9.55(H) Φ12.75(H) Φ15.85(H) General type ( TOYATA MITSUBISH SPACE WAGON GLXI ) LEXUS ES300, HONDA and NISSAN car type G1/4 CHRYSLER Eg: DODGE, BENZ A04B G1/4 CHRYSLER Eg: DODGE, BENZ A09A M EUROPEAN A09B M CHRYSLER A18A A18B Φ15 Bore:Φ16 A19A A19B A A A A Bore:Φ13 Outside port diameter: Φ12 G1/4 G1/4 M G1/4 A Bore:Φ12 13

16 A M No. Parts Number Picture Size Applicable Car Type A A A A A A A A A A M UNF3/4 18 Φ9.5 (H) GENERAL MOTORS, BUICK, CHEVROLET, CADILLAC, EUROPEN, OPEL, SAAB quick insert connect type fuel hose Φ8.0 (H) FORD, LINCOLN, MAZDA, VOLVO, quick insert connect type fuel hose Φ9.5(H) CHRYSLER, DODGE quick insert connect type fuel hose Φ12.5(H) CHRYSLER, DODGE quick insert connect type fuel hose Φ6.0(H) HOSE ADAPTERS General adapter Φ7.5(H) HOSE ADAPTERS General adapter Φ9.5(H) HOSE ADAPTERS General adapter Φ12.5(H) HOSE ADAPTERS General adapter 14

17 Warranty THIS WARRANTY IS EXPRESSLY LIMITED TO PERSONS WHO PURCHASE LAUNCH PRODUCTS FOR PURPOSES OF RESALE OR USE IN THE ORDINARY COURSE OF THE BUYER S BUSINESS. LAUNCH electronic product is warranted against defects in materials and workmanship for one year (12 months) from date of delivery to the user. This warranty does not cover any part that has been abused, altered, used for a purpose other than for which it was intended, or used in a manner inconsistent with instructions regarding use. The exclusive remedy for any automotive meter found to be defective is repair or replacement, and LAUNCH shall not be liable for any consequential or incidental damages. Final determination of defects shall be made by LAUNCH in accordance with procedures established by LAUNCH. No agent, employee, or representative of LAUNCH has any authority to bind LAUNCH to any affirmation, representation, or warranty concerning LAUNCH automotive meters, except as stated herein. a nominal service recharge. Send the unit pre paid to: Attn: Overseas Department LAUNCH Industrial Park, North Wuhe Avenue, Banxuegang Industrial Park, Longgang Dist., Shenzhen, Guangdong Province P.R. China Disclaimer THE ABOVE WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Order Information Replaceable and optional parts can be ordered directly from your LAUNCH authorized tool supplier. Your order should include the following information: Quantity Part number Item description Customer Service If you have any questions on the operation of the unit, please contact us: Tel: , Fax: , E mail: overseasales@cnlaunch.com. If your unit requires repair service, return it to the manufacturer with a copy of the sales receipt and a note describing the problem. If the unit is proved to be in warranty, it will be repaired or replaced at no recharge. If the unit is proved be out of warranty, it will be repaired for 15

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