CAS LCH-TCR302 User manual

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Car Collision Repair System
LCH-TCR302
User Manual
Canada Auto Solutions Inc.
1115 Crestlawn Drive
Mississauga Ontario Canada
905-602-0226

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CONTENTS
Chapter 1 GENERAL INFORMATION.................................................... 3
1.1 GENERAL INFORMATION.........................................................................................................................................3
1.2 TRADEMARK........................................................................................................................................................4
1.3 SYMBOLS ..............................................................................................................................................................4
Chapter 2 FRAME MACHINE DESCRIPTION ...................................... 5
2.1 GENERAL PRESENTATION OF STANDARD COMPONENTS.........................................................................5
2.1.1 FRAME ASSEMBLY.........................................................................................................................................5
2.1.2 CLAMPS/SUPPORTASSEMBLY....................................................................................................................6
2.1.3 HYGRAULIC SYSTEM..............................................................................................................................6
2.1.4 MEASURING SYSTEM..............................................................................................................................5
2.1.5 ACCESSORYASSEMBLY ...............................................................................................................................6
2.2 APPLICABILITY.....................................................................................................................................................7
Chapter 3 INSTALLATION........................................................................ 8
3.1 UNPACKING..................................................................................................................................................................8
3.2 INSTALLATION..................................................................................................................................................................... 8
3.2.1 ADVANCE INSTRUCTIONS......................................................................................................................8
3.2.2 INSTALLATION........................................................................................................................................................9
Chapter 4 SECURITY NORMS................................................................ 11
4.1 GENERAL RULES...............................................................................................................................................11
4.2 QUALIFYING THE PERSONNEL......................................................................................................................10
4.3 SPECIFIC NORMS...............................................................................................................................................11
4.3.1 INSIDE THE REPAIRING OPERATION ENVIRONMENT....................................................................11
4.3.2 USING HYDRAULIC OPERATION..............................................................................................................12
4.3.3 USING PULLING TOOLS ........................................................................................................................12
Chapter 5 OPERATION INSTRUCTIONS............................................. 12
5.1 PRELIMINARY USE INSTRUCTIONS..............................................................................................................12
5.2 CLAMP PROCESS ...............................................................................................................................................13
5.3 FRAME PROCESS...............................................................................................................................................14
5.3.1 The operations for the frame lifting process...............................................................................................14
5.3.2 The operations for the frame landing process.............................................................................................14
5.3.3 Operating the pulling tower........................................................................................................................15
5.4 HYDRAULIC SYSTEM PROCESS......................................................................................................................17
Chapter 6 MAINTENANCE...................................................................... 18
6.1 GENERAL RULES...............................................................................................................................................18
6.2 DETAILED RULES ..............................................................................................................................................18
6.3 FREQUENTLY QUESTIONS..............................................................................................................................18
Chapter 7 MAINTENANCE REGISTER................................................ 19

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Chapter 1 GENERAL INFORMATION
1.1 GENERAL INFORMATION
Read the manual carefully prior to starting the frame machine. The Operators and the
Qualified Technicians have to familiarize themselves with the instructions contained in
the present publication.
1. The goal of this this manual is providing the user all the necessary information so that,
besides a correct use of the frame machine, he is able to use it on the most securityway.
2. It includes information of Technical data, Function, Installation, Maintenance,Spare
Parts and Safety Notice.
3. Any question regarding this instructions, please consult our technical office to get the
necessary explanations.
4. he manual is an integral part of the frame machine, it has to be taken care of by the
buyer, it has to be kept at the immediate vicinity of the frame machine, stored in a
special container and protected from liquids or anything that is liable to jeopardize
its legibility.
5. If the manual has deteriorated, we are happy to resend a new copy. In such cases it is
necessary to communicate with our technical office.The characteristic data stamped on
the special identification nameplate. The manual has to keeped with the machine if it is
sold. The pictures in this manual only prove how to use H-100 frame machine to repair
the accident vehicle. According to the different vehicles, various collision degrees, the
repair method is variation. The operators should analyze the situation and make a set of
appropriate repair method according to actual position.
6. The manual is composed of 19 pages, cover included.
7. Data and drawings are only illustrative; it is prohibited for anyone to copy, modify
or use for personal reasons.
8. Liability: Although every effort has been made to ensure the accuracy and completeness
of this information, the information compiled in this manual cannot guarantee that it is
completely free of errors or omissions. It is the responsibility of the owners and
operators of each facility to ensure that the facility complies with all applicable
regulations. The rules and regulatory interpretations may change without individual
notice to collision repair and automotive refinishingshops.

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1.2 TRADEMARK
When receiving the frame machine,please check the parts of the identification nameplate
that has to correspond to following. Table 1:
Specification
1.3 SYMBOLS
SYMBOL MEANING COMMENT
Caution,
injure foot When moving the tower, operators
should following the regulations in
order to avoid injuring foot.
WARNING Operators are forbidden to stand
behind the tower which is working,
in case the chain or accessory crash
backwards and hurt people. Chains
should not be distorted or knotted.
Max Loading of
overhead puller The Max loading of every bore is
identified on the overhead puller.
All operations marked by this
symbol are strictly to be followed
with maximum attention.
MODEL:
LCH-TCR302
FRAME LENGTH
5600mm
FRAME WIDTH
2200mm
FRAME HEIGHT
580mm
HYDRAULIC PRESSURE
70Mpa(1000psi)
POST MAX. TENSION
95KN
POST WORHING RANGE
360 Degree
PNEUMATIC PRESSURE RANGE
0.8MPa

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Chapter 2 FRAME MACHINE DESCRIPTION
2.1 GENERAL PRESENTATION OF STANDARD COMPONENTS
The frame machine H-100 standard type is composed as follows:
Table 2:
NO
1
MAIN PART
FRAME ASSEMBLY
PART
Frame
QUAN.
1
UNIT
Set
Pulling tower
2
Set
Main chain
2
Piece
Chain with hook
2
Piece
Loading ramp
2
Piece
Overhead boom
1
Set
2
CLAMPS/SUPPORT
Main clamps
4
Set
ASSEMBLY
Air hydraulic pump
2
Set
Air hydraulic cylinder
3
Set
3
ACCESSORY
Pulling tools
14
Piece
ASSEMBLY
Tools board
1
Set
Secondary Air Jack
1
Set
4
Measure System
2-dimension measure system
1
Set
2.1.1 FRAME ASSEMBLY
The frame assembly is the place where the maintenance and repair process is carried out. It
is divided into the following subgroups:
A. Frame.
The maximum applicable lifting weight of the frame with a basement is 3000 Kg.
ATTENTION: it is not permit to overload the maximum lifting weight on the frame
indicated in the Table 1.
B. Pulling tower.
The pulling tower can mobile 360 degrees around the frame.
C. Loading ramps.
The loading ramps are mounted on the frame that help the vehicles load on the frame.
D. Overhead puller.

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The overhead puller is mounted on the tower that repairs the top area of accident vehicle .
2.1.2 CLAMPS/SUPPORTASSEMBLY
The CLAMPS/SUPPORT DEVICE of MEG210C is consisted of four main clamps and two
wheel brackets. The clamp system is used to locate, clamp and support the vehicle. These
clamps can be adjusted up and down. The wheel bracket is used to support the accident
vehicle the way the wheel is.
Main clamp
2.1.3 HYGRAULIC SYSTEM
Two air hydraulic pumps are included.
2.1.5ACCESSORYASSEMBLY
1. Pulling tools assembly.
It consists of a tools board and dolly, 14 pieces of pulling tools. The different pulling
tools are used according to different distortions. The pulling tools may be used by
themselves or in conjunction with other tools. The use method is not rigid but adaptable
according to the model of vehicle,the degree of damage, and personal preference. It may
develop the preference of operators and supply more convenience. These 17 pieces of
pulling tools are part of a 20 tool set.

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Table 3: A list of available pulling tools are shown below
NO.
DESCRIPTION
QUAN.
1
Scissor Clamp
1(Set)
2
Small Clamp
1(Set)
3
Heavy duty Clamp
1(Set)
4
Big mouth Clamp
1(set)
5
Handy Hook
1(Set)
6
Frame rack clamp
1 (Set)
7
Steel wire
1(Set)
8(9)
Chain
2(Piece)
10
Gallus
1(Piece)
11
Double connector
1(pieces)
12
Mini-clamp
1(pieces)
13
Handy Clamp
1(Set)
14
Down pulley assembly
1(Set)
ATTENTION: When operating, do not exceed the Max Load capacity as far as the data
attached on the tools are concerned. Subject to manufacture alterations.
2.2 APPLICABILITY
Frame machine H-100 is used to repair accident vehicles.
Frame machine is used only for repairing the accident vehicles; any other use is to be
considered improper and incorrect.
Any modification of the machine not previously authorized by the manufacturer
absolves the manufacture from damages derived or referable to the aforementioned
actions.

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Chapter 3 INSTALLATION
3.1 UNPACKING
After transportation, remove the wrapping and ensure that:
a. The content of the package corresponds to what was agreed upon in the order.
b. There are not visibly damaged parts.
In both cases, if problems are encountered, do not proceed with the installation of the
machine and warn the manufacturer immediately of the damage and/or of the missing parts
on opening the wrapping.
3.2 INSTALLATION
3.2.1 INSTRUCTIONS AND RECOMMENDATIONS
Before beginning the installation work it is necessary to make sure that the environment
that will keep the frame machine is in conformity with the characteristics below:
Before proceeding to the installation of the frame machine it is necessary to prepare a
device which may lift the frame, for example illustration 1 or other equipment in order to
have an installation environment.

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3.2.2 INSTALLATION
1. TOWER INSTALLATION
a. Firstly the frame of Frame machine should be in an appropriate place. Taking into
consideration that the suitable distance should be left between the frame and the
surrounding walls (recommended about 3 meters) in order to operate conveniently.
b. Lift the tower equal to the edge of the outboard frame orbit, and then push the tower to
land onto the orbit of the frame edge.
c. Joint the lock-arm and tower with M12 screw, and then there should be left a gap of
3-4mm between lock-arm and orbit in order to make the tower around the frame edge
without obstruction.
d. Prepare the necessary parts.
e. Install the stopper screw.
f. Install two handle screw.
ATTENTION: When operating the tower, the handle screw should be fastened. And
there should be a gap between the top of handle screw and the lower plane of frame in
order to make the tower around the frame edge without obstruction. Illustration.
g. Install the Guide-ring.
h. Install the hydraulic cylinder. Insert the cylinder into the bottom of Tower. Make the
connect hole of cylinder is equal to the hole of tower. Then insert the Crossbar for
cylinder. Illustration.
ATTENTION: After Crossbar for cylinder is inserted, don’t forget installing the block
ring.
i. Install Tower collar.
j. Pass upwardly the end without a hook of the chain through the wheel of guide-ring,
then pass the chain Tower collar and fix the chain.
k. Install the overhead boom.

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l. Install the connector onto the cylinder. And attach the hose with the swivel connection.
m. Attach the pump on the other end of the hose. Then attach the thin hose on the
compressor.
Chapter 4 SECURITY NORMS
4.1 GENERAL RULES
ATTENTION: Follow carefully the supplied indications.
The manufacturer is exempted from any responsibility which concerns damage derived
from not respecting the following norms.
a. Keep the use and maintenance manual always within arm’s reach at the place of work.
b. Frame machine is produced in accordance with the actual technical level and the
recognized technical safety rules. Nevertheless it is possible that risks for theconsumer
may occur during use.
c. Observing the accident-prevention safety regulations.
d. Keep to all the signal of danger and safety posted on the framemachine.
4.2 QUALIFYING THE PERSONNEL
a. The personnel employed to operate the frame machine, before beginning the work, has
to study the “SECURITY NORMS " chapter. Because during the work there will not be the

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time to study.
b. The personnel in vocational training will only be able to operate the frame machine if
they are constantly supervised by experienced persons.
4.3 SPECIFIC NORMS
In the paragraphs below are listed all the regulations and prohibitions to be
Observed in order to prevent possible accidents:
4.3.1 INSIDE THE REPAIRING OPERATION ENVIRONMENT
1. It is prohibited for persons who are not be trained operate the frame machine.
2. During the operating process, the operator must consult the operation instructions of the
vehicle and adopt the operation method which vehicle manufacturer recommended in the
vehicle manual.
3. During the operating process, the vehicle must remain N block and apply the brake in
order to avoid slipping.
4. While hoisting or falling the frame, operators must pay attention to not pressing the
hydraulic hoses and the air hoses, etc.. The hydraulic hoses must keep be in good
condition (not allowing to bake the hydraulic hoses).
5. During the operating process, that the operator works under the auto is not allowed.
6. During the operating process, the oil pressure gauge of the air hydraulic pump is not
allowed beyond 6000PSI.
7. While hoisting or falling the frame, anybody is not allowed to stand behind the auto.
And while loading and uploading the frame, there is the person to instruct thedirection.
8. During the operation process, anybody is not allowed to stand behind the tense chains
or the pulling tools that is working.
9. Before using the chains, check that the chain have not been twisted or knotted. The
chains must be checked periodically.
10.It is right that to increase or shorten the length of the chain by special tools, instead of
intercrossing or knotting or forelocking the chain.
11.It is forbidden to heat up the chain.
12.The pulling tools must be located hard on the surface of the vehicle.

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4.3.2 USING HYDRAULIC OPERATION
1. Attention related pressure range. Do not exceed equipment ratings.
2. Never attempt to lift a load weighing more than the capacity of the hydraulicsystem.
3. Checking the sealed capability of the hydraulic system constantly, and if it is not be in
good position, repair and replace it immediately.
4. Do not screws down the connection excessively, only do it by hand.
5. Recommend that use the hydraulic gauge to
measure the pressure.
6. Recommend that use the oil-water segregator and
drain timely.
4.3.3 USING PULLING TOOLS
1. Before using the pulling tools, make the clamps clean.
2. Check frequently the fastness between the distortion position and pulling tools in
order to avoid falling off.
3. When installing the pulling tools, do not damage the electric line or hydraulic line of
vehicle.
4. Pay attention to give a appropriate power when pulling the welding line.
5. During the operation, nobody is allowed to stand behind the tight chain or pulling
tools.
6. Do not exceed the Max Load capacity as far as the data in table 3 are concerned.
Chapter 5 OPERATION INSTRUCTIONS
5.1 PRELIMINARY USE INSTRUCTIONS
Before starting the frame machine it is necessary to do the following controls:

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1. Check that the screws of the various components have not been loosened during the
installation.
2. If the national law requires the approval of use it has to be certified by the expert
nominated on the periodic control card reported at the back of the manual.
3. In order to keep the suitable pulling power within the limit. Generally if the power is
too high it is necessary to increase the power little by little.
4. OPERATION BASIC RULES:
Commend pulling a little every time, and then loosen the chain. Measure and pull
again. When operation, follow the rules of " from inside to outside".
a. Pull lengthways the vehicle along the central line.
b. Pull in the breadthways direction.
c. At last the vertical direction..
After having prepared the vehicle, please follow the indications specified in the paragraph:
5.2 CLAMP PROCESS
Before operation, the accident vehicle must be clamped in order to avoid slipping.
1. According to the degree of damage and part of damage, operators may confirm a
appropriate location where the accident vehicle may be clamped. Commend about 50cm
to 70cm should be left between the tower post and vehicle body.
2. Make the vehicle onto the frame.
ATTENTION: During the operation, nobody is allowed to stand behind the vehicle.
3. Make the vehicle remain N block and apply the brake in order to avoid slipping.And
fix the vehicle tire by the triangular-wood.
4. Observe the shape of the vehicle chassis, and then choose which clamps are available.
5. Adjust the clamp system to the anticipant height (the height is decided by the degree
of damage and the habit of the operators.), and then loosen the screws of the clamps.
6. Lift the vehicle to the appropriate height by the secondary-lift in order to install the
clamps.
7. Tighten the screws of the clamps in order to attach the vehicle body to the clamps.
ATTENTION: After every pulling operation and before the next pulling operation,
check all the screws of the clamp system and screw down them again. If the screws

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loosen, the vehicle body may slip to cause the person injured.
5.3 FRAME PROCESS
5.3.1 The operations for the frame lifting process are:
1. Before lifting the frame, each tower should be located on the respective longer edge of
frame, and then fix them. Illustration.
2. Check whether the hydraulic lines and air lines are in good condition. Make the
connection firm and insure there is not any heavy on thepipeline.
3. Install the loading ramps on the edge of the frame.
4. (1)If the vehicle may start, drive it onto the frame.
(2) Or tow the vehicle onto the frame by the special attractive device.
(3) If the front-wheels have already been broken, put the saddles under the broken
front-wheels and tow it onto the frame.
5. Make the vehicle remain N block and apply the brake in order to avoidslipping.
6. Make use of the air hydraulic pump to lift the frame equal to the availableheight.
7. Then pull lightly the release valve, here the frame will be lifted slowly until the
pneumatic mechanical lock is locked firmly.
5.3.2 The operations for the frame landing process are:
1. Before landing the frame, each tower should be located on the respective longer edge of
frame averagely, and then fix them.
2. Attach the hydraulic pump to the connection of the frame base.
3. Start the air hydraulic pump to lift the frame in order to open the self-stop mechanism.
4. Then pull lightly the release valve, here the frame will be failling slowly until the
frame is fallen to the floor.
ATTENTION: During loading and unloading the vehicle, the operators are allowed
standing behind the vehicle. At the same time, make the vehicle remain N block and apply
the brake, and fix the vehicle by the triangle-wood or the chain.
When falling the frame, it is lightly that the operator pulls the release valve in order to

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avoid the damage caused by falling more quickly.
5.3.3 Operating the pulling tower
1. Locate one pulling tower near the distortion of the accident vehicle. Considering two
pulling towers pull together if the degree of damage is very bad.
2. Install the tower onto the inside orbit and the outside lower orbit of the frame firmly.
3. Tighten every tower.
(1)Firstly fix the stopper screw which is used for connecting the tower to the edge of the
frame.
(2)Secondly fix two handle screws under every tower.
(3)Thirdly fix the fixed screw onto the frame.
ATTENTION: Tighten all the screws used for fixing the towers in order to ensure the
firmness. 3 steps must be in proper order.
4. Check the operation of step 3 and screw down again in order to avoid the tower post
slipping.
5. Choose appropriate pulling tools, and then fix them on the distortion of the vehicle.
Attach the pulling tool to the chain of the tower.
6. Avoid sharp bends and kinks. Adjust the chain if it is.
7. Adjust the height of guide-ring according to the pulling angle.
8. Strain the chain and check whether the chain is fit for the self-locking device on top of
the tower post.
9. Start the hydraulic system.
ATTENTION: Do not overexert when operating the pump.
10.During the pulling operation, some parts need knocking in order to eliminate the
internal power, so the operators should observe the tension of the chain.
ATTENTION: The higher of the guide-ring is heightened, the little the power should
be put on by the hydraulic system. The height of guide-ring cannot be beyond the red warning
line marked on the tower post. Do not load greater than pulling power at 2000PSI.Please see
the drawing and strictly according to the drawing explanation.

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11.If preceding the next operation or pulling again, the operator should open the return-to-
tank valve in order to release the pressure. Then the tower post will be returned to the
primary position.
12.Adjust the chains, guide-ring and other accessories. Then repeat from step 1.
CAUTION: During the operation, nobody is allowed to stand behind the tower post and
the pulling tools in order to avoid the damage caused by chains or tools fly backwards.
5.4 HYDRAULIC SYSTEM PROCESS
1. Check the safety of the hydraulic system. Check every connection and avoid sharp
bends and kinks when routing hydraulic hoses.
2. Attach the hoses of the hydraulic pumps to the connections of tower post and frame.
3. Attach the hydraulic system to air supply, and the air pressure is around 0.8 Mpa.
4. Check the oil level of the pump and add oil if necessary.
Make sure the pump reservoir is vented. This pump must always be vented prior to use.
Use either the “Vent Screw” or “Vent/Fill Plug”.
5. Treadle operation.
a. To advance the cylinder and to retract the cylinder. Depress the “PRESSURE” end of
treadle and the pump will start to pump hydraulic oil to the system so that the tower
post or the mobile legs of the frame are lifted; Depress the “RELEASE” end of the
treadle to retract cylinder so that the tower post or the mobile legs of the

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frames have fallen. Tostop the cylinder from retracting, release the treadle and return
it to the hold position.
b. To hold the cylinder position. The pump will stop and hold pressure when the treadle
is in the free/neutral position (treadle is not depressed in either “PRESSURE” or
”RELEASE” positions.).
CAUTION: Do NOT pull quickly when operating the release valve.
ATTENTION: The working pressure of the hydraulic system is designed for a Max.
pressure of 6000PSI.
Chapter 6 MAINTENANCE
6.1 GENERAL RULES
Maintenance has to be a preventive and planned activity, seen as a fundamental need to
obtain safety, as a presupposition that the machines and the apparatus are subject to wear
which is a potential cause of breakdowns. Therefore the safety of the frame machine
depends also on a good preventive maintenance that allows the substitution of the objects
subject to wear out before the verification of the technical faults.
a. Keep the working yard clean, and clean the frame machine after finishing theoperation.
b. Do not put any sundries on the frame of the frame machine.
6.2 DETAILED RULES
Ordinary maintenance is a kind of periodic maintenance. The procedures of ordinary
maintenance as a rule had better be done by qualified and authorized personnel.
1.Operators should check periodic connections of hydraulic systems in order to insure the
tightness.
2.Operators should check periodically oil level of pump with all cylinders or tools in the
fully retracted position and add oil if necessary. If add oil when the hydraulic cylinder is
advanced, the reservoir will overfilled when they are retracted.

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3.Operators should change hydraulic oil every 200 to 300 working hours. If there is lots of
dust in the work environment, the frequency should be controlled every about 35 working
hours.
ATTENTION: The hydraulic oil must be changed full.
4. Operators should insulate the dust, grease and scrap from the hydraulic components.
5. Operators should lubricate periodically all the joint parts.
6. The pulling tools subject to wear have to have scheduled maintenance. Repair or
replace them if necessary.
7. The chain subject to wear also has to have scheduled maintenance. Ensure there is
no notch, twist and other wearing position. Replace them if necessary.
ATTENTION: If the frame machine is used with greater continuity or for heavy work,
it is necessary to carry out checks with greater frequency.
6.3 FREQUENTLY QUESTIONS
See the chart below for any small problems.
MALFUNCTIONING PROBABLE
Pump will not start Air turned off or line blocked
Motor stalls under load Low air pressure
Inlet filter plugged, insufficient air flow
Pump fails to build pressure External leak in system
Internal leak in pump
Internal leak in system component
Low oil level
Pump builds less than full
pressure
Pump builds pressure, but
load does not move
Cylinder drifts back on its
own
Cylinder will not return
A)Single-acting type
Low air pressure
Internal relief valve set low
External system leak
Internal leak in system component
Load greater than cylinder capacity at full pressure
Flow to cylinder blocked
External system leak
Internal leak in system component
Return flow or coupler restricted / blocked
No load on a “load return” cylinder
Return spring broken on cylinder

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Cylinder will not return
B)Double-acting type
Release valve malfunction
Return flow or coupler restricted/blocked
Low oil flow rate Reserve not vented
Inadequate air supply
Dirty air filter
Clogged inlet filter
Chapter 7 MAINTENANCE REGISTER
TYPE OF
MAINTENANCE DETAILED CONTENT DATA SIGNATURE