Car-O-Liner BenchRack 4200 Bedienungsanleitung

(32163, rev 5) 2018-04 EN

BenchRack

4200 5000 5500 6300

Instruction Manual

Car-O-Liner Group AB BenchRack

232163, EN- rev. 5, 2018-04

Foreword

This equipment is used to facilitate high quality re-

pairs to collision-damaged vehicles. All other use of

the equipment, or use that is contrary to the instruc-

tions in this manual, can cause personal injury and/or

equipment damage.

Car-O-Liner Group AB including any company within

the Car-O-Liner Group of companies ("Car-O-Liner")

can not be held responsible for any claims for loss or

damages as a result from incorrect use of this equip-

ment or its use in a manner not intended. Save for

product liability claims for loss or damages as a result

of personal injury or damage to property to the extent

caused by the negligence, gross negligence, breach of

contract, or other wrongdoing of Car-O-Liner (as

prescribed by the Product Liability Act (1992:18) or

similar legislation applicable on other markets), Car-

O-Liner shall in no event be liable for any loss or

damage to revenues, profits or goodwill or other spe-

cial, incidental, indirect or consequential damages of

any kind.

Warranty

Car-O-Liner offers a one-year limited guarantee from

the date of installation of the equipment at end users

premises. This guarantee covers only material defects

and assumes normal care and maintenance according

to Car-O-Liner specification.

The guarantee assumes that:

The equipment is correctly installed and inspected

in accordance with current local laws and regula-

tions.

The equipment has not been altered or rebuilt

without prior written approval from Car-O-Liner.

Genuine Car-O-Liner spare parts are used in any

repairs and conducted by Car-O-Liner certified

technician.

Operation and maintenance have been carried out

according to the instructions in this manual.

All claims on warranty shall be notified through your

authorized Car-O-Liner Distributor by use of Car-O-

Liner´s VisionWeb platform without undue delay and

shall verify that the fault has occurred within the guar-

antee period and that the unit has been used within its

operating range as stated in the specifications. All

claims shall include the product type and article number

as well as a detailed description of the problem and ac-

tions taken trying to solve it. This data is stamped on the

name plate (refer to section 1.2 "Marking" for location).

Note

This instruction manual provides advice as well as in-

structions for installation, operation, maintenance and

trouble shooting.

IMPORTANT! Read this manual carefully to become

familiar with the proper operation of the equipment.

It is recommended that you use your authorized Car-O-

Liner Distributor for maintaining, servicing and upgrading

your products. Never perform repairs, adjustments or any

other work on the products which may result in personal

injury and damage to the product.

Your Car-O-Liner Distributor employs factory trained

technicians and is focused on offering you the best overall

experience with your new Car-O-Liner product. Any revi-

sions or upgrades of the products, as required by Car-O-

Liner, shall be performed by your authorized Car-O-Liner

Distributor.

The photographs and drawings in this manual are intend-

ed only to be illustrative and do not necessarily show the

design of the equipment available on the market at any

given time. The equipment is intended for use in accord-

ance with current trade practice, applicable laws and safe-

ty regulations. The equipment illustrated in the manual

may be changed without prior notice.

The contents in this publication can be changed without

prior notice.

This publication contains information which is protected

by copyright laws. No part of this publication may be

reproduced, stored in a system for information retrieval or

be transmitted in any form, in any manner, without Car-

O-Liner’s prior written consent.

Conformity with directives and standards

The equipment is designed and manufactured by Car-O-

Liner, which is an EN-ISO 9001 and 14001 accredited

development and manufacturing organisation.

The equipment is CE-approved by Inspecta, Sweden. It is

required that only Car-O-Liner approved spare parts and

accessories are used with the equipment.

BenchRack Car-O-Liner Group AB

32163, EN - rev. 5, 2018-04 3

Conformity with directives and standards

The BenchRack repair system is manufactured by Car-O-Liner AB, which is an ISO 9001:2008 and ISO

14001:2004 accredited organisation.

Below an example of how the EC Declaration of Conformity for the BenchRack is outlined.

A signed and dated copy of the EC Declaration of Conformity, including serial number, is included in

the documentation for the BenchRack. Please contact your distributor if you need a new copy of the

Declaration of Conformity.

Car-O-Liner Group AB Hulda mellgrens gata 1

CAR-O-LINER GROUP AB

Hulda Mellgrens gata 1

SE- 421 32 Västra Frölunda

SWEDEN

20XX-01-15

(Place and date of issue)

(Name, signature and title or equivalent marking

of authorized person)

Car-O-Liner Group AB BenchRack

432163, EN- rev. 5, 2018-04

Contents

1Introduction.....................................................................6

1.1General .................................................................................................6

1.2Marking .................................................................................................7

2Safety ...............................................................................8

2.1General .................................................................................................8

2.2Warnings and important notices ...........................................................8

2.3Safety signs.........................................................................................13

2.3.1Placement of safety signs....................................................14

2.4Safety devices.....................................................................................15

3Installation.....................................................................17

3.1General ...............................................................................................17

3.2BenchRack with lift..............................................................................17

3.2.1Drive-on ramps....................................................................17

3.2.2Drive-on stops B44..............................................................18

3.2.3Bench support for draw aligner height.................................19

3.2.4Crush guard B58..................................................................19

3.2.5Loading trolley/Roll stop B57...............................................20

3.2.6Bench mounting...................................................................20

3.2.7Cam locks B626...................................................................20

3.2.8Pillar jack B633....................................................................20

3.2.9Chassis clamp B106............................................................21

3.2.10Sill support B23....................................................................21

3.3Lift........................................................................................................22

3.3.1Applications .........................................................................22

3.3.2Lift unit.................................................................................22

3.4Transport and inspection of delivery...................................................23

3.4.1Transport protection ............................................................23

3.4.2Storing in workshop/Transport outside workshop ...............23

3.4.3Mains connections check ....................................................24

3.5In shop installation ..............................................................................24

3.5.1 In shop installation, General................................................24

3.5.2Installation............................................................................24

3.5.3Anchoring to the floor ..........................................................28

4Operation 4.1 General...................................................29

4.2 Operating the Lift....................................................................................30

4.3Tilting the bench..................................................................................30

4.4Vehicle setup.......................................................................................31

4.4.1 Drive on to BenchRack.............................................................32

4.4.2Setup with chassis clamps ..................................................35

4.4.3Driving on/Setting up a vehicle without front or rear sub

frame or wheels...................................................................................38

4.4.4Bench mounting...................................................................40

5Service and Maintenance .............................................42

BenchRack Car-O-Liner Group AB

32163, EN - rev. 5, 2018-04 5

5.1General warnings................................................................................42

5.2Inspection and service plan................................................................43

6Troubleshooting ........................................................... 44

6.1General...............................................................................................44

6.2Problem: The lift cannot be raised......................................................44

6.3Problem: The lift drops........................................................................45

6.4Problem: The lift cannot be lowered...................................................46

7Dismantling and salvage.............................................. 48

7.1Mechanical Components....................................................................48

7.2Other Components .............................................................................48

8Technical Specifications.............................................. 49

9Spare Parts.................................................................... 50

9.1Lift.......................................................................................................50

9.2Ramps, standard ................................................................................52

9.2Ramps, wide.......................................................................................53

Car-O-Liner Group AB BenchRack

632163, EN- rev. 5, 2018-04

1 Introduction

1.1 General

BenchRack is used for vehicle alignment and has an integrated, variably

adjusted scissors lift which can raise the bench frame to the maximum

working height of 1170 mm.

The bench frame has drive-on ramps and ramp sections, so-called “side

ramps”.The side ramps are easily hooked to the side tracks of the bench

frame.

The ramps permit a vehicle to be driven on to the bench frame for quick an-

choring of chassis clamps (such as Standard Clamp B106).

The bench frame may be tilted to facilitate driving on the vehicle.

Maximum permitted vehicle weight is 4200 kg.

Maximum load per ramp section is 1000 kg.

IMPORTANT! The complete vehicle shall be positioned on the bench

when carrying out alignment work. The lift and bench frame shall not be

used to lift one end of the vehicle while the other end remains on the floor.

Moreover, the lift’s working platform shall not be used for anything other

than vehicle repair.

BenchRack Car-O-Liner Group AB

32163, EN - rev. 5, 2018-04 7

1.2 Marking

Placing of the BenchRack vehicle lift name plate:

Figure 1.1 Example of BenchRack vehicle lift nameplate

Placing of the BenchRack base frame name plate:

Figure 1.1 Example of BenchRack base frame nameplate

Car-O-Liner Group AB BenchRack

832163, EN- rev. 5, 2018-04

2 Safety

2.1 General

BenchRack has been designed and tested to meet strict safety requirements.

Please read the following instructions carefully before operating BenchRack

and refer to them as needed to ensure the continued safe operation of the

equipment.

Information provided in this manual describes the suggested best working

practices and should in no way take precedence over individual responsibili-

ties or local regulations.

Great effort has been placed on the design and manufacture of BenchRack in

order for it to comply with all applicable safety aspects for this type of

equipment. During operation and other work it is always each individual’s

responsibility to consider:

Their own and other’s personal safety.

The safety of the BenchRack through correct use of the equipment in

accordance with the descriptions and instructions provided in this

manual.

By observing and following the safety precautions, users of BenchRack will

ensure safer working conditions for themselves and their fellow workers.

2.2 Warnings and important notices

The following types of safety signs are used on the equipment and in

Car-O-Liner’s instruction manuals:

Prohibited

Prohibits behaviour that can cause injury.

Command

Prescribes a specific responsibility or action.

Warning

Warns of risks for personal injuries and or damages to equipment.

BenchRack Car-O-Liner Group AB

32163, EN - rev. 5, 2018-04 9

The following warnings and important notices are used in the instruction

manual:

WARNING

Warning (in bold type) is used in this manual to indicate a possible danger

that could lead to personal injury. An instruction is normally given, followed

by a short explanation plus the possible effect if the instruction is not

followed.

IMPORTANT

Important (in bold type) is used to indicate a possible danger that could lead

to damage to the equipment and/or cause environmental damage.

Note: (in bold type) is used to accentuate supplementary information that is

required for problem-free use or optimal use of the equipment.

In addition to the safety signs illustrated in section 2.3 "Safety signs", the fol-

lowing warnings and important notices appear in the manual:

WARNING! Maximum load per ramp = 1000 kg.

WARNING! The drive-off stops should always be correctly fitted to the

bench. Risk of improper weight distribution.

WARNING! Ensure that the crush guard is fitted so that it always drops

down of its own weight and does not jam. Risk of crushing injuries.

IMPORTANT! Exercise care when transporting BenchRack.

IMPORTANT! When a wrench is used to tighten nuts and bolts, ensure that

it is set to a maximum of 200 Nm to avoid damage to the equipment.

WARNING! The lift must be bolted to the floor. Risk of tipping.

IMPORTANT! It is the responsibility of the owner (user) of the equipment

to ensure that inspection, in accordance with current local regulations, is

carried out before the lift is put into use.

IMPORTANT! Transport protection must be used whenever the equipment

is moved.

Car-O-Liner Group AB BenchRack

10 32163, EN- rev. 5, 2018-04

WARNING! All work on the electrical equipment must be carried out by

qualified personnel.

WARNING! Maximum vehicle weight = 4200 kg. Minimum allowed

distance between axles is 2500 mm..

WARNING! During all service and fitting work, the lift must be blocked

up while in the raised position to prevent accidental lowering. Risk of

crushing injuries.

WARNING! The cable protection must be properly fastened over the air

and hydraulic hoses. Risk of tripping.

IMPORTANT! If there is any uncertainty about the quality of the floor,

contact a building engineer for an inspection.

WARNING! During set-up of the vehicle on the bench, care must be

exercised so that the vehicle does not roll or slide out of the supports or

mountings. Risk of crushing injuries.

IMPORTANT! Ensure that the toothed segments are clean and fitted

correctly.

WARNING! When other personnel are in the vicinity exercise care when

operating the lift. Risk of crushing injuries.

WARNING! Ensure that all of the bench legs hang straight down. Risk of

injury.

WARNING! The control lever must be fully pushed in. Risk of injury.

WARNING! Before raising or lowering the lift, ensure that no-one is near

the bench. Risk of crushing injuries.

WARNING! Observe high standards of cleanliness when working with the

hydraulic system. Dirt in the hydraulic oil can cause operating problems.

WARNING! Never lift the vehicle with two pillar jacks placed under the

vehicle´s center of gravity. Risk of instability and of crushing injuries.

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