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Car-O-Liner BenchRack 4200, Instruction Manual

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Car-O-Liner BenchRack 4200 Instruction Manual Download Page 42

 
 

 
 

Car-O-Liner Group AB 

BenchRack 

42

 

32163, EN- rev. 5,

 

2018-04

 

5 Service 

and 

Maintenance 

5.1 General 

warnings 

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!

   All work on the electrical equipment must be carried out by 

qualified personnel. 

 

WARNING!

   Observe high standards of cleanliness when working with the 

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

 

IMPORTANT!

 All nuts and bolts shall be cleaned and greased

 

monthly. 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for BenchRack 4200

Page 1: ... 32163 rev 5 2018 04 EN BenchRack 4200 5000 5500 6300 Instruction Manual ...

Page 2: ... 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 opera...

Page 3: ...mity 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 ...

Page 4: ...0 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 Anchori...

Page 5: ...bleshooting 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 ...

Page 6: ...rame 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 benc...

Page 7: ...3 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 ...

Page 8: ...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...

Page 9: ...trated 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 Ex...

Page 10: ... 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 W...

Page 11: ...ANT Depending on the nature of damage the pillar jacks can be placed to lift the vehicle one side at a time using the B23 sill support IMPORTANT Suitable lifting points when lifted at the front or rear are the front or rear subframe fixations or the axle beams For a lift of a vehicle with separate frame lift straight on the frame For a lift on the sill box of a vehicle with unibody chassis the B23...

Page 12: ...Car O Liner Group AB BenchRack 12 32163 EN rev 5 2018 04 ...

Page 13: ...d on the equipment PROHIBITED For personnel to be on the lift while it is moving WARNING Maximum vehicle weight 4200 kg Minimum allowed distance between axles is 2500 mm WARNING During inspection and maintenance with the lift unit in the raised position the lift unit must be blocked against unintentional lowering WARNING Danger of tripping due to loose hoses etc TILTING OPERATION DECAL SAFETY SIGN...

Page 14: ...Car O Liner Group AB BenchRack 14 32163 EN rev 5 2018 04 2 3 1 Placement of safety signs The safety signs are placed as follows Figure 2 1 Placement of safety signs and tilting operation decal ...

Page 15: ...lift slowly sinks in the event of a hydraulic hose rupture or other leakage To avoid accidental lowering when the bench is more than 500 mm from the floor the mechanical safety latches 2 prevent the lift from sinking more than a maximum of 100 mm in the event of leakage BenchRack has a crush guard 3 to prevent feet from being caught be tween the bench and the floor during tilting operations 1 2 3 ...

Page 16: ...Car O Liner Group AB BenchRack 16 32163 EN rev 5 2018 04 ...

Page 17: ...ed from the side rails of the bench frame There are three types of side ramps 1 A pair equipped with mountings to which the drive on ramps may be attached These side ramps are always placed nearest the drive on end 2 A pair equipped with welded guide plates used to steer the ramp into the forward side rails The enclosed drive off stops are to be fitted to these ramps with the accompanying bolts an...

Page 18: ... drive off stops when the lift is raised The drive on ramps are used with all tilt able BenchRacks NOTE A wider drive on ramp is available for all BenchRack models 3 2 2 Drive on stops B44 The drive off stops should always be properly fitted see illustration The stops not only prevent a vehicle from rolling forward off of the BenchRack but also prevent improper weight distribution on the bench and...

Page 19: ... automatically extended When the bench is subsequently lowered it stops at the proper height for the connec tion of the draw aligner To lower the bench to the floor the bench supports must be folded up manually 3 2 4 Crush guard B58 Used to avoid crushing injuries when tilting the BenchRack The crush guard is designed with a hinge mechanism see illustration WARNING Ensure that the crush guard is f...

Page 20: ...wheel when the vehicle is set up on the bench with the help of the pillar jack to prevent the vehicle from rolling 3 2 6 Bench mounting The bench mountings are fitted to the tracks on the upper side of the bench They may be turned inward or outward depending upon the width of the ve hicle The bench mountings are adjustable in height Variations of the mountings may differ from the illustrated model...

Page 21: ...ents may either be fastened to the clamp s angle or to the mounting plate Alternatives for various vehicles are listed on the data sheets The accompanying illustration shows a toothed segment fitted to the base bracket Special chassis clamps are available for some vehicles Consult the CAR O LINER data sheet for a list of vehicles concerned 3 2 10 Sill support B23 Used to avoid damage to the sill e...

Page 22: ...er Unit version available 3 3 2 Lift unit The lift is hydraulic driven and is built on a base frame to which the scissors arms and the hydraulic cylinder are fitted The base frame is also equipped with a mechanical latch to prevent the lift from sinking This latch 4 is released with the help of an air cylinder 7 so that the lift may be lowered The upper ends of the scissors arms are connected to t...

Page 23: ...must be checked with regard to transport damage If any part is damaged the lift may not be used until the damage has been repaired Contact your supplier All models of BenchRack are equipped with transport protection that holds the base frame against the bottom of the bench IMPORTANT Remove transport protection before the lift is put in use otherwise damage can occur 3 4 2 Storing in workshop Trans...

Page 24: ...stallation General The recommended space for installation is shown in the diagrams below The lift must be bolted to a flat good quality concrete floor section 3 5 3 Anchoring to the floor 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...

Page 25: ...ea and remove the transport protection The control lever must be installed see illustrations below The control lever for tilting is fitted on the left side according to the illustrations below Cover plates not illustrated Bench seen from above Locked position horizontal bench Unlocked position tilted bench Control lever Horizontal bench left side Drive on side Tilted bench left side Drive on side ...

Page 26: ... Raise the lift to the highest position and block up the bench frame 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 Engage the two safety latches Mark the 4 6 mounting holes on the floor and fit the floor brackets according to the section 3 5 3 Anchoring to the floor Raise the lift and re...

Page 27: ... hydraulic hoses Risk of tripping Raise and lower the lift a few times to ensure that the safety latch element Figure 3 2 falls easily into the slot Lubricate if necessary WARNING Ensure that the crush guard is fitted so that it always drops down of its own weight and does not bind Risk of crushing injuries Position the warning decals and signs providing instructions for lift and alignment work se...

Page 28: ...25 Car O Liners Art No 36819 4 bolts are supplied with the BenchRack system Drill holes in the floor using the base plate holes as a template Drill diame ter 16 mm in hole depth 110 120 mm 4 5 in 1 Clean the holes with vaccum cleaner and air hose Unscrew the nut so that only the un threaded top of the bolt is above the nut Gently tap the expander bolts into the holes with a hammer 2 Tighten the bo...

Page 29: ...ehicle may be driven onto the ramps or winched up even if the wheels are damaged The vehicle is lifted free of the ramps with the help of pillar jacks Then the bench mountings and chassis clamps may be fitted IMPORTANT Lifting at two lifting points at the front or rear is recommended IMPORTANT Depending on the nature of damage the pillar jacks can be placed to lift the vehicle one side at a time u...

Page 30: ...l latch position see Fig A When the Down button is fully depressed the air cylinder lifts the safety latch see Fig B Pressing the Down button to the second position fully depressed allows the lift to be lowered to the draw aligner height or to the lowest level NOTE When the lift has been lowered and stopped by the safety latch section 3 3 2 Lift unit and further lowering is desired the lift must b...

Page 31: ...desired height WARNING The control lever must be fully pushed in Risk of injury In this position the draw aligner may be connected Tilting 1 The bench must be in the draw aligner position Pull out the control lever to enable the tilt function Raise the lift until all legs hang free 2 Turn the control lever anti clockwise so that the forward pair of legs fold up and remain there then lower the lift...

Page 32: ...de out of the supports or mountings Risk of crushing injuries 1 Position centre line of the vehicle as closely as possible to the centre line of the bench Winch or drive the vehicle to the correct position on the side ramps Use B57 if wheels can not roll or rotate 2 Place B57 upside down under an undamaged wheel on the side not being lifted to prevent the vehicle from rolling Winch B57 Roll stop B...

Page 33: ...the correct height is obtained when measuring important when using Car O Mech 4 Raise the lift to its highest position and fit two pillar jacks according to picture right and left side of the vehicle Remove ramps where the pillar jacks are to be positioned Adjust the position of the pillar jacks for a suitable lifting point WARNING Never lift the vehicle with two pillar jacks placed under the cent...

Page 34: ...e the cam lock is fully twisted before tightening the pillar jacks IMPORTANT Suitable lifting points when lifted at the front or rear are the front or rear subframe fixations or the axle beams For a lift of a vehicle with separate frame lift straight on the frame For a lift on the sill box of a vehicle with unibody chassis the B23 sill support must be used B23 sill support Pillar jack Cam lock ...

Page 35: ...nt bench mountings and cam locks in the centre of the B mark see section 4 2 1 Drive on to BenchRack Tighten the bench mountings with the cam locks to the bench Fit the chassis clamps to the bench mountings and check that they are placed directly under the sill edge Gently raise the the bench to fit the clamps to the sill flange Tighten the clamps to the sill flange NOTE Do not tighten the bolts f...

Page 36: ... the lift to allow the rear bench mountings and chassis clamps to be fitted Remove side ramps from under the rear wheels 4 Place the rear bench mountings in the centre of the A mark see section 4 2 1 Drive on to BenchRack and tighten the bench mountings with the cam locks to the bench Fit the chassis clamps according to the procedure described in step 2 NOTE Tighten all four chassis clamps to the ...

Page 37: ...to tighten nuts and bolts ensure that it is set to a maximum of 200 Nm to avoid damage to the equipment IMPORTANT All nuts and bolts shall be cleaned and greased regularly 5 Remove pillar jacks Raise or lower the bench to convenient working height The vehicle is now ready for alignment work ...

Page 38: ...he vehicle on the T48 with no ramps on the bench 2 Fit first side ramp and drive on ramp to the bench Continue to roll on the vehicle and fit additional side ramps Pay attention when rolling the T48 wheels over the cable hose protection 3 Gently raise the bench to the highest position with vehicle on T48 support stand 4 Fit two pillar jacks according to picture right and left side of the vehicle R...

Page 39: ...ing of the bench mountings and chassis clamps see section 4 2 2 Setup with chassis clamps NOTE Do not tighten the bolts for the clamp plates to the bench mounting before all 4 chassis clamps are in position NOTE Tighten the chassis clamps first against the sill edge and then against the bench mounting 7 Repeat the procedure described in step 5 8 Repeat the procedure described in step 6 NOTE Do not...

Page 40: ...the clamp against the sill edge Tighten the chassis clamp bolts against the bench mounting forcing the vehicle into the correct position When all of the bolts have been properly tightened alignment work can begin During the course of the alignment work distortion may be checked by loos ening the chassis clamp in question to see if the stress remains IMPORTANT When a wrench is used to tighten nuts ...

Page 41: ...BenchRack Car O Liner Group AB 32163 EN rev 5 2018 04 41 ...

Page 42: ...hile in the raised position to prevent accidental lowering Risk of crushing injuries WARNING All work on the electrical equipment must be carried out by qualified personnel WARNING Observe high standards of cleanliness when working with the hydraulic system Dirt in the hydraulic oil can cause operating problems IMPORTANT All nuts and bolts shall be cleaned and greased monthly ...

Page 43: ...icate safety latch moving parts Check that hydraulic hose and air hoses are positioned properly and are in good condition Check that joint axles and locking screws are tightened Tighten if necessary Check for oil leakage at cylinders and power unit Contact Sevice Support Check the level in the hydraulic oil tank Top up as necessary Change oil and filter at least once a year Check the warning signs...

Page 44: ...motor does not run 1 Phase error blown fuse Check for voltage on all three phases Check the fuse 2 Voltage drop or wrong voltage Check the voltage and make sure that the motor and electrical component box are connected for the correct voltage 3 Faulty contactor Check the contactor and contactor coil Replace any defective components 4 Overcurrent breaker has tripped is set incorrectly or is defecti...

Page 45: ... in the open position Replace the valve 7 Defective relief valve see the separate instruction manual for the Power unit Connect a pressure gauge to the hydraulic hose and check the pressure should be 210 bar Pressure is set at the factory if the pressure is incorrect contact your supplier 8 Defective pump see the separate instruction manual for the Power unit Replace the pump unit 6 3 Problem The ...

Page 46: ...lve is blocked with dirt Clean the valve 3 The valve sticks Change the valve and the oil 4 The latch pawl 4 is stiff or sticks Clean so that the pawl enters the slot easily Mechanical safety latch 3 is jammed Air cylinder 7 does not lift the latch pawl from the slot Check the air supply to the air valve see the separate instruction manual for the Power unit and that the air valve receives 24 V AC ...

Page 47: ...BenchRack Car O Liner Group AB 32163 EN rev 5 2018 04 47 ...

Page 48: ...chanical Components When scrapping or dismantling lift components oil must be emptied from cylinder hoses and pump Waste oil should be sent for disposal or to a recycling station 7 2 Other Components All electrical components plastic hoses steel and aluminium should be sort ed for recycling ...

Page 49: ...conds Lift dimensions Drive on ramps 2060 x 4200 6300 mm 1170 mm without ramps Wide drive on ramps 2320 x 4200 6300 mm 1170 mm without ramps Bottom frame dimensions 780 x 2200 mm Weight lift frame 950 1300 Kg Recommended type of oil Hydraulic oil DIN 51524 del 2 groupe HLP ISO 6743 4 group HM Viscosity class 32 according to ASTM D445 or ISO 3448 Power Unit for BenchRack See separate instruction ma...

Page 50: ...oup AB BenchRack 50 32163 EN rev 5 2018 04 9 Spare Parts The spare parts required for the maintenance of the BenchRack are listed in this chapter Note Only use genuine Car O Liner spare parts for repairs 9 1 Lift 28 ...

Page 51: ...2 32545 15 Shaft for scissors arm 2 32669 16 Locking plate 4 31034 17 Hose protection 1 31040 18 Hose 1 31038 19 Screw MC6S TT 5x20 2 91147 20 Straight connection 6mm R1 8 1 99459 21 Screw M6S 8x14 8 8 10 91274 22 Locking washer SGA 30x1 5 4 91963 23 Screw SK6SS M 10x16 4 91045 24 Straight connection Temeto XGE 10PLR ED 1 99480 25 Screw MF6S 8x15 6 91159 26 Expander bolt M16x125 4 6 36819 27 Plast...

Page 52: ...1 32150 2 Drive off stop ramp 1 32138 3 Drive off stop 1 30964 4 Ramp section short 1 32139 5 Ramp section right 1 32137 6 Ramp section left 1 32136 7 Ramp section 1 32135 8 Decal kit BechRack 1 46062 Ramp kit complete BR4200 1 31927 Ramp kit complete BR5000 1 30984 Ramp kit complete BR5500 1 31934 1 6 7 4 2 3 8 5 ...

Page 53: ...ide ramp section left with hook 1 33979 4 Wide ramp section right with hook 1 33980 5 Wide drive off stop ramp 1 33981 6 Drive off stop 1 30964 7 Wide ramp section short 1 33984 8 Wide ramp section 1 33978 9 Decal kit BechRack 1 46062 Wide ramp kit complete BR4200 1 33986 Wide ramp kit complete BR5500 1 33989 Wide ramp kit complete BR6300 1 33990 1 5 9 4 6 2 3 7 8 ...

Page 54: ...Car O Liner Group AB BenchRack 54 32163 EN rev 5 2018 04 Car O Liner Service Support Department ____________________________________________________ Phone 46 227 412 24 E mail support car o liner se ...

Page 55: ...g and Service Over 55 000 Car O Liner Collision Repair Systems are in use worldwide Car O Liner runs operations of its own in Scandinavia USA UK France Germany Thailand India and China and sells through local distributors in more than 60 countries Car O Liner products are well known for their high quality advanced technology and ergonomic design Telephone 46 227 412 00 www car o liner com info car...

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