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Car-O-Liner Quick 42, Instruction Manual

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Car-O-Liner Quick 42 Instruction Manual Download Page 79

 
 

 
 

Quick 42 

   Car-O-Liner Group AB 

40724, EN - rev. 8, 2017-09 

79

 

 

6 Service 

and 

Maintenance 

6.1 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. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for Quick 42

Page 1: ...40724 rev 8 2017 09 EN Quick 42 The multifaceted bench repair system Instruction Manual...

Page 2: ...nit 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...

Page 3: ...h 541 on 110 V 60 Hz Article no 39754 Serial no beginning with 511 on 230 400 V 50 Hz Article no 39751 For more extensive information see section 3 2 3 Type 1 Power unit Type 2 Power unit For identifi...

Page 4: ...to as Type 1 and Type 2 in this Instruction Manual Type 1 Pendant station For identification of Type 1 see design and control panel For more extensive information see section 3 1 13 Type 1 Pendant sta...

Page 5: ...s an ISO 9001 2008 and ISO 14001 2004 accredited organisation Below an example of how the EC Declaration of Conformity for the Quick 42 is outlined A signed and dated copy of the EC Declaration of Con...

Page 6: ...3 2 Lift unit 27 3 3 3 Type 1 Power unit 28 3 3 4 Type 1 Power unit Electrical supply 29 3 3 5 Electrical diagram for 230 and 400V AC 3 phase for Type 1 Power unit 29 3 3 6 Electrical diagram for 110V...

Page 7: ...aw aligner 57 4 6 Drive on to Q42 58 4 6 Setting up the vehicle 59 4 7 1 Setup with chassis clamps 60 4 7 2 Using Q201 spacers optional 62 4 7 3 Bench Mounting 65 4 7 4 Q63 Quick setup 65 4 7 5 Q62 Qu...

Page 8: ...92 8 2 Other Components 92 9 Technical Specifications 93 10 Spare parts 94 10 1 Bench spare part kits 94 10 2 Type 1 Power unit summary 96 10 2 1 Type 1 Pendant station 98 10 2 2 Type 1 Pump unit 400...

Page 9: ...s 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 drivin...

Page 10: ...he name plate is located at the base frame of the lift Figure 1 2 The Quick 42 name plate The power unit name plate is located on the front of the power unit from serial no Q61116065 Name plate locati...

Page 11: ...l 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...

Page 12: ...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 The draw aligner is meant to be equ...

Page 13: ...etween axle and bench end is 0 5 meter when lifting a vehicle with short a wheel base 1 5 2 meter Otherwise risk of crushing injuries WARNING During all service and fitting work the lift must be block...

Page 14: ...e lifting WARNING Block the wheels or engage the hand brake before tilting the bench Risk of unintentional rolling WARNING All electrical connections must be carried out by authorized personnel Risk f...

Page 15: ...building engineer for an inspection 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 t...

Page 16: ...e between axle and bench end is 0 5 meter when lifting a vehicle with short wheel base 1 5 2 meter Otherwise there is risk for crushing injuries WARNING During inspection and maintenance with the lift...

Page 17: ...in the locking wedge COMMAND The locking pegs must always be pressed in completely TILTING OPERATION DECAL SAFETY Sign with safety rules to be displayed at the power unit 1 and at a highly visible lo...

Page 18: ...EN rev 8 2017 09 2 3 1 Placement of safety signs The safety signs are placed as follows Figure 2 3 1 Placement of safety signs and tilting operation decal Part No 40372 Part No 41642 Part No 41642 Par...

Page 19: ...Quick 42 Car O Liner Group AB 40724 EN rev 8 2017 09 19 Figure 2 3 1 Placement of safety signs on the draw aligner Part no see 2 3...

Page 20: ...s markedly The lift cylinder is a single acting hydraulic cylinder with a built in hose rupture protection This valve ensures that the lift slowly sinks in the event of a hydraulic hose rupture or oth...

Page 21: ...al and air supply Connect the provided plug not provided for the single phase units of the Q42 power unit to a receptable Use a suitable plug for installation of the single phase unit Connect the Q42...

Page 22: ...t new installations and to avoid pushing air into the hydraulic system connect the 2 standard hoses to the rear satellite connection of the bench Plug the adapter described in the tool list to the hos...

Page 23: ...laced between the ramp and the bench This applies only to the ramps where the wheels are positioned NOTE The 300 mm ramps can be positioned in three positions to fit the track width of the vehicle The...

Page 24: ...It is stop ping mechanically in the front and on a micro breaker situated on the inner scissors arm on the run up side When the bench is lowered to its lowest horizontal position it stops at the prope...

Page 25: ...roll freely it may be used as a roll stop This stop must be placed under an undamaged wheel when the vehicle is setup on the bench with the help of the hydraulic jacks to prevent the vehicle from roll...

Page 26: ...setup 3 2 9 Chassis Clamp B106 The B106 Chassis Clamp is bolted to the bench mounting arm and is provid ed with toothed segments that grip the vehicle s sill edge The toothed segments may either be f...

Page 27: ...frame The hydraulic cylin der is fitted between the scissors arms 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...

Page 28: ...OTE The electrical control box is placed inside the power unit 13 1 Oil tank 8 litres 2 1 gallons 2 Pneumatic solenoid valve YV3 3 A1 outlet for lift 4 Flow control valve RPCV 05 5 Upper manifold 6 El...

Page 29: ...d for any of the following voltages 110V 60 Hz single phase 230V 50 Hz 3 phase 400V 50 Hz 3 phase WARNING All electrical connections must be carried out by authorized personnel Risk for electric shock...

Page 30: ...Car O Liner Group AB Quick 42 30 40724 EN rev 8 2017 09 3 3 6 Electrical diagram for 110V AC single phase for Type 1 Power unit K1 Contactor T1 Transformer F1 Fuse 2 5 A glass tube fuse...

Page 31: ...unit S1 Emergency stop button K2 Raising relay scissors lift S2 3 step switch K3 Accessory relay S3 Up K4 Lowering relay scissors lift S4 Down YV1 Solenoid valve SDV1 K1 Contactor YV2 Solenoid valve...

Page 32: ...OTE The electrical control box is placed inside the power unit 13 1 Oil tank 8 litres 2 1 gallons 2 Pneumatic solenoid valve YV3 3 A1 outlet for lift 4 Flow control valve RPCV 05 5 Upper manifold 6 El...

Page 33: ...32 A 24 VAC 3 3 9 Type 2 Power unit Electrical supply The electrical equipment is delivered for any of the following voltages 230 400V 50 Hz 3 phase WARNING All electrical connections must be carried...

Page 34: ...OWN switch 2 step SQ1 Limit switch F2 Thermal fuse motor K1 Contactor 24VAC R1 Relay R2 Relay R3 Relay R4 Relay R5 Relay YV1 Solenoid valve SDV1 YV2 Solenoid valve SCV1 YV3 Solenoid valve Pneumatic YV...

Page 35: ...utton or pulling with the draw aligner 4 2 step Down button or retraction of draw aligner 3 3 14 Type 2 Pendant station How to operate the lift see section 4 2 Operating the lift The pendant station c...

Page 36: ...it and thereby damaging the cable and contact a cable pulling stop art no 45629 is included at delivery Install the pendant station cable according to the instructions below 1 Connect the cable to the...

Page 37: ...the cable through the hole in the base frame opposite side from the wall power outlet and connect it to the Power unit 4 With the bench still at maximum height fix the cable pulling stop to the cable...

Page 38: ...8 40724 EN rev 8 2017 09 3 5 Hydraulics Central satellite locations for hydraulics and air supply Quick couplings 3 5 1 Hydraulic diagram 110V for Type 1 Power unit Schematic hydraulic diagram 110V fo...

Page 39: ...pe 1 Power unit SCV1 Control valve lift SCV2 Control valve accessories SDV1 Directional valve lift SDV2 Directional valve accessories CV 01 Non return valve accessories CV 02 Main non return valve RV...

Page 40: ...l valve accessories 3 SDV1 Directional valve lift 4 SDV2 Directional valve accessories 5 CV 01 Non return valve accessories 6 CV 02 Main non return valve 7 Start up valve 8 RV 03 Over pressure valve 9...

Page 41: ...cylinder mounting The hydraulic cylinder 7 has a capacity of 10 tons and is operates from the build in power unit The mounting bracket 8 at the end of the arm is for an extra pushing cylinder to be us...

Page 42: ...ity of 10 tons 300 bar WARNING Watch out for flying objects during aligning work Do not stand behind or near the draw aligner during a pull IMPORTANT When using the draw aligner remember to protect th...

Page 43: ...rect voltage and fre quency and that it turns in the right direction after connection For connec tion information See section 3 3 3 Power unit 3 8 Space requirements The recommended space for installa...

Page 44: ...the responsibility of the owner user of the equipment to ensure that inspection is in accordance with current local regulations carried out before the lift is put into use Example of space requirement...

Page 45: ...ensure that no one is near the bench Risk of crushing injuries Lower the lift to the draw aligner height Ensure that the draw aligner can be easily connected to all sides of the bench frame See secti...

Page 46: ...g platform is 2 mm m or better Procedure Expander bolts M16x125 Car O Liners Art No 36819 4 bolts are supplied with the Q42 system Drill holes in the floor using the base plate holes as a template Dri...

Page 47: ...e bench mountings and chassis clamps to be fitted Depending upon the type of vehicle and the nature of the damage the hy draulic jacks shall be placed under a strong part of the body The recommendatio...

Page 48: ...pendant station 1 Place the switch to the right position 2 Raise the lift by pressing the up button when releasing the button the lift stops and the lift is standing on the hydraulic cylinder 3 By pr...

Page 49: ...e position 2 Press the down button and the bench tilt the drive on side WARNING Block the wheels or engage the hand brake before tilting the bench Risk of unintentional rolling NOTE When the lift has...

Page 50: ...ition Manoeuvering of the scissors lift B Middle position Tilting of the bench C Lower position Manoeuvring of accessories draw aligner and hydraulic jacks 4 2 4 Raising the bench Type 2 pendant stati...

Page 51: ...g the bench Type 2 pendant station When the bench is in its lowest horizontal position draw aligner height the bench can automatically be tilted 1 Turn the switch to its middle position 2 Press the do...

Page 52: ...Car O Liner Group AB Quick 42 52 40724 EN rev 8 2017 09 4 3 Measuring system 1 Install the Car O Tronic measuring bridge to the bench...

Page 53: ...upports can be mounted in different combinations depending on wheelbase of the vehicle that will be repaired There are three types of ramp supports Front Middle Rear The picture below shows the recomm...

Page 54: ...surement and alignment work The picture below shows the standard start configuration The 300 mm ramps have three width positions depending on wheel track of the vehicle The 400 mm ramps have two width...

Page 55: ...th the side ramps There are three positions for the 300 mm side ramps and two positions for the 400 mm side ramps see previous page Below the fitting for the 400 mm drive on ramp is illustrated Incorr...

Page 56: ...2 Rotate the drawbar 900 by drawing up the locking wedge and safety plate Turn the safety plate back again while holding the wedge in its horizontal position The drawbar and its head are thus pressed...

Page 57: ...s prevents accidents if the clamp should lose its grip WARNING Make sure that the safety wire is correctly fitted and undamaged WARNING Make sure that the draw aligner is correctly secured to the benc...

Page 58: ...NG Always use safety glasses when hammering the locking wedge in or out Risk for splinters WARNING Never release the locking wedge if the bench is not at draw aligner height Risk for injury 4 6 Drive...

Page 59: ...king height NOTE Drive off stop prevent the vehicle to roll off WARNING Block the wheels or engage the hand brake before tilting the bench Risk of unintentional rolling WARNING During setup of the veh...

Page 60: ...e with a separate frame The front or rear axle beams or corresponding structures are also suitable lifting points 1 Mark the gripping points A and B for the chassis clamps The measurements are given i...

Page 61: ...Quick 42 Car O Liner Group AB 40724 EN rev 8 2017 09 61 NOTE Make sure the cam lock is fully rotated before tightening 5 Attach the hydraulic hoses between the jacks and the power supply...

Page 62: ...d place the spacer between cylinder and holder arm according to pictures below To order the Q201 Spacer accessories kit parts no 41146 contact your local Car O Liner distributor WARNING Always lift ve...

Page 63: ...3 With the vehicle supported by the hydraulic jacks place the bench mounting with the cam locks under the marked A or B position 4 Tighten the bench mountings against the bench 5 Place the chassis cla...

Page 64: ...cle and repeat the pro cedure Tighten all the clamp plates to the bench mountings Tighten the chassis clamps first against the sill edge and then against the bench mounting IMPORTANT When a wrench is...

Page 65: ...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 4 7 4 Q...

Page 66: ...5 Q62 Quick setup When using two Q62 it s easy to mount without jacking up the car Depend ing of the damage Q63 could be mounted on the same side or the opposite side NOTE If the wheels have to be rem...

Page 67: ...Quick 42 Car O Liner Group AB 40724 EN rev 8 2017 09 67 2 Tighten the bolts for EVO tower 3 Mount the other EVO tower in the same order...

Page 68: ...thout front or rear sub frame Illustrations show the recommended way to set up the vehicle WARNING It is forbidden to use the T48 on top of the drive on ramps Risk of falling off from the ramps WARNIN...

Page 69: ...desired position 4 Lock the draw aligner to the bench see section 4 5 5 Turn the Switch in Draw aligner position 4 9 1 Pulling a side damage when two fixing points are used 1 Mount the clamp s on the...

Page 70: ...rom the side to avoid interference with the hydraulic hose NOTE To mount the draw aligner in the short end of the bench may create conflict with the quick couplings in some situations 4 9 3 Offset pul...

Page 71: ...Hand tools The drive on ramp s can be used for placing the hand tools or other equip ment during the repair 4 10 3 Width extension possibility Width extension possibility of the ramps makes it easier...

Page 72: ...Car O Liner Group AB Quick 42 72 40724 EN rev 8 2017 09 WARNING Maximum height when using ramps as standing platform is 1 meter...

Page 73: ...s to use the second position of the console holes All wheels are equipped with brakes The wheel swivel can be locked in four positions Wheels can be mounted when a vehicle is fixed on the bench NOTE M...

Page 74: ...Install the transport wheels on the bench sides using the second position of the console holes Make sure that the locking peg fits in the hole of the bench 8 Lower the jack and repeat from step 6 8 at...

Page 75: ...izontal level The switch on the hand control in tilt position 4 Install the transport protection to hold the bench against the bottom of the lift 5 Use two hydraulic jacks and one Q201 spacer kit Medi...

Page 76: ...e of the bench 8 Lower the hydraulic jacks until the wheels stand on the floor Lower the jacks completely and remove them 9 Place the hydraulic jacks according to the picture 10 When mounting the two...

Page 77: ...e are no problems to con nect two Q16 draw aligners on the same bench side of an empty bench But when the bench is mobile not bolted to the floor it is forbidden to con nect two draw aligners to an em...

Page 78: ...O Liner Group AB Quick 42 78 40724 EN rev 8 2017 09 By observing and following the safety precautions users of the Quick 42 will ensure safer working conditions for themselves and their fellow work e...

Page 79: ...rk 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 perso...

Page 80: ...loose or damaged Check for oil leakage at cylinders and power unit Contact Service Support if leaking Hydraulic cylinders equiped with lubrication nipples needs additional lubrication and should be lu...

Page 81: ...pport if leaking Check that all locking pins at at the cylinder attachment points and draw aligner are undamaged and that locking washers are in place and undamaged Replace if necessary Check hose cou...

Page 82: ...box are connected for the correct voltage Faulty contactor Check the contactor and contactor coil Replace any defective components The thermal fuse inside motorwinding has cut off overheated It will a...

Page 83: ...tle the cylinder and change gaskets Change the oil Non return valve in the pump defective or leaking Non return valve defective Replace the non return valve 7 4 Problem The lift cannot be lowered Faul...

Page 84: ...g of the scissors lift does not work remove measuring bridge if any and the lid of the hydraulic unit 3 Remove the lid of the electric box and check the fuse 2 5 A glass fuse 4 Remove all items around...

Page 85: ...that the centre screw M4 is fully in 7 If the security latches are in unlocked position raise the security latches and insert a guide card board or masonite to prevent the security latches from attac...

Page 86: ...out this operation 10 When loosening the brass screw and the lift is starting to move slowly downwards remove the safety supports and immediately move away from the lift SQUEEZE RISK WARNING Wait unti...

Page 87: ...aulic cylinder is placed in the front and one is placed in the rear of the centre line of the bench and must stand on the lift platform they must NOT stand on the floor They shall be raised alternatel...

Page 88: ...of the scissors lift does not work remove measuring bridge if any and the lid of the hydraulic unit 3 Remove the lid of the electric box and check the fuse 2 5 A glass fuse 4 Remove all items around a...

Page 89: ...cked position raise the security latches and insert a guide card board or masonite to prevent the security latches from attaching If in locked position see step 12 15 8 Check that nobody is near the b...

Page 90: ...d when carrying out this operation 10 When loosening the brass screw and the lift is starting to move slowly downwards remove the safety supports and immediately move away from the lift SQUEEZE RISK W...

Page 91: ...aulic cylinder is placed in the front and one is placed in the rear of the centre line of the bench and must stand on the lift platform they must NOT stand on the floor They shall be raised alternatel...

Page 92: ...t is important that the equipment is dismantled in an environmentally friendly way 8 1 Mechanical Components When scrapping or dismantling lift components the oil must be emptied from the cylinder hos...

Page 93: ...60 seconds Total length with approach ramp 5 480 mm 216 in Bottom frame dimensions 780 x 2 200 mm Weight lift frame 755 kg 1 661 lbs Recommended type of oil Hydraulic oil DIN 51524 del 2 groupe HLP I...

Page 94: ...ower Unit please contact the service department at Car O Liner AB Note Use only genuine Car O Liner spare parts in any repairs 10 1 Bench spare part kits Position Quantity Part No Object 1 1 39669 Hyd...

Page 95: ...Quick 42 Car O Liner Group AB 40724 EN rev 8 2017 09 95 Figure 10 1 Bench spare part kits 1 3 4 2 5 6...

Page 96: ...Hz 2 1 43609 Motor 230 400V 3 PH 50Hz 3 1 See section 10 2 2 Pump unit 400V Q42 3 1 See section 10 2 3 Pump unit 110V Q42 4 1 See section 10 2 4 Upper manifold Q42 5 1 39878 Hose cylinder 6 1 See sect...

Page 97: ...Quick 42 Car O Liner Group AB 40724 EN rev 8 2017 09 97 Figure 10 2 Type 1 Power unit summary 4 7 7 1 3 2 8 6 5...

Page 98: ...t No Object 1 1 43511 Stop with key 2 1 43648 Control switch label 3 1 43509 Switch button 4 1 41389 Complete pendant with cable 5 1 43514 Block for emergency stop 6 2 43516 Block for switch button 7...

Page 99: ...124 Tank with cover 8L 2 1 43529 Flow control valve A2 3 1 43529 Flow control valve A1 4 1 43533 Pump 400V Q42 with pipe and filter 4 1 44245 Pump 440V Q42 with pipe and filter 5 1 33985 Valve SCV 1 6...

Page 100: ...ct 1 1 33124 Tank with cover 8L 2 1 43529 Flow control valve A2 3 1 43529 Flow control valve A1 4 1 43531 Pump 110V Q42 with pipe and filter 5 1 33985 Valve SCV 1 6 1 33945 Coil SCV 1 7 1 43523 Connec...

Page 101: ...ion Quantity Part No Object 2 1 44003 Adapter between manifolder and block 3 4 44004 O ring for adapter 4 1 33985 Valve SCV 2 5 1 33945 Coil SCV 2 6 1 43523 Connector 9 2 43524 Valve and coil kit SDV...

Page 102: ...lectrical components Position Quantity Part No Object 1 1 44233 Fuse 2 5A 5x20 mm 2 3 43611 Relay 3 1 43613 Contactor 400V 3 1 43612 Contactor 110V 4 1 43614 Transformer 230 400V 4 1 43615 Transformer...

Page 103: ...43609 Motor 230 400V 3 PH 50Hz 3 1 See section 10 2 2 Pump unit 400V Q42 46510 Pneumatic valve 4 1 See section 10 2 4 Upper manifold Q42 5 1 44278 Hose cylinder 6 1 See section 10 2 5 Connection bloc...

Page 104: ...Car O Liner Group AB Quick 42 104 40724 EN rev 8 2017 09 Figure 10 8 Type 2 Power unit summary 8...

Page 105: ...17 09 105 10 3 1 Type 2 Pendant station Position Quantity Part No Object 1 1 45899 Pendant complete with cable 2 1 45918 Pendant complete without cable 3 1 46473 Cable with connector 4 1 46529 Cable p...

Page 106: ...V Position Quantity Part No Object 1 1 46472 Valve SCV 1 2 1 33945 Coil SCV 1 Position Quantity Part No Object 1 1 48425 Valve SCV 1 2 1 48426 Coil SCV 1 Figure 10 10 Type 2 Pump unit 1 2 ATTENTION Ne...

Page 107: ...3 Type 2 Upper manifold Position Quantity Part No Object 1 1 42242 Coil SCV SDV 2 1 42239 Valve SDV 1 2 3 1 46555 O ring kit SDV Valve 4 1 46554 O ring kit SCV Valve 5 1 46472 Valve SCV 2 6 1 44110 E...

Page 108: ...09 Type 2 Upper manifold from serial no 61117065 see nameplate Position Quantity Part No Object 1 1 48426 Coil SCV SDV 2 1 48429 Valve SDV 1 2 3 1 46555 O ring kit SDV Valve 4 1 46554 O ring kit SCV...

Page 109: ...nents Position Quantity Part No Object 1 1 44233 Fuse 2 5A 5x20 mm 2 1 46505 PCB Complete 3 1 44236 Contactor 400V 4 1 44235 Transformer 230 400 24V 4 1 46912 Transformer 440 460 24V 5 1 46510 Pneumat...

Page 110: ...No Object 1 1 30952 Wheel 2 2 39845 Wheel 142383N 3 1 30312 Wire 4 1 30408 Connecting Rod 5 1 30358 Lock washer 6 1 30326 Wedge 7 2 30334 Peg 24 8 1 39756 Q161 Cylinder Q16 9 1 44366 Seal kit Q16 10 1...

Page 111: ...ve on right 3 12 41448 Console welded 4 2 36891 Roll off stop front 5 2 41079 Drive on ramp width 300 mm 5 2 42725 Drive on ramp width 400 mm 6 8 41443 Ramp long width 300 mm 6 8 42720 Ramp long width...

Page 112: ...Car O Liner Group AB Quick 42 112 40724 EN rev 8 2017 09...

Page 113: ...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 Singapore India and China and sells throu...

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