Car-O-Liner D16 User manual

(30308, rev 1) 2012-02, ENG
Instruction manual
Draw Aligner D16

Foreword
D16
GB/1994-05
CA
R
-O-LINE
R
The Draw Aligner D16 is designed to perform alignment work on Mark-
and Bench Rack- series of alignment benches. D16 can easily be locked to the
bench frame. Its adjustment possibilities give it a large range of movement,
making alignment work fast and effective.
Conformity with directives and standards
The Draw Aligner D16 is designed and manufactured by Car-O-Liner, which is
an EN-ISO 9001 and 14001 accredited development and manufacturing
organisation.
It is required that only Car-O-Liner approved spare parts and accessoires are
used with the Draw Aligner D16.
This manual gives tips and directions for installation, operation and maintenance.
IMPORTANT! Read these instructions carefully to become familiar with proper
operation of the draw aligner. Do not neglect this, since improper operation
can result in personal injury and damage to the equipment.
Warranty
Car-O-Liner AB offers a one-year guarantee from the date of delivery.
This guarantee covers material defects and assumes normal care and
maintenance.
The guarantee assumes that:
The equipment is correctly installed and inspected in accordance with current
local regulations.
The equipment has not been altered or rebuilt without approval from
Car-O-Liner AB.
Genuine Car-O-Liner AB spare parts are used in any repairs.
Operation and maintenance have been carried out according to the
instructions
in this manual.
All claims on warranty must verify that the fault has occurred within the
guarantee period, plus that the unit has been used within its operating range as
stated in the specifications. All claims must include the product type and article
number.
This data is stamped on the name plate, refer to page A.3.
The photographs and drawings in this manual are merely illustrative and do not
necessarily represent the actual appearance of equipment available. The equipment
is designed to be used in accordance with established practices and in observation of
applicable safety regulations. The design of the equipment presented in this manual
may be changed without prior notice.

General
D16
CA
R
-O-LINE
R
The draw aligner is solely intended for the performance of
alignment work on the coachwork of a vehicle that is
properly mounted on Mark- and Bench Rack- series of
alignment benches.
During alignment work the draw aligner shall be secured to
the bench frame according to instructions.
The draw aligner shall only be used with a hydraulic
cylinder with a maximum capacity of 10 tons.
1 APPLICATIONS
GB/2012-02 A. 1

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/1995 A . 2
2 DRAW ALIGNER The draw aligner can be placed at any position along the
four sides of the base frame. It is secured to the base frame
with the locking wedge (1). The draw aligner rotates side-
ways and is locked in the desired position with a peg (2).
The arm (3) can be inclined sideways to obtain the optimum
pulling angle. It is locked in position with a peg (4). The arm
is fitted with an extension (5). A stop wire (6) limiting the
outward movement of the arm is connected between the
arm and the hydraulic cylinder mounting.
The hydraulic cylinder (7) has a capacity of 10 tons and is
operated with the help of a pneumatic pump (8).
The mounting bracket (9) at the end of the arm is for an
extra hydraulic cylinder.
General
1. Drawbar with locking wedge and safety plate
2. Peg for horizontal locking
3. Draw aligner arm
4. Peg for vertical locking
5. Arm extension
6. Stop wire
7. Hydraulic cylinder
8. Pneumatic hydraulic pump
9. Mounting bracket for extra hydraulic cylinder
10. Device for converting from BenchRack to
Mark and vice versa.
11. Nameplate
6
7
10
11
GB/2012-02

General
D16
GB/2012-02
CA
R
-O-LINE
R
The manufacturer´s nameplate is placed at the lower mounting
point of the draw aligner arm
3 NAMEPLATE
1. CE label
2. Product type
3. Product name
4. Article number
5. Weight
6. Manufacturers serial number
7. Date of manufacture
8. Year of construction
1
2
3
4
5
6
7
8

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/2012-02 B . 1
Alongside the illustrations and important descriptive texts in
this manual are various warnings and notices. Safety signs
shall also be in place on the equipment. These are meant to
warn for hazardous situations or to draw attention to incor-
rect use of the equipment.
By observing these safety precautions, the user of the draw
aligner will ensure safer working conditions both for himself
and his fellow workers.
1 GENERAL
2 WARNINGS,
IMPORTANT NOTICES
AND INFORMATION
”WARNING” (in italic type) means that you can injure your-
self or others if you do not follow the instructions. When you
see the warning symbol shown in part B3 of this section,
follow the safety instructions to prevent personal injury.
”IMPORTANT” (in italic type) indicates practical information
or that the equipment may be damaged if the instructions in
the notice are ignored.
In addition to the safety signs illustrated in part 3, the follow-
ing warnings and important notices appear in the manual.
See next page.
Safety

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/2012-02
WARNING! The draw aligner is meant to be equipped
with a hydraulic cylinder with a maximum capacity of
10 tons.
WARNING! Make sure that the safety wire is correctly
fitted and undamaged.
WARNING! Never release the locking wedge if the bench
is not at draw aligner height. Risk for injury.
WARNING! Make sure that the draw aligner is correctly
secured to the bench frame.
WARNING! The locking pegs must be pressed in
completely.
WARNING! Always use safety glasses when hammering
the locking wedge in or out. Risk for splinters.
WARNING! Watch out for flying objects during aligning
work. Do not stand behind or near the draw aligner during
a pull.
WARNING! Before moving the draw aligner, always lock
the arm in an upright position. Risk for tipping
WARNING! To avoid damage to the draw aligner ,chain
must run as parallell as possible to hydraulic cylinder.
IMPORTANT! When using the draw aligner, remember to
move the measuring studs away from the damaged area
to avoid damage to the measuring system.
B . 2
2 WARNINGS,
IMPORTANT NOTICES
AND INFORMATION
(cont’d.)
Safety

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/2012-02 B . 3
3 SAFETY SIGNS
Command. Safety glasses must be used when hammering
in the locking wedge.
Command. The locking pegs must always be pressed in
completely.
Warning. The draw aligner is to be equipped with a hydrau-
lic cylinder with a maximum capacity of 10 tons.
Warning. Watch out for flying objects during aligning work.
Do not stand behind or near the draw aligner during a pull.
Art. no. 31897
Safety
Warning. Risk for tripping; loose hoses, etc.
Art. no. 31901
Art. no. 31895
Art. no. 31892
Art. no. 31898
max
10 ton

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/2012-02
Red with white background, black symbol.
Prohibition - Prohibits behaviour that can cause injury.
Blue with white symbol.
Command - Prescribes a specific responsibility.
Yellow with black symbol.
Warning - Warns for safety risk.
Undamaged safety signs shall always be affixed at the
indicated places. See page B.5.
If any signs are damaged or missing the user is responsible
for their immediate replacement. Safety signs are available
as spare parts.
3 SAFETY SIGNS (cont’d.)
B . 4
Safety

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/2012-02 B . 5
4 PLACEMENT OF
SAFETY SIGNS
DRAW ALIGNER D16
Safety
max
10 ton

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/1994-0 C . 1
1 FITTING 1.1 D16 can be used with BenchRack- and Mark-series.
Adaptation to the respective bench frames is
accomplished by transposition of parts A and B. The
draw aligner is delivered set up for use with Mark series.
By loosening and removing A and loosening
B, rotating it 900 and bolting it to the lower pair of
holes, D16 can be used with BenchRack series.
See page C.2.
If D24 (see page C.2) is inserted in the track in the
head of the drawbar, D16 can also be used with earlier
models MKIII and MKIV.
1.2 Fit the hydraulic cylinder in the mounting points on the
arm and the body of the draw aligner. Ensure that the
spring washers that hold the locking pins are locked
and undamaged.
WARNING! The draw aligner is meant to be equipped
with a hydraulic cylinder with a maximum capacity of
10 tons.
1.3 Fit the safety wire (6). See page A.2.
WARNING! Make sure that the safety wire is correctly
fitted and undamaged.
Installation
max
10 ton
GB/2012-02

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/2012-02
2.1 The head of the drawbar must be horizontal. The
wedge and safety plate should hang straight down with
the drawbar pushed against the safety plate. The sup-
ports of the bench frame must be adjusted so that the
head of the draw aligner is free when the draw aligner
is pushed in toward the bench frame.
WARNING! Before moving the draw aligner, always
lock the arm in an upright position. Risk for tipping.
2.2 Rotate the drawbar 900 by lifting 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 against
the inner side of the bench frame and the head of
the drawbar engages the steel strip on the inside of
the bench.
2.3 The draw aligner is secured to the bench frame by
driving in the locking wedge with a copper hammer.
WARNING! Always use safety glasses when hammer-
ing the locking wedge in or out. Risk for splinters.
2.4 The draw aligner is detached by performing the preced-
ing steps in reverse order.
WARNING! Never release the locking wedge if the
bench is not at draw aligner height. Risk for injury.
C . 3
2 CONNECTION TO THE
BENCH FRAME See the figures on pages C.4 and C.5
Installation

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/2012-02 C . 4
Installation
2 CONNECTION TO THE
BENCH FRAME
(cont’d.)
IMPORTANT! Make sure that the draw aligner is correctly
secured to the bench frame.
BenchRack series
2.1
2.4
2.2
2.3

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/1994-05 C . 5
Installation
IMPORTANT! Make sure that the draw aligner is correctly
secured to the bench frame.
2.4
2.3
2.2
2 CONNECTION TO THE
BENCH FRAME
(cont’d.)
Mark series
2.1
GB/2012-02

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/2012-02 D . 1
The safety plate under the locking wedge on the drawbar
(1) prevents the head of the drawbar from losing its pur-
chase on the steel strip on the inner side of the bench frame
when the wedge is hammered out.
WARNING! Never release the locking wedge if the bench
is not at draw aligner height. Risk for injury.
The safety wire between the draw aligner arm and the body
prevents the arm from falling too far backwards during
movement or if the pull should come loose.
WARNING! Make sure that the safety wire is correctly
fitted and undamaged.
When a pulling chain is delivered from CAR-O-LINER
together with the D16, a safety wire is included which is to
be fastened between the vehicle and the draw clamp. This
prevents accidents if the clamp should lose its grip.
WARNING! Make sure that the safety wire is correctly
fitted and undamaged.
WARNING! Watch out for flying objects during aligning
work. Do not stand behind or near the draw aligner during
a pull.
Safety Devices

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/2012-02 E .
Operation
WARNING! Before moving the draw aligner, always lock
the arm in an upright position. Risk for tipping.
Position the draw aligner based on the impact angle of the
damage.
The bench frame must be at a height that is suited to the
draw aligner. If, for instance, the floor is uneven, the height
of the draw aligner can be adjusted with the support screws
on the legs or supports of the aligning bench.
WARNING! The locking pegs must be pressed in com-
pletely.
Correct positioning of the draw aligner minimizes the num-
ber of times it must be moved during the course of the
work.
IMPORTANT! To avoid damage to the draw aligner,
the chain must run as parall ell as possible to the
hydraulic cy linder.
When a suitable anchoring angle has been determined,
secure the draw aligner to the bench frame with the locking
wedge (see figures on pages C.4 and C.5).
WARNING! 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.
1 POSITIONING AND
LINKING THE
DRAW ALIGNER
1
Stop wire

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/2012-02 E .
Operation
TO AVOID INJURIES, OBSERVE THE
FOLLOWING:
Make sure that the safety wire between the arm
and the body is undamaged and correctly fitted.
Make sure that the safety wire between the
vehicle and the draw clamp is undamaged and
correctly fitted.
Make sure that the draw aligner cylinder is rated
at a maximum of 10 tons.
Make sure that the draw aligner is correctly
secured to the bench frame.
Make sure that the pegs locking vertical and
lateral movement are pressed in completely.
Always use safety glasses when hammering the
locking wedge in or out.
Watch out for flying objects and do not stand
behind or near the draw aligner during a pull.
Never release the locking wedge if the bench is
not at draw aligner height.
2
WARNING

D16
CAR-O-LINERCAR-O-LINER
CAR-O-LINERCAR-O-LINER
CAR-O-LINER
GB/2012-02 E .
Operation
Before using the draw aligner, observe the following:
Clean the area on the vehicle to which the clamp is to be
fastened in order to ensure a good grip.
Always use an approved pull chain such as CAR-O-LINER
T33 and see that the clamp, hook or plate are in good
shape.
Make sure that the hydraulic hose is undamaged. The
working pressure is approximately 600 bar. If the hose
springs a leak, the oil under high pressure can cause
damage.
Make sure that there is no air in the hydraulic system.
Bleed the system as follows:
1. Connect the pump hose to the cylinder.
2. Extend the cylinder fully.
3. Hold the pump 1.5 to 2 metres above floor level
and release pressure. The built-in spring will
force the cylinder back and expel any air from
the system.
4. Repeat this procedure once more.
Never leave the draw aligner unattended when it is
under pressure.
IMPORTANT! When using the draw aligner, remember to
move the measuring studs away from the damaged area
to avoid damage to the measuring system.
2 PREPARATIONS
BEFORE COMMENCING
ALIGNMENT
3