Car-O-Liner D20 User manual

Speed Draw aligner D20
Instruction Manual
(138 03 85 231, rev. 0) 2001-04, GB/US
approved
Excellence
in Collision
Repair

Foreword
(138 03 85 231_f, rev. 0), 2001-04 , GB/US
Speed Draw aligner D20Car-O-Liner AB
Foreword
The Speed Draw aligner D20 is designed to perform
minor alignment work on the Speed lifting platform. All
other use of the equipment, or use which is contrary to
the instructions given in this manual, can cause personal
in ury and/or machine damage.
Car-O-Liner can in no way be held responsible for
intentional or unintentional damage, and consequent
unlimited loss of profit, loss of income, loss of business
opportunity, loss of use or other similar nuisance,
irrespective of how this has arisen, that originates from
incorrect use of this equipment or its use in a manner not
intended.
Warranty
Car-O-Liner 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.
- genuine Car-O-Liner spare parts are used in any
repairs.
- operation and maintenance has been carried out
according to the instructions in this manual.
- the draw aligner is not equipped with a hydraulic
cylinder with a capacity of over 5 tons.
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,
article number and serial number. This data is to be
found stamped on the name plate, see section 1.3
Marking for location.
Note
This instruction manual gives advice as well as instruc-
tions for installation, operation and maintenance.
IMPORTANT! Read this manual care-
fully to become familiar with the proper
operation of the draw aligner. Do not
neglect to do this as improper handling may
result in personal in ury and damage to the
equipment.
The photographs and drawings in this manual are in-
tended 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 accordance with current trade practice and appro-
priate safety 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 written consent.
Conformity with directives and standards
The Speed Draw aligner D20 is designed and manufac-
tured by Car-O-Liner, which is an EN-ISO 9001 accred-
ited development and manufacturing organisation.
The Speed Draw aligner is CE-approved by S.A. Swe-
den. Therefore, it is required that only CE-approved
hydraulic equipment is used with the draw aligner.
Copyright©Car-O-LinerAB,2001

Contents
(138 03 85 231_c, rev. 0), 2001-04, GB/US
Speed Draw aligner D20 Car-O-Liner AB
i
Contents
1 Introduction ......................................1.1
1.1 General .......................................................... 1.1
1.2 Drawaligner ................................................... 1.2
1.3 Marking .......................................................... 1.4
2 Safety ................................................2.1
2.1 General .......................................................... 2.1
2.2 Warnings and important notices ..................... 2.2
2.3 Safety signs.................................................... 2.4
2.3.1 Placement of safety signs ................. 2.5
2.4 Safetydevices ................................................ 2.6
3 Installation........................................3.1
3.1 General .......................................................... 3.1
3.2 Packaging and delivery inspection.................. 3.1
3.3 Fitting ............................................................. 3.2
3.3.1 Fitting the hydraulic cylinder .............. 3.3
3.3.2 Fitting the stop wire ........................... 3.5
3.3.3 Fitting the pneumatic pump ............... 3.6
4 Operation..........................................4.1
4.1 General .......................................................... 4.1
4.2 Fastening the vehicle to the lifting platform ..... 4.2
4.3 Connecting the draw aligner
to the lifting platform ....................................... 4.7
4.4 Handling of the draw aligner ......................... 4.10
4.4.1 Preparations prior to alignment ....... 4.10
4.4.2 Alignment ........................................ 4.10
4.5 Disconnecting the draw aligner
from the lifting platform ................................. 4.12
4.6 Releasing the vehicle
from the lifting platform ................................. 4.13
5 Maintenance .....................................5.1
5.1 General .......................................................... 5.1
5.2 Hydraulics ...................................................... 5.1
5.3 Mechanical ..................................................... 5.1
6 Dismantling and salvage.................6.1
6.1 General .......................................................... 6.1
6.2 Mechanical components................................. 6.1
6.2 Other .............................................................. 6.1
7 Technical specifications..................7.1
8 Spare parts .......................................8.1
8.1 Drawaligner ................................................... 8.2
8.2 Fasteningarm ................................................ 8.4

1 Introduction (138 03 85 231, rev. 0), 2001-04, GB/US
1. 1
Speed Draw aligner D20 Car-O-Liner AB
1 Introduction
1.1 General
The Speed Draw aligner D20 is intended to perform minor alignment work on
the structure of a vehicle that is properly mounted on the Speed Lifting
platform.
The draw aligner makes the alignment work fast and effective. It is easy to
install and use.
The ad ustment possibilities of the draw aligner give it a large range of move-
ment. It can be continuously inclined 120 degrees sideways, and it can
continuously rotate 180 degrees along the circular front of the lifting platform.
WARNING! The draw aligner must only be used with a hydraulic cylinder
with a maximum capacity of 5 tons. Risk of in ury.
IMPORTANT! The draw aligner is CE-approved and requires that only
CE-approved hydraulic equipment is used.

1 Introduction (138 03 85 231, rev. 0), 2001-04, GB/US
1.2
Speed Draw aligner D20Car-O-Liner AB
1.2 Draw aligner
The draw aligner can easily be locked to the lifting platform. During alignment
work, the vehicle must be fastened to the lifting platform according to the
instructions in Section 4.2.
The draw aligner knob [1]
is placed on the draw aligner body [2], see
Figure 1.1. The draw aligner knob is pushed into a rail underneath the lifting
platform. The console [3] is placed on the lifting platform and can be moved
along the circular end of the platform. The draw aligner can be rotated side-
ways, but by using the locking wedge [4], the draw aligner is prevented from
moving along the circular end of the platform. The hydraulic cylinder [5]
allows the draw aligner arm to tilt continuously backwards. The draw aligner
arm [6] can also be continuously inclined 120 degrees sideways to obtain the
optimum pulling angle. A stop wire [7], which limits the outward movement
of the arm, is connected along the cylinder between the draw aligner arm and
the draw aligner body.
The hydraulic cylinder has a capacity of 5 tons and is operated with the help
of a pump [8].

1 Introduction (138 03 85 231, rev. 0), 2001-04, GB/US
1. 3
Speed Draw aligner D20 Car-O-Liner AB
Figure 1.1 The Speed Draw aligner.
Draw aligner knob [1]
Drawalignerbody [2]
Console[3]
Lockingwedge[4]
Hydraulic cylinder [5]
Drawalignerarm[6]
Pump[8]
Nameplate[9]
Stopwire[7]
Locking
device[10]

1 Introduction (138 03 85 231, rev. 0), 2001-04, GB/US
1.4
Speed Draw aligner D20Car-O-Liner AB
1.3 Marking
The name plate is placed on the lower mounting point of the draw aligner
arm. For the exact placement, refer to Figure 1.1, position [9].
Figure 1.2 The name plate.
CElabel
Productnameandtype
Articlenumber
Weight
Manufacturer’sserialnumber
Dateofmanufacture
Yearofmanufacture

2 Safety (138 03 85 231, rev. 0), 2001-04, GB/US
2.1
Speed Draw aligner D20 Car-O-Liner AB
2 Safety
2.1 General
Information given in this manual describes the suggested best working prac-
tices and should in no way take precedence over individual responsibilities or
local regulations.
Great effort has been placed on the design and manufacture of the
Speed Draw aligner D20 so that it will 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 others personal safety.
 The safety of the draw aligner through correct use of the equipment in
accordance with the descriptions and instructions given in this manual.
By observing and following the safety precautions, users of the draw aligner
will ensure safer working conditions for themselves and their fellow workers.
To avoid personal in ury, the following regulations must be observed:
- The draw aligner must only be used with a hydraulic cylinder with a
maximum capacity of 5 tons.
- Check to make sure that the vehicle is securely fastened to the lifting
platform (refer to Section 4.2) and that the vehicle cannot be set in motion
during pulling.
- Make sure that you use a soft headed hammer when hammering the
locking wedge.
- Always wear safety glasses when hammering the locking wedge in or out.
- Check to make sure that there are no ob ects obstructing the movement of
draw aligner.
- Always keep a careful watch on the draw aligner and the vehicle during
alignment.
- Read the manual carefully for installation (refer to Chapter 3), operation
(refer to Chapter 4) and maintenance (refer to Chapter 5).
Various warnings and notices are placed beside the illustrations and important
descriptive texts in this manual. These warnings and notices are important to
ensure the safety of the user and others.
Safety signs must also be in place on the equipment. These are intended to
warn of hazardous situations or to draw attention to incorrect use of the
equipment.

2 Safety (138 03 85 231, rev. 0), 2001-04, GB/US
2.2
Speed Draw aligner D20Car-O-Liner AB
2.2 Warnings and important notices
The following types of safety signs are used on the draw aligner and in the
instruction manual:
Command (blue with white symbol)
Describes a specific responsibility.
Warning! (yellow background, black symbol, black
border). Warns of safety risks.
The following warnings and important notices are used in the instruction
manual:
WARNING! (in bold, italic type) is used in this manual to indicate a
possible danger that could lead to personal in ury. An
instruction is normally given, followed by a short explana-
tion plus the possible effect if the instruction is not fol-
lowed.
IMPORTANT! (in bold, italic type) is used in this manual to indicate
practical information. It is also used to indicate a possible
danger that could lead to damage to the draw aligner or
other equipment and/or cause environmental damage.
Note! (in bold, italic type) is used to accentuate supplementary
information that is required for problem-free use or
optimal use of the draw aligner.
In addition to the safety signs illustrated in Section 2.3, the following warn-
ings and important notices appear in the manual:
WARNING! The draw aligner must only be used with a hydraulic cylinder
with a maximum capacity of 5 tons. Risk of in ury.
WARNING! Make sure that the stop wire is correctly fitted and undamaged.
Otherwise, the draw aligner arm might hit somebody if the hydraulic cylinder
malfunctions.
WARNING! Make sure that the safety wire is correctly fitted and undam-
aged. Otherwise, the pulling chain might cause in uries if it looses its grip on
the vehicle.
WARNING! Watch out for flying ob ects during alignment work. Do not
stand behind or near the draw aligner during a pull. Risk of in ury.

2 Safety (138 03 85 231, rev. 0), 2001-04, GB/US
2.3
Speed Draw aligner D20 Car-O-Liner AB
WARNING! Watch out for tripping on loose hoses. Risk of in ury.
WARNING! Always be extremely careful when working with acks or
hydraulic equipment. Risk of falling or flying ob ects.
WARNING! Do not perform any alignment work if the vehicle is not fas-
tened with the clamps. The draw aligner might overturn the vehicle and cause
in uries.
WARNING! Inspection and maintenance must take place each time the draw
aligner is put to use. Risk of malfunction, which may cause in uries.
WARNING! Before moving the draw aligner, always place the arm in an
upright position. Risk of tripping.
WARNING! Always wear safety glasses when hammering the locking wedge
in or out. Risk of splinters.
WARNING! Make sure that you use a soft headed hammer when hammer-
ing the locking wedge. Risk of splinters.
WARNING! Make sure that the hydraulic hose is undamaged. The working
pressure is approximately 700 bar (10 200 PSI). If the hose springs a leak, the
oil under high pressure can cause in uries and/or damage.
WARNING! Make sure that the draw aligner is correctly secured to the
lifting platform. Risk of in uries.
WARNING! Never leave the draw aligner unattended when it is under
pressure. Risk of in uries.
WARNING! Make sure not to release the locking wedge when performing
alignment. Risk of in uries.
WARNING! Make sure that the lifting pads are placed correctly underneath
the sill flange of the vehicle. Otherwise, Risk of vehicle overturning and
causing in uries.
IMPORTANT! The draw aligner is CE-approved and requires that only CE-
approved hydraulic equipment is used.
IMPORTANT! It is the responsibility of the owner to ensure that the draw
aligner has been installed as specified in the instructions provided. It is also
the owners responsibility to ensure that the draw aligner is inspected in
accordance with current and local regulations before it is used.
IMPORTANT! The draw aligner should not be used for anything other than
alignment work on vehicles.

2 Safety (138 03 85 231, rev. 0), 2001-04, GB/US
2.4
Speed Draw aligner D20Car-O-Liner AB
IMPORTANT! Make sure that the serrated aws are clean and fitted prop-
erly. This ensures the best possible grip on the sill flange.
IMPORTANT! To obtain maximum performance and to avoid damage to
the draw aligner, the pulling chain must run in the same direction as the
hydraulic cylinder.
IMPORTANT! For the sake of the environment, dismantle the equipment in
an environmentally friendly way.
2.3 Safety signs
Undamaged safety signs must always be affixed at the indicated places, refer
to Section 2.3.1. If any signs are damaged or missing, the user is responsible
for their immediate replacement. The safety signs are available as accessories.
The following safety signs can be found on the draw aligner:
Command!
Safety glasses must be worn when hammering in the locking wedge. For
placement, refer to Section 2.3.1. The label has article No. 99791.
max
5 ton
Warning!
The draw aligner is to be equipped with a hydraulic cylinder with a maximum
capacity of 5 tons. For placement, refer to Section 2.3.1. The label has article
No. 99812.
Warning!
Watch out for flying ob ects during aligning work. Do not stand behind or
near the draw aligner during a pull. For placement, refer to Section 2.3.1. The
label has article No. 99789.
Warning!
Risk of tripping due to loose hoses, etc.. For placement, refer to
Section 2.3.1. The label has article No. 99786.

2 Safety (138 03 85 231, rev. 0), 2001-04, GB/US
2.5
Speed Draw aligner D20 Car-O-Liner AB
2.3.1 Placementof safety signs
The safety signs are placed as follows:
max
5 ton
Figure 2.2 Placement o the sa ety signs.

2 Safety (138 03 85 231, rev. 0), 2001-04, GB/US
2.6
Speed Draw aligner D20Car-O-Liner AB
2.4 Safety devices
The stop wire between the draw aligner arm and hydraulic cylinder mounting
prevents the arm from falling too far backwards during movement or if the
pull should come loose.
WARNING! Make sure that the stop wire is correctly fitted and undamaged.
Otherwise, the draw aligner arm might hit somebody if the hydraulic cylinder
malfunctions.
The safety wire must be fastened between the vehicle and the draw clamp.
This wire prevents accidents if the clamp should loose its grip.
WARNING! Make sure that the safety wire is correctly fitted and undam-
aged. Otherwise, the pulling chain might cause in uries if it looses its grip on
the vehicle.
WARNING! Watch out for flying ob ects during aligning work. Do not stand
behind or near the draw aligner during a pull. Risk of in ury.

3 Installation (138 03 85 231, rev. 0), 2001-04, GB/US
3.1
Speed Draw aligner D20 Car-O-Liner AB
3 Installation
3.1 General
The Speed Draw aligner D20 is inspected and checked prior to leaving the
factory to guarantee consistent quality and maximum reliability.
Instructions for installation, with general tips and directions, are provided as
follows.
3.2 Packaging and delivery inspection
Check the delivery against the packing list, consignment note, or other
delivery documentation to verify that everything is included in the correct
quantity. Check the draw aligner carefully to make sure that no damage has
occurred during transport. If any part is damaged or missing, the draw
aligner may not be used until the component is repaired or replaced. Please
contact your supplier.
Remove all packaging material from the draw aligner.

3 Installation (138 03 85 231, rev. 0), 2001-04, GB/US
3.2
Speed Draw aligner D20Car-O-Liner AB
3.3 Fitting
The draw aligner must be fitted as follows:
- Fitting the hydraulic cylinder
- Fitting the stop wire
- Fitting the pneumatic pump
Figure 3.1 Fitting the draw aligner.
Stop wire
Hydraulic cylinder
Pump hose

3 Installation (138 03 85 231, rev. 0), 2001-04, GB/US
3.3
Speed Draw aligner D20 Car-O-Liner AB
3.3.1 Fitting the hydraulic cylinder
1 Place the hydraulic cylinder so that its mounting holes are centered
on the big holes on the mounting flanges.
Note! Make sure that the cylinder is placed so that the piston rod points
downwards.
Figure 3.2 Fitting o the hydraulic cylinder.
WARNING! The draw aligner must only be used with a hydraulic cylinder
with a maximum capacity of 5 tons. Risk of in ury.
Mounting flange
Hydraulic cylinder

3 Installation (138 03 85 231, rev. 0), 2001-04, GB/US
3.4
Speed Draw aligner D20Car-O-Liner AB
2 Place the locking pins so that they run straight through the
cylinder mounting holes and through the big mounting holes on the
draw aligner .
Figure 3.3 Fitting the cylinder with locking pins.
3 Fasten the locking pins by placing one circlip in each track on the
locking pins.
Figure 3.4 Placing the circlip on the locking pins.
Note! There are four tracks on the locking pins. Make sure that all four are
secured with a circlip.
Locking pin
Mounting hole
Circlip

3 Installation (138 03 85 231, rev. 0), 2001-04, GB/US
3.5
Speed Draw aligner D20 Car-O-Liner AB
3.3.2 Fitting the stop wire
Secure the hydraulic cylinder by fitting the stop wire:
1 Fit the stop wire by inserting the screws through the small holes on
the mounting flanges. ock the screws by fasten the nuts.
Figure 3.5 Fitting the stop wire.
Mounting flange
Screw
Nut
Stop wire

3 Installation (138 03 85 231, rev. 0), 2001-04, GB/US
3.6
Speed Draw aligner D20Car-O-Liner AB
3.3.3 Fitting the pneumatic pump
1 Remove the nipple cap from the nipple at the upper side of the
cylinder. Also remove the nozzle cap from the hoses nozzle.
Note! Do not entirely remove the cap from the cylinder and from the
nozzle. The caps should be replaced on the nipple and on the nozzle if the
pump hose is removed.
2 Connect the nozzle to the cylinder nipple.
Figure 3.6 Connecting the pump to the cylinder.
WARNING! Watch out for tripping on loose hoses. Risk of in ury.
Nozzle cap
Nipple Nozzle
Nipple cap

3 Installation (138 03 85 231, rev. 0), 2001-04, GB/US
3.7
Speed Draw aligner D20 Car-O-Liner AB
Releasing the pneumatic pump:
1 Pull back the locking ring to unlock the nozzle from the cylinders
nipple.
2 Remove the nozzle from the nipple.
3 Replace the caps on the nipple and on the hoses nozzle.