Car-O-Liner BenchRack 4200 User manual

(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.
Copyright © Car-O-Liner AB, 2012

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

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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.

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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.

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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.

BenchRack Car-O-Liner Group AB
32163, EN - rev. 5, 2018-04 11
WARNING! Never lift the vehicle with two pillar jacks placed under the
center of gravity of the vehicle. Risk of instability and of crushing injuries.
WARNING! Make sure the cam lock is fully twisted before tightening the
pillar jacks.
IMPORTANT! It is not recommended to use the T48 on top of the drive
on ramps. Risk of falling off from the ramps.
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.
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 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 sill
support must be used.
IMPORTANT! Before first vehicle setup, remove all grease from the milled
surfaces of the bench tracks to prevent the bench mountings from slipping.
IMPORTANT! Do not use abrasives to remove rust from the milled bench
tracks. Use rotating steel brush or similar tool. Risk of material damage.
IMPORTANT! All nuts and bolts shall be cleaned and greased monthly.
IMPORTANT! BenchRack must only be used together with Car-O-Liner
T6XX range Power Unit, see separate Car-O-Liner T6XX range
Instruction Manual.
There is also a 220V 1 phase UL approved Power Unit version available.

Car-O-Liner Group AB BenchRack
12 32163, EN- rev. 5, 2018-04

BenchRack Car-O-Liner Group AB
32163, EN - rev. 5, 2018-04 13
2.3 Safety signs
Undamaged safety signs shall always be affixed at the indicated places (see
section 2.3.1 "Placement of safety signs"). If any signs are damaged or miss-
ing, the user is responsible for their immediate replacement. The following
safety signs can be found 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 SIGNS
The sign must be placed in the vicinity of the lift/bench and in such a way
that it can be seen clearly by the operator.
!

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.
!

BenchRack Car-O-Liner Group AB
32163, EN - rev. 5, 2018-04 15
2.4 Safety devices
The lift cylinder is a single-acting hydraulic cylinder with fixed flow regula-
tor [1]. This flow regulator ensures that the 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

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16 32163, EN- rev. 5, 2018-04

BenchRack Car-O-Liner Group AB
32163, EN - rev. 5, 2018-04 17
3 Installation
3.1 General
3.2 BenchRack with lift
The bench frame is made up of welded square section. The top face is milled
and equipped with tracks for fitting bench mountings and pulling compo-
nents.
The sides are also equipped with tracks for fitting side ramps and the draw
aligner.
On the underside are legs upon which the bench frame rests in its lowest po-
sition as well as bench supports for the draw aligner position.
The side ramps are suspended 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 and nuts as
shown.
3Side ramps that may be fitted between ramp types 1 and 2.
NOTE! A wider ramp is available for ramp models 1-3.
The ramps may be removed as necessary to facilitate access during
measurement and alignment work.
WARNING! Maximum load per ramp = 1000 kg.
BR 5500
BR 6300
BR 4200
BR 5000
1
2
3
1
2
3
1
3
2

Car-O-Liner Group AB BenchRack
18 32163, EN- rev. 5, 2018-04
3.2.1 Drive-on ramps
The drive-on ramps are attached to the brackets on the end of the bench and
to the two side ramp brackets.
The drive-on ramps may remain in place while the bench is raised or
lowered, but can be removed if necessary.
NOTE! The vehicle must be firmly attached to the bench frame!
The drive-on ramps also act as 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 lift.
1 Applies to BR5500 and BR6300
2Applies to BR4200 and BR5000
WARNING! The drive-off stops should always be correctly fitted to the
bench. Risk of improper weight distribution.
1
2

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3.2.3 Bench support for draw aligner height
The enclosed bench supports are fitted as shown in the illustration. The other
bench supports are fitted to the underside of the bench. When the bench is
raised from floor level, the supports are 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 fitted so that it always drops
down of its own weight and does not jam. Risk of crushing injuries.

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3.2.5 Loading trolley/Roll stop B57
The loading trolley is designed to be placed under a damaged (locked)
wheel, thus allowing the vehicle to be winched on to the bench.
By turning the loading trolley upside down so that it does not roll freely, it
may be used as a roll stop. This stop must be placed under an undamaged
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.)
3.2.7 Cam locks B626
Used for fitting bench mountings, track plates, etc.
3.2.8 Pillar jack B633
Fitted to the bench tracks. Used to lift a vehicle when setting up on the
bench.