Car-O-Liner Quick 42 User manual

(40724, rev 8) 2017-09 EN
Quick 42
The multifaceted bench repair system
Instruction Manual

Car-O-Liner Group AB Quick 42
240724, EN- rev. 8, 2017-09
Foreword
This equipment is used to facilitate high quality repairs
to collision-damaged vehicles. All other use of the
equipment, or use that is contrary to the instructions 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 equipment
or its use in a manner not intended. Save for product
liability claims for loss or damages as a result of per-
sonal 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 legisla-
tion 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 special,
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 regulations.
The equipment has not been altered or rebuilt with-
out 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 tech-
nician.
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
guarantee 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, ad-
justments 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 over-
all experience with your new Car-O-Liner product. Any
revisions 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 in-
tended only to be illustrative and do not necessarily
show the design of the equipment available on the mar-
ket at any given time. The equipment is intended for use
in accordance with current trade practice, applicable
laws and 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 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

Quick 42 Car-O-Liner Group AB
40724, EN - rev. 8, 2017-09 3
This Quick 42 Instruction Manual describes two different Power Unit versions,
henceforward reffered to as "Type 1" and "Type 2" in this Instruction Manual.
Type 1 Power unit
For identification of Type 1, see design and name
plate. Serial no. beginning with 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 identification of Type 2, see design and name plate.
Serial no.beginns with Q611 followed by manufacturing
year and a serial number.
For more extensive information, see section 3.3.8 Type 2
Power unit.
Type 1 exterior
Type 1 interior
Name plate
Type 2 exterior
Type 2 interior
!
!
Name plate
(up to serial no.
Q61116064)

Car-O-Liner Group AB Quick 42
440724, EN- rev. 8, 2017-09
This Quick 42 Instruction Manual describes two different Pendant station
versions, henceforward reffered 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 station.
Type 2 Pendant station
For identification of Type 2, see design and
control panel. For more extensive information,
see section 3.1.14 Type 2 Pendant station.

Quick 42 Car-O-Liner Group AB
40724, EN - rev. 8, 2017-09 5
Conformity with directives and standards
The Quick 42 bench 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 Quick 42 is outlined.
A signed and dated copy of the EC Declaration of Conformity, including serial number, is included in
the documentation for the Quick 42. Please contact your distributor if you need a new copy of the
Declaration of Conformity.

Car-O-Liner Group AB Quick 42
640724, EN- rev. 8, 2017-09
Contents
1Introduction.....................................................................9
1.1General .................................................................................................9
1.2Marking ...............................................................................................10
2Safety .............................................................................11
2.1General ...............................................................................................11
2.2Warnings and important notices .........................................................11
2.3Safety signs.........................................................................................16
2.3.1Placement of safety signs....................................................18
2.4Safety devices.....................................................................................20
3Installation.....................................................................21
3.1 Connection of electrical and air supply..........................................21
3.2 Bleeding of the hydraulic system ...................................................22
3.2Quick 42 With Lift................................................................................23
3.2.1Drive-on Ramps...................................................................23
3.2.2 Roll-off stops.......................................................................24
3.2.3Bench Supports For Draw Aligner Height ...........................24
3.2.4Crush Guard........................................................................25
3.2.5 Loading Trolley/Roll Stop B57 (Optional)............................25
3.2.6 Bench Mounting...................................................................25
3.2.7Cam Locks B626 .................................................................25
3.2.8Hydraulic Jacks Q170, 2 pcs...............................................26
3.2.9 Chassis Clamp B106...........................................................26
3.2.10Sill Support B23...................................................................26
3.3Lift and Power unit ..............................................................................27
3.3.1Applications .........................................................................27
3.3.2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 AC, single-phase for Type 1
Power unit...........................................................................................30
3.3.7Electrical diagram for 110V AC (single-phase) and 230/400V
AC (3-phase) (for 24V low voltage circuit) for Type 1 Power
unit 31
3.3.8Type 2 Power unit................................................................32
3.3.9Type 2 Power unit - Electrical supply..................................33
3.3.10Electrical diagram for 230/400V AC, 3-phase for Type 2
Power unit...........................................................................................33
3.3.11Connection of motor block, 230/400V ................................34
3.3.12Electrical diagram for 24V low voltage circuit......................34
3.3.13Type 1 Pendant station........................................................35
3.3.14Type 2 Pendant station........................................................35
3.4 Installation of pendant station cable for type 2 power unit.............36
3.5Hydraulics ...........................................................................................38
3.5.1Hydraulic diagram, 110V for Type 1 Power unit..................38
3.5.2Hydraulic diagram, 230/400V for Type 1 Power unit...........39
3.5.3Hydraulic diagram, 230/400V for Type 2 Power unit...........40

Quick 42 Car-O-Liner Group AB
40724, EN - rev. 8, 2017-09 7
3.6 Draw aligner Q16................................................................................41
3.6.1 Preparations before starting alignment...............................42
3.7Transport and inspection of delivery...................................................42
3.7.1Transport Protection............................................................43
3.7.2Mains Connections Check...................................................43
3.8Space requirements............................................................................43
3.8.1Anchoring to the floor..........................................................46
4Operation....................................................................... 47
4.1General...............................................................................................47
4.2Operating the lift .................................................................................48
4.2.1Raising the bench, Type 1 pendant station.........................48
4.2.2Lowering the bench, Type 1 pendant station......................48
4.2.3Tilting the bench, Type 1 pendant station...........................49
4.2.4Raising the bench, Type 2 pendant station.........................50
4.2.5Lowering the bench, Type 2 pendant station......................51
4.2.6Tilting the bench, Type 2 pendant station...........................51
4.3Measuring system...............................................................................52
4.4Ramp support and Side ramps...........................................................53
4.5 Connect the Q16 to the benchframe ..................................................56
4.5.1Positioning and linking the draw 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 Quick setup..................................................................66
4.8Set up of a vehicle without front or rear sub frame.............................68
4.9Q16 Draw aligner................................................................................69
4.9.1Pulling a side damage when two fixing points are used .....69
4.9.2Pulling straight forward when two fixing points are used....70
4.9.3Offset pulling when two fixing points are used....................70
4.10Useful when working with the vehicle.................................................71
4.10.1Compressed air...................................................................71
4.10.2Hand tools ...........................................................................71
4.10.3Width extension possibility..................................................71
5Mobile unit..................................................................... 73
5.1General...............................................................................................73
5.2Installation of transport wheels, using trolley jack ..............................73
5.3Installation of transport wheels, using hydraulic jacks........................75
5.4 Safety..................................................................................................77
5.4.1Two Q16 on the same bench side on an empty unbolted
bench 77
6Service and Maintenance............................................. 79
6.1General warnings................................................................................79
6.2Bench inspection and service plan.....................................................80
6.3Draw aligner inspection and service plan...........................................81

Car-O-Liner Group AB Quick 42
840724, EN- rev. 8, 2017-09
7Troubleshooting............................................................82
7.1General ...............................................................................................82
7.2Problem: The lift can not be raised.....................................................82
7.3Problem: The lift drops........................................................................83
7.4Problem: The lift cannot be lowered ...................................................83
7.5 Emergency lowering of the lift, earlier design of SDV 1 valve ................84
7.6 Emergency lowering of the lift, later design of SDV 1 valve ...................88
8Dismantling and Salvage..............................................92
8.1Mechanical Components ....................................................................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 400/440V................................................99
10.2.3Type 1 Pump unit 110V.....................................................100
10.2.4Type 1 Upper manifold......................................................101
10.2.5Type 1 Electrical components ...........................................102
10.3 Type 2 Power unit – summary ..........................................................103
10.3.1Type 2 Pendant station......................................................105
10.3.2Type 2 Pump unit 400V.....................................................106
10.3.3Type 2 Upper manifold......................................................107
Type 2 Upper manifold (from serial no 61117065, see nameplate!) 108
10.3.4Type 2 Electrical components ...........................................109
10.4 Draw aligner Q16 ..............................................................................110
10.5 Ramps...............................................................................................111

Quick 42 Car-O-Liner Group AB
40724, EN - rev. 8, 2017-09 9
1 Introduction
1.1 General
Quick 42 is used for vehicle alignment and has mobility, automatic tilt,
pulling power integrated and a variably adjusted scissors lift which can raise
the bench frame to the maximum working height of 1 480 mm (58 in).
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 3 000 kg (6 600 lbs)
Maximum static load per ramp section is 1 000 kg (2 200 lbs).
The entire vehicle must be positioned on the bench when carrying out
alignment work. The lift and bench frame may not be used to lift one end of
the vehicle while the other end remains on the floor. Moreover, the lift’s
working platform may not be used for anything other than vehicle repair.

Car-O-Liner Group AB Quick 42
10 40724, EN- rev. 8, 2017-09
1.2 Marking
The 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 location up to serial no. Q6116064, see page 3.)
Figure 1.3 The Q605 name plate.

Quick 42 Car-O-Liner Group AB
40724, EN - rev. 8, 2017-09 11
2 Safety
2.1 General
Quick 42 has been designed and tested to meet strict safety requirements.
Please read the following instructions carefully before operating Quick 42
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 Quick 42 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 Quick 42 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 Quick 42 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.

Car-O-Liner Group AB Quick 42
12 40724, EN- rev. 8, 2017-09
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! The draw aligner is meant to be equipped with a hydraulic
cylinder with a maximum capacity of 10 tons (300 bar).
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 two locking pegs in the front of the draw aligner must be
pressed in completely.
WARNING! Always use safety glasses when hammering the draw aligner
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.

Quick 42 Car-O-Liner Group AB
40724, EN - rev. 8, 2017-09 13
WARNING! Before moving the draw aligner, always lock the arm in an
upright position. Risk for tipping.
WARNING! Ensure that the rear crush guard is fitted so that it always drops
down of its own weight and does not jam. Risk of crushing injuries.
WARNING! Maximum static load per ramp = 1 000 kg (2 200 lbs).
WARNING! Maximum static load per hydraulic jack = 900 kg (2 000 lbs).
WARNING! The drive-off stops should always be correctly fitted to the
bench. Risk of driving off the bench and cause improper weight distribution.
WARNING! All work on the electrical equipment must be carried out by
qualified personnel.
WARNING! Minimum allowed distance between 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 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
hose and electrical cable. Risk of tripping.
WARNING! During setup of the vehicle on the bench, care must be
exercised so that the vehicle does not roll or slide out of the hydraulic jacks
or bench mountings. Risk of crushing injuries.
WARNING! When other personnel are in the vicinity exercise care when
operating the lift. Risk of crushing injuries.
WARNING! Ensure that the bench supports hang straight down. Risk of
injury.
WARNING! Before raising or lowering the lift, ensure that no-one is near
the bench. Risk of crushing injuries.

Car-O-Liner Group AB Quick 42
14 40724, EN- rev. 8, 2017-09
WARNING! Observe high standards of cleanliness when working with the
hydraulic system. Dirt in the hydraulic oil can cause operating problems.
WARNING! Never drive the car onto the bench with the lift in raised
position. Risk for vehicle overturning which may cause injuires.
WARNING! The vehicle must be firmly attached to the bench frame before
the run up ramps are dismounted.
WARNING! Always be extremely careful when working with jacks or
hydraulic equipment. Risk for falling or flying objects.
WARNING! Make sure to lift on a safe lifting point, so that the vehicle
doesn’t slide during the 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 for electric shock.
WARNING! Forbidden to use the T48 on top of the drive on ramps. Risk
of falling off from the ramps.
WARNING! Maximum one ramp support can be added on the other. Risk
of crushing injuries.
WARNING! The floor underneath the bench with wheels must be level.
Always set the wheel brakes. Risk of unintentional rolling.
WARNING: Risk of rolling bench. The wheel assemblies shall be locked
after the bench has been moved.
WARNING! Always lift vehicle with hydraulic jacks on both sides of the
vehicle. Risk of personal injuries and material damage.
WARNING! Make sure that the holding arm cam locks are tightened in 90°
angle to the bench tracks.

Quick 42 Car-O-Liner Group AB
40724, EN - rev. 8, 2017-09 15
WARNING! Maximum hydraulic jack lifting capacity t is 900 kg (2000
lbs). Risk of personal injuries and material damage.
IMPORTANT! Exercise care when transporting Quick 42.
IMPORTANT! When an air 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.
IMPORTANT! Transport protection must be used whenever the equipment
is moved.
IMPORTANT! Ensure that the toothed segments are clean and fitted
correctly.
IMPORTANT! If there is any uncertainty about the quality of the floor,
contact a 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 the lift is put into use.
IMPORTANT! To obtain maximum performance and to avoid damage to
the draw aligner, the chain must run parallel to the hydraulic cylinder.
IMPORTANT! When using the draw aligner, remember to protect the
measuring system from the damaged area to avoid damage to the measuring
system.
IMPORTANT! Remove transport protection before the lift is put in use;
otherwise damage can occur.
IMPORTANT! For the sake of the environment, it is important that the
equipment is dismantled in an environmentally friendly way.
WARNING! Maximum height when using ramps as standing platform
is 1 meter.

Car-O-Liner Group AB Quick 42
16 40724, EN- rev. 8, 2017-09
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
The highest allowed vehicle weight is 3 000 kg (6 600 lbs).
WARNING
Minimum allowed distance 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 unit in the raised position,
the lift unit must be blocked against unintentional lowering.
WARNING
Danger of tripping due to loose hoses, etc.
WARNING
The draw aligner is to be equipped with a hydraulic cylinder with a maxi-
mum capacity 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.
Part No 44307 (kit)
Part No 41642 (kit)
Part No 41642 (kit)
Part No 44307 (kit)
Part No 35721 (kit)
Part No 35721 (kit)
Part No 35721 (kit)

Quick 42 Car-O-Liner Group AB
40724, EN - rev. 8, 2017-09 17
COMMAND
Safety glasses must be used when hammering 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 location (2). Choose your language.
1 2
Part No 35721 (kit)
Part No 35721 (kit)
Part No 44307 (kit)
Part No 40372 (kit)

Car-O-Liner Group AB Quick 42
18 40724, 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
Part No 44307
Part No 44307
Part No 41642

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

Car-O-Liner Group AB Quick 42
20 40724, EN- rev. 8, 2017-09
2.4 Safety devices
The power unit has a built-in relief valve to prevent overloading. The relief
valve shunts the oil back to the tank in case of excessive pressure. The pres-
sure setting is made at the factory and the valve is sealed.
When the hydraulic pump is overloaded, its sound changes 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 other leakage.
To avoid accidental lowering when the under-side of bench frame is higher
than 500 mm (20 in) from the floor, a safety latch prevents the lift from sink-
ing more than a maximum of 100 mm (4 in) in the event of leakage.
Quick 42 have a crush guard to prevent feet from being caught between the
bench and the floor during tilting operations.