Globaljig SYSTEM User manual

SYSTEM
USERS’ MANUAL
Via Aurelia Ovest, Km. 383 - 54100 Massa (MS) - ITALY - Tel.: [phone] - Fax: [phone] - www.globaljig.it
Società unipersonale sotto la direzione e controllo della Bellini Srl. -
Iscritta al Reg. Imprese di Massa Carrara al N° 01064230459
Capitale sociale € 100.000,00 i.v.

SYSTEM
USERS’ MANUAL
Year of Manufacture: .......................

USER’S MANUAL
SYSTEM/VECTOR CONTENTS
1. INTRODUCTION.........................................................5
2. SAFETY......................................................................7
3. TECHNICAL CHARACTERISTICS AND DATA ................9
4. TRANSPORT AND UNPACKING .................................11
5. INSTALLATION ........................................................13
6. START-UP ................................................................17
7. CONTROLS...............................................................19
8. OPERATIONS ...........................................................21
9. MAINTENANCE.........................................................23
10. REPAIRS / SPARE PARTS.........................................25
11. DRAWINGS..............................................................27
12. DEMOLITION ...........................................................35

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 1
1. INTRODUCTION
Globaljig International S.r.l., manufacturer of the SYSTEM bench with
VECTOR arm, invites you to thoroughly read the indications in this manual
to gain familiarity with the information contained herein.
The Manual explains how to use the Machine, and provides instructions and
useful tips to ensure the best possible performance.
The SYSTEM straightening bench with VECTOR arm has been designed and
manufactured to guarantee long life and to ensure safe operations.
The Manual also provides indications on what the User should and should
not do to prevent, or reduce to an absolute minimum, any form of injury.
Read the Safety messages indicated with the symbols below and follow
them to the letter:
ATTENTION Non-compliance with these instructions
can lead to injury.
WARNING Non-compliance with these instructions
can damage the machine.
This Manual is an INTEGRAL PART of the Machine and must be carefully
preserved for the entire life of the machine.
It must be kept complete and intact, as received, and in a safe place
protected from damage. Always consult it without damaging it in any way.
The manual must follow the Machine if it changes ownership.
The Manufacturer cannot be held directly or indirectly responsible for any
injuries or damages pursuant to non-compliance with the instructions
contained in this Manual, improper use of the Machine or any use different
from what is outlined herein.
The present Manual makes reference to the EC MACHINE DIRECTIVE 98/37
and subsequent modifications.
The Manufacturer has made a great effort to ensure that the information
contained in this Manual is complete and precise. Nevertheless, due to the
ongoing evolution in the product, some Machine data may differ from what
is reported here. If precise specifications are required, contact our Customer
Services Department directly.

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 2
2. SAFETY
BEFORE ASSEMBLING AND USING THE MACHINE, READ THIS MANUAL VERY
CAREFULLY.
The machine can only be used by specially trained, authorized personnel.
Never tamper with, or modify, the machine without the Manufacturer’s
authorization. Such acts relieve the Manufacturer of any responsibility for
damages that may ensue.
Tampering with, or modifying, the safety devices is in violation with
European Safety Standards.
The SYSTEM unit can only be used indoors.
It must be installed by Qualified Personnel and in compliance with the
instructions contained in this Manual.
We recommend the use of original accessories.

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 3
3. TECHNICAL CHARACTERISTICS AND DATA
3.1. CHARACTERISTICS
•Name of the Machine: SYSTEM bench with VECTOR arm is the market
name of this Machine, which is a MECHANICAL ARM. The force of this
machine derives from the combined application of a link chain with a
hydraulic cylinder. This cylinder is activated by a manual or pneumatic pump
and transforms the hydraulic pressure into pulling force. The configuration
can be varied, appropriately setting the points where the pulling force is
exerted, modifying both the intensity and direction. This makes it possible to
use this unit on any deformed part of the body of the vehicle that is to be
repaired.
It has three main, mechanically integrated units:
The first consists of a circular notched plate that secures the VECTOR to the
SYSTEM bench.
The second consists of a horizontal body that makes the radial movements
and supports the vertical body.
The third is the vertical body which supports the hydraulic cylinder, the snub
pulley for the chain and the chain itself.
•Operations and Safety
Hydraulic thrust cylinder, driven by a manual or pneumatic pump.
Safety Device to prevent crushing the hand with the lever that
engages/releases radial positioning.
All movements and all operations are operator-controlled.
•Use
The VECTOR unit has been designed and built to be used as the arm that
exerts the force to straighten wrecked motor vehicles. It is to be used in
body shops and can be used on the Benches indicated by the Manufacturer.
Any other use is to be considered improper and, therefore,
unreasonable.
THE MANUFACTURER CANNOT BE HELD RESPONSIBLE FOR DAMAGES
CAUSED BY IMPROPER, ERRONEOUS OR UNREASONABLE USE OF THE
MACHINE.
The noise produced by the machine is always less than 85 dB (A).

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 3
•Machine ID
Brand: Globaljig International S.r.l.
Via Aurelia Ovest, Km 383
54100 Massa - ITALY
The serial number and CE labelling are reported on the label indicated in the
figure below. This label is positioned on the:
- front crossbeam of the SYSTEM bench
- Vector work arm close to the engage/release lever
The identification data are reported on the fixed label secured to the
Machine structure: never remove, alter or damage these labels.
3.2. TECHNICAL DATA for the VECTOR pulling arm
LENGTH:........................................................2.15 m
WIDTH:............................................................1.0 m
HEIGHT: ........................................................1.77 m
WEIGHT:...................................................... 330 daN
PULLING FORCE:.............................................. 5/10 t
HYDRAULIC CYLINDER STROKE:...................... 200 mm
MAX. OPERATING PRESSURE: .......................... 600 bar

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 4
4. TRANSPORT AND UNPACKING
4.1. TRANSPORT DATA TABLE
WEIGHT [kg]
POS. CODE DESCRIPTION OF PACKAGE Qty NET GROSS
01 E428 VECTOR CRATE 1 330 400
02 G101 SYSTEM PALLET 1
All packages and packaging must be loaded, unloaded, and handled using
appropriate procedures and equipment as outlined in current Safety
standards.
The personnel performing these operations must wear the necessary
personal protective equipment.
Globaljig International S.r.l. declines any responsibility for injury and/or
damage caused by neglecting to take suitable precautions and by non-
compliance with the procedures and standards regarding transport.
4.2. CHECKING THE PACKAGE
When checking the goods delivered, be sure that:
The package is not dented or broken and shows no signs of dampness or
water. This must be done in the presence of the person making the delivery.
Take a good look at the package since the Manufacturer cannot be
held responsible for any damage to the equipment derived from
shipping.
Globaljig International S.r.l. guarantees the suitability of the materials used
in its packaging and the best procedure for setting the goods in these
packages.
Depending on the supply conditions, the goods always travel at the
customer’s risk unless otherwise agreed upon at the order confirmation
stage.

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 5
5. INSTALLATION
5.1. Bench SYSTEM on wheels
Each operation of assembling, disassembling and substitution of wheels
and/or crossbeam of wheel supports must be done without any vehicle on
bench.
In case of equipments present these must be fixed in manner that they
cannot move in any direction.
The lifting bracket B4525 (see page 33 of this manual) must be used
exclusively when the bench is unloaded.
In case of urgent and immediate intervention use a hydraulic jack (of
adequate lifting capacity) directly on the lower profile of the bench paying
attention and applying always the elementary rules of security.
MAXIMUM WEIGHT CAPACITY OF THE BENCH SYSTEM ON WHEELS Kg 3100.
5.2. HANDLING the SYSTEM bench and VECTOR arm (see page 19)
Once the work area has been selected, move the package into position with
a forklift or lift truck.
The package containing the “VECTOR” appears as indicated in
(Fig. 05-01)

The SYSTEM and VECTOR must be installed by Qualified Personnel carefully
following the instructions given in this Manual.

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 5
5.3. UNPACKING
Remove the lid and open one side of the crate. Withdraw all the wooden
parts used to lock the unit in place during shipping. Withdraw the vertical
body and then push out the horizontal body on its own wheels.
WARNING
Be very careful when performing this operation.
Make certain that the wheels do not bang against
the floor when the unit is removed from the crate
as they could break.
List of the components contained in the package (Fig. 05 - 02) 
-A horizontal body with tool-holding
pocket.
-A vertical body complete with snub
pulley chain.
-Upper connection and lower fork
connection for application of the
hydraulic cylinder.
-A 36 mm. combo hexagonal wrench
(to secure the VECTOR to the
Bench).

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 5
5.4. ASSEMBLY
The horizontal body is delivered
preassembled. At this point the tool-
holder must be installed by simply
inserting it as indicated in fig. 05 - 02.
Then remove the large half ring from its
housing and install the vertical body on
the flange.
Then install the large half ring as shown
in fig. 05 - 03 
and tighten all screws.
(fig. 05 - 04).

Edit. 01/95 Page 08
ATTENTION
Before starting up the Vector, to prevent risks for
yourself and the tool, make certain that all the
screws on the two half rings have been
thoroughly tightened.

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 5
5.5. ASSEMBLY OF THE HYDRAULIC CYLINDER
The components involved are shown in
fig. 05 - 05 
1) Male connection
2) Hydraulic cylinder
3) Female connection with fork
Insert the male connection in its position as shown in
fig. 05 - 05 and lock it in place with its plug.
Secure the plug with the Safety ring.
Screw down the hydraulic cylinder all the way and
leave the hydraulic connection positioned to the side
as shown in fig. 05 - 06. 
Tighten the fork connection all the way.
Insert the pump hose into the connection on the
hydraulic cylinder and tighten the ring nut all the
way.
Fig. 05 - 07.
THE VECTOR IS NOW READY
FOR START-UP.

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 6
6. START-UP
6.1. COUPLING TO THE BENCH
The vector can be inserted and
secured to the Bench from both the
front and side.
The vector is pushed in from the
front, rolling on the three wheels,
until it enters the profile of the
Bench and is flush with the two
pins as shown in fig. 06 - 01
Then the two side brackets are
locked in place one at a time and the
nuts are tightened all the way with
the 36 mm wrench as shown in fig.
06 - 02. 
To insert the vector from the side,
one of the brackets and its screws
must be removed so that the
notched wheel can pass under the
Bench.
(fig. 06 - 03).
Push the Vector under the Bench
until it is flush with the other
bracket which was not removed
(fig. 06-04) 
Then, on the opposite side, install the
two screws with their springs and the
bracket which was previously removed.
Tighten the nuts on the brackets all the
way.
(fig. 06 - 05).

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 7
7. CONTROLS
7.1. POSITIONING THE VECTOR
The manual engage/disengage
lever on the horizontal body inside
the notched plate is used to secure
the Vector in the best position for
pulling.
Positioning is then performed by
moving the lever as shown in
fig. 07 - 01. 
Lever up: the Vector can be set in the best pulling position, pushing the
vertical body by hand as shown in fig. 07 - 02. 
7.2. OPERATING THE HYDRAULIC CYLINDER
The device that controls the hydraulic cylinder is made up of either a manual
or a pneumatic pump.
In both cases, the controls let the Operator move and operate from a Safe
position.

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 7
7.3. APPLYING THE PULLING CHAIN
One end of the 3-meter-long, high resistance steel link chain is free while
the other end is fit with a pulling hook.
7.4. DIRECT PULLING
Connect the pulling hook to the terminal secured
to the body, insert the free end over the snub
pulley located inside the vertical body,
positioning it on one of the holes present (the
position of the snub pulley determines the
pulling direction height). (fig. 07 - 03). 
Lower the end of the
chain until the snub
pulley is set in the fork
connection. Then pull
it until it engages the
position that has
been arranged for it
(fig. 07 - 04).
fig. 07 - 05
Depending on the desired
pulling direction, the chain runs
as indicated in fig. 07 - 05 or
fig. 07 - 06.


USER’S MANUAL
SYSTEM/VECTOR CHAPTER 8
8. OPERATIONS
8.1. WARNINGS
Once the installation (see Chap. 05) and start-up (see Chap. 06) procedures
have been completed, the Vector is ready. It does not require any specific
calibration.
However, remember, no equipment is risk-free during operations. Therefore,
always apply the following precautions:
⇒Before using the Vector check that all bolts securing it to the Bench and
securing the half rings are fully tightened.
⇒Check that the engage/release lever is in the horizontal position
(locked).
⇒Check that the chain, running from the Hook Connection, is fully
aligned and there are no loops.
⇒Make certain that the pulley pins and hydraulic cylinder connections are
fully secured with the supplied Safety rings.
8.2. OPERATIONS
Starting conditions: vehicle to be repaired secured to the Bench following
the indications in the GLOBALJIG data sheet.
•Determine what part of the body needs to be straightened.
•Position the Vector on the SYSTEM Bench following the instructions in
Chapter 06. Then arrange it to achieve the correct pulling direction by
correctly positioning the snub pulley–chain on the axial wheels of the
vertical arm and on the radial rotation of the horizontal body.
•Body side: connect the chain Hook to the terminal secured to the body
sheet.
•Vector side: pull and stretch the chain until the free end of the chain
engages the arranged hooking site.
•Start up the manual or pneumatic pump that drives the hydraulic cylinder
so the Vector can apply the pulling force.

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 9
9. MAINTENANCE
Scheduled maintenance is limited to general cleaning of the Vector at the
end of the work shift and after vehicle repair cycle.
Maintenance of the hydraulic pump must only be performed by
Qualified Personnel following the instructions given in the User’s
Manual supplied with the pump itself.
9.1. CHECKS AND MAINTENANCE OPERATIONS
The notched plate and the Bench securing bracket must be kept free of dust
and dirt, oil deposits and any other form of dirt that may fall from the
vehicle being repaired.
The operations required for the hydraulic cylinder are limited to a periodic
“visual” check for any oil leaks. A dry unit, free of any traces of oil indicates
that the hydraulic circuit is tight. Check and if necessary tighten the
connections.
WARNING For general cleaning operations, do not use water, gasoline or flammable liquids. Use rags or paper
and possibly jets of dry, compressed air.
PERIODICALLY CHECK THE SCREWS ON THE HALF RINGS FOR TIGHTNESS.

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 10
10. REPAIRS / SPARE PARTS
10.1. REPAIRS
A breakdown of the hydraulic system may depend on a pump or cylinder
malfunction.
To determine the cause of the defect, include all components in the
troubleshooting procedure. Do not remove the components. Contact an
Authorized Service Centre for assistance.
10.2. SPARE PARTS
The drawing in CHAPTER 11 shows the mechanical parts that make up the
VECTOR unit.
Please note that it is not possible to supply all the parts in the blowup and,
specifically, all the structural components. If problems arise in these parts,
the Manufacturer reserves the right to make a detailed examination at its
own facilities or at one of the shops in its technical services network.
Globaljig International S.r.l. is at your complete disposal for any
clarification you may require regarding parts to ensure that your Machine
keeps running perfectly.
The hydraulic parts are supplied after the Manufacturer has adequately
examined the technical reason for the problem.
WARNING The supply and technical services are always performed through Authorized, Qualified Retailers.
Contact your dealer for spare parts and repairs.
•The Manufacturer cannot be held responsible for injury or damages
pursuant to repairs performed outside its own Site or by Personnel which
are not part of its own organization.

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 11
11. DRAWINGS
11.1. VECTOR WORKING ARM DIMENSIONS

USER’S MANUAL
SYSTEM/VECTOR CHAPTER 11
11.2. SYSTEM BENCH WORK AREA AND DIMENSIONS
MODEL A B C D E F
SYSTEM (4 m.) 500 585 1630 4020 6700 3340
SYSTEM (5 m.) 500 585 1630 5020 7700 3340