1999-01

GB
System

BenchRack 4200 4700 5000 5500 5500L

Instruction Manual

-approved

CAR-O-LINER AB
Box 7
S-736 21 KUNGSÖR
SWEDEN

Tel: Int. + 46 227 412 00

Fax: Int. + 46 227 319 00
e-mail info@car-o-liner.se
Internet: www.car-o-liner.se
1330110235
 BenchRack
Foreword CAR-O-LINER

Congratulations on your purchase of the CAR-O-LINER BenchRack system.

There are four different base frame lengths, with designations corresponding
to those lengths.
BR4200, BR4700, BR5000 and BR5500 all may be tilted in the lowest posi-
tion. The longest frame also comes in a non-tilting version, BR5500L.
The system is suitable for most private cars and light commercial vehicles.
The ramp system allows the vehicle to be secured to the bench quickly and
easily.
The bench racks are equipped with built-in hydraulic lifts as standard, making
it possible to quickly obtain a suitable working height for the repair in hand.
The equipment is approved for CE marking by SIS SAQ Certifying AB.
This Instruction Manual contains a description of the equipment as well as
directives for installation, operation and maintenance.
IMPORTANT! Incorrect operation can result in personal injury and/or
damage to equipment or vehicles. Read the instructions carefully and
familiarise yourself with the equipment before beginning any repair
work.
Unless otherwise noted, these instructions apply to all BenchRack models.

GB/1999-01 Foreword 2
 Contents BenchRack
CAR-O-LINER

Page number:
Foreword ----------------------------------------------------------------------- 2
Guarantee --------------------------------------------------------------------- 5
Safety Considerations ------------------------------------------------------- 6
General ...................................................................................... 6
“Warning“ and “Important“ ......................................................... 6
Safety -------------------------------------------------------------------------- 7
Safety Signs .............................................................................. 7
Positioning of the Safety Signs ................................................. 12
BenchRack – General ------------------------------------------------------ 13
Applications .............................................................................. 13
BenchRack With Lift ................................................................. 14
Side Ramps .............................................................................. 14
System Parts ----------------------------------------------------------------- 15
Drive-on Ramps ........................................................................ 15
Drive-off Stops B44 .................................................................. 15
Bench Support For Draw Aligner Height .................................... 16
Crush Guard B58 ...................................................................... 16
Roll Stop B57 ........................................................................... 17
Loading Trolley .......................................................................... 17
Bench Mounting ........................................................................ 17
Track Plate B66-9 ..................................................................... 18
Clamp Bracket Pillar B627 ........................................................ 18
Clamp Bracket Pillar B628 ........................................................ 18
Holder B629 .............................................................................. 18
Angle Arm B630 ....................................................................... 18
Chain Holder B631 .................................................................... 19
Cam Locks B626 ...................................................................... 19
Pillar Jack B632 ....................................................................... 19
Adjustable Clamp B620 ............................................................ 19
Clamp Bracket Pillar Extension B621 ....................................... 20
Angle Arm B66-2 ...................................................................... 20
Cylinder Mounting B63-18 ......................................................... 20
Component Trolley B90 ............................................................. 20
Chassis Clamp B106 ................................................................ 21
Sill Support B23 ....................................................................... 21
Spare Parts .............................................................................. 21
Lift ----------------------------------------------------------------------------- 22
Applications .............................................................................. 22
Lift Unit ..................................................................................... 23
Drive Unit .................................................................................. 24
Rating Plate .............................................................................. 25
Setting Up the Vehicle ------------------------------------------------------ 26
General ..................................................................................... 26
Set-up With the Pillar Lift
BR 4200, 4700, 5000, 5500 ....................................................... 27
Set-up With the Pillar Lift
BR 5500L .................................................................................. 27
Driving On To BenchRack
4200, 4700, 5000, 5500 ............................................................ 27
Driving On To BenchRack 5500L (non-tilting) ............................. 27
Setting Up With Chassis Clamps .............................................. 30
Bench Mounting ........................................................................ 31
Anchoring Using Chains ............................................................ 32

GB/1999-01 Contents 3
 BenchRack
CAR-O-LINER

Operation --------------------------------------------------------------------- 33
Safety Regulations ................................................................... 33
Operating the Lift ...................................................................... 34
Tilting the Bench ....................................................................... 35
Emergency Lowering ------------------------------------------------------- 36
Safety Equipment ----------------------------------------------------------- 37
Functions .................................................................................. 37
Maintenance ----------------------------------------------------------------- 38
Check List ................................................................................ 39
Recommended Types of Oil ...................................................... 39
General Warnings ...................................................................... 40
Electrical Equipment -------------------------------------------------------- 41
General ..................................................................................... 41
Electrical Installation ................................................................ 42
Circuit Diagrams ....................................................................... 43
Hydraulics Diagram -------------------------------------------------------- 46
Transport --------------------------------------------------------------------- 47
Inspection On Delivery ---------------------------------------------------- 48
Transport Protection .................................................................. 48
Mains Connections Check ........................................................ 48
Installation ------------------------------------------------------------------- 49
Installation In Premises, General .............................................. 49
Installation, Fitting .................................................................... 50
Bolting To the Floor ................................................................... 53
Troubleshooting ------------------------------------------------------------- 54
1. Problem: The lift cannot be raised ......................................... 54
2. Problem: The lift cannot be raised (cont’d.) ............................ 55
3. Problem: The lift drops .......................................................... 56
4. Problem: The lift cannot be lowered ....................................... 57
Dismantling / Salvage ------------------------------------------------------ 58
Mechanical Components ........................................................... 58
Other Components .................................................................... 58
Technical Specifications ---------------------------------------------------- 59
Appendix 1, Inspection Report ------------------------------------------- 60

GB/1999-01 Contents 4
 BenchRack
Guarantee CAR-O-LINER

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.

- maximum vehicle weight of 3200 kg has not been

exceeded.

- genuine CAR-O-LINER spare parts are used in any

repairs.

- operation and reasonable and necessary maintenance

has been carried out according to the instructions in this
manual.

The photographs and drawings in this instruction manual are solely

illustrative and do not necessarily show design of the equipment on the
market at any given time. The equipment is intended to be used accor-
ding to established trade practices, with observation of the appropriate
safety regulations. The equipment illustrated in the manual may be
changed without prior notice.

GB/1999-01 Guarantee 5
Safety Considerations
CAR-O-LINER

General Warnings and important notices have been inserted next to

illustrations and texts in this manual
Safety signs shall also be affixed to the equipment. These
are intended to warn of hazards in the operation of the equip-
ment or to point out improper use of the equipment. See
page 12.
By observing these safety directives, the user can help to
create a safer working environment for himself and those
around him.

"Warning!" and "Important" A text in italics with the heading “WARNING!“ indicates that
you may cause injury to yourself or others if you do not follow
the instructions. When you see the warning sign, follow the
safety instructions to avoid injury.
A text in italics with the heading “IMPORTANT“ contains
prac-tical information or indicates that the equipment may be
da-maged if the instructions are not followed.

GB/1999-01 Safety Considerations 6

Safety CAR-O-LINER

Safety signs

Red with a white background, black symbol.

Prohibited - Prohibits actions that can cause damage or injury.

Blue with white symbol.

Directive - Prescribes a specific obligation.

Yellow with a black symbol.

Warning - Warning for danger.

Undamaged safety signs must always be in place in their de-

signated positions (see page 12).

If signs are damaged or go missing, they should be replaced

immediately by the owner/user. Signs may be ordered through
the supplier.

GB/1999-01 Safety 7
 CAR-O-LINER

Prohibited for personnel to be on the lift while it is in

movement.

VISUEL

Part. no. 99790

Warning. The maximum permitted vehicle weight is 3200 kg

and the minimum distance between axles at maximum
weight is 2500 mm.

Part. no. 99797

! Warning. During all service and fitting work, the lift must be
blocked up while in the raised position to prevent accidental
lowering.

Part. no. 99794

Warning. Risk of tripping, lose hoses etc.

Part. no. 99786

GB/1999-01 Safety 8
 CAR-O-LINER

Tilting Operation Decal

This sign does not apply to BenchRack 5500L

Part. no. 99776

GB/1999-01 Safety 9
 CAR-O-LINER

This collective safety sign should be set up in a clearly visible

position close to the alignment area.

WARNING
TO AVOID INJURY
n Read the instruction manual
n Get to know the equipment
n Keep safety equipment readily available and in
good condition.
n Ensure that no-one is in the way when you operate
the draw aligner or lift.
n Do not leave the draw aligner under pressure when
it is unattended.
n Always secure the designated safety line to the pull
chain when the draw aligner is used.
n Never stand behind the draw aligner when in use.
n Ensure that all chassis clamps are in good condi-
tion and that the toothed jaws are correctly fitted.
n Ensure that the clamping areas on the vehicle are
clean and do not contain body filler.
n Ensure the hydraulic cylinder has been bled.
n Make sure the draw aligner is correctly attached to
the bench.
n Only use CAR-O-LINER original spare parts.
n Check that the chain to be used is undamaged and
that it is intended for a 10 ton pulling force.
Part. no. 99706

GB/1999-01 Safety 10
 CAR-O-LINER

This safety sign should be placed on the pump unit (see page 12).

WARNING
TO AVOID PERSONAL INJURY:
n Read the Instruction Manual carefully
n Ensure that the lift is stable and is anchored
in accordance with this Instruction Manual
and with applicable regulations.
n Check that there are no obstacles in the path
of the lift.
n Check that the vehicle is correct positioned
on the lift and that it cannot move when the
lift is moving.
n The lift and its load must be under supervi-
sion when operated.
n Ensure that no-one is in the vicinity of the lift
during operations.
n For service instructions and trouble shooting
read the Instruction Manual carefully.
n During all service and fitting work the lift
must be supported while in the raised posi-
tion to prevent accidental lowering.
Part. no. 99770

GB/1999-01 Safety 11
 CAR-O-LINER

Positioning of the Safety Signs

WARNING
!

WARNING

GB/1999-01 Safety 12
 BenchRack
BenchRack General CAR-O-LINER

Applications BenchRack is used for vehicle alignment and has an inte-

grated stepless scissors lift which can raise the bench frame
to the maximum working height of 1020 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 placement of chassis clamps (such as
Standard Clamp B106).
The bench frame may be tilted to facilitate driving on the
vehicle.
BR5500 may also be had without the tilting option
(BR5500L). This model comes with longer drive-on ramps
and the bench frame’s lowest position is 100 mm lower than
on other models.
Maximum permitted vehicle weight is 3200 kg.
Maximum load per ramp section is 1000 kg.
When carrying out alignment work, the vehicle should be
positioned wholly on the bench. The lift and bench frame
may not be used to lift one end of the vehicle while the other
end rests on the floor. Moreover, the lift’s working platform
may not be used for anything other than vehicle repair.
See Operation, page 33.

GB/1999-01 BenchRack General 13

 BenchRack
CAR-O-LINER

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 components.
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 position as well as bench supports for the draw
aligner position.
Description of lift - see page 23.

Side Ramps The side ramps are suspended from the side rails of the
bench frame. There are three types of side ramps:
A A pair equipped with mountings to which the drive-on
ramps may be attached. These side ramps are always
A placed nearest the drive-on end.
B A pair equipped with welded-on 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
B accompanying bolts and nuts as shown.
C Side ramps which may be fitted between ramp types A
and B.
The ramps may be removed as necessary to facilitate access
during measurement and alignment work.

WARNING! Maximum load per ramp = 1000 kg.

GB/1999-01 BenchRack General 14

 BenchRack
System Parts CAR-O-LINER

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 may be removed as necessary.
D
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. Drive-on Ramp D is used with all tiltable
BenchRacks.
Drive-on Ramp E is used with BenchRack 5500L (non-
tiltable).

Drive-off Stops B44 The drive-off stops should always be properly fitted (see
illustration). The stops not only prevent a vehicle from rolling
forward off the BenchRack, but also prevent improper weight
distribution on the bench and lift.

WARNING! The drive-off stops should always be correctly

fitted to the bench. Risk of improper weight distribution.

Applies to BR4700, BR5000, BR5500 and BR5500L

Applies to BR4200

GB/1999-01 System Parts 15

 BenchRack
CAR-O-LINER

Bench Support For Draw The enclosed bench supports are fitted as shown in the
Aligner Height illustration. The other bench supports are fitted to the under-
side 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 con-
nection of the draw aligner. To lower the bench to the floor,
the bench supports must be folded up manually.
See page 35.

(Applies only to BR 5500L)

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 bind.
Risk of crushing injuries.

GB/1999-01 System Parts 16

 BenchRack
CAR-O-LINER

Loading Trolley/Roll Stop B57 The loading trolley is designed to be placed under a dama-
ged (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.

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 vehicle. The bench mounts
are adjustable in height. (Variations of the mount may differ
from the illustrated model.)

GB/1999-01 System Parts 17

 BenchRack
CAR-O-LINER

Track Plate B66-9 Fitted to the bench tracks. Used principally for holding appli-
cations.

Clamp Bracket Pillar B627 Fitted to the bench tracks. Used principally together with
Clamp Bracket Pillar B628 adjustable clamp, pillar jack, etc.

Holder B629 Fitted to the bench tracks. Used together with the angle arm
for holding applications.

Angle Arm B630 Fitted to the bench tracks. Used in alignment work and down
pulls.

GB/1999-01 System Parts 18

 BenchRack
CAR-O-LINER

Chain Holder B631 Fitted to the side tracks of the bench. Used when the vehicle
is secured using chains.

Cam Locks B626 Used for fitting bench mountings, track plates, etc.

Pillar Jack B632 Fitted to the bench tracks. Used to lift a vehicle when setting
up on the bench.

Adjustable Clamp B620 Used as an extra anchor when securing the vehicle to the
bench and for fitting new parts to the vehicle.

GB/1999-01 System Parts 19

 BenchRack
CAR-O-LINER

Clamp Bracket Used for holding applications and to provide extra anchoring.
Pillar Extension B621

Angle Arm B66-2 Used together with Holder B629 to provide lateral support
during alignment work.

Cylinder Mounting B63-18 Used with an angle arm. Increases placement possibilities
for a hydraulic cylinder during alignment work.

Component Trolley B90 This trolley is intended for hanging and storage of bench and
holding components.

GB/1999-01 System Parts 20

 BenchRack
CAR-O-LINER

Chassis Clamp B106 The B106 Chassis Clamp is bolted to the bench mounting
arm and is provided with toothed segments that grip the
vehicle’s sill edge.
The toothed segments may either be fastened to the clamp’s
angle or to the mounting plate. Alternatives for the various
vehicles are listed in the data sheets.
The accompanying illustration shows a toothed segment
fitted to the angle.
Special chassis clamps are available for some vehicles.
Consult the check list on the data sheet for the vehicles to
which this applies (see the Instruction Manual for the Mecha-
nical Measuring System).

Sill Support B23 Used to avoid damage to the sill edge when setting up the
vehicle.

Spare Parts Spare Parts: See System Car-O-Liner Spare Parts

Catalogue 1310110245.

GB/1999-01 System Parts 21

Lift BenchRack
CAR-O-LINER

Applications The scissors lift is designed solely to lift the bench system
and vehicle.
The maximum permitted vehicle weight is 3200 kg and the
minimum distance between axles at maximum weight is
2500 mm.

The lift consists of two main components:

- Lift Unit, page 23

- Drive Unit, page 24

GB/1999-01 Lift 22
 BenchRack
CAR-O-LINER

Lift Unit The lift is hydraulic-driven and is built on a base frame to

which the scissors arms and the hydraulic cylinder are fitted.
The base frame is also equipped with a mechanical catch to
prevent the lift from sinking. This catch is freed with the help
of an air cylinder so that the lift may be lowered.
The upper ends of the scissors arms are connected to the
bench frame.
The hydraulic cylinder is single-acting, with hydraulic pres-
sure provided by the drive unit.

1. Base frame
2. Scissors arms
3. Mechanical catch
9
4. Catch pawl
5. Hydraulic cylinder
6. Hose rupture valve
7. Air cylinder
8. Expander bolts
6
9. Rating plate

GB/1999-01 Lift 23
 BenchRack
CAR-O-LINER

Drive Unit Hydraulic pressure is supplied by the pump unit which

consists basically of an electric motor, a pump and a hy-
draulic oil tank.
The pump operates only when lifting. When the pump is
stopped, the lift stops and maintains its level with the aid of
a non-return valve built in to the pump. There is also a
lowering valve on the pump.
Other parts of the drive unit are an electrical connection box
and a control unit.

24 10. Electric motor

11. Pump
12. Lowering valve
13. Relief valve
15
10
14. Tank
16
15. Electrical connection box
19 16. Control unit
11 17. Bleed valve
17
20 18 18. Oil filler/dip stick

13 12 19. Compressed air input, (1/4“)

21 20. Compressed air to lift
22
21. Hydraulic hose
22. Mains connection
23. Control unit connector
24. Key operating switch
23 Emergency stop
14

GB/1999-01 Lift 24
 BenchRack
CAR-O-LINER

Rating Plate The rating plate is located at the bottom of the hydraulic
cylinder mounting beam. See page 23.

2
3

4
7
8

5 6 10 9

1. CE-approval 6. Total weight, lift and bench

frame
2. Product name
7. Maximum air pressure
3. Part number
8. Serial number
4. Maximum hydraulic pressure
9. Date of manufacture
5. Maximum weight on the bench
frame 10. Part number of the sign

GB/1999-01 Lift 25
Setting Up the Vehicle BenchRack
CAR-O-LINER

General 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.

The vehicle may be driven onto the ramps or winched up if

there is wheel damage.
The vehicle can be lifted free of the ramps with the help of
pillar jack(s) after which either the bench mountings and
chassis clamps or the chain holders may be fitted.
Depending upon the type of vehicle and the nature of the
damage, the pillar jack(s) can be placed to lift the vehicle
one side at a time or at the front and rear.

GB/1999-01 Setting Up the Vehicle 26


Set-up With the Pillar Lift
BR 4200, 4700, 5000, 5500
Set-up With the Pillar Lift
BR 5500L
Driving On To BenchRack
4200, 4700, 5000, 5500
Driving On To BenchRack
5500L (non-tilting)
GB/1999-01
BenchRack
CAR-O-LINER
Fold up the bench supports for draw aligner height and
lower the bench to the lowest tilt height. All of the side and
drive-on ramps are to be fitted. Ensure that the drive-off
stops are fitted to the forward side ramps.
Fold up the bench supports for draw aligner height and
lower the bench to the lowest position. All of the side and
drive-on ramps are to be fitted. Ensure that the drive-off
stops are fitted to the forward side ramps.
WARNING! Maximum vehicle weight = 3200 kg.
Minimum allowed distance between axles at maximum
weight = 2500 mm.
WARNING! Maximum load per ramp = 1000 kg.
Drive or winch the vehicle onto the ramps. If the vehicle is
damaged so that a wheel is locked, place a loading trolley
under the damaged wheel.
Winch
Winch
Try to position the vehicle’s centre line as closely as pos-
sible to the centre line of the bench.
Setting Up the Vehicle 27
 BenchRack
CAR-O-LINER

Place a roll stop under an undamaged wheel on the side not

to be lifted to prevent the vehicle from rolling.

Roll Stop

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.

Mark the placement points A and B for the chassis clamps.

The measurement is given in the data sheet (see Measuring
System). Clean the sill edge from underseal and dirt to give
the chassis clamps a good purchase and so that the correct
height is obtained when measuring.

GB/1999-01 Setting Up the Vehicle 28

 BenchRack
CAR-O-LINER

Raise the lift to its highest position and fit one or two pillar
jacks.

Adjust the position of the pillar jack(s) for a suitable lifting

point. The ramps must be removed where the pillar jacks
are to be positioned.

Suitable lifting points for a side lift are on the frame of a

vehicle with a separate frame, or on the sill box of a vehicle
with a self-supporting chassis. In the later case a sill support
must be used. If the vehicle is to be lifted at the front or rear,
the front or rear axle beams or corresponding structures are
suitable lifting points.

Tighten the pillar jacks.

GB/1999-01 Setting Up the Vehicle 29

 BenchRack
CAR-O-LINER

Setting Up With Chassis With the vehicle supported by the pillar jack, lower the lift
Clamps carefully so that the ramps may be removed to allow fitting
of the bench mountings and chassis clamps.

Place the bench mounts on centre of the A and B marks

(page 28) and tighten the bench mounts to the bench. Place
the chassis clamps on the bench mounts and see that they
lie directly under the sill edge.

IMPORTANT! Ensure that the toothed segments are

clean and fitted correctly. See page 21.

Remove the side ramps from under the wheels. Raise the
bench carefully so that the chassis clamps are correctly
positioned against the sill edge.

Move the pillar jack to the other side of the vehicle and
repeat the procedure.

GB/1999-01 Setting Up the Vehicle 30

 BenchRack
CAR-O-LINER

The vehicle’s two sill edges are now in the chassis clamps.
Tighten the chassis clamps; first against the sill edge and
then against the bench mounting.

IMPORTANT! When a nut runner is used to tighten nuts

and bolts, ensure that it is set to a maximum of 120 Nm to
avoid thread damage.

Bench Mounting Please note that there are different types of bench
mountings.
If the vehicle is damaged so that it does not lie correctly in
one or more of the chassis clamps, the following procedure
is recommended:
- Lift the chassis clamp toward the sill edge with a suit-
able tool, then tighten the clamp against the sill edge.
- Tighten the chassis clamp bolts against the bench
mounting, forcing the vehicle into the correct position.
- When all of the bolts have been properly tightened,
alignment work can begin.
During the course of the alignment work, distortion
may be checked by loosening the chassis clamp in
question to see if the stress remains.

GB/1999-01 Setting Up the Vehicle 31

 BenchRack
CAR-O-LINER

Anchoring Using Chains In some cases the vehicle may be secured to the bench
using chains and chain holders. The vehicle rests directly
upon the bench mountings. Four chain holders are normally
used, two at the front and two at the rear.

Do not wind a chain around a Use a chain holder.

milled surface.

High chain anchorage using Side support.

shackle and hook.

GB/1999-01 Setting Up the Vehicle 32

Operation BenchRack
CAR-O-LINER

Safety Regulations The following safety regulations must always be observed

when using the lift:

WARNING!
To avoid injury the following must be observed:

- Maximum vehicle weight = 3200 kg!

- Minimum distance between axles at maximum
weight = 2500 mm!
- Ensure that the lift is firmly anchored according to
current local safety regulations.
- Ensure that nothing prevents movement of the lift.
- Ensure that the vehicle is correctly positioned on
the lift and that it cannot move while being lifted.
- Always keep a watch on the lift and its load while
raising and lowering the lift.
- Ensure that no-one is near the lift when it is in
operation.
- For service and troubleshooting, read the
instruction manual carefully.
! - During all service and fitting work with the lift in the
raised position, the bench must be blocked up to
prevent accidental lowering. See page 51.
- Prevent unauthorised use of the lift by turning off
the key switch after use and removing the key.

GB/1999-01 Operation 33
 BenchRack
CAR-O-LINER

Operating the Lift WARNING! Be careful when operating the lift with personnel in
the vicinity. Risk of crushing injuries.

To operate the lift, the emergency stop (pos. 24, page 24) must be
released with the key.
Raising and lowering is controlled by push-buttons on the control
unit. These push-buttons are designed with a “dead man’s handle“
function.
Pressing the Down button to the first position lowers the lift to the
nearest mechanical catch position, see Fig. A.
Pressing the Down button to the second position (fully depressed)
Control Unit allows the lift to be lowered to draw aligner height or to the lowest
level.
When the Down button is fully depressed, the air cylinder frees the
mechanical catch, see Fig. B.
NOTE! When the lift has been lowered and stopped by the mecha-
nical catch (pos. 3, page 23) and further lowering is desired, the lift
must be raised slightly to release the catch. When the Down button
is subsequently depressed fully, the lift will be lowered past the
mechanical catch stops.

Fig. A

Fig. B

GB/1999-01 Operation 34
 BenchRack
CAR-O-LINER

Tilting the Bench (Applies to all models with the exception of BR5500L)

Raising:
Raising
1. The bench is in the tilted position.
2. Raise the lift until all legs hang free.

WARNING! Ensure that all of the bench legs hang straight

down. Risk of injury.
Lowering
3. Lower the lift so that the bench is supported by the four
legs. Push in the control lever to lock the bench in a
horizontal position.

WARNING! The control lever must be fully pushed in.

Risk of injury. See also illustration on page 50.

In this position the draw aligner may be connected.

Lowering:
1. The bench must be in the draw aligner position. Pull
Locking the control lever out the control lever to enable the tilt function.
Raise the lift until all legs hang free.

2. Turn the control lever so that the forward pair of legs

fold up and remain there, then lower the lift.

Unlocking the control lever

3. The bench is now in the lowest position and tilted.

Turning the control lever

GB/1999-01 Operation 35
 BenchRack
Emergency Lowering CAR-O-LINER

WARNING! Before raising or lowering the lift, ensure that

no-one is near the bench. Risk of crushing injury.

See pages 23 and 24 for illustrations of the parts with num-

bers in parentheses.

Emergency lowering may be accomplished through use of

the lowering valve (12).
First ensure that the air cylinder lifts the pawl (4) of the
mechanical catch (3).
If this is not the case, the catch must be released manually.

Lowering:
Carefully unscrew the knurled locking knob (A, illustration
below) a few turns, opening the valve.
The lift should now lower. If it does not, screw in the locking
knob again and refer to Troubleshooting, page 54.
If the mechanical catch has been lifted manually, remember
to remove the blocking before the lift is operated.

Cleaning the valve:

The bench must be lowered to the rest position.
Disassemble valve C by unscrewing the locking knob (A)
and removing the coil (D).
The valve may now be unscrewed from the pump. Take
care that the O-rings (B) do not fall off of valve (C).
Remove valve E from the pump housing using narrow flat-
nosed pliers.
Blow the components clean with compressed air.
Refit the valves in the pump housing and coil.
Ensure that knob (A) is tightened against the valve.

E
C

A
B

GB/1999-01 Emergency Lowering 36

Safety Equipment BenchRack
CAR-O-LINER

Function See pages 23 and 24 for illustrations of the parts with num-
bers in parentheses.

To prevent unauthorised use, the lift is equipped with a key

switch (24) for operating power.

The pump has a built-in relief valve (13) to prevent over-

loading. The relief valve shunts the oil back to the tank in
case of excessive pressure. The pressure setting is made at
the factory and the valve is sealed.

When the pump is overloaded, its sound changes markedly.

The lift cylinder is a single-acting hydraulic cylinder with a

built-in hose rupture valve. This valve ensures that lift locks
up completely or slowly sinks in the event of a hydraulic
hose rupture or other leakage.

To avoid accidental lowering when the lift is more than

400 mm from the floor, a mechanical catch prevents the lift
from sinking more than a maximum of 100 mm in the event
of leakage.

BenchRack has a crush guard to prevent feet from being

caught between the bench and the floor during tilting opera-
tions.

Permanently fitted drive-off stops on the forward ramp sec-

tions prevent the vehicle from accidentally rolling off as well
as preventing improper positioning of the vehicle.

For inspection and maintenance, see page 39.

GB/1999-01 Safety Equipment 37

 BenchRack
Maintenance CAR-O-LINER

WARNING! During all service and fitting work, the lift must
be blocked up while in the raised position to prevent acci-
! dental lowering. 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.

GB/1999-01 Maintenance 38
 BenchRack
CAR-O-LINER

Check List
Recommended Types of Oil
The lift shall be checked at least once a month with re-
spect to the following points (see illustrations on pages 23
and 24):
1. The safety catch mechanism’s catch element (4)
should drop easily into its slot. Clean and lubricate
moving parts. Axles fitted with grease nipples are
lubricated with chassis grease.
2. See that the crush guard does not bind.
3. See that the drive-off stops have not become
loose or are damaged.
4. See that the tilting mechanism travels freely and
that the folding legs do not jam.
5. See that the hydraulic hoses and air hoses are
lying properly and are undamaged.
6. See that the joint axles and locking screws have
not loosened. Tighten if necessary.
7. Check for possible oil leakage at the cylinder and
drive unit. Correct leakage if necessary.
8. Check the level in the hydraulic oil tank. Add oil if
necessary. The oil and oil filter should be changed
at least once a year.
9. Check all warning signs and replace those dama-
ged or missing.
10. Check the bolts in the foundation. Tighten if ne-
cessary. (See the warning about working under
the lift!)

BRAND OIL 11. Check the lift arms for cracks in welds, wear or
other damage.
BP Bartran 32
Castrol Hyspin AWS 32 12. Check the electrical system including switches.
ESSO Uniovis N42
GULF Harmony 43 AW 13. Check the functioning of the hand-held operating
Mobil DTE24 box.
Shell Tellus Oil 27
Texaco Rondo Oil HD-17 14. Check the electrical wiring and conduits.
Valvoline Ultra max AW 15
15. Ensure that the lift is fused properly.

Maintenance may be documented with help of the

Inspection Report, Appendix 1.

GB/1999-01 Maintenance 39
 BenchRack
CAR-O-LINER

General Warnings

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! All work on the electrical equipment must be

carried out by authorised personnel.

WARNING! Observe high standards of cleanliness when

working with the hydraulic system. Dirt in the hydraulic oil
can cause operating problems.

GB/1999-01 Maintenance 40
Electrical Equipment BenchRack
CAR-O-LINER

General Electrical equipment is supplied for 400 V/50 Hz/3-

phase, 230 V/50 Hz/3-phase or 200 V/50-60 Hz/3-
phase.

For installation, 4-wire cable (three phases and earth)

must be used to connect a main power switch and the
electrical component box.
A main switch is not supplied.
The connection is to be fused with a 16 A fuse.

WARNING! All work on the electrical equipment must

be carried out by authorised personnel.

5
L1 T1 U
R
L2 T2 V
S

T
L3 T3 W 3
400V 230V 200V 2

9 1
0 A2 6 6
6
5
4
1A

24V
3 A1
2
2
UP

2 95 96 1 6 7
4 4
8
1 1
DOWN
5 5

7 7

1. Contactor 6. Coil, air valve

2. Overcurrent relay 7. Coil, hydraulic lowering valve
3. Motor, pump unit 8. Control unit
4. Fuse, 1 A 9. Key switch/Emergency stop
5. Terminal block

GB/1999-01 Electrical Equipment 41

 BenchRack
CAR-O-LINER

Supply voltage
Electrical Installation
R S T 9
230 V Alternative

Connections, motor terminal block 1 3 5 13

A1
L1 L2 L3 NO

Setting,
overcurrent relay T1 T2 T3
A2
2 4 6 14
230 V = 6.5 A

123456789
Reset button 123456789
123456789
T1 T2 T3 95
2 4 6
96

2
W 1
U V

To hydraulic motor

400 V Alternative
Supply voltage
R S T 9
Connections, motor terminal block

1 3 5 13
A1
L1 L2 L3 NO

Setting,
overcurrent relay T1 T2 T3
A2
400 V = 3.7 A 2 4 6 14

123456789
Reset button 123456789
123456789
123456789
T1 T2 T3 95
2 4 6
96
2

U V W 1

To hydraulic motor

GB/1999-01 Electrical Equipment 42

 BenchRack
CAR-O-LINER

Circuit diagram 400 V Lifting

5
400V L1 T1 U
R
L2 T2 V
S

T
L3 T3 W 3
400V 230V 200V 2

9 1
0 A2 6 6
6
5
4
1A

24V
3 A1
2
2
UP

2 95 96 1 6 7
4 4
8
1 1
DOWN
5 5

7 7

1. Contactor 6. Coil, air valve

2. Overcurrent relay 7. Coil, hydraulic lowering valve
3. Motor, pump unit 8. Control unit
4. Fuse, 1 A 9. Key switch/Emergency stop
5. Terminal block

GB/1999-01 Electrical Equipment 43

 BenchRack
CAR-O-LINER

The lift is lowered to the mechanical catch stop. The Down

button is depressed to the first position.

5
L1 T1 U
R
L2 T2 V
S

T
L3 T3 W 3
400V 230V 200V 2

9 1
0 A2 6 6
6
5
4
1A

24V
3 A1
2
2
UP

2 95 96 1 6 7
4 4
8
1 1
DOWN
5 5

7 7

1. Contactor 6. Coil, air valve

2. Overcurrent relay 7. Coil, hydraulic lowering valve
3. Motor, pump unit 8. Control unit
4. Fuse, 1 A 9. Key switch/Emergency stop
5. Terminal block

GB/1999-01 Electrical Equipment 44

 BenchRack
CAR-O-LINER

The lift is lowered past the mechanical catch. The Down

button is depressed to the second position.

5
L1 T1 U
R
L2 T2 V
S

T
L3 T3 W 3
400V 230V 200V 2

9 1
0 A2 6 6
6
5
4
1A

24V
3 A1
2
2
UP

2 95 96 1 6 7
4 4
8
1 1
DOWN
5 5

7 7

1. Contactor 6. Coil, air valve

2. Overcurrent relay 7. Coil, hydraulic lowering valve
3. Motor, pump unit 8. Control unit
4. Fuse, 1 A 9. Key switch/Emergency stop
5. Terminal block

GB/1999-01 Electrical Equipment 45

 BenchRack
Hydraulics Diagram CAR-O-LINER

1. Hydraulic pump
2. Non-return valve
3. Lowering valve
4. Manual emergency lowering
5. Non-return check valve
6. Hydraulic hose
7. Hose rupture valve
8. Hydraulic cylinder
9. Relief valve
10. Intake filter
11. Exhaust filter
12. Tank

See pages 23 and 24, Lift Unit.

GB/1999-01 Hydraulics Diagram 46

Transport BenchRack
CAR-O-LINER

The bench and the bottom frame are held together with
transport hooks to ensure safe transport.
These hooks must be used when the bench and frame are
moved at any time. Weight is 1200 kg.
A fork lift used to move the unit must have a fork width of at
least 850 mm. The lift must be centred on the long side of
the unit.

IMPORTANT: Exercise care when transporting BenchRack.

GB/1999-01 Transport 47
Inspection On Delivery BenchRack
CAR-O-LINER

Transport Protection On delivery the equipment must be checked with regard to

transport damage.
If any part is damaged, the lift may not be used until the
damage has been repaired.
Contact your supplier.
All models of BenchRack are equipped with transport pro-
tection which holds the base frame against the bottom of the
bench.

IMPORTANT! Remove transport protection before the lift

is put in use; damage can occur otherwise.

Mains Connections Check Ensure that the electric motor is supplied with the correct
voltage and frequency and it turns in the right direction after
connection. For connection information, see Electrical
Equipment, page 41.

GB/1999-01 Inspection On Delivery 48

 BenchRack
Installation CAR-O-LINER

Installation In Premises, The recommended space for installation is shown in the

General diagrams below.
The lift must be bolted to a good quality, flat concrete floor.
Minor unevenness can be compensated using steel shims.
See page 53.

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 in use.

Example of space requirements:

BenchRack

Cable protection, max. length 5.0 m

Drive unit

BenchRack 5000

Cable protection, max. length 5.0 m

Drive unit

GB/1999-01 Installation 49
 BenchRack
CAR-O-LINER

Installation, Fitting
IMPORTANT! Transport protection must be used
whenever the equipment is moved.
Move the bench and lift to the installation area.
Lower the bench and lift to the floor and remove the
transport protection. On all models except BR5500L,
the control lever must be installed (see illustrations
below).

Fitting of Control Lever The control lever for tilting is fitted on the left side
(All models except BR5500L) according to the illustrations below. (Cover plates not
drawn.)

Bench seen from above. Locked position (bench level).

Control lever
Bench seen from above. Unlocked position.

GB/1999-01 Installation 50
 BenchRack
CAR-O-LINER

WARNING! All work on the electrical equipment must be

carried out by authorised personnel.

Make the electrical and hydraulic connections to the lift and

drive unit. For electrical installation, see Electrical Equip-
ment, page 41.

WARNING! Maximum vehicle weight = 3200 kg.

Minimum allowed distance between axles at maximum
weight = 2500 mm.

Raise the lift to the highest position and block up the bench
frame.

WARNING! During all service and fitting work, the lift must
! be blocked up while in the raised position to prevent acci-
dental lowering. Risk of crushing injuries.

Fit the four mechanical catch stops.

Mark the six mounting holes on the floor and fit the floor
brackets according to the section “Bolting to the Floor“,
page 53.

Raise the lift and remove the blocks under the bench frame.

WARNING! Before raising or lowering the lift, ensure that

no-one is near the bench. Risk of crushing injury.

Lower the lift to draw aligner height.

GB/1999-01 Installation 51
 BenchRack
CAR-O-LINER

Ensure that the draw aligner can be easily connected to all

sides of the bench frame (see section on draw aligner).
Adjust with support screws if necessary.

Install the supplied cable protection over the air and hydrau-
lic hoses.

WARNING! The cable protection must be properly faste-

ned over the air and hydraulic hoses. Risk of tripping.

Raise and lower the lift a few times to ensure that the safety
catch element (pos. 4, page 23) falls easily into the slot.
Lubricate if necessary (four grease nipples).

Attach the ramps.

Fit the drive-off stops.

Fit the crush guard (BenchRack 5000). Used to avoid the

risk of injuries caused by crushing when tilting BenchRack
5000. The crush guard is fitted with a hinge mechanism as
shown in the illustration.

WARNING! Ensure that the crush guard is fitted so that it

always drops down of its own weight and does not bind.
Risk of crushing injuries.

Position the warning decals and signs providing instructions

for lift and alignment work. See Safety, page 54.

GB/1999-01 Installation 52
 BenchRack
CAR-O-LINER

Bolting To the Floor BenchRack must be anchored to the floor.

WARNING! The lift must be bolted to the floor. Risk of

tipping.

Four expander bolts M12x113 UPAT EXPR., Car-O-Liners

part no. 91215, 4 bolts are supplied with the bench system.

The lift should be anchored to a flat floor with the follo-

wing properties:
- A minimum of K25 concrete floor quality.
- A minimum slab thickness of 15 cm.

Procedure:
- Drill holes in the floor using the lift’s holes as a tem-
plate. Drill diameter 12 mm, hole depth 95-100 mm.
- Clean the holes and gently tap the expander bolts into
the holes with a hammer.
- Tighten the bolts with a torque wrench set to 53 Nm.
- NOTE! If the above torque is not attained, the anchor-
age is not satisfactory.
- 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 in use.

GB/1999-01 Installation 53
 BenchRack
Troubleshooting CAR-O-LINER

1. Problem: The lift cannot be raised.

Fault Cause Action

The motor does not run. 1. Phase error, blown fuse. Check for tension on all three phases.
Check the fuse.

2. Voltage drop or wrong Check the voltage and make sure that
voltage. the motor and electrical component
box are connected for the correct
voltage.

See Electrical Equipment, page 41.

3. Faulty contactor. Check the contactor and contactor

coil. Replace any defective compo-
nents.

4. Overcurrent breaker has Ensure that the overcurrent breaker

tripped, is set incorrectly has not tripped. Check settings on the
or is defective. switch and reset.

See Electrical Equipment, page 41.

5. Fault in the lifting control Check the auxiliary contactors 95 and

circuits. 96 in the overcurrent breaker.

Check the fuse and control circuits.

See Electrical Equipment, page 41.

Replace or repair any defective com-

ponents.

See pages 23 and 24 for illustrations of the parts with

numbers in parentheses.

GB/1999-01 Troubleshooting 54
 BenchRack
CAR-O-LINER

2. Problem: The lift cannot be raised (cont’d.)

Fault Cause Action

The motor runs, but the 1. Excess load on the lift. Maximum load on the lift is 3200 kg.
lift cannot be raised.

2. Motor rotating in the Change the phase order on the electri-

wrong direction. cal connection and check the direction
of rotation.

3. Low oil level. Check the oil level. Top up with oil if
necessary. See “Recommended Types
of Oil“, page 39.

4. Oil leakage. Check the hoses and couplings. Re-

place defective components.

5. Dirt in the lowering valve Clean. Change the oil. See Emergency
(12). Lowering, page 36.

6. Defective lowering valve The lowering valve has jammed in the

(12). open position. Replace the valve.

7. Defective relief valve Connect a pressure gauge to the

(13). hydraulic hose and check the pressure
(should be 180-190 bar). Pressure is
set at the factory; if the pressure is
incorrect, contact your supplier.

8. Defective pump (11). Replace the pump unit.

See pages 23 and 24 for illustrations of the parts with

numbers in parentheses.

GB/1999-01 Troubleshooting 55
 BenchRack
CAR-O-LINER

3. Problem: The lift drops

Fault Cause Action

Lowering valve leaks. Dirt in the lowering valve Lower the lift and dismantle the
(12). lowering valve.

Blow out the valve. See Emergency

Lowering, page 36.

Change the oil.

Oil leakage. Leakage from the hose or Check hoses and couplings for
coupling. leakage. Replace defective compo-
nents.

Oil leakage in the cylin- Worn gaskets. Dismantle the cylinder and change
der. gaskets. Change the oil.

Non-return valve in the Pump unit defective. Replace the pump unit.
pump defective or
leaking.

See pages 23 and 24 for illustrations of the parts with

numbers in parentheses.

GB/1999-01 Troubleshooting 56
 BenchRack
CAR-O-LINER

4. Problem: The lift cannot be lowered

Fault Cause Action

Lowering valve (12) No current to the magnetic Check the voltage at the coil
fails to open. coil. (24 V AC). Trouble shoot according
to the diagram.

The valve is blocked with Clean the valve. See Emergency

dirt. Lowering, page 36.

The valve sticks. Change the valve and the oil.

Mechanical catch (3) is The catch pawl (4) is stiff or Clean so that the pawl enters the
jammed. sticks. slot easily, see Maintenance, page
38.

Air cylinder (7) does not lift Check the air supply to the air valve
the catch pawl from the (17) and that the air valve is getting
slot. 24 V AC. Make sure that the air
hose is not crushed or blocked.

See pages 23 and 24 for illustrations of the parts with

numbers in parentheses.

GB/1999-01 Troubleshooting 57
 BenchRack
Dismantling / Salvage CAR-O-LINER

Mechanical Components When scrapping or dismantling lift components the oil must
be emptied from the cylinder, hoses and pump.
Waste oil should be sent for disposal or to a recycling sta-
tion.

Other Components All electrical components, plastic hoses, steel and aluminium
should be sorted for recycling.

GB/1999-01 Dismantling / Salvage 58

 BenchRack
Technical Specifications CAR-O-LINER

BenchRack BenchRack
4200 4700 5000 5500 5500L
Maximum vehicle weight _______ 3 200 kg 3 200 kg

Maximum lifting height ________ 1 020 mm 1 020 mm

Min. height (equipment height) __ 400 mm 240 mm

Lifting time __________________ 20 - 25 seconds 20 - 25 seconds

Lift dimensions ______________ 2 030 x 4 200 - 5 500 mm 2 030 x 5 500 mm

(1170 w/o ramp)

Bottom frame dimensions ______ 780 x 2 200 mm 780 x 2 200 mm

Weight (lift + frame) __________ 950 - 1200 Kg 1200 Kg

Drive Unit for BenchRack

Motor output ________________ 1.5 kW

Rated current _______________ 230 V / 6.5 A or 400 V / 3.7 A

Supply voltage ______________ 230 V or 400 V 3-phase, 50 Hz

Control voltage ______________ 24 V AC / 1.5 A

Hydraulic unit type ___________ GRDP62

Noise level__________________ Under 70 dB(A)

Working pressure, factory set ___ 21.0 MPa

Flow _______________________ 6.8 litres/minute

Hydraulic oil ________________ See “Recommended Types of Oil“, page 33.

Tank volume _________________ 6 litres

GB/1999-01 Technical Specifications 59

Appendix 1, Inspection Report
BenchRack
(See Check List, page 39.)
CAR-O-LINER

BenchRack modell ___________________________________________________

Check Point Action Date Sign.

GB/1999-01 60
The Zeteco Group develops, manufactures and markets qualified technical products for the transport sector
Copyright©
CAR-O-LINER AB
Sweden