Guangzhou Junliye Import-Export Co., Ltd.

Universal Collision Repair Equipment

Operation Manual

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Content
Standard Configuration Components and Brief Introduction of Function.................................................- 2 -
Working Platform....................................................................................................................................... - 5 -
Pulling Equipment......................................................................................................................................- 6 -
Measuring System.....................................................................................................................................- 7 -
Mechanism Measuring System....................................................................................................... - 7 -
Extension Measure Ruler:................................................................................................................- 9 -
Tool Room................................................................................................................................................ - 13 -
Vehicle Loading Ramp....................................................................................................................- 13 -
Clamps.............................................................................................................................................. - 13 -
Special Tools.................................................................................................................................... - 15 -
Tools Storage Cart.......................................................................................................................... - 15 -
Lifting Frame of Working Platform Lifting Frame........................................................................................- 16 -
Operation instruction of Working Platform Lift Frame....................................................................... - 17 -
Scissors style lifting frame (optional)....................................................................................................- 17 -
General Vehicle Collision Repair System Operation Procedure:............................................................ - 18 -
Preparation before Vehicle Loading..................................................................................................... - 18 -
Vehicle Loading and Clamping ............................................................................................................ - 18 -
Measuring................................................................................................................................................. - 20 -
Straightening Operation Routine.......................................................................................................... - 22 -
Universal Vehicle Collision Repair Equipment Safety Operation and Maintenance.............................- 24 -
Safety Operation Item:............................................................................................................................- 24 -
Maintenance.............................................................................................................................................- 25 -
Series Universal Collision Repair Equipment Operation Regulations.................................................... - 25 -
Drive on or off the vehicle operation rulers......................................................................................... - 26 -
Vehicle fix operated rules....................................................................................................................... - 26 -
The Measure Device Operated Rules..................................................................................................- 27 -
Stretch operate rule................................................................................................................................ - 27 -
Equipment maintenance operation rules............................................................................................. - 28 -
Hydraulic pressure system common problems and solutions..................................................................- 28 -

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Standard Configuration Components and Brief Introduction of

Function
The Standard Configuration Components of Universal Collision Repair Equipment consist of 4 parts
such as Working Platform , Pulling Equipment, Measuring System, Tool Room 。
The Universal Collision Repair Equipment could be divide into 5 kinds according to the working
platform structure, Shown in Fig. 1

Single Side Incline

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Single Cyclinder Vertical Lift

Double Cyclinders Vertical Lift

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Fixed Type

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Frame Style

Fig.1 Universal Collision Repair Equipment

1．Working Platform 2．Pulling Equipment 3．Measuring System 4．Tool Room

Working Platform
Working Platform is the base parts of Universal Collision Repair Equipment and is used to fix and
straighten vehicles just like “operation table”. It mainly consists of 2 parts, Working Platform Frame and
Main Clamps . Shown in Fig 2. Repairing Vehicles could be fixed on Working Platform reliably via
Clamps and Auxiliary Support.
Main Clamps could be fixed at any part of Working Platform Frame via pressing plates and bolts.
Main Clamps is mainly used to clamp vehicles’ undamaged edge to fix vehicles’ bodies. It could be
dynamic load adjusted upward. The adjustable scope is “300~380mm”. If you unscrew the Clamps Nut
using special socket wrench, the main clamp chops could splay flexibly. The Main Clamps could
dynamic load adjustable in the height direction. For heavy damaged chassis, you could make Main
Clamps directly push upward the damaged part to straighten the vehicle. Wande series have one
battery (four parts) main clamps.
Crossbeam Clamp is mainly used to clamp crossbeam vehicle such as minibus 、 off-road cars,
crossbeam clamp includes flat nose pliers and back pin shaft clamp. The flat nose pliers is used to
clamp crossbeam, back pin shaft clamp is used to fix suspension point of crossbeam vehicles, the
Crossbeam Clamp could adjust along longitudinal 、 transverse 、 height directions, fit for clamp
crossbeam of any vehicles. The Crossbeam Clamp only equipped with above W-5 types, other types
could choose it.
Auxiliary Support could used for assist clamp、support and fix of good part or other part vehicle, in order
to protect the right place in the process of straightening operation, enhance work efficiency, the
adjustable scope is “280-370mm”, if add adjustable seat, the adjustable range is “280-470mm”.The
Auxiliary Support upside could change small clamp to assist clamp the skirt panel, also could change
locating pin 、locating sleeve, cooperate with craft hole or screw hole on the vehicles, so that could
realize the effect of auxiliary support and fixed.

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Fig.2 Working Platform

1.Working Platform Frame 2.Main Clamp 3. Auxiliary Clamp

Pulling Equipment
Pulling Equipment is mainly used to straighten vehicle’s damaged area. It consists of hydraulic cylinder,
air-driven hydraulic pump, and pulling tower etc. Shown in Fig 3. The pull force of straightening is
provided by hydraulic cylinder and air-driven hydraulic pump.
Pulling Equipment could slide along track and can be fixed at any position for 360-degree access to
straighten vehicle. According to the vehicle part to be straightened, pull out the locating block of the
pulling equipment, insert locating pin to connect with the working platform, and then wedge tightly with
the wedge block, so that the pulling equipment could fix on the working frame, One end of the chain is
fixed in the groove of the upper part of the inner tower column; the other end is connected with the
clamps that clamp the damaged area via guide wheel. Hydraulic cylinder, pneumatic pump and manual
pump are all make use of the famous brand of hydraulic of America. The maximum pushing force of
hydraulic cylinder is 10t. The maximum oil pressure of Manual pump and hydraulic cylinder is
69MPa(1000 PSI). Read the manual among the attachments with the equipment to get information of
operation and maintenance of hydraulic cylinder and Manual pump. Hanging arm of the pulling tower
could upward stretch the straightening part. The Hanging arm and the pulling tower are locked via pin
roll.
Attention: When hanging arm stretch, pulling force couldn’t beyond 1.5 ton, pulling arm
couldn’t be used to hoist heavy, avoid to cause any injury to person and repaired auto.

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Fig 3 Pulling Equipment

1、Guide Wheel 2、Running Gear 3、Locating Pin 4、Located Block
5、Wedge Mas6.Cylinder7、setting wheel 8、pin roll 9、Hanging Arm

Measuring System
Measure System divided into mechanical measure system, extension measure
ruler and laser measure system. CWF-III is equipped with extension measure ruler or
mechanical measure system .

Mechanism Measuring System

Mechanism Measuring System offers the function of 3-dimention measuring for vehicle’s body and
chassis. So you can check the damaged area of the vehicle. Referring the data of original vehicle, you
can decide the straightening direction and the straightening data. Repair the damage area as it was at
the beginning.
Measuring system consists of Measuring Ladder, Chassis Measuring Ruler and Gantry Measuring
Frame. Shown in fig 10
Measuring System offers such feathers as light, flexibility, practical etc. The installing and measuring
datum plane is the surface of working platform.

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1. Measuring Ladder 2. Chassis Measuring Ruler

Fig.10 Mechanism Measuring System

Measuring Ladder
Measuring Ladder consists of horizontal bar and vertical bar. Chassis Measuring Ruler and Gantry
Measuring Frame can be put on the Measuring Ladder. It can slide along measuring ladder in the
longitudinal direction. Measuring Ladder is located on the machining area of working platform. It is fixed
with ‘G’ shape clamp.

Chassis Measuring Ruler

Chassis Measuring Ruler mainly consists of Chassis Slide Seat; Chassis Cross Bar, Measuring
Seat, Standard Measuring Rod, Rod Extension and Measuring Elements etc. Shown in fig 11. Chassis
Measuring Ruler can slide along Measuring Ladder as a whole. Measuring Seat can slide along
Chassis crossbar with Standard Measuring Rod. Standard Measuring Rod can slide in the Measuring
Seat with Measuring Elements. So it can implement 3-dimension measuring of the chassis feature
point.
The Chassis Slide Seat’s end toward the front of vehicle (with red mark) is the place of longitudinal
reading. The place with red mark on the Measuring Seat is Place of Landscape Orientation Reading.
The top surface of Measuring Rod is Place of Height Reading. Shown in fig 8
There is one set of Standard Measuring Rods, which can cover most of measuring points. There are
two sets of Rod Extensions, which can expand the height measuring scope to 700mm, and can
measuring higher feather position. Measuring Elements include Round Measuring Pointer, L Type
Measuring Pointer and Elbow etc. They are suitable to measuring all kinds of type measuring position.
Shown in fig 8. If the Elbow is equipped with Measuring Cup, Round Measuring Pointer, the equipment
can measure the position in the horizontal direction. It offers the advantage that it is convenient to
measure some special position.
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Fig 11Chassis Measuring Ruler

1. Standard Measuring Rod 2. Measuring Element 3. Measuring Rod 4. Measuring Seat 5. Chassis
Cross Bar 6. Chassis Slide Seat A. Place of Height Reading B. Place of Longitudinal Reading C.
Place of Landscape Orientation Reading

Extension Measure Ruler:

Extension measure ruler is designed for enhance inspect, measure precision, and convenient during
repair the accidental car. It solve the problem that result from traditional three dimension mechanical
measurement ruler, such as measurement cumulative error is large, data need to convert,
measurement process is complex, measure rule volume is large, weight is high, the measurement
couldn’t be finish by one person and auto body parameter measure scope isn’t enough. Such
measure ruler is aluminum extension mechanical measure ruler. It’s measure precision is high, operate
easy, with crossover coupling could make three dimension measure, measure process wouldn’t be
limited by place and equipment. It could match with the legal copy of auto body data that supported by
maintenance station, make measure inspect convenient during process of metal sheet repair. There is
evidence for the estimate of the vehicle body structure.

Packing size:1020mm×200mm×120mm(Length x Width xHeight)

Gross Weight:5kg
1、 Measure Scope:
X coordinate 200mm～2250mm
Y coordinate 20mm～150mm(or 340mm)
Z coordinate 20mm～150mm(or 340mm)
Measure Precision< 1mm

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2、Product Configuration

NO. Picture Item Qty

1 Measure Main Ruler 1

2 20mm～150mm Measure Ruler 1

3 20mm～340mm Measure Ruler 1

4 Screw Thread Probe 1

5 Magnetism Probe 1

6 Magnetism Probe Lengthening Seat 1

7 Three Dimension Crossover Coupling 1

8 Large Location Probe 1

9 Longitudinal Location Measure Probe 1

10 Small Location Probe 1

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Screw Cap
11 1
Probe

3、Part Introduction

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4、Operational Introduction
1)、 200mm～ 910mm ：Screw tread
probe seat left end reading data: distance
between screw thread probe and measure ruler end probe.
(Attention:when measure, balance bubble
of air level should be in the middle, middle
drivepipe and small drivepipe of main measure ruler
should be closed to the right end of large drivepipe, showed in the
picture)
2)、 910mm～1590mm：
Put the magnetism probe into the end of tested measure size,
unscrew fastening screw, move the middle drivepipe in the main ruler.
Main ruler large drivepipe display data is distance between
magnetism probe and measure ruler end probe. (Attention: small
drivepipe should close to middle drivepipe,
showed in the picture:magnetism rotate head and main ruler should
be vertically.)

3)、1590mm～2250mm：
Put the magnetism probe into the end of tested measure
size, unscrew fastening screw, move the middle drivepipe
in the main ruler.When middle drivepipe extension to the
end.location pin would be popup,then pull out middle
drivepipe. Measure ruler of main ruler. Main ruler middle
drivepipe right end display data is the distance between
magnetism probe and ruler end probe.(Attention: when
middle drivepipe
popup, then could use small drivepipe ruler, or else small drivepipe right end displayed date isn’t the
real distance between magnetism probe and ruler end probe. showed in the picture)

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Tool Room
The Tool Room of General Vehicle Collision Repair Equipment mainly consists of Vehicle Loading
Accessory, Clamps, moving accessory, Special Tools etc. It can meet all kinds of straightening needs. It
is easy operation and high efficiency.

Vehicle Loading Ramp

Vehicle Loading Ramp is used to guide vehicle drive on working platform. The ramp position show as
follows:

Clamps
Clamps are defined as tools that clamps vehicle damaged area. Clamps offer all kinds of types to meet
various damaged areas. It is flexible to use them. Universal Collision Repair Equipment provides nearly
ten kinds of clamps, which can meet all kinds of repair need. When using them we shall follow such
principles as Convenient Clamping, Safety, Reliability, and Not Damaging Structure Parts. The
following table is about the pulling force limiting of the clamp with the equipment, when operation, it
should not beyond the pulling force limiting range. The fig 10 show some special example.

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fig 10. typical clamp

The Limited Force of Universal Collision Repair Equipment’ Tools
No. and
No. Name Able to support maximum load
Specification
Pulling force the same direction to jaw 4
1 Multidirectional Pulling Plate 01 ton
Veridical Direction 3 ton

2 Chassis Pulling Hook 02 5 ton

3 Clamp with Chain 03 3 ton

4 Big bent hook 04 5 ton

5 Chain shorten tool 5104 8 ton

6 Wide clamp 06 3 ton

7 Dual clamp 08 3 ton

8 Movable Idle Wheel 09 5 ton

9 Long plate 10 5 ton

10 Horizontal Pulling Plate 12 5 ton

11 Vertical Pulling Plate 13 5 ton

12 Fibre lifting strap φ1000（ring） 2 ton

13 Crossbeam Pulling Plate 11 5 ton

14 Hanger chain accessories 14 8 ton

3 meter with draw
15 Chain 10 ton
hook

16 Shock Absorber Struts puller 15 5 ton

17 Small clamp 16 3 ton
18 Heavy clamp M1 5 ton

19 C clamp M2 5 ton

20 G clamp M3 5 ton

21 Narrow clamp M4 5 ton

22 Wide Clamp M5 3 ton

Attention: specific configuration see accessory configuration list of leave

factory.

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Special Tools
Special tools are shown in fig 13
Special Tools include Socket Wrench and Hex. Wrench. Socket Wrench is specially used to tighten jigs
and clamps. Hex. Wrench is mainly used to tighten clamp seat. Special Tools can increase efficiency.

Fig 13 Special Tools

1.Socket Wrench 2. Hex. Wrench

Tools Storage Cart

Tools Storage Cart is used to accommodate and move accessories with the equipment. Shown in fig
14. It is equipped with foot wheel. You can ease move There are some special device to put the
accessories with the equipment on Tools Storage Cart, such as pothook and small case.

Fig 14Tools Storage Cart

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Lifting Frame of Working Platform Lifting Frame

The single side incline working platform lifting frame consists of main lift frame, oil cylinder, air hydraulic
pump, Shown in fig 15

Fig 13 CRE-Ⅲ Working Platform Lifting Frame

1.Main Lift Frame 2. Check Valve3.Air Hydraulic Pump 4. Two-position Five-access Air Commute Valve
5. Pawl 6. Oil cylinder 7. Air Cylinder 8. Pawl Rack

CWF-III Working Platform Lifting Frame

1. Lift Frame 2. Oil cylinder 3. Air Hydraulic Pump

图 15

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Operation instruction of Working Platform Lift Frame

1.Connect the exit pipe of the pneumatic pump with the joint of intake pipe of the two position five
connection pneumatic shuttle valve, connect high pressure oil pipe with pneumatic pump. Purge the air
of the oil pump, and then connect another end of the oil pipe with oil cylinder. Checking each
connecting part, to ensure the connection is reliable, there is no revelation. Another way of air of the
two position five connection pneumatic shuttle valve is connected with the pneumatic pump of the
self-lock device via the nylon tube.
2.Setting the press of the pneumatic pump between 6～8 Bar, turn on the power of the pneumatic pump,
so as to supply air.
3. Pull out the handle of two positions five connection pneumatic shuttle valve at first, then step on the
switch of the pneumatic pump to “PRESSARE”, so as to realize the lift of the working platform. At the
time releasing the switch, the working platform can stop and maintain at one place.
4. In order to realize the rise and drop of the working platform, pushing the handle of the two position
five connection pneumatic shuttle valve, inflation the pneumatic cylinder, making the ratchet of the
self-lock device to break away from the rack, then step on the switch of the pneumatic pump to
“RELEASE”, to realize the drop of the working platform. If the pneumatic pump can not jacking the
ratchet of the self-lock device, making the oil cylinder of the lifting frame of the working platform
extension and rise 5-10cm, then push the handle of two position five connection pneumatic shuttle
valve, making the cylinder full of air, then making the ratchet of the mechanism self lock to break away
from the rack, then step on the switch of the pneumatic pump to “RELEASE”, to realize the drop of the
working platform.
If the equipment without mechanical self-lock device, it need to lift to the working platform to 5-10 cm
higher than level height, and then turn the back support leg leave to the support place, then step the
switch of pneumatic pump to “RELEASE”, then could realize the platform descend.

Scissors style lifting frame (optional)

General Vehicle Body equips with a small type Scissors Lifting Frame, is used to lift when clamp vehicle,
it convenient and quick. Rating lift weight is 1800Kg, maximum lift capacity is 2000kg, maximum lift
height (from working platform plane) 408mm. it consists of Base、Oil cylinder、extension arm etc. show
as fig.17, the way of operation is connect the hand pump with high pressure oil pipe, after exhaust the
air in the oil pipe and then connect with the oil cylinder of scissors lifting frame, turn off hand pump
switch, rock the hand-pressure role time after time, then the scissors lifting frame will rise. If lifting width
is not enough, a long arm could be added to adjust.

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Fig.17 Scissors Lifting Frame
Base 2.Oil Cylinder 3.Outer Lifting Arm 4.Inner Lifting Arm 5.Up Cover 6.Extension Arm

General Vehicle Collision Repair System Operation Procedure:

General Vehicle Repair Collision Repair System straightens the damaged vehicles should follow the
following procedures:
1. Preparation before Vehicle Loading
2 .Vehicle Loading and Clamping
3. Measuring
4. Straightening Operation

Preparation before Vehicle Loading

1. Ascertaining the straightening project. According the status of vehicles’ damage, ascertain the
pulled part, direction and the part to be protected during the pulling process. If necessary, some parts
shall be taken down and cleaned, for example, the battery shall be taken down.
2. Ascertaining the chassis data and the body data suitable for the damaged vehicles. The detailed
check way as follows:
1) 、 Ascertain the damaged vehicle’s category, model, manufacturer, and produced age, etc. And
according these you can find the vehicle’s No. from the data and vehicle body’s data catalogue.
2)、 According the vehicle’s No., you can find the respective chassis data and vehicle’s body data.

Vehicle Loading and Clamping

1、Vehicle Loading:
Push the repaired vehicle along the loading ramp or pull the vehicle via the winch on the working
platform. Move away the loading ramp. Then the vehicle loading is finished.
2、Vehicle Clamping：
1) Loading and Clamping when vehicle’s front or rear is damaged.
a、Equip the clamp bases (It could not be taken down when vehicle loading and unloading each
time)
b、Equip the four clamps on the clamp bases, and adjust the clamps’ height to 350mm.
c、Move the Scissors Type Lift Frame to the vehicle’s one end, and lift up the end. Use a couple of
clamps to clamp the vehicle’s skirt panel. Then move the lift frame to another end of vehicle. Use
another couple of clamps to clamp the vehicle’s respective skirt panel. The vehicle clamping is finished.
Shown in fig 18.

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Fig.18
2、Loading and clamping when vehicle’s one side is damaged
The process of the one damaged side vehicle loading and clamping is primary the same as the
one whose front or rear is damaged. The difference is that the edge is damaged so severely that it is

suitable to be clamped by no clamp or by only one clamp. Under this condition, use two clamps to
clamp the edge of vehicle undamaged side and use the accessory clamps to support, clamp, and fix
the good parts. According the damaged status of the vehicle edge you elevate and lower the clamp.
And clamp the damaged side front or rear. Then pull and straighten the damaged side. When the
damaged side is straightened primary good, you may clamp this side. Then you can straighten the
other damaged parts.
3、 Loading and clamping when there isn’t skirt edge on the vehicle
If there is no skirt edge on the vehicle to be repaired, you can weld two couples of steel slats
symmetrically on the suitable position of its chassis. After loading the vehicle, you can clamp it via the
four steel slats.
4、Loading and clamping when the vehicle to be repaired is crossbeam type frame
The skirt panel of the crossbeam type vehicle is weak, so it is unsuitable to be clamped. If necessary
you may clamp skirt panel to perform as assistant support. General the clamped parts of crossbeam
type vehicle is the suspension fulcrum and the front part of the crossbeam. You shall use crossbeam
special clamp to clamp the front of crossbeam and use outer suspension bracket to clamp the
suspension fulcrum. You can use accessory support to fix the crossbeam type vehicle.
5、The following items shall be paid attention to during the vehicle loading and clamping process
a. During the process of loading the vehicle, you shall try to keep the longitudinal centerline of the
vehicle coinciding with the longitudinal centerline of working platform.
b. After loading the vehicle, try to locate its gravity center in the middle part of the working platform.
c. If the vehicle length is beyond the length of the working platform, you should move the vehicle
according to the damaged part (front damaged or rear damaged) so that
d. After loading the vehicle, you shall use small clamp, Locating pin, and positioning jacketing to
perform as assistant support.

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Measuring
When using Measuring System, you shall understand the measuring system’s data table at first.
1. The explanation of the data table
The vehicle body data provided with the equipment includes chassis data table and body data
table.
1.1 The layout of the chassis data table and explanation is shown in the Laser Measuring System
Vehicle Chassis Data layout
1.2 All kinds of measuring elements in chassis data and their installation type during operation is
shown in table 1
2. Measuring System Positioning
After loading the damaged vehicle, you shall roughly measure it to ascertain the straighten project.
During the straightening process, you shall precisely measure the part to be straightened, so that you
can judge if it is well straightened.
When using the measuring system, you shall posit it at first. The operation method is listed below.
(1) Referring to the data table suitable for the vehicle, find two points in the undamaged area on the
front or on the rear of the chassis. In general the rear point is the front fulcrum of the rear suspension
(When the point is damaged you may choose other points). In the data table the front fulcrum of the
rear suspension fulcrum is marked with‘o’especially. According the absolute portrait distance and
landscape distance, you can determine another point.
(2) Put the measure ladder on the working platform, and mount the four sets of chassis rulers on the
measuring ladder. In general the rear set of chassis rulers shall use the short crossbeam ones.
According the installation type illustrated in the data table, you can install the measuring rob and the
measuring elements well.
(3) Brick by brick adjust chassis measuring ruler, measuring sliding seat, and measuring position to
make the numbers in sympathy with the numbers illustrated in data table. And brick by brick adjust the
measuring ladder’s position to make the measuring elements correspond to the positioning point (2-mm
error is allowed). Tighten the tacking screws.
Here two notes shall be special explained
a. The data table given by us is worked out in accordance with some special vehicle type and
some period vehicle. For the vehicle type made by the same manufacture but in different period, due to
the rapid progress and the improving of the manufacture technology, case-by-case data may not be at
one.
b. When using data table, you shall pay attention to that the measuring precision of the measuring
system is 2 mm., but the vehicle manufacture tolerance almost is under 3 mm. More over because of
the manufacture technology, the tolerance of the chassis and vehicle body is 10 mm at times.
3. Measuring system operation
3.1 Installation of the chassis measuring ruler and the gantry measuring frame
After the measuring system being positioned, you shall install the gantry-measuring frame and
other chassis-measuring ruler and measuring elements, etc. The installation approaches are listed
below.
3.1.1 Installation of the gantry measuring frame
1. Choose the place of the gantry-measuring frame according the parts to be measured.

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2. Take down the top bar, vertical beam (including vertical seat) assembly. Place the bottom seat
body on the measuring ladder.
3. Fit together the vertical beam assembly and the top bar on the bottom seat body.
3.1.2 Installation of the chassis measuring ruler
1. Take down measuring sliding seat, measuring seat, and measuring rod.
2. Place the chassis crossbeam assembly on the measuring ladder.
3. Place the measuring sliding seat, measuring seat, and measuring rod on the chassis
crossbeam.
3.2 Measuring the chassis and the vehicle body
3.2.1 Measuring the Feather Points of the chassis
1. According the character of the chassis measuring point and the measuring method illustrated in
the data table, you can select the appointed measuring rod and measuring elements and fix them
together.
2. Adjust the position of the chassis ruler, measuring sliding seat, and measuring rod to make the
elements touch the measuring point.
3. Read the portrait, landscape, and height number illustrated by the chassis ruler. And compare them
with the number illustrated in the data table. If the error is in the range of 2 mm, the point position is
correct. Otherwise it is incorrect.
3.2.2 Measuring the vehicle body measuring points
1. According the character of the vehicle measuring point and the measuring method illustrated in
the data table, you can select the appointed measuring rod and measuring elements and fix them
together.
2. Adjust the position of the gantry-measuring frame, left and right vertical beam-sliding seat, and
cross-measuring rod to make the elements touch the measuring point.
3. Read the portrait, landscape, and height number. And compare them with the number illustrated
in the data table. Then you can judge weather the point’s position is correct.
3.2.3 Measuring vehicle when there is no available data
If there is no available data table for the vehicle to be repaired in the provided data, you can repair
it in accordance with the following method.
1. Find two couples of symmetrical points in the undamaged area of the vehicle. The distance
between the two couples of symmetrical points shall as possible as long. Position the measuring
system via the two couples of symmetrical points.
2. Adopt traditional method to measure the vehicle or according some important structure
dimensions or installation dimensions prosecute measuring. It is of course that you can measure the
vehicle according your experience.
3. The following shall be noted during the process of the measuring:
The distance between the two sliding seats on chassis measuring ruler is adjusted well. Generally
do not release the tacking screws. After using for a long time if you find the clearance between the
chassis-measuring ruler and measuring ladder is too long, you can release the tacking screws to adjust
the clearance. The adjust principle is that the chassis left and right measuring ruler shall be symmetry
base on the center line of the chassis ladder. The adjustment error shall not more than ±0.5 mm.

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Straightening Operation Routine

1、Preparation for the straightening the vehicle
1). Take down the battery to avoid the acidity leaking and to protect other parts from eroding.
2). Take down the parts, which get in the way during the straightening process.
3). Measuring the vehicle and ascertain the straightening project.

2、Connection of the pulling system and the working platform

At first you shall ascertain the suitable connection point in accordance with the part to be straightened.
Ascertaining the connection point shall follow the following principle: During the process the
straightening, when some part being applied stronger force, the chain shall be parallel to the towers’
crossbeam to protect the tower from being damaged. After the connection position being ascertained,
the positioning mass shall be pulled out. And insert the positioning pin, and then wedge it with wedging
mass. The pulling equipment is fit together with the working platform tightly.

3. Connection of the hydraulic system and pulling system

Fit together the manual pump, oil pipe, oil cylinder. Check the oil volume of the
manual pump. If the volume is not enough, please pour hydraulic oil (refer to the detail
method in the manual book). Exhaust the air in the oil pipe.
4、Connection of pulling tower and straightened point
Select the clamps to be used in accordance with the damaged parts. For the rigid parts the pulling hook,
pulling plate, and big clamps shall be selected in general. Connect the clamps and the chains reliably.
And fixed the other end of the chain in the chamfer on the upper part of the inner tower beam.

5、Straightening Operation
Turn off the switch of the manual pump. Rock the handle of the manual pump. Then the pump pumps
the oil. The cylinder is extended.
During the process of straightening, you shall adjust the height and position of the chain as well as the
pulling system connection position.

6、Typical pulling operation

1.) When some parts of the damaged area need to be pulled downward, you can change the chain
direction via idle wheel. Shown in fig 19.
2.) The straightening of the rear of the vehicle is shown in fig20.
3.) When the top of the vehicle body need to be pulled upward, you can use the hanging bar and the
Pushing Upward Components to implement this task. Shown in fig 21.

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Fig 19 stretch the vehicle body downward

Fig 20 stretch upward of the vehicle rear

Fig 21 stretch upward of the vehicle top

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7、Some items shall be paid attention to during the process of straightening:

1). Some parts shall be supported and fixed according to the feathers of straightening. For example,
when pulling downward some damaged points on the chassis, you shall support or fix the start point of
the crook. When the top part being straightened, the front end of the vehicle or the rear end of the
vehicle chassis shall be fixed. And when the front end of the vehicle being pulled toward left or right,
you must fix the front end of the chassis.
2). Measuring system shall be moved to the undamaged area to avoid that the chain and accessories
can destroy the measuring system.
3). None is permitted to stand behind the pulling tower during the process of straightening.
So the accident can be avoided.

Universal Vehicle Collision Repair Equipment Safety Operation and

Maintenance

Safety Operation Item:

The equipment only could be use for crossbeam straightening, and couldn’t be used for other, or else
there is any problem, we wouldn’t responsible for this. Safety Operation can avoid the personal injury
and abnormal damage of equipment. Any injury and lost caused by unsafely operation, lack
maintenance or wrong equipment operation, we wouldn’t responsible for it. Safety operation shall be
paid attention to during operation:
1. Before using the Universal Collision Repair Equipment you must read the operation manual and
spare parts operation manual carefully. The equipment should be operated by the worker with
proficiency training. The equipment must be used in indoor.
2. Before using you shall check the performance of the cylinder, oil pipe, air hydraulic pump of the lifting
frame hydraulic system. You shall make sure their performance good. And you shall check the
performance of the cylinder, oil pipe, Manual pump of the pulling system, ensure the performance well
of each component. The oil pump and air pipe between of electric pump and equipment must add
protecting pipe for sleeve.
3.Don’ t touch the oil pipe when it is under pressure, the splashed pressure would shoot the skin and
cause serious injury.
4.Forbid lift oil pipe or rotated connector to lift the hydraulic equipment, and should make use of handle
or other safety method.
5.Assorted air-hydraulic pump of lifting frame air supply pressure could not beyond 0.8Mpa.

6. When the working platform stop at some height, you must rotate back support frame to the support
position to lock; if with the self-lock equipment, must make the ratch of self-lock equipment to support
the fixed rack effectively.

7. When you want to lowers the working platform, you must separate the pawl from the pawl rack.
8. The connection between the pulling system and the working platform must be firm. Before

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straightening you must check it.

9.Before straightening, you shall check the chain to assure it undamaged. Chain, hoist strap couldn’t be
used to hoist heavy object

10. Before straightening, the clamps must clamp the vehicle tightly.

11. The connection among the chain, the clamps and the clamped parts must be reliable

12. During the straightening process, man is forbidden to stand behind the tower and in the direction of
the chain pulling force, in order to ensure safety.

13. When hanging arm stretch, pulling force couldn’t beyond 1.5 ton, pulling arm
couldn’t be used to hoist heavy, avoid to cause any injury to person and
repaired auto.

Maintenance
1. After finishing your work, you shall clean up the dust. And you shall put away the clamps and
measuring elements.
2. The hydraulic oil in the cylinder, air hydraulic pump and manual pump shall be replaced every half a
year. For the operation ways you can read the manual books.

Series Universal Collision Repair Equipment Operation Regulations

1. Must wear the work clothes 、 glove when come into the sheet metal operation area, disallow to

wear babooshes or high-heel shoes.

2. Equipment operation environment illuminate should not under 500LX, the temperature range

-30℃～+40℃。If exceed the temperature, it should equip the ventilating device or heating furnace

according to the situation.

3. Equipment could not make use overload, or else would cause the invalidation of the equipment or

staff injure.

4. Check work before operate the equipment

1 Should clear up the work area before operate the equipment, forbid pile up anything around

the working platform, in order to avoid workers lip and stumble, and cause fire and explosion, to cause

workers injured.

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2 Clean up the oil gas pipeline, avoid pressing the pipeline when operate. Check the adaptor of

pipeline whether connect well, if there is breakage in the pipeline, it should be changed immediately if

there is breakage, and forbid use again.

3 Check the oil pump, change the hydraulic pressure oil when it work every three months (four

hours /day), spill all the used oil, clean up the dunghill of the reservoir, fill with the Mobil No. 24 25 or

Great Wall No. 46 etc. high quality hydraulic pressure oil.

4 Supply the air of the air hydraulic pump should be no-dust, no-water. Must connect the

oil-water separator on the air line, change the sieve core every three month. Air pressure scope is

0.6-0.8MPa, Firstly eliminate all the seeper before use it every time.

5. Air supply must add separate switch, the switch should indicate clearly, such switch should lock up,

and could unloading after cut off the energy.

Drive on or off the vehicle operation rulers

1. During the working platform rise and drop, forbidden to stand around the equipment, the distance
between the operated air pump and the working platform should be more than 0.5m. Except with the

mechanism self lock, don’t stand on the upside or underside of the working platform only depend on the

support of hydraulic pressure.

2. Operate stabilily when the working platform rise and drop, it is better to operate slowly by hand when

the working platform drop need release pressure, avoid foot operation to cause release pressure

quickly so that the working platform fall sharply and cause shock to damage the equipment and the

vehicle.

3. When the working platform rise and drop, the pulling tower fixed on the end of the working platform

by the bolt, prevent slippage. Place the secondary lifting on lower position.

4. The vehicle stop at the appointed position, stop at park/neutral place.

5. Forbid worker carry in the maintain operation under the platform.

6. When the platform rise, forbid non-operational worker manipulate the pneumatic pump, avoid

mistaken operate cause worker injure.

Vehicle fix operated rules

1. Check the clamp mouth, without the oil dust before clamp the vehicle.

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2. Check all the clamp part whether distortion and crack or not, if it have, should be changed. Avoid

fracture under force and fly off to injure people.

3. Main clamp fix bolt \ the clamp mouth, fix the bolt tightly, it should be screw down.

4. The pulling tower pin holes around the working platform shouldn’t be used as the vehicle fixed

holes.

The Measure Device Operated Rules

1. The measuring tool should put up or down lightly, do not collide, prevent it mangling.

2. The eyes should parallel with the reading mark, reduce the reading tolerance.

3. The measuring tools should take back the original place of tool cart after finish measure.

4. Don’t screw down with stronger force when the connect bolts of the measuring tools loose.

Stretch operate rule

1.Check the chain、sheet metal tool ,pulling Ring whether completely good、if there is breakage and rift

in pulling ring, make sure it is right, then used it.

2.Check the chain direction、lock mechanism, chain can’t distortion , all the chains should be on the

same line direction.

3. When pulling, it must add safety rope on the chain, connect the safety rope with the solid element of

the vehicle chassis, avoid the slipping of clamp, chain collapse break, fly off to injure people.

4. The pulling force do not exceed the rating load of the tool, the rating load of the tool is 5 ton, the

chain shorten tool rating load is 8 ton, the chain hook rating load is 10 ton.

5. Don’t whack the sheet metal tools and the chain when pulling.

6. Wedge the locating block slanting rion tightly of the pulling tower before pulling, and two

bolts insert to the right position.

7. Never be at the same line direction between the worker and the chain force direction when

pulling.

8. Put the heavy goods on the chain when pulling, to avoid mistake operation and the chain fly off to

injure the worker and equipment.

9. Fix the vehicle spindle on the working platform by the chain on the reverse side of the pulling force,

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when the pulling force is stronger.

10. Clean up the working area after operation. The sheet metal tools 、the measuring tools、the

clamps should be clean then put back the tool cart neatly.

Equipment maintenance operation rules

1. Do usually besmear the butter to the race of the pulling tower, defend the race to rust then affect the

pulling tower rotate agilitily.

2. When pneumatic pump (manual pump) and oil cylinder are not work, must screw on the dust cap

of the quick coupling quickly, avoid the entrance of dirt, avoid the invalidation of the pump, oil

cylinder etc.

3.When the hydraulic pressure system appear any problem, don’t disassemble it for repair by yourself,

avoid to attaint or lost the components and then could not repair, Never adjust the relief valve by

yourself, if have any question, please contact with Yantai Primacy Industry Co.,Ltd as soon as

possible.

Hydraulic pressure system common problems and solutions

1. Hydraulic cylinder plunger leaks oil:

Change the cylinder inside seals, if change it, still leaks seriously, it indicate the plunger fray seriously,

need change the plunger, should mail to our company repair.

2. Hydraulic cylinder coupler leaks oil:

Screw off the adaptor and quick coupling, wrap the airproof belt, then screw tighten again, if still leaks

seriously, need change the adaptor.

3. Hydraulic pump oil pump adaptor leaks oil:

The solution is same as above.

4. Hydraulic oil pipe leaks oil:

If two adaptor position leak oil, the solution is same as above, if the pipe have damaged , need to

change it, strictly prohibit re-used.

5. Oil cylinder plunger could not extensionto the place:

Check the oil capacity, supplement hydraulic oil.

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6. Hydraulic cylinder could not retract

Air block phenomenon, the cylinder have air.

(1) Press again and again, release pressure many times, place the pump on the higher than cylinder,

let air return oil box.

(2) Use the jack replace cylinder to support, screw down the cylinder adaptor, let the plunger recur , oil、

air will push out, then screw up the couplers, assemble pipe, press again and again, release pressure

many times.

(3) Quick coupling may not screw tighten , two couplers and the unilateralism value have gap, return

flow restricted.

7.Lifting、pulling force less than full force

(1)Check the air pressure whether below 0.6MPA or not,

(2)Check the air、oil pipe couplers whether leak out or not,

(3)Check the pump whether block or not,

(4)The relief valve of hydraulic pump return flow don’t close down completely, have the dirty blocked,

please mail to our company repair.

8. Press on the hydraulic treadle, it doesn’t work.

(1) Air channel isn’t open.

(2) Control valve damage

(3) Much water、dirty in pump, lead to air plunger can’t work, need to mail our company repair.

9. without pressure after press on pump treadle

(1) Oil-in blank off and oil couldn’t enter

(2) Oil-in check valve, overflow valve blank off, damage, please mail to our company for repair.

10. Do not keep pressure:

(1) Oil pipe leaks oil

(2) The pump inside check valve blank off or damage, please mail to our company for repair.

11. Leak oil below the pump treadle

Replace the airproof pillow.

12. If the damaged parts in the pump, please mail to our company for repair. Do not disassemble for

repair by yourself, avoid to attaint or lost the components, can’t repair. The client disassemble for repair,

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lost , damage the part of oil pump, oil cylinder, our company has no responsible for maintenance or

receive all the cost for purchase the new component.

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Attached list 1

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Attached list 2

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Important description of Goods Receipt:

Visual inspection all parts, whether there is transportation damage, it

not include in contract repairing that the damage made during the

transportation. If there is transportation damage, please inform

carrier. Carrier should responsible for the transportation damage,

they should pay for maintain and change cost that cause by

transportation damage.

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