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Operation Manual
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 -
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
Fixed Type
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.
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.
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 .
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.
5 Magnetism Probe 1
Screw Cap
11 1
Probe
3、Part Introduction
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)
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.
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.
19 C clamp M2 5 ton
20 G clamp M3 5 ton
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.
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
图 15
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.
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.
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.
Maintenance
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
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.
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
3. Equipment could not make use overload, or else would cause the invalidation of the equipment or
staff injure.
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.
pipeline whether connect well, if there is breakage in the pipeline, it should be changed immediately if
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
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,
mechanism self lock, don’t stand on the upside or underside of the working platform only depend on the
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.
6. When the platform rise, forbid non-operational worker manipulate the pneumatic pump, avoid
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.
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.
2.Check the chain direction、lock mechanism, chain can’t distortion , all the chains should be on the
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
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
9. Fix the vehicle spindle on the working platform by the chain on the reverse side of the pulling force,
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.
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.
Change the cylinder inside seals, if change it, still leaks seriously, it indicate the plunger fray seriously,
Screw off the adaptor and quick coupling, wrap the airproof belt, then screw tighten again, if still leaks
If two adaptor position leak oil, the solution is same as above, if the pipe have damaged , need to
(1) Press again and again, release pressure many times, place the pump on the higher than cylinder,
(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.
(4)The relief valve of hydraulic pump return flow don’t close down completely, have the dirty blocked,
(3) Much water、dirty in pump, lead to air plunger can’t work, need to mail our company repair.
(2) Oil-in check valve, overflow valve blank off, damage, please mail to our company for repair.
(2) The pump inside check valve blank off or damage, please mail to our company for repair.
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,
Attached list 1
Attached list 2
not include in contract repairing that the damage made during the
they should pay for maintain and change cost that cause by
transportation damage.