PB30
The Blackhawk mobile repair system PB30 offers
a completely portable repair system that can easily
be moved around the workshop. This ensures ease
of access to the most difficult repair job even in
a limited space. The equipment is available in a
single-pull or a two-pull version. Easy working
access is ensured by the absence of lift corner
posts. It provides a body shop with a versatile and
comprehensive means of undertaking crash repairs
accurately and efficiently, with minimal disruption
to vehicle components.
The complete repair system consists of a base
frame and two main elements: a totally independent
measuring system allowing complete flexibility
of operation, and a pulling system using the Vector
principle for precise directional pulling and pushing.
The base frame is manufactured from polarized
steel. It supports the vehicle, the pulling arm
and the measuring system. The vehicle is attached
to the frame using sill clamps which are wedged
into lateral beams. The vehicle may be loaded on
to the sill clamps by using a high-lift trolley jack,
a two-post lift or a side loading lift (Figure 14.39).
by the vehicle manufacturers to establish vehicle
dimensions. The extension scale not only measures
height, but when installed on a telescopic cross slide
it also measures width. These cross slides glide
backwards and forwards on a longitudinal beam to
record length measurements. Data sheets provide
the necessary information to identify the cars main
measuring points. Pneumatic activators (air bellows)
align the system to key datum points on the vehicle
using respective adaptors from the range supplied.
These adaptors rise to contact the car underbody and
are held firmly in position by air pressure. They stay
with the vehicle owing to the elasticity of the air
bellows, and any pressure changes on the measuring
unit are controlled by internal regulators. The measuring
unit is then perfectly located and parallel to
the zero plane and the manufacturers datum line.
These adaptors are engineered to locate precisely,
and in use are selected according to the information
given on the vehicles data charts which show adaptor
type, datum points and their coordinates (see
Figure 14.40).
The hydraulic repair system includes a multidirectional
push-pull facility together with accessories.
The measuring system can be used with ground
anchorage collision repair systems as well as mobile
repair systems.
Car-O-Liner repair and measuring
Systems
Car-O-Liner have introduced the Mark 5 alignment
jig system together with a drive-on collision repair
system called BenchRack and an electronic measuring
system called Car-O-Tronic which can be
used on both jigs.
The Mark 5 collision repair system
This is a universal measuring system developed
from the Mark 4 system. It can be either mobile,
static or with a built-in lift. The Mark 5 is capable
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of lifting a car to a height of 1.4 metres using the
scissor lift, thus allowing the bodyshop staff to
work standing up, and therefore reducing stress and
increasing speed and productivity. It provides
increased working room between the jig and the
vehicle, therefore allowing ease of access for movement
and tools. Positioning the vehicle is achieved
with the help of rolling ramps. After the ramps have
been used, they can be folded up and used as stands
Figure 14.39 Blackhawk PB 31/8 mobile straightening
and measuring system (Blackhawk Automotive Ltd)
The measuring system works on the principle that
a measuring scale can locate vital alignment points
in the length, width and height on every vehicle
model. These measurements are taken from the zero
plane or datum line. The zero plane is the most basic
but accurate of all available references, and is used
Major accident damage 429
or as a work stool, thus helping to keep the workshop
free from additional equipment. The correct
pulling angle is essential for successful alignment
work. The Draw aligner finds the pulling angles
easily with almost continuous adjustment and has a
built-in telescopic extension arm which allows for
repairs needing high pulls.
The Mark 5 equipment consists of the following:
alignment bench, Draw aligner, measuring system
(Figure 14.41).
The base frame of the alignment bench is a
welded structure built from square cross-section
tubing, and can be fitted with an integral scissor lift
or a single column lift. The upper surface of the
frame is milled flat to serve as a reference plane,
and there are milled tracks on all four sides for
attachment of bench wheels, bench mountings and
jack plates. The bench mountings are located in the
side tracks of the base frame and can be adjusted
for height. The mounting arms can be turned either
inwards or outwards to suit the width of the vehicle.
The chassis clamps are bolted to the arms of
the bench mountings and are fitted with tooth jaws
which grip the sill flanges of the vehicle.
The dolly sets consist of a number of components
which can be used in various combinations and are
mounted on the bench frame. Any required point on
the vehicle can be fixed in position by the use
of these dolly combinations. They can also be used
for controlling the pull in certain directions during
alignment and as a welding fixture when new parts
are to be welded in.
Figure 14.40 Blackhawk PB30 measuring system (Blackhawk Automotive Ltd)
Figure 14.41 Mark 5 collision repair system
(Car-O-Liner (UK) Ltd)
430 Repair of Vehicle Bodies
The Draw aligner is used with a 10 tonne hydraulic
ram operated by a pneumatic foot pump, and can be
placed at any position along the four sides of the base
frame, being locked on to the base frame by the locking
wedge. The Draw aligner pivots in the sideways
direction and is locked in the required position by a
peg. Next the arm can be inclined in the sideways
direction to give the optimum pulling angle, then
locked in position. The arm is fitted with an extension
for high pulls. A safety wire is fitted between the arm
and the hydraulic ram mounting in order to limit the
outward movement of the arm (Figure 14.42).
data sheet for the particular vehicle (Figure 14.43).
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Equipment is also available to measure the upper
anchor points of MacPherson struts together with the
dimensions of the engine compartment and the
whole of the upper body (Figure 14.44).
Figure 14.42 Mark 5 bench showing the scissor lift
and Draw aligner (Car-O-Liner (UK) Ltd)
Figure 14.43 Mark 5 measuring system (mechanical)
(Car-O-Liner (UK) Ltd)
Figure 14.44 MacPherson strut measuring
equipment (manual) (Car-O-Liner (UK) Ltd)
The measuring system can be either mechanical or
electronic. The mechanical system consists of a
measuring bridge which is made of aluminium and is
provided on both sides with movable measuring
tapes for length measurements. It is designed to be
placed on the flat milled surface of the base frame.
The measuring slides decide the width measurements
and run along the measuring bridge. There is a pullout
slide on each side of these which is provided with
three mounting holes for height tubes. Readings are
made on scales on the side of the tubes. These height
tubes are of various lengths and marked with sliding
scales with millimetre graduations for reading height
measurements. There are various measuring adaptors
such as sockets, cones and angle blocks which are
fitted into the top of these height tubes. The combination
of height tube and scale adaptor that should
be used at the point to be measured is shown in the
Major accident damage 431
The data sheet files contain checklists for most
car models and show height, length and width
dimensions at a number of measuring points on the
vehicle. The data sheet also gives information on
the correct points for placing the chassis clamps
for locating the vehicle on the bench.
Drive-on collision repair system BenchRack
The BenchRack can be used on passenger
vehicles and light transport vehicles. The ramp
system enables the vehicle to be secured to the
bench quickly. The BenchRack is equipped with
a built-in hydraulic scissor lift which can lift a
weight of 3 tonnes to a height of 1.4 metres,
allowing the operator to select quickly a suitable
height for any type of repair undertaken. The 12
removable ramp sections are made from lightweight
alloy and fitted in the tracks on the side
of the bench. The ramps can be removed when
necessary to facilitate access when measurements
are taken or alignment work is carried out.
Adjustable chassis clamp arms may be raised or
lowered as needed, or can also be turned in for
use on pick-up trucks and other narrow framed
vehicles. Chassis clamps hold the vehicle secure
while pulling is taking place. Two 9 tonnes Draw
aligners provide the pulling force, 360 degrees
around the BenchRack. The side support system
is used to hold undamaged and already repaired
components in place while pulling other areas.
The measuring can be carried out using the
Mark 5 mechanical system or the Car-O-Tronic
electronic system, for fast and accurate measurements
of any vehicle damage.
Car-O-Tronic measuring system
The Car-O-Tronic is an electronic computerized
measuring system that is universal. It is designed
primarily to measure and check the dimensional
correctness of vehicle chassis. Car-O-Tronic
measures either with reference to the Car-OLiner
data sheet or on an absolute basis. Advanced
mathematics and computer technology mean that
this system can be used without any other special
equipment. All that is needed to make the system
operational is a flat smooth surface, a measuring
bridge, the electronic measuring arm and a hand
terminal (Figure 14.45). The system is easy to
operate: the measuring arm is moved along the
bridge underneath the vehicle and simultaneously
measures the length, width and height at the
precise data measuring points, displaying this on
the hand terminal and then comparing the results
with the manufacturers data stored in its data
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bank. This immediate, accurate information
regarding the extent of the distortion sustained by
the vehicle determines whether or not the vehicle
will need straightening and subsequently pulling.
This information is then fed back to a remote
computer terminal upon which it is displayed.
A hard copy can be taken via a printer linked to
the computer. The measuring system can be left
in place while the pulling process is being carried
out and can be used to determine the amount
of overpull required to bring the vehicle into
alignment with its specific manufacturers data
(Figure 14.46).
The Car-O-Tronic can also be linked into the
Auto-quote management control computer package.
This effectively allows for complete computerization
of the entire bodyshop operation.
Figure 14.45 Car-O-Tronic electronic computerized
measuring system (Car-O-Liner (UK) Ltd)
432 Repair of Vehicle Bodies
