Blackhawk mobile repair system

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 car’s 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 manufacturer’s datum line.

These adaptors are engineered to locate precisely,

and in use are selected according to the information

given on the vehicle’s 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

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 14.39Blackhawk 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 14.40Blackhawk PB30 measuring system (Blackhawk Automotive Ltd )

Figure 14.41Mark 5 collision repair system

(Car-O-Liner (UK) Ltd )

430Repair 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).

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 14.42Mark 5 bench showing the scissor lift

and Draw aligner (Car-O-Liner (UK) Ltd )

Figure 14.43Mark 5 measuring system (mechanical)

(Car-O-Liner (UK) Ltd )

Figure 14.44MacPherson 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 manufacturer’s data stored in its data

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 manufacturer’s 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 14.45Car-O-Tronic electronic computerized

measuring system (Car-O-Liner (UK) Ltd )

432Repair of Vehicle Bodies