Position body on straightening bench, check and align if necessary

AR60.10-P-0100SO

Position body on straightening bench, check and align if necessary

08.03.2019

Model

450.3/4

BLACKHAWK straightening systems

1

Straightening bench

2

Anchoring attachments

1

Straightening bench

2

Anchoring attachments

3

Universal longitudinal member RH

4

Universal longitudinal member LH

5

Universal cross supports

Setup, removal

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

Notes on performing repair, body work and welding on vehicles with airbags and RTE units

AH91.00-P-0002-01M

1

Install straightening bench (1)

 The assembly instructions must be taken from the BLACKHAWK assembly plan.

2

Secure universal longitudinal member LH (4), universal longitudinal member RH (3) and universal cross supports (5) on left and right on straightening bench (1)

 The number and position of universal cross supports (5) and position of universal longitudinal member LH (4) and universal longitudinal member RH (3) depend on the BLACKHAWK assembly plan. Straightening bench (1) is divided in longitudinal direction into grids (arrow). The grids (arrow) are identified by numbers (arrows) on side straightening bench flange.

3

Secure anchoring attachments (2) on left and right on straightening bench (1)

 Anchoring attachments (2) are float-mounted on straightening bench (1).
It must be ensured that anchoring attachments (2) are attached so that body weight is optimally distributed.

4

Mount modular bases according to damage history on universal longitudinal member LH (4), universal longitudinal member RH (3) and universal cross supports (5)

 To align body, two measuring points must, in each case, be set up on left and right in non-deformed area of body.
The assembly instructions must be taken from the BLACKHAWK assembly plan enclosed with the straightening set.

5

Assemble and set up measuring points in each case on left and right on modular bases

 Measuring points that impede the attachment of the body are only assembled and set up at a later point in time.
The assembly instructions must be taken from the BLACKHAWK assembly plan enclosed with the straightening set.

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

6

Lift body with vehicle lift and align straightening bench (1) underneath by means of the setup measuring points

7

Align anchoring attachments (2) with lift support points at longitudinal member outer shell of body

8

Lower body with vehicle lift, position in anchoring attachments (2) and attach steel clamping jaws of anchoring attachments (2)


It must be ensured that body is securely clamped in steel clamping jaws of anchoring attachments (2),
as it can otherwise be torn out during the straightening processes.

9

Assemble and set up measuring points that have not yet been set up, in each case, on left and right on modular bases

 The assembly and setup instructions must be taken from the BLACKHAWK assembly plan enclosed with the straightening set.



Check

10

Compare position of measuring points with approach points at body, read off measured values at corresponding scales and compare with BLACKHAWK assembly plan

11

Check entire body for offset

Straightening

12

Release measuring points in deformation area from body

13

Mount straightening equipment on straightening bench (1)

 The assembly instructions must be taken from the BLACKHAWK assembly plan.

14

Straighten body with straightening equipment

15

Approach and set up measuring points in deformation area

 The setup instructions must be taken from the BLACKHAWK assembly plan enclosed with the straightening set.



Check

16

Compare position of measuring points with approach points at body, read off measured values at corresponding scales and compare with BLACKHAWK assembly plan

 Repeat straightening process and subsequent test process if necessary.

17

Remove straightening bench (1) in reverse order

18

Repair all paint damage that has occurred on body in area of measuring points and anchoring attachments (2)