Assembly - Chief Automotive Technologies

Assembly - Chief Automotive Technologies

Excelerator
Parts Manual
2002 © Chief Automotive Systems, Inc.
EXCELERATOR
PARTS MANUAL
CHIEF’S LIMITED TWO-YEAR
WARRANTY & LIABILITY
Chief Automotive Systems, Inc. warrants for two years from date of
installation and/or purchase any of its products which do not perform satisfactorily due to defect caused by faulty material or workmanship. Chief’s obligation under this warranty is limited to the
repair or replacement of products which are defective and which
have not been misused, carelessly handled, or defaced by repair
or repairs made or attempted by others.
CHIEF AUTOMOTIVE SYSTEMS, INC. DOES NOT ASSUME
RESPONSIBILITY FOR ANY DEATH, INJURY OR PROPERTY
DAMAGE RESULTING FROM THE OPERATOR’S NEGLIGENCE
OR MISUSE OF THIS PRODUCT OR ITS ATTACHMENTS.
CHIEF MAKES NO WRITTEN, EXPRESS OR IMPLIED WARRANTY WHATSOEVER OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE OR OTHERWISE REGARDING
THE EQUIPMENT OR ANY PART OF THE PRODUCT OTHER
THAN THE LIMITED TWO-YEAR WARRANTY STATED ABOVE.
Returned merchandise requires a “RETURNED GOODS AUTHORIZATION NUMBER” on the package. Authorization numbers can
be obtained by calling or writing the Customer Service
Department, Chief Automotive Systems, Inc. No returned merchandise will be accepted without an authorization number. All
returned merchandise must be shipped freight prepaid (and may
be subject to a handling and restocking charge) to:
Chief Automotive Systems, Inc.
Attn: Returned Goods Department
1924 E. Fourth St.
or
P.O. Box 1368
Grand Island, Ne. 68802-1368
308-384-9747
Your Authorized
Chief Automotive Systems, Inc.
Representative
EXCELERATOR
PARTS MANUAL
Parts Information
To order replacement parts for the Chief Excelerator
System, contact an authorized representative of Chief
Automotive Systems, Inc., 1-308-384-9747 or 1-800-4459262 (USA only).
When contacting Chief Automotive Systems, Inc. by telephone or mail, provide the following information: name,
name of business, business telephone number and
busines address. Additional information needed when
ordering: description of parts and part numbers.
NOTE: Chief reserves the right to alter parts specifications
and/or package components without notice.
Bolts and Fasteners
All bolts and fasteners must be replaced with Chief
Automotive Systems, Inc. authorized replacement parts and
must not be less than Grade 5 (Class 8.8). Any bolt used in
a pulling clamp that is frequently tightened must be a Grade
8 (Class 10.9). All bolt lengths and diameters must be equal
to those installed at the factory.
CAUTION: Always use Chief Automotive Systems,
Inc. authorized replacement parts with Excelerator
Systems. When replacing any part, make certain
the part meets the original equipment requirements.
In addition to general parts information, this parts manual
contains Chief’s Warranty and Liability Statement,
Hydraulic / Pneumatic Diagrams and Machine
Specifications.
Chain
The 1/2 inch tower chain furnished with this product is a
special alloy frame straightening chain designed exclusively for Chief Automotive Systems, Inc. to meet the rigid
requirements of the collision repair industry. The 1/2” chain
is proof tested to 28,000 lbs. and has a normal working load
limit of 13,000 lbs. If replacement is required, purchase only
the original Chief product from an authorized Chief
Automotive Systems, Inc. representative.
Electrical Components
All electrical cords and components must be replaced with
Chief Automotive Stystems, Inc. authorized replacement
parts.
Hydraulic Hoses
The 3/8” auxiliary chain furnished with this product is a special allow frame straightening chain designed exclusively
for Chief Automotive Systems, Inc. to meet the rigid requirements of the collision repair industry. The 3/8” chain is proof
tested to 20,000 lbs. and has a normal working load limit of
7,300 lbs. If replacement is required, purchase only the original Chief product from an authorized Chief Automotive
Systems, Inc. representative.
The 1/4” I.D., two wire hydraulic hoses furnished with this
product meet the requirements of SAE 100R2 and have a
working pressure of 5,000 psi. They should not be used
with any other system having a higher than 5,000 psi output. All hydraulic components must be replaced with Chief
Automotive Systems, Inc. authorized replacement parts.
Pneumatic Hoses
CAUTION: DO NOT use the 3/8” auxiliary chain on
Excelerator towers.
The pneumatic components with this product meet the
specified requirements and have a working pressure at or
above 150 psi. They should not be used with any other system having a higher psi output. All pneumatic components
must be replaced with Chief Automotive Systems, Inc.
authorized parts.
Labels
Replacement SAFETY and WARNING labels are available
in several languages and may be ordered by contacting an
authorized Chief Automotive Systems, Inc. representative.
1
EXCELERATOR
PARTS MANUAL
Mainframe — Overview
2
4
18
3
9
7
6
1
19
8
6
5
20
17
10
11,12
13
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
602870
601169
607161
305548*
305215
305203
305202
305214
539350
305024*
305051
305062
692334
305746
305811
305489
305784
648880
702076
305536*
305178*
305038
305422
305421
305722
305037
305035
305293
305294
634012
*
Description
Tower Chain/Hook
Tower Head
Collar Assembly
Force Arm Assembly
Loading Ramps
Ramp Pivot Support (RH)
Ramp Pivot Support (LH)
Pivot Support Lock
Pin, Ball Dent, 5/32 Dia. x 2” Ring
Crossmember Assembly
Leveling Pad
Leveling Adjustment Screw
Leveling Nut
Pressure (Force) Gauge
Remote Control, Includes Cord
Bar, Rub Rail, Removable (Short)
Manifold Plug
Wheel Stop
Universal Anchoring Stand, Set of 4
Tower Mast/Arm Weldment
Scissor Lift Assembly
Screw 10-32 x 1/2 Self-Locking
Stainless Trim Ring, Manifold
Coupler Guard, Manifold
Connector, Male Flat Face
Screw 10-32 x 1 Self-Locking
Screw,7/16 x14 .750 Socket Hd.Cap
Weldment, Carriage Stop LH
Weldment, Carriage Stop RH
Bolt, 5/8-11 x 1 1/2 gr. 8 Hex
See also exploded views
14
10
11, 12
26
16
15
25
27
24
28
2
23
21
22
EXCELERATOR
PARTS MANUAL
Crossmember Assembly
3
4
2
5
1
Ref. Part No.
1
2
3
4
5
305024
305484
305485
657782
305066
305039
Description
Crossmember Assembly
Weldment, Crossmember
Weldment, Crossmember Release
Handle, Lock Pin Auxiliary
Spring, 3/4 bore x 2.5 length x k32
Screw, 1/4-20 x 4 1/2 Socket Head Cap
3
EXCELERATOR
PARTS MANUAL
Force Arm Assembly
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
305548
305549
305557
305552
305608
305553
707479
770105
305560
305542
305044
305045
Description
9
Force Arm Assembly
Weldment, Force Arm Tower Collar
Weldment, Force Arm Taper Block
Tube, Force Arm Outer Telescope
Machined Inner Telescope
Pin, Grooved 1.00 Dia x 4.81 Long
Washer, 1” Thrust Plated
HD Retaining Ring
Pin, Force Arm Vertical Position
Knob, Force Arm
Pin, Self-locking Shoulder Style - 3”
Pin, Force Arm Taper Block
11
2
Item 9 must be
threaded until
holes line up
with Item 2
stud, and Item
11 can be
pressed into it.
4
10
3
7
1
6
Item 8 to be centered
in Item 3.
6
8
4
5
7
EXCELERATOR
PARTS MANUAL
Manifold Assembly
Ref. Part No.
1
2
3
4
305711
305710
305712
305713
305714
5
305715
6
7
305718
305717
8
305714c
9
305713c
10
305715n
11
305712n
12
13
601046
305721
14
305729
15
305029
Description
9
Manifold Assembly
Manifold Block
Valve, Tandem 3 Position, 4 Way
Valve, Double Poppet 2 Way
Valve, Normally Open Poppet 2
Way
Valve, Normally Closed Poppet 2
Way
Coil, 120 VAC, 14 Watt DIN
Coil, 120 VAC Series 10-20 Watt
DIN
Retainer, Plastic-Included with
305718 Valve
Retainer, Plastic-Included with
305718 Valve
Retainer, Nut-Included with
305715 Valve
Retainer, Nut-Included with
305712 Valve
Fitting, Hyd #6MB-#6MJ
Fitting, Hyd - 6MB Hollow Hex
Plug
Flow Control, Pressure
Compensated Front
#8 Flat Washer
11
9
6
10
6
7
6
7
8
3
6
3
6
15
14
2
4
4
5
12
5
1
13
EXCELERATOR
PARTS MANUAL
5
6
4
3
2
Tower
(Mast)
Assembly
5 6
7
8
9
1
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
305536
602829
607161
601201
693468
707487
680747
601070
601169
305538
601050
601055
601738
305189
305730
16
17
305727
602870
Description
Tower Mast/Arm Weldment
Locking Knob, Tower Collar
Machined Collar
Roller, 5 x 1/2 Chain - S21/Posi Trak Collar
Snap Ring, HD for 1 1/4 Shaft
Washer, Flat - 1 1/4 ID x 1 7/8 OD x 14 ga. pl.
Pin, Grooved for Cast Collar
Screw, 3/4-10 x 3.5 Socket Head Cap
Tower Head Weldment
Tower Linkage
Pin, 3/16 x 1 3/8 Spring
Nut, 3/4-16 Hex Slotted
Washer, 3/4 Flat
Pin, Scissor Lift Short
Ram, Tower-3” Bore x 10 1/8 Stroke, Bottom
Load
Tower Hydraulic Line Assembly
Chain, 10-Ton
17
10
12
13
14
5
5
15
16
6
11
EXCELERATOR
PARTS MANUAL
Tower (Arm) Assembly
Ref. Part No.
1
2
3
4
305536
305574
305067
707487
5
6
7
8
693468
11059
305567
305730
9
10
11
12
13
305419
12452
18069
305528
305057
14
15
16
17
18
629853
305530
305527
305036
305380
19
20
21
22
305383
629837
305034
697029
23
305065
24
305568
Description
1
Tower Mast/Arm Weldment
Bar, Carriage Release
Grip, Carriage Release Bar
Washer, Flat-1 1/4 ID x 1 7/8 OD x 14
ga. pl.
Snap Ring, HD for 1 1/4 Shaft
Screw, 1/4-20 x 1 3/4 SHC
Washer, Cable Release Retainer
Ram, Tower-3” bore x 10 1/8 Stroke,
Bottom Load
Pin, Tower Cylinder Retainer
Bolt, 1/4-20 x 1/2 Hex Head
Nut, 1/4-20 Hex
Force Arm Inner Telescope Assembly
Spring, Die, 5/8 Bore x 1 1/2 Long
x 656k
Washer, 1/4 Split Lock
Housing Cap, Tower Lock Arm
Spring Pusher, Tower Arm Lock
Bushing, 3 1/2 Bore x 2 3/8 Length DU
Washer, Tower Arm to Carriage Pin
Thrust 1/8 Thick
Cap, Tower Arm to Carriage Retainer
Washer, 3/8 Split Lock
Nut, 3/8-24 Hex
Bolt, 3/4-10 Countersunk Socket
Head Cap Screw
Cam Follower, 7/8 Roller x 3/8-24
Thread Sealed Stud Type
Cable Jacket, Carriage Release
2
23
16
17
3
13
12
17
11
18
19
5
4
20
9
21 22
10
5
4
14
15
24
7
6
7
8
EXCELERATOR
PARTS MANUAL
Tower Carriage Assembly
Torque to 75 ft. lbs.
17
9
10
11
Outer Spacer
12
Inner Spacer
Outer race - two per
bearing ass’y
18
4
20
Inner race and cage two per bearing ass’y
Apply anti - seize
compound to shaft
and threads before
installation
14
24
Torque to 18 ft. lbs.
21
3
Torque to
76 in. lbs
1
15
6
22
8
26 16
13
7
2
Torque to 11 ft. lbs. dry
Ref. Part No.
1
2
305493
011064
305026
3
4
5
305027
305032
305033
6
305053
7
305055
8
9
305056
305058
10
11
305060
305061
Description
23RH
5 19LH
Ref. Part No.
Tower Carriage Assembly
Screw, 1/4-20 x 3.0 Socket Hd Cap
Bushing, 1/2 bore x 3/4 Long DU
Flange
Busing, 1” bore x 1” Long DU
Bearing Set, Double Taper
Screw, 5/16-18 Thread 3/8 x 1/2
Shoulder
Spring, 1” Bore x 1 1/2 Length Extra
Heavy Die
Cam Follower, 5/8 Roller x 1/4 - 28
Thread Sealed Stud
Nut, 1/4-28 Hex
Cam Follower, 2 1/4 OD 7/8-14
Thread Sealed Stud Type
Nut, 7/8-14 Hex Nylock
Spring, 1” Bore x 3.5 Long Hvy Duty
8
12
305063
13
14
15
16
17
18
19
20
21
22
23
24
25
26
305064
305338
305341
305347
305353
305448
305492
305494
305497
305498
305499
305504
692334
629853
Description
Washer, 3/4 ID x 1 1/4 OD x 3/32
Thick Shim
Spherical Washer Set
Pin, Carriage Tensioner
Bar, Carriage Tensioner
Roller, Carriage Vertical
Pin, Carriage to Deck
Wheel, Carriage Outside
Rest Pad, Carriage LH
Vertical Pin
Axle, Carriage
Weldment, Carriage
Rest Pad, Carriage RH
Washer, Bearing Dust Cover
Nut, 5/8-11 Hex Jam
Washer, 1/4 Split Lock
EXCELERATOR
PARTS MANUAL
Scissor Lift
3
9
Long Pin Exploded
3
7
8
2
6
5
2
10
1
Short Pin Exploded
7
6
5
4
6
7
5
Ref. Part No.
1
2
3
4
5
6
305178
305168
305170
305176
305189
693468
707487
7
305030
8
9
10
305161
305184
305445
Description
Assembly, Scissor Lift
Weldment, Scissor Channel
Assembly, Inner Scissor Leg
Assembly, Outer Scissor Leg
Pin, Scissor Lift Short
Snap Ring, HD for 1 1/4 Shaft
Washer, Flat-1 1/4 ID x 1 7/8 OD x
14 ga. pl.
Washer, Thrust-1 1/4 ID x 2 1/2 OD
x 1/16 Self Lubricating
Pin, Scissor Lift Long
Lock Arm, Excelerator Herringbone
Assembly, Lift Cylinder
9
7
7
7
7
7
6
5
EXCELERATOR
PARTS MANUAL
Hydraulic System Components
Remove Coil To
Access Bolt.
3
Loosen Nut
And Remove
Coil To Access
Bolt.
14
15
13
11
10
10
6
5
7
8
9
12
2
Rotate Coil To Right To
Access Bolt Hole.
Right
Side - A
Right
Side - B
13
16
8
9
Tank
4
Left Side- A
1
Left Side - B
7
8
9
17
Ref. Part No.
1
2
3
305823
305711
305700
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
305735
305748
305749
707410
629853
629247
012452
629781
706302
601046
305752
305720
305736
305777
305780
305781
305785
305786
305787
305788
305789
305790
305791
Pump 1
Front Lift
Back Lift
Pump 2
Description
Control Box Assembly
Assembly, Control Manifold
Power Unit, 220VAC Double w/2.5
gallon reservoir
Filter, Return Line
Fitting,. Hyd. - 6MBX - 6MJ-6MJ Run T
Fitting, Hyd. - 6FJX - 6MJ-6MJ Run T
Washer, 1/4 Flat
Washer, 1/4 Split Lock
Nut, 1/4-20 NC gr. 2 Hex pl.
Screw, 1/4-20 x 1/2
Bolt, 1/4-20 NC x 2” gr. 2 Hex pl.
Bolt, 1/4-20 NC x 4” gr. 5 Hex pl.
Straight Adapter, 6400-6-6
Straight Adapter, 8MB-6MJ
Fitting, Hyd. - 6MBX-6MJ
Filter Head
Valve Assembly
Solenoid Valve, 2 pos-5way
Filter
Fitting, 1/8 NPT Short Nipple
Fitting, Male Y, 1/8 NPT to 5/32 PTF
Breather, 1/8 NPT
Fitting, Adapter, 1/4 NPT to 1/8 NPT
Fitting, 1/4 NPT Union T
Fitting, Male Run T, 1/4 NPT to 3/8 PTL
Coupler, Pneumatic
22
26
21
23
25
24
21
18
22
19
10
20
EXCELERATOR
PARTS MANUAL
Decal Packages
Decal Package
Chief
Excelerator
305095
Decal Package
Mainframe
Excelerator
305099
Decal Package
Tower
Excelerator
305097
Part No. Req’d
305080
305081
305082
305083
305084
305085
305086
305087
305088
305089
305090
305091
305092
305093
305094
692140
692143
693337
693338
693339
693340
683673
Part No.
305080
305081
305082
305086
305088
305089
305090
305091
305093
305094
692140
692143
693338
693339
093340
Part No.
693337
305092
305087
305085
305083
2
2
2
6
44’
6
6
6
4
1
1
4
6
6
1
2
2
3
1
2
1
4’
Description
Decal, Excelerator
Decal, “Z” Art
Decal, Chief EZ Liner
Decal, Tower Gusset Indian Head
Tape, Black Striping 1”
Label, WARNING — Excelerator Force Arm
Label, CAUTION — Excelerator Crossmember
Label, CAUTION — Excelerator Tower Arm
Label, CAUTION — Excelerator
Label, CAUTION — Excelerator Machine Operation
Label, IMPORTANT — Excelerator Oil Reservoir
Label, CAUTION Excelerator Safety Lock Arms
CAUTION, Excelerator — Objects Clear Of Tower
Label, CAUTION — Excelerator Wheel Stops
WARNING, Excelerator DO NOT Enter Enclosure
Decal, 308 - 384 - 9747
Label, CAUTION : Lifting Of Persons Is Prohibited
Label, WARNING DO NOT Position Yourself
Label, WARNING — Fire
Label, CAUTION, Egress / Ingress
Label, Nuts, Bolts & Clamps
Tape, Red, 1” Wide
Req’d
2
2
2
6
4
1
1
4
6
1
2
2
1
2
1
Description
Decal, Excelerator
Decal, “Z” Art
Decal, Chief EZ Liner
Label, CAUTION — Excelerator Crossmember
Label, CAUTION — Excelerator
Label, CAUTION — Excelerator Machine Operation
Label, IMPORTANT — Excelerator Oil Reservoir
Label, CAUTION — Excelerator Safety Lock Arms
Label, CAUTION — Excelerator Wheel Stops
WARNING, Excelerator — DO NOT Enter Enclosure
Decal, 308 - 384 - 9747
Label, CAUTION : Lifting Of Persons Is Prohibited
Label, WARNING — Fire
Label, CAUTION, Egress / Ingress
Label, Nuts, Bolts & Clamps
Req’d
1
2
2
2
2
Description
Label, WARNING — DO NOT Position Yourself
Label, CAUTION — Excelerator Objects Clear Of Tower
Label, WARNING — Fire
Label, WARNING — Excelerator Force Arm
Decal, Tower Gusset Indian Head
11
EXCELERATOR
PARTS MANUAL
305424
H
D
305776
Ref
601046
Ref
305722
(4)
305848-5/32” Airline
Cut to 15’-5/32”: Qty. 2
Ref
305720
Ref
305777 (4)
N
System Schematics
F
I
Q
Q
H
Ref
305722 (4)
Front Lift
G
Ref
601046
I
305753
Q
305747
305423
Ref
305749
K
305738
V2 .082
Ref
305752
L
Ref
305742
J
Relief Valve
3600 PSI
305737
V5
Q
C
305742
305744
305735 Return Filter
Ref
601046
I
305739
Ref
601046
305740
I
305711 V4 )(.078 T P1 P2
12
Relief Valve
3600 PSI
L2 L3 L3 L1
305741
305743
V6
Up
V1
V3
305852 - 3/8” Airline
Cut to 34” L
305852 - 3/8” Airline
Cut to 74” L
Ref
305722 (4)
P
305750
(Next Page)
o
305747
305423 C
E
H
305723
305753
305750
Ref
305720
305723
H
Ref
305724
Cut to 13’ 5”
Conduit Down Left Side Of Machine Along Inside Wall
Cut to 42” : Qty 2
F
Ref
601046
305848 - 5/32” Airline
305776
N
G
305852 - 3/8” Airline
L
305852 - 3/8” Airline Cut to 13’ 5”
Ref
305724
Ref
305720
See Control
Manifold Layout
D
Back Lift
305424
I
305777
Ref
305720
Ref
305720
H
EXCELERATOR
PARTS MANUAL
Control Manifold Layout
Part No. 305711
L1
L2
P1
P2
T
A1
A2
=
=
=
=
=
=
=
1U
To Front Lift
To Rear Lift
Pressure In From Pump 1
Pressure In From Pump 2
To Filter And Then Tank
Supplies “A” Side
Supplies “B” Side
1D
V4
L2
P2
V5
V2
L1
P1
V6
V3
A1
B1
A1
B1
T
Machine Specifications
Weight Of Machine
Lift Capacity . . . . . .
Power Required . . .
Hydraulic Power . .
Hydraulic Fluid . . . .
Controls . . . . . . . . .
Length . . . . . . . . . .
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Width . . . . . . . . . . . . . . . . . . . . . . . .
Tower Height . . . . . . . . . . . . . . . . . .
Clearance . . . . . . . . . . . . . . . . . . . .
Working Heights . . . . . . . . . . . . . . .
Tie Down Openings . . . . . . . . . . . .
Radius Of Pull . . . . . . . . . . . . . . . . .
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. 9,860 lbs (with three towers)
. 8,500 lbs.
. 220V/60Hz. single phase, 16 amps (20 amp breaker)
. 10 tons per tower (89kN) at the hook
. L SUS 215 Viscosity, 100 Degrees F (38C), 10W
. Programable logic control with 5 button cord deck size controller
. 22’ mainframe only
27’ 9” w/ towers extended to front and rear
23’ 6 1/2” w/one tower extended
26’ 2” w/loading ramps installed
. .89” mainframe only
119” with one tower extended to side
148” with two towers extended to both sides
. .108 1/2” with mainframe at highest working height
128” with tower extended at end of mainframe and opposite
end of mainframe at lowest working height
118” with mainframe at highest working height and tower head
extended upward
. .150” required on all sides
. .34”
33”
31”
29”
26”
22”
18”
. .299
. .360 degrees
13
P.O. Box 1368
Grand Island, Nebraska 68802-1368
Phone 308-384-9747
Fax
308-384-8966
CHIEF AIRCO EUROPE
CA de TREMBLAY CHARLES DE GAULLE
18, rue Henri FARMAN
93297 TREMBLAY EN FRANCE CEDEX
TEL 01 41 51 16 80
FAX 01 48 60 09 88
www.chiefautomotive.com
Form EPM (9/03)
Part No. 305103