Chief EZ Liner

1 OWNERS MANUALC hief EZ LinerR1996 Chief Automotive Systems, Included:EZ Liner IIEZ Liner ClassicEZ Liner S21 RCHIEF EZ LINEROWNERS MANUALCHIEF'S LIMITED ONE-YEARWARRANTY & LIABILITYC hief Automotive Systems, Inc. warrants for one year from date of instal-lation and/or purchase any of its products which do not perform satisfactori-ly due to defect caused by faulty material or workmanship. Chief s obliga-tion under this warranty is limited to the repair or replacement of productswhich are defective and which have not been misused, carelessly handled, ordefaced by repair or repairs made or attempted by AUTOMOTIVE SYSTEMS, INC. DOES NOT ASSUMERESPONSIBILITY FOR ANY DEATH, INJURY OR PROPERTYDAMAGE RESULTING FROM THE OPERATOR S NEGLIGENCE ORMISUSE OF THIS PRODUCT OR ITS NO WRITTEN, EXPRESS OR IMPLIED WARRANTY WHAT-SOEVER OF MERCHANTABILITY OR FITNESS FOR A PARTICU-LAR PURPOSE OR OTHERWISE REGARDING THE EQUIPMENTOR ANY PART OF THE PRODUCT OTHER THAN THE LIMITEDONE-YEAR WARRANTY STATED merchandise requires a RETURNED GOODS AUTHORIZA-TION NUMBER on the package.

2 Authorization numbers can be obtainedby calling or writing the Parts Department, Chief Automotive Systems, returned merchandise will be accepted without an authorization returned merchandise must be shipped freight prepaid (and may be sub-ject to a 15 percent handling and restocking charge) to: Chief Automotive Systems, : Returned Goods Authorized1924 E. Fourth Chief Automotive Systems, Box 1368 RepresentativeGrand Island, NE 68802-1368 RCHIEF EZ LINEROWNERS MANUALCHIEF EZ LINERM odels Included:EZ Liner IIEZ Liner ClassicEZ Liner S21 This owners manual is written to familiarize opera-tors with the safe and efficient operation of the ChiefEZ Liner System. The EZ Liner System features aunique multiple/simultaneous pulling method toreturn the vehicle s damaged structure and sheetmetal to its original EZ Liner models to which this manual applyinclude the EZ Liner II, EZ Liner Classic, and EZLiner S21. While the S21 features three towers at itsfront, the EZ Liner II and Classic are outfitted withtwo to four pulling towers at the front.

3 One or twooptional towers can be added at the rear of all threesystems providing 360 degree access to the vehicle. Allthree machines tilt hydraulically for either drive on orwinch positioning of the there are subtle differences among the threesystems in regard to size and pulling capability, allthree function basically the same. Any differences thataffect basic usage are noted in this text and/or in con-junction with illustrations :Illustrations shown in this manual may varyslightly from actual manual is not intended to replace ChiefAutomotive Training. For information concerningTraining, contact Chief Automotive Systems, :1. DO NOT attempt to operate Chief EZ Liner with-out first reading this entire Complete safety information is highlightedthroughout this manual and is identified by:This safety alert symbol identifies safety informa-tion. Operator injury could result if these CAU-TION notes are not Qualified service personnel must check opera-tional capacity of EZ Liner system prior to its ini-tial use and at intervals of no more than one Chief Automotive Systems, Inc.

4 Or contactyour authorized Chief Automotive Systems, Persons operating EZ Liner repair system must beat least 18 years of age, must be trained in opera-tion of EZ Liner system, and must have demon-strated their qualifications to the employer. Theymust also be specifically assigned to operate theEZ Liner system by the employer and this assign-ment must be made in writing.!RCHIEF EZ LINEROWNERS MANUALHYDRAULIC SYSTEM COMPONENTSThe EZ Liner system is powered by an electricallyoperated hydraulic pump which is operated by aremote control switch. The components of this systemare identified in Figure pressure is distributed to tower rams, aux-iliary rams, and lift ram. The flow of hydraulic fluid toeach of these rams is controlled by a valve. Hydraulicpressure is monitored by a pressure gauge mounted onthe machine s front crossmember. To exert hydraulicpressure, press up button on hand-held switch and torelease hydraulic pressure, press down :Tower rams and auxiliary rams can beoperated either simultaneously (withequal hydraulic pressure) or individu-ally.

5 The lift ram must be operatedindividually. Whenever using thehydraulic system, close all valveswhere hydraulic pressure is :By holding switchwith Control Corddown,stress is reduced in thisarea of Button1. Pedestal2. Motor3. Pressure Gauge Hose4. Solenoid5. Valve Body6. Surge Valve7. Filter Fitting8. Hydraulic Oil Reservoir9. Lift Hose10. Pump Hose11. Hose Block12. Tower Hoses13. Auxiliary Hoses1381211110567943214. Tower Valve15. Tower Ram16. Auxiliary Ram Line Valve17. Lift Ram Valve18. Lift Ram19. Pressure Gauge20. Quick CouplerFigure 1 RCHIEF EZ LINEROWNERS MANUALF igure 2 Figure 3 Figure 4To operate hydraulic valves to the hydraulic ram(s) to be used. Closevalves to all other hydraulic rams. (See Figure 2-4.)NOTE:To open, turn valve 1/2 turn to left (coun-terclockwise). To close, turn valve to right(clockwise). DO NOT overtighten. Over-tightening can damage valve s needle Press upbutton on remote control switch to exerthydraulic pressure and press downbutton torelease hydraulic pressure.

6 (See Figure 1 Page 2.)NOTE:Hold remote control switch so its cord is ina downward position. This positioningreduces stress in this area of the Monitor pressure gauge whenever exertinghydraulic pressure. The gauge shows the amount ofhydraulic fluid pressure in the lines. Readings rep-resent pounds per square inch (psi) or barometers(bar).NOTE:Pounds per square inch (psi) readings canbe used to determine the amount of pres-sure each ram applies to its respectivechain (and vehicle). Such pressure is mea-sured in tons (kilo Newtons). For every1000 psi (70 bar) of pressure showing on thepressure gauge, there is 1 ton (9kN) of pres-sure exerted on the chain (and vehicle).Each ram that is in use will exert thisamount of :Monitor pressure gauge continuallyduring repair. Even though the EZLiner system is capable of makingstrong pulls [EZ Liner II and Classic 5 ton (45kN) maximum rating, EZLiner S21 10 ton (90kN) maximumrating], most repairs can be made at2000 psi (140 bar) or less by usingmultiple pulls and proper stressrelieving of work hardened (folded) Valve Quick CouplerTower ValveOpenCloseAuxiliary Ram Line ValveOpenCloseOpenCloseRCHIEF EZ LINEROWNERS MANUALMOVABLE CROSSMEMBERSThe EZ Liner system features two movable crossmem-bers that mount to the channels on the inner edges ofthe mainframe.

7 They can be used in front, center orrear sections of machine. Illustration on Page 1 showsnormal location of primary use of movable crossmembers is to sup-port and secure towers at ends of machine. They canalso be used as a base for making hydraulic pulls orpushes when auxiliary rams are positioned perpendic-ular (90 degrees) with top or bottom of remove crossmember from machine, hold cross-member secure while turning it counterclockwise. (SeeFigure 5.) To reinstall crossmember, reverse the proce-dure making sure it engages the channels on the inneredges of the :EZ Liner II and Classic crossmembersfeature safety crossmember locks thatmust be lifted when removing cross-member from mainframe. (See Figure6.) After crossmember is reinstalled,safety crossmember locks must belowered into position. (See Figure 7.)NOTE:EZ Liner S21 crossmembersdo not feature safety cross-member movable crossmembers are used in front or rearsections of machine, crossmember locks (see Figure 8)must be used to prevent unintentional :1.

8 Do not use movable crossmembers as a Do not use movable crossmembers as a base tomake a hydraulic pull or push unless auxiliary ramis positioned perpendicular (90 degrees) with top orbottom of During removal and installation:a. Hold crossmember Disengage and engage safety crossmember lockscorrectly. (EZ Liner II/Classic only.)c. Install crossmember locks to prevent uninten-tional movement. Crossmember locks are notdesigned to secure crossmember as a base forhydraulic 5 Figure 6 Figure 7 Figure 84!Safety Crossmember Locks in position.(EZII and Classic only.)Lift SafetyCrossmember Locks(EZII and Classic only.)Movable Crossmember LocksRCHIEF EZ LINEROWNERS MANUALTOWERSThe EZ Liner System is equipped with pulling towersat front of machine. Optional rear towers are alsoavailable. Multiple pulls can be set up quickly and arecontrolled by a hand-held remote control and elevated pulling angles can be made orchanged in just a fraction of a :(EZ Liner II/Classic Systems)Normal working range of 3/8 inch (10mm)tower chain and tie down chain is 500 to3,650 psi (35 to 250 bar) on pressure gaugewith applied force to the chain of 7,400 lbs.

9 (33kN). Proof test on this tower chain andtie down chain is 20,000 lbs. (90kN).CAUTION:(EZ Liner S21)Normal working range of 1/2 inch (13mm)tower chain is 650 to 4,745 psi (45 to 325bar) on pressure gauge with applied force tothe chain of 9,620 lbs. (43kN). Proof test onthis tower chain is 28,000 lbs. (125kN). Thenormal working range of 3/8 inch (10mm)tie down chain is listed in preceding CAU-TION :The following information on towersrelates to front towers only! Although much ofthis information is applicable to rear towers,refer to Auxiliary Tower Owners Manualforspecific operate front towers:NOTE:Tower operation requires use of tower pins ortower tie bolts. The following procedure refer-ences use of tower pins. Tower tie bolt applica-tions appear on Page Swing tower to desired lateral pulling angle and pinit to mainframe or movable crossmember. (SeeFigure 9.) Tower pin can be used in any tie downhole or along edge of machine.

10 (See Figure 10.) DONOT position tower pin in front of or at rear of mov-able crossmember as it will apply excessive stressto crossmember locks. Instead, install tower pinthrough crossmember tie down hole. (See Figure 9.)Tower pin must be fully seated in lower pinninghole to avoid damage to top pinning hole. (SeeFigure 11.) adjust slack tower chain, grip chain on each sideof tower. (See Figure 12.) Lift out on tail of chainuntil it is approximately 45 degrees from disengage chain from tower head and pullchain to either increase or decrease amount of 9 Figure 10 Figure 125 Tower PinTower PinPinning PlatePin must be seated inthis Lower 11 Pull in this chain herewith opposite Grip chainhere withone hand.!!RCHIEF EZ LINEROWNERS MANUAL3. Support collar with one hand while loosening collarlocking knob with opposite hand. Then position col-lar approximately 3 inches (75 mm) above desiredpulling height and retighten collar locking knob.