Clarke CS 10SBRK, 7617010 User guide

BODY REPAIR KIT

MODEL NO: CS4BRK, CS10BRK & CS10SBRK

PART NO: 7617000, 7617005 & 7617010

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS DL0922 - Rev 5

INTRODUCTION

Thank you for purchasing this CLARKE Body Repair Kit. This manual covers the
compact 4 Tonne Kit and the larger 10 Tonne kits, the CS10SBRK featuring a
faster acting hydraulic pump.

Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.

GUARANTEE

This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.

This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.

Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.

This guarantee does not effect your statutory rights.

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SPECIFICATIONS

CS4BRK CS10BRK CS10SBRK

Weight (complete in case 17.6 kg 30 kg

Moulded case dims (LxWxH) mm 580x215x170 720x390x160

Length of handle 265mm 465 mm

Pressure relief pressure 4 ton 10 ton

Pump unit dimns (LxWxH) 330x130x140 510 x140 x140mm

Pump rated operating pressure 63 Mpa 62 Mpa

Pump oil capacity 250 g 500 g

Hose dimns (Lx O/D) 1150 x17mm 1350 x17mm

Max operating pressure 140 psi

Ram unit length (ret/ext) 270 x 395 mm 370 x 512mm

Ram rated operating force 4 Tonne 10 Tonne

Ram piston stroke 125 mm 142 mm

Hydraulic spreader dimns 230x50x60mm 230 x 50 x 65mm

Spreader max rated load 0.5 Tonne

Spreader opening 16-90mm 20-100mm

Base rated load 4 tonne 10 tonne

Angled toe rated load 4 tonne 4 tonne

Circular head rated load 4 tonne 10 tonne

Square V-head 4 tonne 10 tonne

Rubber head 4 tonne 10 tonne

Plate head 4 tonne 10 tonne

Removable connector 4 tonne 10 tonne

Extension tubes 2 tonne 5 tonne

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SAFETY PRECAUTIONS

WARNING: THE OPERATOR MUST FOLLOW ALL INSTRUCTIONS WITHIN THIS
INSTRUCTION BOOKLET

WORK AREA

1. Keep the work area clean and well lit. Cluttered and dark areas invite
accidents.

2. Keep children and bystanders away while working. Distractions can cause
you to lose control and bystanders should be kept at a safe distance from
the working area especially when work is in progress.

PERSONAL SAFETY

1. Stay alert, watch what you are doing and use common sense when using
this equipment. Do not operate this equipment when you are tired, ill or
under the influence of alcohol, drugs or medication.

2. Do not over-reach. Keep your proper footing and balance at all times. This
enables better control of the equipment in unexpected situations.

3. Concentrate on the job in hand, no matter how trivial it may seem. Be
aware that accidents are caused by carelessness due to familiarity.

4. Do not wear loose clothing or jewelry which may get caught in moving
parts. Wear protective hair covering to contain long hair. For best footing,
wear rubber soled footwear. Keep floor clear of oil, scrap wood, etc.

5. Before working on a vehicle with this repair kit, ensure the vehicle is well
supported and completely stable.

6. Remember that during body repair, there is always the possibility of a fixture
slipping or a body part failing, which could cause the vehicle to jolt
suddenly. If the vehicle is not adequately supported, it could fall with
possibly serious consequences.

7. Never use an additional extension handle to operate the pump.

8. Never modify this equipment in any way.

9. Check the equipment for damage before use. Any damaged part should
be discarded and replaced. Check for alignment of parts, breakage of
parts, and any other condition that may affect the operation. Any
damage should be properly repaired or the part replaced. If in doubt, DO
NOT use. Consult your local Clarke dealer.

10. Store out of the reach of children and do not allow persons unfamiliar with
these instructions to use this product.

4

UNPACKING

This complete kit contains the heavy duty hydraulic equipment needed for
lifting, pushing, pulling, straightening and spreading.

When unpacking, check for damage or shortages etc. Any found should be
reported to your CLARKE dealer where the product was originally purchased.

This Body Repair Kit is supplied with the following components:

1 Hydraulic Spreader Wedge 7 Plate Head

2 Pump Assembly with Hose 8 Wedge Head

3 Hydraulic Ram 9 Male Connector

4 Flat Base 10 Angled Toe

5 Rubber Head 11 Serrated Cap

6 Square V-Head 12 4 x Extension Tubes

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OVERVIEW

This body repair kit is designed for bending chassis frames and repairing dents
in vehicle body panels. In most cases, the kit will only return the vehicle body
parts to approximately their original position. Additional work will be required
to complete the repair.

There are two attachments which can be connected to the pump unit.

• The Hydraulic Ram is for use in larger spaces where greater force is

needed and where there is sufficient room. It requires a solid
immovable base, directly in line with the damaged area.

• The Spreader Wedge is used in tighter spaces where the Ram and

other accessories will not fit.

THE ATTACHMENTS

Several different attachments are provided that may be used in conjunction
with the Hydraulic Ram dependant upon the nature of the damage.

•The Flat Base is used to spread the load of the Hydraulic Ram. It

should be connected to the static end of the Hydraulic Ram using
the Male Connector.

•The Rubber Head is typically used for popping dents out of sheet

metal such as doors and body panels when plugged into the
moving end of the Hydraulic Ram or the Extension Tubes.

•The Square V-Head is used to align the force of the Hydraulic Ram

when bearing against an angled frame, and may be attached to
the Hydraulic Ram or the Extension Tubes.

•The Wedge Head is used to repair small dents and areas located in

angles and tight spaces and attaches to the Hydraulic Ram or
Extension Tubes.

•The Male Connector plugs into the female end of the Hydraulic Ram.

•The Angled Toe and Plate Head are normally attached to the

extension tubes but could be used as a substitute for the flat base if
space is limited.

•The Serrated Cap is used for pushing during frame repair. It may be

plugged into either end of the Hydraulic Ram or Extension Tubes.

•The Extension Tubes plug together in different combinations to reach

the desired length.

•The Hydraulic Spreader Wedge is used in restricted spaces when the

Hydraulic Ram cannot be used. Connect the wedge directly to the
hose of the pump unit.

6

ASSEMBLY

When assembling the Hydraulic Ram, Pump unit and attachments, unscrew
and retain the plastic end plugs on the connections of the Ram and Hydraulic
Spreader Wedge for future use. Ensure the hydraulic hose is tightly screwed to
the connection.

1. Screw the Pump Handle into the socket in the pump unit.

2. If the Hydraulic
Spreader Wedge is
to be used, connect
the screw-in
connector of the
pump hose to the
spreader wedge as
shown in Fig 1.

3. If the Ram is to be
used, fit the Flat Base to the static end of the Ram using the male
connector. Connect other attachments to the moving end as required.

• Various combinations of extension tubes and attachments can be

assembled as shown in Fig 2, according to the distance between
the work surface and the supporting frame.

7

OPERATION

Assemble the components including the flat base and as many extension
tubes as required.

CAUTION: NOTE THAT WHEN ADDING FURTHER EXTENSION TUBES, THE
MAXIMUM RATED LOAD IS REDUCED. (SEE WARNING LABEL)

1. Connect the Hydraulic Ram or Hydraulic Spreader to the connecting hose
using the screw-on hose connector. Use the male connector to join the
ram to your selected attachment or any extension tube.

2. To operate the Hydraulic Pump, position it on a stable, level surface close
to the damaged area. Close the Release Valve by turning it clockwise and
pump the handle to create pressure.

3. Turn the Release Valve counter-clockwise to release the pressure.

• The pump may be positioned horizontally or vertically. When using

the Hydraulic Ram in a vertical position, always keep the hose end
facing downward.

CAUTION: NEVER OVERLOAD THE RAM BEYOND ITS CAPACITY. ENSURE
THE BEARING POINT IS STABLE AND PROPERLY CENTRED ABOVE THE
RAM. NEVER OVERLOAD THE ATTACHED COMPONENTS BEYOND THEIR
RATED CAPACITIES AS STATED IN THE SPECIFICATION.

Always apply the load slowly to be sure that everything is secure. Take care
that the load is always in line with the ram.

USING THE RAM

1. Determine in which direction the target area needs to be pushed.

2. Remove any obstructions that are in the way and could be damaged.

3. Connect the Flat Base to the stationary side of the Hydraulic Ram and
connect the appropriate attachment to the working end of the Ram.

NOTE: When repairing larger body panel dents such as a dented door,

wing or quarter panel, the correct pushing attachment will be
the Rubber Head.

4. Position the Hydraulic Ram so that the flat base is resting against a frame
member opposite the damaged area. It must be in line with the direction
in which the damaged area needs to be pushed and have enough
support that only the damaged area will be displaced by the ram pressure.

• Use soft pads or wooden supports where necessary to protect the

body.

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5. Aim the pushing end towards the damaged area and slowly apply
pressure with the pump.

6. Once contact is established at each end, keep as well clear as practical
and slowly apply pressure to the damaged area until the desired
correction has been made.

CAUTION: KEEP HANDS AWAY FROM CONTACT AREAS AND TIGHT
SPACES IN CASE THE COMPONENTS SHOULD SLIP AND CAUSE INJURY.

7. When the damaged area has been bent to the desired position, slowly turn
the release valve on the pump unit in a counterclockwise direction to
release hydraulic pressure before removing the Ram.

USING THE SPREADER WEDGE

1. Determine in which direction the metal needs to be spread.

2. Remove any obstructions that are in the way and could be damaged.

3. Place the Spreader Wedge so that the hinged arm is resting against the
part to be moved and the stationary base is bearing against a rigid
support. Hold the Spreader Ram in position and apply the pump pressure.

4. Once contact is established at each end, keep as well clear as practical
and slowly apply pressure to the damaged area until the desired
correction has been made.

CAUTION: KEEP HANDS AWAY FROM CONTACT AREAS AND TIGHT
SPACES IN CASE THE COMPONENTS SHOULD SLIP AND CAUSE INJURY.

5. When the damaged area has been bent to the desired position, slowly turn
the release valve on the pump in a counterclockwise direction to release
hydraulic pressure before removing the wedge.

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MAINTENANCE

If the pump has been stored for long
periods, check the oil level before
use. Stand the pump on a level
surface and remove the breather
valve on the oil reservoir. If necessary,
top up via the breather valve which is
then screwed on finger tight.

NOTE: Only unscrew this when the

system is not under pressure.

The oil level should be near the
bottom of the opening. If required, oil can be topped top using Clarke
Hydraulic Oil. (part no. 3050830 for 1 litre).

After extensive use, the hydraulic oil should be replaced to ensure longer
equipment life. Do not overfill, or the piston rod will be unable to move freely.
Replace the breather valve after re-filling. The required oil volumes are as
follows.

• CS4BRK - 250 ml +

• CS10BRK/CS10SBRK - 500 ml +

5ml

5ml

STORAGE

After use, screw the valve cover on
to the pump to keep the connection
clear of dust and dirt and cover the
hydraulic hose end with the plastic
cap.

When not in use, the pump should be
stored with the release valve open.
Store all the equipment in its case in a
clean, dry environment protected
from the weather.

ENVIRONMENTAL PROTECTION

One of the most damaging sources of environmental pollution is oil products.
Never throw away used hydraulic oil with domestic refuse or flush it down a
sink or drain. Collect any hydraulic oil in a leak proof container and take it to
your local waste disposal site.

If disposing of this product or any damaged components, do not dispose of
with general waste. This product contains valuable raw materials and should
be taken to your local civic amenity site for recycling of metal products.

10

SPARE PARTS

In the event of lost or damaged components, replacements are available
from Clarke Parts & Service. Please refer to the following parts list and
diagrams, quoting the Clarke part numbers:

• HT-CS4BRK-01 to 69

• HT-CS10BRK-01 to 69 or

• HT-CS10SBRK-01 to 69

FAULT F IN DI NG

PROBLEM CAUSE SOLUTION

Ram does not
operate when
handle is
pumped

Ram will not hold
load.

Ram reluctant to
lower when load
removed.

Ram will not
extend to full
range of stroke

Release valve not
tightly closed.

Air trapped in
system

Release valve not
tightly closed.

Malfunction in
pump such as dirt
inside valve
mechanism.

Oil reservoir
overfilled.

Piston binding. Clean and lubricate moving parts.

Low oil level. Add hydraulic oil to the reservoir.

Firmly close the release valve.

Purge air from the system by
pumping the operating handle.

Firmly close the release valve.

Return pump to dealer for overhaul.

Drain oil to the correct level

Ram tries to tilt to
one side.

If any of these remedies fail to restore your equipment’s performance, consult
your CLARKE dealer.

Poor positioning of
the footing

Stop work and reposition ram and
base, ensuring it is well supported
and as close to the perpendicular to
the repair as possible.

11

COMPONENT PARTS

No Description No Description

1 Plastic Case 29 Screw

2 Tube Set (4 pieces) 30 Steel Ball

3 Flat Base 31 Ball Cup

4 Angled Toe 32 Spring

5 Plate Head 33 Screw

6 Wedge Head 34 Screw Protector

7 Square V-Head 35 O-ring

8 Male Connector 36 Nylon Sealing Ring

9 Serrated Cap 37 Screw

10 Rubber Head 38 O-ring Seal

11 Valve Body 39 Piston

12 Oil Filter 40 Hinge Pin

13 O-ring 41 Circlip

14 Oil Reservoir 42 Pivot Pin

15 Seal Ring 43 Handle Socket

16 Thumb Nut 44 Operating Handle

17 Sealing Ring 45 Handle Grip

18 Tie Rod 46 Ram Cylinder

19 O-ring 47 Cylinder End Cap

20 Pump Foot 48 Screw-on Cover

21 Hydraulic Hose 49 Screw M6

22 Coupling 50 Connecting Nut

23 Dust Seal 51 Cylinder Screw

24 Steel Ball 52 O-ring

25 O-ring 53 Dust Cover

26 Hand Release Valve 54 Tension Spring

27 Sealing Ball 55 Circlip

28 Spring 56 Nylon Sealing Ring

12

COMPONENT PARTS - GENERAL ASSEMBLY

13

COMPONENT PARTS - SPARE

No Description No Description

57 Bushing 64 O-ring

58 O-ring 65 Screw Cover

59 Piston Rod 66 Moving Jaw

60 Piston End Cover 67 Circlip

61 Fixed Jaw 68 Hinge Pin

62 Small Piston 69 Spring

63 Piston Ring

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DECLARATION OF CONFORMITY

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