Draper BR4/KIT, BR10/KIT Instructions Manual

4 TONNE BODY REPAIR KIT

10 TONNE BODY REPAIR KIT

■ MODEL No.BR4/KIT ■ STOCK No.37874

■ MODEL No.BR10/KIT ■ STOCK No.37875

04/2000

• INSTRUCTIONS •

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY TO ENSURE

THE SAFE AND EFFECTIVE USE OF THIS TOOL.

KNOW YOUR BODY REPA IR KIT

1. METAL STORAGE CASE

2. 495mm EXTENSION BAR

3. 420mm EXTENSION BAR

4. 215mm EXTENSION BAR

5. 100mm EXTENSION BAR

6. 85mm EXTENSION BAR

7. SERRATED CAP

8. HYDRAULIC SPREADING WEDGE

9. RUBBER HEAD 60mm DIA

10. FLAT SERRATED BASE

11. RAM TOE

12. PLUNGER TOE

13. CLEFT HEAD

14. ‘V’ BASE

15. DOUBLE END MALE SNAP CONNECTOR

16. 4 TONNE PUMP UNIT

17. HYDRAULIC PUSH RAM UNIT

18. HYDRAULIC HOSE

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■ MODEL No.BR4/KIT. 4 TONNE BODY REPA IR KIT

(1)

(2)

(17)

(16)

(15)

(14)

(13)

(12)

(11)

(10)

(9)

(8)

(7)

(6)

(5)

(4)

(3)

(18)

KNOW YOU R BODY RE PAIR KIT

1. METAL STORAGE CASE

2. 685mm EXTENSION BAR

3. 455mm EXTENSION BAR

4. 250mm EXTENSION BAR

5. 100mm EXTENSION BAR

6. SERRATED CAP

7. HYDRAULIC SPREADING WEDGE

8. RUBBER HEAD 80mm DIA

9. FLAT SERRATED BASE

10. RAM TOE

11. PLUNGER TOE

12. CLEFT HEAD

13. ‘V’ BASE

14. DOUBLE END MALE SNAP CONNECTOR

15. 10 TONNE PUMP UNIT

16. HYDRAULIC PUSH RAM UNIT

17. HYDRAULIC HOSE

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■ MODEL No.BR10/KIT. 10 TONNE BODY REPAIR KIT

(1)

(2)

(16)

(15)

(14)

(13)

(12)

(11)(10)

(9)

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IMPORTANT SAFETY RULES

1. Never exceed the maximum load capacity of the ram.

2. Do not over extend the ram, as it is possible to force the plunger out of the top of
the ram.

3. When coupler valves are disconnected always insert dust cap to keep the oil lines
clean.

4. If the load is not centred to the ram plunger, pump carefully. If you have to use
excessive pressure to pump the ram, stop the operation and adjust the set-up so
that the load is more central. This should decrease the effort required.

5. Do not drop any heavy objects onto the hose, and do not allow the hose to kink.

6. Always allow clearance for the hose to avoid damage to the hose and couplers.

7. Keep the equipment away from heat or fire, as this may damage or weaken the
equipment.

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OPERATING INS TRUC TIONS

PUMP U NIT

1. Connect the hydraulic ram and pump unit
hose together, ensure you have securely
fastened the couplings before pumping.

2. Firmly close the release valve (A) by
turning it in a clockwise direction. Fig.1.

3. Apply pressure to the pump (B) by
pumping the handle up and down. Fig.1.

4. To release the pressure turn the valve
anti-clockwise.

NOTE: The pump can be used in any

position ie horizontal to vertical.
Always keep the hose end of the
pump unit facing downwards when
positioned vertically. Fig.2.

ATTACHMENT COMBINATIONS

The pump unit can be used with the multi
directional ram. This enables many
attachment combinations, some of which are
shown on page 4.

Fig.1.

Fig.2.

SUGGESTED SYSTEM ASSEMBLIES

- 4 -

For confined areas the hydraulic spreading
wedge should be used

RAM EXTENSION EXTENSION

FLAT
BASE

RUBBER RAM
HEAD

RUBBER RAM
HEAD

FLAT
BASE

FLAT
BASE

RUBBER
HEAD

PLUNGER

TOE

RAM

SADDLE RAM

PUMP

SPREADER

PUMP

CARE A ND MA INTENANCE

1. When the body repair kit is not in use, the pump unit should be stored with the
release valve open.

2. To check oil level, place the pump unit in
an upright position. As indicated on the
diagram opposite. Remove the dip stick
and the oil level will be indicated.
If required add hydraulic oil until it is
level with the full mark on the stem. YOUR
JACK WAS FILLED AT THE FACTORY
WITH HIGH GRADE HYDRAULIC OIL.
ONLY USE APPROVED OIL.*

3. After extensive use, the oil supply should
be replaced to ensure longer equipment
life. To drain, remove the dip stick and
open release valve. Ensure that no dirt
gets into the system. Refill with approved
jack oil, as paragraph 2.

* We recommend Shell Telus 22.

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NOTES:

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TROUBLE SHOOTING

TROU BLE PROBA BLE CA U S E REMEDY

Pump unit will not work. Dirt on valve seats/Worn seals. Replace with new seals.

Pump unit will not produce Air block (1) Open the release
pressure

or

valve and remove oil
filler plug.

Pump unit feels unsteady Air block (2) Pump handle a couple
under load.

or

of full strokes and close
the release valve.

Pump unit will not lower Air block (3) Replace filler plug.
completely.

Pump unit will not produce The reservoir could be To check the oil level.
pressure overfilled or low on Remove the filler plug. Top

hydraulic oil level. up oil to correct level.

Pump unit feels unsteady The pump cup seal could Replace the cup seal with
under load. be worn out. a new one.

Pump unit will not lower Air block. Release air by removing
completely filler plug.

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DRAPER TOOLS LIMITED,

Hursley Road, Chandler's Ford, Eastleigh,
Hants. SO53 1YF. U.K.
Helpline: [phone].
Sales Desk: [phone].
General Enquiries: [phone].
Fax: [phone].

©Published by Draper Tools Ltd.

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