DRAPER 94185 4 Tonne Body Repair Kit User Manual

DRAPER 94185 4 Tonne Body Repair Kit

• These instructions accompanying the product are the original instructions. I his document is part or the produCt,
• Keep it tor the lite o the product passing it on to any subsequent holder of tne product. Head all these instructions
• Derore assemoling, operating or maintaining this product.
• This manual has been compiled by Draper Tools describing the purpose for which the product has been designed, and contains all the necessary intormation to ensure its correct and sare use. By Tollowing, all the general sarety instructions contained in this manual, it will ensure both product and operator safety, together with longer life of the product itself.
• All photographs and drawings in this manual are supplied by Draper Tools to help illustrate the operation of the product.
• Whilst every effort has been made to ensure the accuracy of information contained in this manual, the Draper Tools policy of continuous improvement determines the right to make modifications without prior warning.

TITLE PAGE

INTRODUCTION

USER MANUAL FOR:4 TONNE BODY REPAIR KIT

• Stock No: 94185
• Part No: BR4/KITC

REVISION HISTORY:

• Date first published November 2019
• First revision June 2022
• As our user manuals are continually updated, users should make sure that they use the very latest version.
• Downloads are available from: http://drapertools.com/manuals
• Draper Tools Limited
• Hursley Road
• Delta International
• Delta International BV
• Oude Graaf 8
• 6002 NL
• Chandler’s Ford
• Eastleigh
• Hampshire
• SO53 1YF
• Weert
• Netherlands
• UK
• Website: drapertools.com
• Product help line: +44 (0) 23 8049 4344
• General Fax: +44 (0) 23 8026 0784

UNDERSTANDING THIS MANUALS SAFETY CONTENT

• WARNING!- Information that draws attention to the risk of injury or death.
• CAUTION!- Information that draws attention to the risk of damage to the product or Surroundings.

COPYRIGHT © NOTICE:

• Copyright © Draper Tools Limited.
• Permission is granted to reproduce this publication for personal and educational use only. Commercial copying, redistribution, hiring or lending is prohibited.
• No part of this publication may be stored in a retrieval system or transmitted in any other form or means without written permission from Draper Tools Limited.
• In all cases this copyright notice must remain intact.

WARRANTY

• Draper tools have been carefully tested and inspected before shipment and are guaranteed to be free from defective materials and workmanship.

• Should the tool develop a fault, please return the complete tool to your nearest distributor or contact

• Draper Tools Limited, Chandler’s Ford, Eastleigh, Hampshire, SO53 1 YF. England.
  Telephone Sales Desk: (023) 8049 4333 or Product Help Line (023) 8049 4344.

• Proof of purchase must be provided with the tool.

• If upon inspection it is found that the fault occurring is due to defective materials or workmanship, repairs will be carried out free of charge. This warranty period covering parts & labor is 12 months from the date of purchase except where tools are hired out when the warranty period is 90 days from the date of purchase. This warranty does not apply to any consumable parts, any type of battery or normal wear and tear, nor does it cover any damage caused by misuse, careless or unsafe handling, alterations, accidents, or repairs attempted or made by any person other than the authorised Draper warranty repair agent.

• Note: If the tool is found not to be within the terms of warranty, repairs and carriage charges will be quoted and made accordingly.

• This warranty applies in lieu of any other warranty expressed or implied and variations of its terms are not authorised.

• Your Draper warranty is not effective unless you can produce upon request a dated receipt or invoice to verify your proof of purchase within the warranty period.

• Please note that this warranty is an additional benefit and does not affect your statutory rights.

Draper Tools Limited.

INTRODUCTION

SCOPE

• This body repair kit is designed for use in garages or bodywork workshops.

SPECIFICATION

• Stock No ……….. ……………………………………………………………………………………………………….. 94185
• Part no. . …………………………………………………………………………………………………………….. BR4/KITC
• Safe working load … ……………………………………………………………………………………………….. 4 Tonne
• Ram max. height …. ………………………………………………………………………………………………… 270mm
• Pump working pressure …………………………………………………………………………………………… 63 Mpa
• Pump oil capacity ………………………………………………………………………………………………………. 0.25L

HANDLING AND STORAGE

• Care must be taken when handling this product.
• Dropping this tool could have an effect on its accuracy and could also result in personal injury.
• This product is not a toy and must be respected.
• Environmental conditions can have a detrimental effect on this product if neglected.
• Exposure to damp air can gradually corrode components.
• If the product is unprotected from dust and debris, components will become clogged.
• If not cleaned and maintained correctly or regularly, the machine will not perform at its best.

HEALTH AND SAFETY INFORMATION

GENERAL SAFETY INSTRUCTIONS

• Read all safety warnings and instructions. Failure to heed these markings may result in personal injury and/or property damage.
• Save all warnings and instructions for future reference.
• The warnings, precautions and instructions discussed in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.

WORK AREA

• Turn off the engine, set the parking brake and block the tyres before working on a vehicle.
• Keep the work area clean and well lit. Cluttered benches and dark areas increase the risk of injury to persons.
• Keep bystanders and children away while operating the tool. Distractions can result in loss of control of the tool.

PERSONAL SAFETY

• Stay alert. Watch what you are doing and use common sense when operating the tool.
• Do not use the tool while tired or under the influence of drugs, alcohol or medication.
• A moment of inattention while operating the tool increases the risk of injury to persons.
• Dress properly. Do not wear loose clothing or jewellery. Contain long hair. Keep hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair increases the risk of injury to persons as a result of being caught in moving parts.
• Use safety equipment. Wear safety goggles and heavy-duty work gloves during use.

TOOL USE AND CARE

• Do not force the tool. Use the correct tool for the application. The correct tool will do the job better and safer at the rate for which the tool is designed.
• Store the tool when it is idle out of reach of children and other untrained persons. A tool is dangerous in the hands of untrained users.
• Check for misalignment or binding of moving parts, breakage of parts and any other condition that affects the tool’s operation. If damaged, have the tool serviced before using.
• Many accidents are caused by poorly maintained tools.
• Use only accessories that are identified by the manufacturer for the specific tool model.
• Use of an accessory not intended for use with the specific tool model, increases the risk of injury to persons.
• Avoid off-centre loads. If the Pump seems unusually hard to operate, immediately stop.
• Adjust the Ram to eliminate or diminish an off-centre load. The Flange Base and Flange Head must QD..!y be used together to prevent an off-centre load.
• Protect the Hose. Do not drop heavy objects on the Hose. Avoid kinks in the Hose. Maintain proper clearance to avoid damage to the Hose and Couplers. Inspect repair before using vehicle. Repairs to structural or frame members must be inspected by a qualified technician to ensure that the structure is still strong enough to safely fulfil its potential.

SERVICE

• Tool service must be performed only by qualified repair personnel.
• When servicing a tool, use only identical replacement parts. Use only authorised parts.

TECHNICAL DESCRIPTION

IDENTIFICATION

1. Handle
2. Breather Valve (Oil Filler Screw)
3. Pump
4. Release Valve
5. Hose
6. Warning Line
7. Hose Coupler
8. Ram
9. Ram Coupler

Warning

• Ensure that the rated working pressure of each pressurised attachment be equal to or greater than the rated working pressure developed by the hydraullc pump.
• Always check connections before using. Alteratlon of these products Is strlctly prohibited.
• Use only those adapters and attachments provided and approved by the manufacturer.
• When extension tubes and/or offset attachments are used, the rated capacity is always reduced by 50% for each tube or offset attachment connected.
• Do not attempt to operate pump unless the Breather Valve is open.
• Do not overextend the Ram. (Do not go over the Warning Line on the Ram’s Piston.
• Do not exceed rated capacity.

UNPACKING AND CHECKING

PACKAGING

• Carefully remove the product from the packaging and examine it for any sign of damage that may have happened during shipping. Lay the contents out and check them against the parts shown below. If any part is damaged or missing please contact the Draper help line (the telephone number appears on the Title page) and do not attempt to use the tool.
• The packaging material should be retained at least during the warranty period in case the tool needs to be returned for repair.

Warning!

• Some of the packaging materials used may be harmful to children. Do not leave any of these materials in the reach of children.
• If any of the packaging is to be thrown away, make sure they are disposed of correctly according to local regulations.

WHAT’S IN THE BOX?

• As well as the Pump and Ram there are parts not fitted or attached to it.

1. Spreader
2. Extension Bars
3. Flat Base
4. Flange Base
5. Flange Head
6. Wedge Head
7. 90° V Base
8. Male Connector
9. Cap Head
10. Rubber Head

ASSEMBLY

RAM ATTACHMENTS

• The Extensions ® connect in different combinations to reach desired lengths.
• The Male Connector ® is used to connect the female end of the Ram (8) to a Base.
• The Flat Base @ is typically used on the stationary side to spread out the force of the Ram (8).
• The 90′ V Base ® is used to offset the force of the Ram ® when there is not a straight line between the stationary side and the damaged side, or to spread out forces on curved surfaces.
• The Cap Head 00 is typically used on the pushing end to prevent slipping.
• The Rubber Head @ is typically used for popping dents out of sheet metal such as doors or body panels and to minimize damage to the work surface.
• The Wedge Head @ is used to repair small dents and areas located in angles and tight spaces.
• The Flange Base ® and Flange Head ® are used together to allow spreading in areas that the Ram cannot fit into.
• Note: The Flange Base and Flange Head must only be used together to prevent an off-centre load.

SPREADER SETUP – FIG. 1

• The Spreader GQ) is used when the Ram ® is too long to fit between the stationary side and the damaged area.
• Clean the end of the Hose® and the inlet on the Spreader GQ).
• Unscrew and save the Dust Covers located on the end of the Hose® and Spreader GQ).
• Attach the Hose® to the Spreader Wedge GQ), as shown below:

FIG.1

ASSEMBLY

RAM SET UP – FIG. 2

• When extension tubes and/or offset attachments are used, the rated capacity is always reduced by 50% for each tube or offset attachment connected.
• Clean the end of the Hose CD and the inlet on the Ram®· Unscrew and save the Dust
• Covers located on the end of the Hose CD and Ram®·
• Attach the Hose to the Ram.
• Assemble attachments as shown below:

FIG.2

Push and stretch

Spread

OPERATION AND USE

TO OPERATE PUMP – FIGS. 3 – 5

• Check the Hydraulic Fluid Level, following the instructions in the Cleaning and Maintenance section.
• Determine which direction the frame needs to be bent.
• Remove any obstructions that could be damaged or are in the way.
• Position the Pump Unit on a stable, flat and level surface.
• Close the release valve by turning it clockwise until it is firmly closed. Pump Handle to apply pressure.
• Turn the Release Valve counter-clockwise to release the pressure.
• Note: The Pump Unit may be positioned horizontally or vertically. When using the Hydraulic Pump@ in a vertical position, always keep the Hose ® end of the Hydraulic Unit downward.

TO OPERATE RAM

• Connect the appropriate Base(@,@, 00) to the stationary side of the Ram® and connect the appropriate head to the pushing end of the Ram.
• Note: When repairing larger body panel dents such as a dented door, fender or quarter-panel use the Rubber Head ® on the pushing end.
• If using the Flange Base ® or Flange Head ®: Thread the Flange Base onto the Ram completely and align the Flange Head to it. The Flange Base and Flange Head must only be used together to prevent off-centre load.
• Position the Ram ® so that the Base is resting against a frame member opposite the damaged area. It must also be in line with the direction in which the damaged area needs to be pushed. The vehicle body part must be stronger than the area to be bent or it may be damaged. A block of wood or a towel may be used to protect the body part.
• Aim the pushing end towards the area that needs to be repaired and slowly apply pressure with the Pump ®·
  Note: To prevent damage, do not overextend the Ram.

TO OPERATE SPREADER (C)

• Place the Spreader G[) so that the hinged (pushing) arm is resting against the part to be moved and the stationary arm is resting against a non-movable base.
• Carefully hold the Spreader in position and apply pressure with the Pump®·

Warning!

• Once both ends have made contact, move as far away as possible and continue to slowly apply pressure to the damaged area until the desired bend has been made.
• CAUTION! Keep hands away from contact areas and tight spaces. The tool may slip and cause injury.
• When the damaged area has been bent to the desired position, slowly turn the Release Valve counter-clockwise to release the hydraulic pressure and remove the Ram ® or Spreader G[).
• Clean all hydraulic ports and cover them with clean Dust Covers to prevent contamination and damage

MAINTENANCE

CLEANING AND MAINTENANCE

• Keep the surface of this tool and its accessories free of hydraulic fluid and grease. Use only a mild detergent and damp cloth when cleaning. Do not use a flammable or combustible solvent to clean this tool or its accessories.
• Before each use, examine the general condition of the tool and its accessories. Check for loose components, misalignment, binding of moving parts, broken parts and any other condition that may affect its safe operation. Do not use a damaged tool or its damaged accessories.
• Keep hydraulic connections clean. Clean all hydraulic ports and replace Dust Covers immediately after use.
• Store the Pump® with the Release Valve open.

FILLING AND BLEEDING HYDRAULIC FLUID – FIG. 6

• If the Pump ® operation feels spongy, or the Ram ® lowers while the Release Valve is closed, there may be air in the Pump. Bleed the Pump as follows:
• Set Pump ® flat on a level surface.
• Remove the Fill Screw®· The Seal Ring should come off with it.
• The fluid level should be near the bottom of the opening. If required, add high grade hydraulic fluid.
• Make sure the Seal Ring is still in place around the Fill Screw and thread the Fill Screw into the
• Pump securely. Do not use thread seal tape.
• Firmly close the Release Valve by turning it clockwise.
• Press the tip of the Coupler against a hard surface and pump the pump handle.
• Continue pumping until the hydraulic fluid coming out the end of the Coupler tip is free of air bubbles.
• Recheck the fluid level and add fluid if necessary.
• Turn the Release Valve counter-clockwise to release the pressure in the Pump and Hose.

CHANGING HYDRAULIC FLUID

• Change the hydraulic fluid yearly.
• Remove the Fill Screw and tilt the Pump ® to drain out the old fluid.
• Refill the hydraulic fluid and bleed the system several times to ensure all air is out of the system.

TROUBLESHOOTING

TROUBLESHOOTING GUIDE

closed.

–    Air in the pump.

–    The steel ball is immersed inside for too long a time.

| –     Firmly close the release valve.

–     See Filling and Bleeding Hydraulic Fluid on page 13.

–     Please follow these steps:

1.  Open the release valve by turning it counter-clockwise, pump up the handle

10 – 15 times.

2.  Close the release valve by turning it clockwise, pump up the handle 5 – 1O times.

3.  Repeat steps 1 and 2 about 3 times.

Ram will not hold load.| –    Release valve not tightly closed.

–    Malfunction in pump such as dirt inside valve mechanism.

| –     Firmly close the release valve.

–     Please follow these steps:

1.  Open the release valve by turning it counter-clockwise, pump up the handle

10 – 15 times.

2.  Close the release valve by turning it clockwise, pump up the handle 5 – 10 times.

3.  Repeat steps 1 and 2.

Ram reluctant to lower when load removed.| –    Oil reservoir overfilled .

–    Piston binding.

–    Overextend the Ram .

| –     Drain oil to correct level.

–    Clean and lubricate moving parts.

–     Replace Ram.

Ram will not extend to full range of stroke.| – Low oil level.| – Add hydraulic oil to the reservoir.
Ram tries to tilt to one side.| – Incorrect use of connection or unbalanced footing.| – Stop work and reposition Ram and base, ensuring it is well supported and as close to perpendicular to the repair

as possible.

DISPOSAL

• At the end of the machine’s working life, or when it can no longer be repaired, ensure that it is disposed of according to national regulations.
• Contact your local authority for details of collection schemes in your area.

In all circumstances:

• Do not dispose of tools with domestic waste.
• Do not incinerate.
• During decommissioning of the equipment, certain hazards should be understood and avoided:
• Only with the line pressure released shall the equipment be disassembled.
• Goggles should be worn.

CONTACT US

• Draper Tools Limited, Hursley Road,
• Chandler’s Ford, Eastleigh, Hampshire. SO53 1 YF. U.K.
• Delta International BV, Oude Graaf 8, 6002 NL, Weert, Netherlands
• Help line : +44 (0) 23 8049 4344
• Sales desk: +44 (0) 23 8049 4333
• Internet: www.drapertools.com
• E-mail: sales@drapertools.com
• General inquiries : (023) 8026 6355

Service/Warranty Repair Agent:

• For aftersales servicing or warranty repairs, please contact the Draper Tools help line for details of an agent in your local area.

YOUR DRAPER STOCKIST

• DBTL1119

©Published by Draper Tools Limited.

• No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical photocopying, recording or otherwise without prior permission in writing from Draper Tools Ltd.

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