Draper BR4/KIT User 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 YOU R 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
- 1 -
■MODEL No.BR4/KIT. 4 TONNE BODY REPAIR KIT
(1)
(2)
(17)
(16)
(15)
(14)
(13)
(12)
(11)
(10)
(9)
(8)
(7)
(6)
(5)
(4)
(3)
(18)

KNOW YOU R BODY REPA IR 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
- 2 -
■MODEL No.BR10/KIT. 10 TONNE BODY REPAIR KIT
(1)
(2)
(16)
(15)
(14)
(13)
(12)
(11)(10)
(9)
(8)
(7)
(6)
(5)
(4)
(3)
(17)

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.
- 3 -
OPERATING INS TRU CTIONS
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 AND MAINTENANCE
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.
- 5 -

NOTES:
- 6 -

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.
- 1 -
DRAPERTOOLS 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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