kincrome K15145 User manual

4T & 10T
HYDRAULIC BODY
REPAIR KITS
12
QUICK FIT
ACCESSORIES
STURDY
METAL
STORAGE
BOX
4T & 10T
RATED
CAPACITY
K15145 - 4 Ton
K15146 - 10 Ton
ED1 (Jan 17)

2
4T & 10T HYDRAULIC BODY REPAIR KITS
50FAN
Table of Contents
Know Your Product..................................... 2
Understanding Your Product ..................... 4
Assembly Instructions................................ 5
Operation Instructions ............................... 5
Care & Maintenance................................... 6
Trouble Shooting ........................................ 7
Warranty...................................................... 9
11 10
12 13
14
15 16
9
6
7
8
2
1
3
45
SPECIFICATION
Model No...................................................... K15145 ............................................ K15146
Rated Capacity............................................. 4Ton................................................. 10 Ton
Minimum Ram Height................................... 230mm ............................................ 310mm
Maximum Ram Height................................. 355mm ........................................... 445mm
Ram Extension............................................. 125mm ............................................ 135mm
Weight……………………….............................. 17kg................................................. 30kg
17
Know Your Product
1. Pump Assembly
2. Handle
3. Hydraulic Hose w/Coupling
4. Ram
5. Extension Tube (430mm (4T) / 550mm (10T))
6. Extension Tube (140mm (4T) / 200mm (10T))
7. Extension Tube (210mm (4T) / 300mm (10T))
8. Extension Tube (80mm (4T) / 100mm (10T))
9. Release Valve
10. Plunger Toe
11. Combination Head
12. Ram Toe
13. Rubber Head
14. Wedge Head
15. Spreader
16. Flat Base
17. Male Connector
18
* Please Note: (4T) Refers to K15145, (10T) Refers to K15146

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4T & 10T HYDRAULIC BODY REPAIR KITS
General Safety Warnings
Save all warnings and instructions for future reference.
Read and understand the entire contents of this manual before attempting to use the body repair kit.
IMPORTANT SAFETY INFORMATION
This body repair kit is designed and intended for use by properly trained and experienced personnel only.
If you are not familiar with the proper and safe use of a body repair kit, do not use until proper training and knowledge has
been obtained.
Failure to comply with all of these warnings may cause serious injury.
The use of a Body Repair Kits has inherent dangers to avoid risk of personal injury or property damage make sure you are fully
aware of the operating instructions for this product.
Do not exceed maximum rated capacity of this Body Repair Kit.
Preparing Work Area
Before using body repair kit, it is important to prepare work area properly. Follow this procedure each time the body repair kit is
used to help prevent property damage and or serious injury.
1. Do not exceed the maximum load capacity of the ram.
2. Use only on hard level surfaces capable of sustaining the load.
3. Do not open oil filler screw unless ram is fully retracted and pressure is released.
4. Do not use as a vehicle lifting device, or as a vehicle support.
5. When extension tubes and/or offset attachments are used, the rated capacity is reduced by 50% for each tube or
attachment connected.
6. Make sure all attachments are fully engaged before applying load or pressure.
7. If bowing or bending of ram or any attachment occurs during use, STOP, release pressure immediately and reconsider
application. Application may not be compatible with product, a ram kit with a higher rated capacity may be required.
8. Do not over extend the ram, as it is possible to force the plunger out of the top of the cylinder.
9. When coupler valves are disconnected, insert dust cap to keep the oil lines clean.
10. Make sure the load is centrally applied to attachment or ram saddle. Do not load off centre.
11. Control the load. Always use a slow controlled release of system pressure. Failure to comply may result in serious
injury or death. Avoid rapid releases of pressure.
12. Do not drop any heavy objects onto the hose and do not allow the hose to kink.
13. Allow clearance for the hose to avoid damage to the hose and couplers.
14. Keep equipment away from heat or fire, as this may damage or weaken the equipment.
15. Keep the floor around the body repair kit clean and free of scrap material, oil, and grease.
16. Use the right tool. Do not force a tool or attachment to do a job which it was not designed for.
17. Replace warning labels if they become obscured or removed.
18. Give your work undivided attention. Looking around, carrying on a conversation, and “horse-play” are careless acts
that can result in serious injury.
19. Keep visitors a safe distance from the work area.
20. Use recommended genuine Kincrome accessories. Improper accessories may be hazardous.
21. Keep children and unauthorized persons away from the work area.
10. Plunger Toe
11. Combination Head
12. Ram Toe
13. Rubber Head
14. Wedge Head
15. Spreader
16. Flat Base
17. Male Connector

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4T & 10T HYDRAULIC BODY REPAIR KITS
50FAN
Personal Safety
1. 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.
2. 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.
3. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the
tool in unexpected situations.
4. Use safety equipment. A dust mask, non-skid safety shoes and a hard hat must be used for the applicable conditions.
5. Always wear eye protection. Wear ANSI-approved safety goggles.
6. Have a qualified person maintain the equipment in good condition. Keep it clean for best and safest performance.
7. If the equipment needs repairing and/or there are parts that need to be replaced, have it repaired by authorized
technicians. Only use the replacement parts supplied by the manufacturer.
Unpacking
When unpacking the Body Repair Kit carefully inspect each component for damage that may have occurred during transit.
1. Check for any missing or damaged components and report these to the supplier for instructions.
2. Ensure all packaging materials are disposed of as per your local council guide lines.
Understanding Your Product
There are several different attachments which are provided, which are to be used with the Hydraulic Body Repair Kits, depending
on the damage and the location of the vehicles damage.
a. Flat Base (16): is to be used to spread the load of the Hydraulic Ram. It should be connect to the female end of the
hydraulic ram (4), using the male connector (17).
b. Combination Head (11): is used to allign the pushing/pulling force of the hydraulic ram, when bearing against angled
frames. This accessory can be attached directly to the ram, or to extension tubes.
c. Rubber Head (13) : Is generally used to pop out dents from sheet metal, such as vehicle doors and body panels.
This accessory can be attached directly to the ram, or to extension tubes.
d. Wedge Head (14): is used to repair small dents in areas which are hard to reach and on angles.
This accessory can be attached directly to the ram, or to extension tubes.
e. Male Connector (17): Plugs into the female end of the Ram (4).
This accessory can be attached directly to the ram, or to the extension tubes.
f. Ram Toe & Plunger Toe (10 & 12): are generally used to push/pull the vehicles chassis.
This accessory can be attached directly to the ram, to the extension tubes or used in place of the flat plate when
space is limited.
g. Serrated Cap (18): is generally used for pushing during vehicle frame repairs.
This accessory can be attached directly to the ram, or to the extension tubes.
h. Extension Tubes (5, 6, 7 & 8): plug into one another for additionional combinations to reach the desired length.
i. Spreader (15): is to be used in restricted saces, when the Ram (4) can’t fit.
This accessory must be attached directly to the hose (3) of the hydraulic pump unit (1).

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4T & 10T HYDRAULIC BODY REPAIR KITS
Assembly
Note: Refer to page 7 for other additional assembly combinations.
1. Unscrew the end caps from the Hydraulic Hose w/Coupling (3) and hydraulic Ram (1) (Fig1).
Retain end caps for use when storing the kit.
2. Align and connect the Hydraulic Hose w/Coupling (3) from the Pump Assembly (1) to the Ram (4) then fasten the coupling
clockwise to tighten securely (Fig 2). Do NOT overtighten.
3 Fit the pump handle to the pump unit by rotating clockwise - DO NOT over-tighten. (Fig 4)
Note: To provide maximum versatility a combination of pump accessories may be used.
(Please refer to page 7 for combination options)
4. Fit the flat base plate (16) male connector (17) and desired Extension tubes (5-8) with the hydraulic Ram (4) (Fig.3).
5. With the desired accessoriy fitted (10-17) to the extension (5-8) tube or hydraulic ram (4), it is now ready for use (Fig 4).
Bleeding / Venting Trapped Air
Note: Before use, the hydraulic ram may need to be purged. Some air may intrude in the hydraulic system due to movement
during shipping. Air bubbles can become trapped inside the hydraulic system, preventing the jack from functioning or reducing its
efficiency, thereby reducing the efficiency of the jack.
Purge air from the system if efficiency drops.
1. Once the product is assembled, open the Release Valve (9) by rotating it 1-1/2 turns, counter-clockwise (Fig 5).
2. Using the handle (2), rapidly pump continuously 15-20 full strokes to purge air from the hydraulic system (Fig 6).
3. Close the Release Valve (9) clockwise until tight (DO NOT over-tighten) (Fig 7).
4. If the Ram (4) does not feel like it is operating correctly, repeat the above process until all air has been purged from the
system. If the problem continues contact Kincrome Customer Service.
Fig.3 Fig.4
Fig.5 Fig.6
Fig.1 Fig.2
Fig.7
3
43
416
43
13
6
43
2
1

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4T & 10T HYDRAULIC BODY REPAIR KITS
50FAN
OPERATION
Caution: If any heavy weight squashes (comes into contact with) the hydraulic hose, replace the hose immediately!
(Spare parts are available)
Before first using Body Repair Kit carry out the following preparation:
Check oil level -
a. Release pressure and disconnect the Ram (4) from the pump Assembly (1) (Fig 8).
b. Place Pump Assembly (1) horizontally on a flat and leveled surface (Fig 9).
c. Remove filler plug (Fig 9) and add high quality hydraulic oil such as Kincromes’ K12400 (HYDRAULIC JACK OIL 500ML)
until the oil reaches the bottom of the filler plug (Fig 10).
d. Reinstall the filler plug (Fig 9)
Caution: Do not let dirt get into the system, wipe the area clean around the filler plug, to prevent and dirt falling in.
e. Bleed system - refer to “Bleeding/Venting Trapped Air” on page 5.
Raising the Ram Plunger (using the Handle (2))
WARNING!: Do not overload this Body Repair Kit. For the Maximum capacity, refer to the specification section for the max working
limits DO NOT commence operation of ram until you are sure of total deflection requirement. Comprehensive
planning for all operations is essential. Ensure the task undertaken falls within the capacity of the pump and any
attachment.
Note: When adding further extensions to the Ram (4) the maximum rated load is reduced.
1. Ensure the unit is assembled for the task at hand (Refer to page 7 for additional assembly combination options).
2. To operate the hydraulic pump, position it on a stable, leveled surface close to the damaged area/work area. Ensure the
release valve (9) is closed by turning it clockwise (Fig 11), then pump the handle (2) to create pressure (Fig 12).
3. Turn the release valve (9) counter clockwise to release the pressure (Fig 13).
Fig.11 Fig.12 Fig.13
Fig.8 Fig.9 Fig.10

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4T & 10T HYDRAULIC BODY REPAIR KITS
CARE & MAINTENANCE
Caution: Prior to making any adjustments ensure the pressure is removed from the hydraulic system.
Note: These procedures are in addition to the regular checks and maintenance explained as part of the regular operation of the
hydraulically operated tool.
1. BEFORE EACH USE, inspect the general condition of the tool. Check for:
a) loose hardware or housing.
b) misalignment or binding of moving parts.
c) cracked or broken parts, and damaged hoses.
d) any other condition that may affect its safe operation.
2. When not in use, store the equipment horizontaly in a dry location with the Ram (4) fully retracted.
3. Periodically check the Pump Assembly (1) lever and Ram (4) pistons for signs of rust or corrosion.
Clean exposed areas with a clean oiled cloth.
WARNING! : Never use sandpaper or abrasive material on these surfaces!
4. Periodically lubricate the pivot point, axles and hinges with a light lubricating oil as needed, this will help to prevent rust and
assure that pump assemblies move freely.
Periodically lubricate the pivot point, axles and hinges with a light lubricating oil as needed.
5. With ram fully lowered, set unit in its normal, level position. Remove the oil filler screw to check the hydraulic oil level.
If it is not adequate, add high quality hydraulic jack oil such as Kincromes K12400 (HYDRAULIC JACK OIL 500ML) as necessary.
WARNING! DO NOT use brake fluid or any other improper fluid and avoid mixing different types of oil when adding hydraulic oil.
6. To ensure best performance and longer equipment life, replace complete hydraulic oil at least once a year.
With ram fully lowered, remove the oil filler screw and drain the oil into a suitable container.
Ensure that no dirt gets into the system.
Set the pump in its normal level position, fill with K12400 Kincrome Hydraulic Jack Oil, then replace the oil filler screw.
Note: Dispose of hydraulic oil in accordance with local regulations.
7. When equipment efficiency drops, purge air from the hydraulic system: turn the release counter-clockwise by 1-1/2 turns,
with ram fully retracted and release valve open, pump the handle rapidly 10 to 20 times.
It is recommended that an annual inspection be performed by a qualified technician.
Assembly Combinations
Vertical Push Horizontal Push Horizontal Push With Extension
Vertical Spread Horizontal Spread 0.5T Spreader

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4T & 10T HYDRAULIC BODY REPAIR KITS
50FAN
Caring For The Environment
When a tool is no longer usable it should not be disposed of with household waste, but in an environmentally friendly way.
Please recycle where facilities exist. Check with your local council authority for recycling advice.
Recycling packaging reduces the need for landfill and raw materials. Reuse of recycled material decreases pollution
in the environment. Please recycle packaging where facilities exist. Check with your local council authority for recycling advice.
Symbol Property or statement
T/Ton Weight in Tonne
WARNING marking concerning Risk of Eye Injury.
Wear ANSI-approved eye protection.
WARNING marking concerning Risk of Hearing Loss. Wear hearing protection.
WARNING marking concerning, Risk of Respiratory Injury. Wear NIOSH-approved dust mask/respirator.
WARNING or Marking concerning/Risk of Injury.
Spare Parts List
K15145 - 4T Hydraulic Body Repair Kit K15146 - 10T Hydraulic Body Repair Kit
Part No. Description Qty. Part No. Description Qty.
K15145-1 Extension Tube (430mm) 1 K15146-1 Extension Tube (550mm) 1
K15145-2 Extension Tube (210mm) 1 K15146-2 Extension Tube (300mm) 1
K15145-3 Extension Tube (140mm) 1 K15146-3 Extension Tube (200mm) 1
K15145-4 Extension Tube (80mm) 1 K15146-4 Extension Tube (100mm) 1
K15145-5 Flat Base 1 K15146-5 Flat Base 1
K15145-6 Ram Toe 1 K15146-6 Ram Toe 1
K15145-7 Plunger Toe 1 K15146-7 Plunger Toe 1
K15145-8 V Base 1 K15146-8 V Base 1
K15145-9 Combination Head 1 K15146-9 Combination Head 1
K15145-10 Male Connector 1 K15146-10 Male Connector 1
K15145-11 Serrated Cap 1 K15146-11 Serrated Cap 1
K15145-12 Rubber Head 1 K15146-12 Rubber Head 1
K15145-13 Handle Assembly 1 K15146-13 Handle Assembly 1
K15145-14 Hydraulic Pump Assembly 1 K15146-14 Hydraulic Pump Assembly 1
K15145-15 Hydraulic Hose 1 K15146-15 Hydraulic Hose 1
K15145-16 Hydraulic RAM Assembly 1 K15146-16 Hydraulic RAM Assembly 1
K15145-17 Hydraulic Spreader 1 K15145-17 Hydraulic Spreader 1
* Please note: K15145 & K15156 share the same spare part no for the Hydraulic Spreader (K15145-17).

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4T & 10T HYDRAULIC BODY REPAIR KITS
Warranty given by Kincrome Australia Pty Ltd of 3 Lakeview Drive, Caribbean Park, Scoresby, Victoria (Tel [phone]). The applicable warranty
period (12 months) commences on the date that the product is purchased. If this product has materials or workmanship defects (other than defects
caused by abnormal or non warranted use) you can, at your cost, send the product to place of purchase, an authorised Kincrome service agent or one
of Kincromes addresses for repair or replacement. Your rights under this warranty are in addition to any other rights you have under the Australian
Consumer Law or other applicable laws. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are
entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled
to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. For further
details please visit www.kincrome.com.au or call us. Due to minor changes in design or manufacture, the product you purchase may sometimes differ
from the one shown on the packaging.
Trouble Shooting
Symptom Cause Remedy
Pump unit will not work 1. Release valve (9) is open.
2. Dirt on valve seats.
3. Worn seals.
1. Close the release valve (9).
2. Clean valve seats.
3. Replace seals.
Pump unit will not produce
pressure
1. The reservoir could be overfilled or low
on hydraulic fluid .
2. Leak in the hose, seals, or connections
3. Air trapped in the system.
1. Check the fluid level. Do not
overfill.
2. Check the hose and replace if
necessary. Make sure all connections
are tight.
3. Open the release valve (9).
Pump the handle a couple of full
strokes. Close the release valve (9).
4. Contact Kincrome customer Service
Pump unit will not lower
completely
1. Air trapped in the system.
2. The reservoir could be overfilled or low
on hydraulic fluid.
1. Open the release valve (9) .
Pump the handle a couple of full strokes.
Close the release.
2. Check the fluid level is correct. Do not
overfill.
Ram will not fully extend Low on hydraulic fluid. 1. Check that oil level is correct.
2. Check oil with ram fully retracted.
3. Add hydraulic fluid.
Fluid leaking from release
valve
Worn O-ring. Replace O-ring.
Fluid leaking from hose Damaged hose. Replace hose.
Fluid leaking around
hydraulic ram piston
Worn seal or piston. Please contact Kincrome customer
service.
Office Contact Details:
Phone: [phone]
Fax: [phone]
Email: [email protected]om.au
Website: www.kincrome.com.au
WARRANTY

www.kincrome.com.au