King Tony 9TY120-10A-B User manual

[email protected] www.kingtony.com 899TY120-10A-KT 297x210mm
Please wear proper safety gear while working.

NO.9TY120-10A-B
HYDRAULIC BODY
REPAIR KIT
OPERATION MANUAL
HYDRAULIC BODY
REPAIR KIT
OPERATION MANUAL
10

WARNING
• Read these instructions carefully and take note of all safety notices and warnings.
• Use this product with due care and attention and only for the use for which it is intended.
• Failure to respect these instructions may result in material damage and/or serious personal injury.
• Keep these instructions in a safe place for future reference.
• Failure to respect the following instructions may result is a loss of product capacity, damage or a
permanent defect which may in turn result in material damage and/or serious personal injury.
• Make sure that all instructions and safety warnings included in this kit have been read and fully
understood prior to use.
• The owner of this kit is responsible for the equipment and must check that its installation and use are in
accordance with all legal safety requirements.
• All safety labels must remain on the product and be replaced as soon as they become difficult to read.
• Always wear safety equipment (goggles, visor/face guard) when using this equipment.
• This kit is designed for use with bodywork and chassis. Using this kit for uses other than those for which
it was designed may result in overload, a reduced load capacity, reduced stability, and damage to the
equipment.
• Do not overload the hydraulic system. Exerting a pressure exceeding the pump and cylinder’s rated
capacity may result in serious personal injury. Bent and unstable extension bars are a sign of overload.
• Some parts within this kit do not have the same rated capacity as the pump and cylinder. Always use a
pressure gauge when installing to monitor the hydraulic pressure. Refer to the instruction manualfor
typical applications and the corresponding rated capacity.
• All attachments and extension bars must be correctly aligned and slotted into place for the force of the
cylinder to be balanced, or the load will be unstable.
• Make sure all instructions and safety warnings have been read and fully understood before use.
• Steel and other materials may snap or break when exposed to strong force; always wear adequate
safety equipment (goggles, visor/face guard) when using this equipment.
• If you detect or even suspect that there may be a possible defect in the structure, discontinue use
immediately, and do not use the pump.
• Always replace the dust cap when the connections are not attached in order to keep the oil lines clean.
• Do not bend or drop heavy objects onto the pipe. Always make sure that the work area is clean and
tidy in order to avoid damaging the pipe and connectors. To avoid damage and a loss in performance,
keep this equipment away from fire and heat.
• Failure to respect these instructions may result in damage to the jack and/or a malfunction which may
cause material damage and/or personal injury.
• Check over the equipment before each use.
SAFETY INSTRUCTIONS FOR BODYWORK & CHASSIS REPAIR

OPERATING INSTRUCTIONS
The pump may be used horizontally or vertically, with the head facing downwards as shown.
1. Assemble the pipe between the pump and the cylinder.
2. Correctly prepare the load depending on your application. Place the load on the jack.
IMPORTANT
• The use of extension bars or off-centre loads greatly reduces the capacity of the hydraulic system.
When using extension bars, place the shortest ones furthest away. Never place the shortest extension
bars in the middle.
• Some parts within this kit do not have the same rated capacity as the pump and cylinder.
• Always respect the pump’s rated maximum load capacity. Never modify the high pressure reducing
valve. Creating pressure higher than the rated capacity can cause serious personal injury.
• Always fully lower the cylinder before opening the pump’s refill hole to refill the hydraulic fluid.
Overfilling can cause personal injury due to the excess pressure created in the reservoir when the
cylinder is lowered.
• Always respect the cylinder’s rated maximum load capacity.
• Creating pressure higher than the rated capacity can cause serious personal injury.
• Never place an unbalanced or an off-centre load onto the cylinder or the load could fall and cause
personal injury.
• Before using the pump, tighten all of the connections with the correct tools and the connections should all
be airtight.
• Do not overtighten, overtightening can cause premature wearing of the pipe and the parts which are
resistant to high pressure can crack at a pressure lower than their rated capacity.
• In the case of a breakage, explosion or if the pipe must be disconnected, shut off the pump immediately
and open the pressure valve to let out all the built-up pressure.
• Never touch a leaking pressure pipe with your hands, the force of the leaking liquid can cause injury.
• Keep the pipe away from dangerous conditions, such as fire, extreme cold, heat, sharp surfaces,or heavy
shocks.
• Never bend or twist the pipe, the liquid will not be able to circulate properly.
• Never use the pipe to pull or move the equipment attached to it.
• Regularly check that the pipe is in good working order as each of these conditions can damage it and
cause injury.
• The parts and joints used must be compatible with the type of hydraulic fluid used. The pipe must never
come into contact with corrosive substances, items impregnated with creosote, or certain paints. Check
with a King Tony technician before painting the pipe.
• Never paint the connections. The deterioration of the pipe caused by corrosive substances may cause
personal injury.
SAFETY INSTRUCTIONS FOR PUMP AND JACK OPERATION
SAFETY INSTRUCTIONS FOR USING THE PIPE

ALWAYS USE A PRESSURE GAUGE WHEN INSTALLING
TO MONITOR THE HYDRAULIC PRESSURE.
• Turn the pressure reducing valve clockwise to close it. only close by hand, applying too much force on
the valve may damage the system.
• Pump the pump handle up and down to send oil down the pipe towards the jack, making it extend.
• Check the pressure gauge whilst using.
• NOTE: The pump is equipped with an overload valve which sends the oil back to the pump reservoir if
the system reaches its rated maximum pressure and overloads. If this happens, pumping will have no
effect of the system.
• In order to reduce the pressure, slowly turn the pressure valve in an anti-clockwise direction.
(The pressure release speed is controlled by the speed at which the valve opens).
Air can build up in the hydraulic system after the first use or prolonged use. This makes the jack slow or
unstable.
Purging trapped air:
• Place the jack lower down than
the pump with the end of the
piston facing downwards.
• Extend and retract the cylinder
multiple times, without putting
any load on the system. The air
is in the pump reservoir.
• Make sure that the cylinder is
not extended, the pump is
horizontal and that there is no
pressure on the hydraulic
system. Remove the refill cap.
Fill the reservoir with a suitable
hydraulic fluid; it should
reach 12.7mm below the top of
the reservoir.
• When you use extension bars
with the cylinder, the rated
capacity of the hydraulic
system is reduced by 50%.
The hydraulic system’s rated
capacity is reduced by 50%
again for each additional
extension used.
• When using two or more
extensions, always place the
shortest extension the furthest
from the cylinder.
PURGING THE AIR FROM THE SYSTEM
Duck bill spreader = 1/2 tonne 50% of the rated capacity
100% of the rated capacity 100% of the rated capacity
50% of the rated capacity
25% of the rated capacity
25% of the rated capacity
50% of the rated capacity
6% of the rated capacity

Part Description Qty
1
2
3
4
5
6
7
8
9
Blow case
685mm Extension bar
456mm Extension bar
250mm Extension bar
127mm Extension bar
Serrated cap
Spreading wedge
Big rubbe head
Base plate
Part Description Qty
10 1
11 1
12 1
13 1
14
15
16
17
1
1
1
1
Ram toe
Plunger toe
Cleft cap
'V' base
Male connector
10 Ton pump unit
Ram unit
Hydraulic hose
1
1
1
1
1
1
1
1
1

[email protected] www.kingtony.com 899TY120-040A-KT 297x210mm
Please wear proper safety gear while working.

NO.9TY120-040A-B
HYDRAULIC BODY
REPAIR KIT
OPERATION MANUAL
HYDRAULIC BODY
REPAIR KIT
OPERATION MANUAL
4

WARNING
• Read these instructions carefully and take note of all safety notices and warnings.
• Use this product with due care and attention and only for the use for which it is intended.
• Failure to respect these instructions may result in material damage and/or serious personal injury.
• Keep these instructions in a safe place for future reference.
• Failure to respect the following instructions may result is a loss of product capacity, damage or a
permanent defect which may in turn result in material damage and/or serious personal injury.
• Make sure that all instructions and safety warnings included in this kit have been read and fully
understood prior to use.
• The owner of this kit is responsible for the equipment and must check that its installation and use are in
accordance with all legal safety requirements.
• All safety labels must remain on the product and be replaced as soon as they become difficult to read.
• Always wear safety equipment (goggles, visor/face guard) when using this equipment.
• This kit is designed for use with bodywork and chassis. Using this kit for uses other than those for which
it was designed may result in overload, a reduced load capacity, reduced stability, and damage to the
equipment.
• Do not overload the hydraulic system. Exerting a pressure exceeding the pump and cylinder’s rated
capacity may result in serious personal injury. Bent and unstable extension bars are a sign of overload.
• Some parts within this kit do not have the same rated capacity as the pump and cylinder. Always use a
pressure gauge when installing to monitor the hydraulic pressure. Refer to the instruction manualfor
typical applications and the corresponding rated capacity.
• All attachments and extension bars must be correctly aligned and slotted into place for the force of the
cylinder to be balanced, or the load will be unstable.
• Make sure all instructions and safety warnings have been read and fully understood before use.
• Steel and other materials may snap or break when exposed to strong force; always wear adequate
safety equipment (goggles, visor/face guard) when using this equipment.
• If you detect or even suspect that there may be a possible defect in the structure, discontinue use
immediately, and do not use the pump.
• Always replace the dust cap when the connections are not attached in order to keep the oil lines clean.
• Do not bend or drop heavy objects onto the pipe. Always make sure that the work area is clean and
tidy in order to avoid damaging the pipe and connectors. To avoid damage and a loss in performance,
keep this equipment away from fire and heat.
• Failure to respect these instructions may result in damage to the jack and/or a malfunction which may
cause material damage and/or personal injury.
• Check over the equipment before each use.
SAFETY INSTRUCTIONS FOR BODYWORK & CHASSIS REPAIR

OPERATING INSTRUCTIONS
The pump may be used horizontally or vertically, with the head facing downwards as shown.
1. Assemble the pipe between the pump and the cylinder.
2. Correctly prepare the load depending on your application. Place the load on the jack.
IMPORTANT
• The use of extension bars or off-centre loads greatly reduces the capacity of the hydraulic system.
When using extension bars, place the shortest ones furthest away. Never place the shortest extension
bars in the middle.
• Some parts within this kit do not have the same rated capacity as the pump and cylinder.
• Always respect the pump’s rated maximum load capacity. Never modify the high pressure reducing
valve. Creating pressure higher than the rated capacity can cause serious personal injury.
• Always fully lower the cylinder before opening the pump’s refill hole to refill the hydraulic fluid.
Overfilling can cause personal injury due to the excess pressure created in the reservoir when the
cylinder is lowered.
• Always respect the cylinder’s rated maximum load capacity.
• Creating pressure higher than the rated capacity can cause serious personal injury.
• Never place an unbalanced or an off-centre load onto the cylinder or the load could fall and cause
personal injury.
• Before using the pump, tighten all of the connections with the correct tools and the connections should all
be airtight.
• Do not overtighten, overtightening can cause premature wearing of the pipe and the parts which are
resistant to high pressure can crack at a pressure lower than their rated capacity.
• In the case of a breakage, explosion or if the pipe must be disconnected, shut off the pump immediately
and open the pressure valve to let out all the built-up pressure.
• Never touch a leaking pressure pipe with your hands, the force of the leaking liquid can cause injury.
• Keep the pipe away from dangerous conditions, such as fire, extreme cold, heat, sharp surfaces,or heavy
shocks.
• Never bend or twist the pipe, the liquid will not be able to circulate properly.
• Never use the pipe to pull or move the equipment attached to it.
• Regularly check that the pipe is in good working order as each of these conditions can damage it and
cause injury.
• The parts and joints used must be compatible with the type of hydraulic fluid used. The pipe must never
come into contact with corrosive substances, items impregnated with creosote, or certain paints. Check
with a King Tony technician before painting the pipe.
• Never paint the connections. The deterioration of the pipe caused by corrosive substances may cause
personal injury.
SAFETY INSTRUCTIONS FOR PUMP AND JACK OPERATION
SAFETY INSTRUCTIONS FOR USING THE PIPE

ALWAYS USE A PRESSURE GAUGE WHEN INSTALLING
TO MONITOR THE HYDRAULIC PRESSURE.
• Turn the pressure reducing valve clockwise to close it. only close by hand, applying too much force on
the valve may damage the system.
• Pump the pump handle up and down to send oil down the pipe towards the jack, making it extend.
• Check the pressure gauge whilst using.
• NOTE: The pump is equipped with an overload valve which sends the oil back to the pump reservoir if
the system reaches its rated maximum pressure and overloads. If this happens, pumping will have no
effect of the system.
• In order to reduce the pressure, slowly turn the pressure valve in an anti-clockwise direction.
(The pressure release speed is controlled by the speed at which the valve opens).
Air can build up in the hydraulic system after the first use or prolonged use. This makes the jack slow or
unstable.
Purging trapped air:
• Place the jack lower down than
the pump with the end of the
piston facing downwards.
• Extend and retract the cylinder
multiple times, without putting
any load on the system. The air
is in the pump reservoir.
• Make sure that the cylinder is
not extended, the pump is
horizontal and that there is no
pressure on the hydraulic
system. Remove the refill cap.
Fill the reservoir with a suitable
hydraulic fluid; it should
reach 12.7mm below the top of
the reservoir.
• When you use extension bars
with the cylinder, the rated
capacity of the hydraulic
system is reduced by 50%.
The hydraulic system’s rated
capacity is reduced by 50%
again for each additional
extension used.
• When using two or more
extensions, always place the
shortest extension the furthest
from the cylinder.
PURGING THE AIR FROM THE SYSTEM
Duck bill spreader = 1/2 tonne 50% of the rated capacity
100% of the rated capacity 100% of the rated capacity
50% of the rated capacity
25% of the rated capacity
25% of the rated capacity
50% of the rated capacity
6% of the rated capacity

Part Description Qty
1
2
3
4
5
6
7
8
9
Blow case
495mm Extension bar
418mm Extension bar
215mm Extension bar
125mm Extension bar
82mm Extension bar
Serrated cap
Spreading wedge
Rubber head
Part Description Qty
10 1
11 2
12 2
13 2
14
15
16
17
2
2
2
2
Base plate
Ram toe
Plunger toe
Cleft cap
'V' base
Male connector
4 Ton pump unit
Ram unit
17 2Hydraulic hose
1
1
1
1
4
1
4
4
4