OEM Tools 24820 Service manual

UNPACKING
After unpacking the unit, inspect carefully for
any damage that may have occurred during
transit. Check for loose, missing, or damaged
parts. If any damage is observed, a shipping
damage claim must be filed with the carrier.
DO NOT use the OEMTOOLS™Body Repair
Kit if broken, bent, cracked or damaged
parts (including labels) are noted. Any Body
Repair Kit that appears damaged in any way,
operates abnormally or is missing parts should
be removed from service immediately. If you
suspect that the Body Repair Kit was subjected
to shock load (a load that was dropped
suddenly, unexpectedly, etc.), immediately
discontinue use until it has been checked by
a factory authorized service center.
Please read and save these instructions. Read through this owner’s manual carefully before using product. Protect yourself and
others by observing all safety information, warnings, and cautions. Failure to comply with instructions could result in personal
injury and/or damage to product or property. Please retain instructions for future reference.
The following safety information is provided as a guideline to help you operate your Body Repair Kit under the safest possible
conditions. Any tool or piece of equipment can be potentially dangerous to use when safety or safe handling instructions are
not known or not followed. The following safety instructions are to provide the user with the information necessary for safe use
and operation. Please read and retain these instructions for the continued safe use of your tool. Failure to follow instructions
listed below may result in serious injury. In addition, make certain that anyone who uses the equipment understands and follows
these safety instructions as well.
Operating Instructions and Parts Manual 24820 / 24821
FOR CUSTOMER SERVICE
Technical Question?
CALL 1-866-458-2472
[email protected]
BODY REPAIR KIT
Thank you very much for choosing an OEMTOOLS™Product!
For future reference, please register your new tool at www.oem-tools.com and complete the owner’s record below:
Model: _______________ Purchase Date: ___________
Save the receipt, warranty and these instructions. It is important that you read the entire manual to become familiar with this product
before you begin using it. This product is designed for certain applications only. OEMTOOLS™cannot be responsible for issues
arising from modification. We strongly recommend this product is not modified and/or used for any application other than that for
which it was designed. If you have any questions relative to a particular application, DO NOT use the product until you have first
contacted customer service to determine if it can or should be performed on the product.ç
Explanation of Safety Signal Words
WARNING:Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION:Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION:Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result
in property damage.
NOTES:Provide clarity and helpful information.
WARNING
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IMPORTANT INSTRUCTIONS
AND SAFETY RULES
1. Know your tool. Read this manual carefully. Learn
the tool’s applications and limitations as well as
potential hazards specific to it.
2. Keep work area clean and well lit. Cluttered or dark
work areas invite accidents.
3. Keep children away. All children should be kept
away from the work area. Never let a child handle a
tool without strict adult supervision.
4. DO NOT operate this tool if under the influence
of alcohol or drugs. Read warning labels on
prescriptions to determine if your judgment or
reflexes are impaired while taking drugs. If there is
any doubt, DO NOT attempt to operate.
5. Use safety equipment. Eye protection should be
worn at all times when operating this tool. Use ANSI
approved safety glasses. Everyday eyeglasses are
NOT safety glasses. Dust mask, non-skid safety
shoes, hard hat or hearing protection should be
used in appropriate conditions.
6. Wear proper apparel. Loose clothing, gloves, neck-
ties, rings, bracelets or other jewelry may present a
potential hazard when operating this tool. Keep all
apparel clear of the tool.
7. DO NOT overreach. Keep proper footing and
balance at all times when operating this tool.
8. Check for damage. Check your tool regularly. If
part of the tool is damaged, it should be carefully
inspected to make sure that it can perform its
intended function correctly. If in doubt, the part
should be repaired. Refer all servicing to a qualified
technician. Consult your dealer for advice.
9. Keep away from flammables. DO NOT attempt
to operate this tool near flammable materials or
combustibles. Failure to comply may cause serious
injury or death.
10. Store idle tools out of the reach of children and
untrained persons. Tools may be dangerous in the
hands of untrained users.
11. Maintain tools with care.
12. Keep tools dry and clean.
13. Properly maintained tools are less likely to bind and
are easier to control. DO NOT use a damaged tool.
Tag damaged tools “DO NOT use” until repaired.
14. Check for misalignment or binding of moving parts,
breakage of parts, and any other condition that may
affect the tool’s operation.
15. If damaged, have the tool serviced before using. Many
accidents are caused by poorly maintained tools.
16. Use only accessories that are recommended by the
manufacturer for your model. Accessories that may
be suitable for one tool may become hazardous
when used on another tool.
17. Tool service must be performed only by qualified repair
personnel. Service or maintenance performed by
unqualified personnel could result in a risk of injury.
18. When servicing a tool, use only identical
replacement parts. Use of unauthorized parts or
failure to follow maintenance instructions may create
a risk of injury.
19. Maintain a safe working environment. Keep the
work area well lit. Make sure there is adequate
surrounding workspace. Keep the work area free of
obstructions, grease, oil, trash, and other debris.
DO NOT use this product in a damp or wet location.
20. Maintain labels and nameplates on this product.
These carry important information. If unreadable or
missing, contact OEMTOOLS™for a replacement.
21. Keep the handle dry, clean, and free from brake fluid,
oil, and grease.
22. Before use, read and understand all warnings, safety
precautions, and instructions as outlined in the
vehicle manufacturer’s service manual. It is beyond
the scope of this manual to properly describe the
correct procedure and test data for each vehicle.
23. The warnings, precautions, and instructions
discussed in this manual cannot cover all possible
conditions and situations that may occur. The
operator must understand that common sense and
caution are factors which cannot be built into this
product, but must be supplied by the operator.
24. We believe the information contained herein to be
reliable. However, general technical information
is given by us without charge and the user shall
employ such information at their own discretion
and risk. We assume no responsibility for results or
damages incurred from the use of such information
in whole or in part. Always refer to specific
instructions and technical information supplied by
vehicle manufacturer.
25. The manufacturer declines any and all responsibility
for damage to vehicles or components if said
damage is the result of unskillful handling by the
operator, or of failure to observe the basic safety
rules set forth in the instruction manual.
26. The procedures documented in this manual are to
serve as guidelines for the use of this equipment.
27. Remember that during body repair there is always
the possibility of a fixture slipping or a body
part failing, which could cause the vehicle to jolt
suddenly. If the vehicle is not adequately supported,
it could fall with possibly serious consequences.
28. Never use an additional extension handle to operate
the pump.
PRODUCT DESCRIPTION
The OEMTOOLS™Body Repair Kit is great for body
and frame repair. Use to straighten, bend or spread
any piece of metal that requires hydraulic power.
PRODUCT SPECIFICATIONS
Repair Kit includes hydraulic pump, hydraulic ram,
(4) extension rods, rubber ball foot and duckbill
hydraulic spreader.

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BODY REPAIR KIT
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OVERVIEW
This body repair kit is designed for bending chassis
frames and repairing dents in vehicle body panels. In
most cases, the kit will only return the vehicle body parts
to approximately their original position. Additional work
will be required to complete the repair. There are two
attachments which can be connected to the Pump unit.
1. The Hydraulic Ram is for use in larger spaces where
greater force is needed and where there is sufficient
room. It requires a solid immovable base, directly in
line with the damaged area.
2. The Spreader Wedge is used in tighter spaces where
the Ram and other accessories will not fit.
THE ATTACHMENTS
Several different attachments are provided that may be
used in conjunction with the Hydraulic Ram dependant
upon the nature of the damage.
Description 4 Ton 24820 10 Ton 24821
Weight (complete in case) 17.6 kg 30 kg
Moulded case dims (L x W x H) 580 x 315 x 170 mm 720 x 390 x 160 mm
Length of handle 265 mm 465 mm
Pressure relief operating pressure 4 Ton 10 Ton
Pump unit dimensions (L x W x H) 330 x 130 x140 mm 510 x 140 x140 mm
Pump rated operating pressure 63 Mpa 62 Mpa
Pump oil capacity 250 g 500 g
Hose dimensions (L x O/D) 1150 x 17 mm 1350 x 17 mm
Hose max operating pressure 140 PSI 140 PSI
Ram unit length (ret/ext) 270 x 395 mm 370 x 512 mm
Ram rated operating force 4 Tons 10 Tons
Ram piston stroke 125 mm 142 mm
Hydraulic spreader dims (L x W x H) 230 x 50 x 60 mm 230 x 50 x 65 mm
Spreader max rated load 0.5 Ton 0.5 Tons
Spreader opening 16 - 90 mm 20 - 100 mm
Base rated load 4 Tons 10 Tons
Angled toe rated load 4 Tons 4 Tons
Circular head rated load 4 Tons 10 Tons
Square V-head 4 Tons 10 Tons
Rubber head 4 Tons 10 Tons
Plate head 4 Tons 10 Tons
Removable connector 4 Tons 10 Tons
Extension tubes 2 Tons 5 Tons
Please note that the details and specifications contained herein are correct at the time of going to print.
However, OEMTOOLS™ reserves the right to change specifications at any time without prior notice.
1. The FLAT BASE is used to spread the load of the
Hydraulic Ram. It should be connected to the static
end of the Hydraulic Ram using the Male Connector.
2. The RUBBER HEAD is typically used for popping
dents out of sheet metal such as doors and body
panels when plugged into the moving end of the
Hydraulic Ram or the Extension Tubes.
3. The SQUARE V-HEAD is used to align the force of
the Hydraulic Ram when bearing against an angled
frame, and may be attached to the Hydraulic Ram or
the Extension Tubes.
4. The WEDGE HEAD is used to repair small dents
and areas located in angles and tight spaces and
attaches to the Hydraulic Ram or Extension Tubes.
5. The MALE CONNECTOR plugs into the female end
of the Hydraulic Ram.
6. The ANGLED TOE and PLATE HEAD are normally
attached to the extension tubes but could be used
as a substitute for the flat base if space is limited.

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7. The SERRATED CAP is typically used for pushing
during frame repair. It may be plugged into either
end of the Hydraulic Ram or the Extension Tubes.
8. The EXTENSION TUBES plug together in different
combinations to reach the desired length.
9. The HYDRAULIC SPREADER WEDGE is used in
restricted spaces when the Hydraulic Ram cannot
be used. Connect the wedge directly to the hose of
the pump unit.
ASSEMBLY
When assembling the Hydraulic Ram, Pump unit and
attachments, unscrew and retain the plastic end plugs
on the connections of the Ram and Hydraulic Spreader
Wedge for future use. Ensure the hydraulic hose is
tightly screwed to the connection.
1. Screw the Pump Handle into the socket in the
pump unit.
2. If the Hydraulic Spreader Wedge is to be used,
connect the screw-in connector of the pump hose
to the spreader wedge as shown in Fig 1.
3. If the Ram is to be used, fit the Flat Base to the
static end of the Ram using the male connector.
Connect other attachments to the moving end
as required.
4. Various combinations of extension tubes and
attachments can be assembled as shown in Fig 2,
according to the distance between the work surface
and the supporting frame.
OPERATION
Assemble the components including the flat base and
as many extension tubes as required.
Note: WHEN ADDING FURTHER EXTENSION
TUBES, THE MAXIMUM RATED LOAD IS REDUCED.
(SEE WARNING LABEL)
1. Connect the Hydraulic Ram or Hydraulic Spreader
to the connecting hose using the screw-on hose
connector. Use the male connector to join the ram to
your selected attachment or any extension tube.
2. To operate the Hydraulic Pump, position it on a
stable, level surface close to the damaged area.
Close the Release Valve by turning it clockwise
and pump the handle to create pressure.
3. Turn the Release Valve counter-clockwise to
release the pressure.
4. The pump may be positioned horizontally or
vertically. When using the Hydraulic Ram in a
vertical position, always keep the hose end
facing downward.
WARNING
NEVER OVERLOAD THE RAM BEYOND ITS
CAPACITY. ENSURE THE BEARING POINT IS STABLE
AND PROPERLY CENTERED ABOVE THE RAM.
NEVER OVERLOAD THE ATTACHED COMPONENTS
BEYOND THEIR RATED CAPACITIES AS STATED IN
THE SPECIFICATION.
Always apply the load slowly to be sure that everything is
secure. Take care that the load is always in line with the ram.
USING THE RAM
1. Determine the direction in the which the target area
needs to be pushed.
2. Remove any obstructions that are in the way and
could be damaged.
3. Connect the Flat Base to the stationary side of
the Hydraulic Ram and connect the appropriate
attachment to the working end of the Ram.
Note: When repairing larger body panel dents such
as a dented door, wing or quarter panel, the correct
pushing attachment will be the Rubber Head.
4. Position the Hydraulic Ram so that the flat base
is resting against a frame member opposite the
damaged area. It must be in line with the direction
in which the damaged area needs to be pushed and
have enough support that only the damaged area
will be displaced by the ram pressure.
5. Use soft pads or wooden supports where necessary
to protect the body.
Pump Unit
Hydraulic
Spreader
Wedg e
Fig 1
Pump
Handle
Base
Hydraulic Ram ExtensionTube
Spreader
Ram To e
Fig 2 Male Connector
Flat Base
Rubber
Head
Hose end cap remains attached
Pump Unit
Fig. 1
Fig. 2 Male Connector
Flat Base
Hose end cap remains attached
Rubber
Head
Hydraulic Ram Extension Tube
Spreader
Ram Toe
Base
Hydraulic
Spreader
Wedge
Pump
Handle

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5. Aim the pushing end towards the damaged area and
slowly apply pressure with the pump.
6. Once contact is established at each end, keep
clear as well as practical and slowly apply
pressure to the damaged area until the desired
correction has been made.
CAUTION:KEEP HANDS AWAY FROM CONTACT
AREAS AND TIGHT SPACES IN CASE THE
COMPONENTS SHOULD SLIP AND CAUSE INJURY.
7. When the damaged area has been bent to the
desired position, slowly turn the release valve on the
pump unit in a counterclockwise direction to release
hydraulic pressure before removing the Ram.
USING THE SPREADER WEDGE
1. Determine the direction in which the metal needs
to be spread.
2. Remove any obstructions that are in the way and
could be damaged.
3. Place the Spreader Wedge so that the hinged arm
is resting against the part to be moved and the
stationary base is bearing against a rigid support.
Hold the Spreader Ram in position and apply the
pump pressure.
4. Once contact is established at each end, keep
clear as well as practical and slowly apply
pressure to the damaged area until the desired
correction has been made.
CAUTION:KEEP HANDS AWAY FROM CONTACT
AREAS AND TIGHT SPACES IN CASE THE
COMPONENTS SHOULD SLIP AND CAUSE INJURY.
5. When the damaged area has been bent to the
desired position, slowly turn the release valve on
the pump in a counterclockwise direction to release
hydraulic pressure before removing the wedge.
MAINTENANCE
If the pump has been stored for long periods, check
the oil level before use. Stand the pump on a level
surface and remove the breather valve on the oil
reservoir. If necessary, top up via the breather valve
which is then screwed on finger tight.
Note: Only unscrew this when the system is not under
pressure. The oil level should be near the bottom of
the opening. If required, oil can be Topped. Top using
high quality Hydraulic Oil.
After extensive use, the hydraulic oil should be
replaced to ensure longer equipment life. Do not overfill,
or the piston rod will be unable to move freely. Replace
the breather valve after re-filling. The required oil
volumes are as follows.
24820 - 250 ml + 5ml
24821 - 500 ml + 5ml
STORAGE
After use, screw the valve cover on to the pump
to keep the connection clear of dust and dirt and
cover the hydraulic hose end with the plastic cap.
When not in use, the pump should be stored with
the release valve open. Store all the equipment in its
moulded case in a clean, dry environment protected
from the weather.
ENVIRONMENTAL PROTECTION
If disposing of old oil or any damaged components, do
not dispose of them with general waste. Any escaping
oil should be captured with some absorbent material
which should then be disposed of appropriately.
This product and its packaging contain valuable raw
materials and should be taken to your local civic
amenity site for recycling.
SPARE PARTS
In the event of lost or damaged components,
replacements are available from OEM Parts & Service.
Please refer to the following parts list and diagrams,
quoting the OEM part numbers:
4 Ton: 24820-01 to 69.
10 Ton: 24821-01 to 69.
Problem Possible Cause Remedy
Ram does not operate
when handle is pumped.
Release valve not tightly closed. Air
trapped in system.
Firmly close the release valve. Purge air
from system by pumping operating handle.
Ram will not hold load.
Release valve not tightly closed.
Malfunction in pump such as dirt inside
valve mechanism.
Firmly close the release valve. Return
pump to dealer for overhaul.
Ram reluctant to lower
when load removed. Oil reservoir overfilled. Piston binding. Drain oil to correct level. Clean and lubricate moving parts.
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. Poor positioning of the footing.
Stop work and re-position ram and base,
ensuring it is well supported and as close
to perpendicular to the repair as possible.
FAULT FINDING

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Parts Diagram

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No. Description No. Description No. Description
1 Plastic Case 24 Steel Ball 47 Ram Cylinder
2 Tube Set (4 pieces) 25 O-ring 48 Screw Cover
3 Flat Base 26 Hand Release Valve 49 Screw M6
4 Angled Toe 27 Sealing Ball 50 Connecting Nut
5 Plate Head 28 Spring 51 Cylinder Screw
6 Wedge Head 29 Screw 52 O-ring
7 Square V-Head 30 Steel Ball 53 Dust Cover
8 Male Connector 31 Ball Cup 54 Tension Spring
9 Serrated Cap 32 Spring 55 Circlip
10 Rubber Head 33 Screw 56 Nylon Sealing Ring
11 Valve Body 34 Screw Protector 57 Bushing
12 Oil Filter 35 O-ring 58 O-ring
13 O-ring 36 Nylon Sealing Ring 59 Piston Rod
14 Oil Reservoir 37 Screw 60 Piston End Cover
15 Seal Ring 38 O-ring Seal 61 Fixed Jaw
16 Thumb Nut 39 Piston 62 Small Piston
17 Sealing Ring 40 Hinge Pin 63 Piston Ring
18 Tie Rod 41 Circlip 64 O-ring
19 O-ring 42 Pivot Pin 65 Screw Cover
20 Pump Foot 43 Handle Socket 66 Moving Jaw
21 Hydraulic Hose 44 Operating Handle 67 Circlip
22 Coupling 45 Handle Grip 68 Hinge Pin
23 Dust Seal 46 Ram Cylinder 69 Spring
Parts List
NOTE:
Not all components of the Body Repair Kit are
replacement items, but are illustrated as a convenient
reference for location and position in the assembly
sequence. The manufacturer and/or distributor
have provided the parts list and assembly diagram
in this manual as a reference tool only. Neither the
manufacturer nor distributor makes any representation
or warranty of any kind to the buyer that he or she is
qualified to make any repairs to the product, or that he
or she is qualified to replace any parts of the product.
In fact, the manufacturer and/or distributor expressly
states that all repairs and parts replacements should
be undertaken by certified and licensed technicians,
and not by the buyer. The buyer assumes all risk and
liability arising out of his or her repairs to the original
product or replacement parts thereto, or arising out of
his or her installation of replacement parts thereto.

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OEMTOOLS™Limited 90 Day WARRANTY
If within 90 days from the original date of purchase of this OEMTOOLS™product, you find any defect in
material or workmanship, through normal usage, return it to the place of purchase, or to OEMTOOLS™for
repair or replacement at our discretion. In order to obtain this service, send your tool and proof of purchase,
transportation pre-paid, to OEMTOOLS™Q.A. Dept., 3580 E. Raines Road #3, Memphis, TN 38118. We will not
be responsible for lost or damaged goods during transportation; please insure your package. If our inspection
verifies the defect, we will either repair or replace the product at our election, or we may elect to refund the
purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products
at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the
scope of our warranty, then you must bear the cost of returning the product.
OEMTOOLS™does not provide warranty for products labeled other than OEM®or OEMTOOLS™. OEMTOOLS™
will not provide any warranty for products subjected to abnormal use. Abnormal use includes, but is not limited
to, abuse, accident, alteration, neglect, and unauthorized or unreasonable use or repairs. This warranty does not
cover bits, blades, files, batteries, or calibration. We recommend that you maintain your tools and sharpen or
replace blades, bits, files, and batteries as necessary. OEMTOOLS™reserves the right to make any changes in
construction or design at any time without any obligation in incorporating such changes to tools or equipment
previously sold.
OEMTOOLS™makes every effort to ensure that its products meet high quality and durability standards, and
warrants to the original purchaser that this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, normal wear and tear or to lack of maintenance.
We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or
consequential damages arising from the use of our product. Some states do not allow the exclusion or limitation
of incidental or consequential damages, so the above limitation of exclusion may not apply to you. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS. This warranty gives you specific legal rights, and you may
also have other rights, which vary from state to state.
Don’t forget to register your new OEMTOOLS™product at www.oem-tools.com.
CONTACT US
3580 E. Raines Road, Suite 3, Memphis, TN 38118
Tel: [phone]
www.oem-tools.com