PRO-TEK 9078 Service manual

9078
4 Ton Body Repair Kit
Trousse de réparation pour châssis
4 tonnes
OPERATING INSTRUCTIONS AND PARTS MANUAL
MODE D’EMPLOI ET MANUEL DES PIÈCES
www.pro-tek.ca www.pro-teksprayequipment.com

IMPORTANT
Please read these instructions carefully. Note the safety instructions
and warnings. Use the product correctly and with care for the purpose
for which it is intended. Failure to do so may cause damage to property
and/or serious personal injury. Please keep this instruction manual
safe for future use.
SAFETY INSTRUCTIONS AND WARNINGS
1. The maximum ram capacity is 4 tons. DO NOT exceed this
rated capacity.
2. When extension tubes are used, the rated capacity is always
reduced by 50% for each tube connected.
3. The maximum spreader capacity is 0.5 tons. Maximum ram toe
and plunger toe capacity is 0.5 tons (4-ton repair kit). DO NOT
exceed these rated capacities when using these attachments.
4. DO NOT use this equipment as a vehicle lifting device or as a
vehicle support. 0 Do not make any alterations to this product.
5. Do not adjust the safety valve.
6. Keep children and unauthorized persons away from the work
area.
7. Remove loose clothing. Remove ties, watches, rings and other
loose jewellery, and contain long hair.
8. Always wear ANSI approved safety goggles when operating
the repair kit.
9. Keep proper balance and footing, do not overreach and wear
nonslip footwear.
10. Only use this equipment on a surface that is stable, level, dry
and not slippery, and capable of sustaining the load. Keep
the surface clean, tidy and free from unrelated materials and
ensure that there is adequate lighting.
11. When using this equipment, open the breather valve (P09).
Close it when not in use.
12. DO NOT allow the piston rod (R03) of ram to extend so far as to
exceed the maximum ram stroke.
13. When coupler valves are disconnected, always use dust cap to
keep the hydraulic system clean.
14. DO NOT drop any heavy objects onto the hose and DO NOT
twist the hose. Always keep the hose clean to avoid damage
to the hose and couplers.
15. Keep the equipment away from heat or re, as this may cause
damage or weaken the seals.
16. DO NOT operate this equipment when you are tired or under
the inuence of alcohol, drugs or any intoxicating medication.
17. DO NOT allow untrained persons to operate the equipment
and DO NOT make any modications to it.
18. DO NOT expose the equipment to rain or any other kind of
bad weather.
19. Use a qualied person to maintain the equipment in good
condition. Keep it clean for best and safest performance.
20. If the equipment needs repairing and/or there are any parts
that need to be replaced, have it repaired by authorized
technicians and only use the replacement parts supplied by
the manufacturer.
SPECIFICATIONS
Rated capacity: ............................... 4 tons
Ram min. height: ............................. 10 - 1/2’’
Stroke: ................................................ 4-3/4’’ (120 mm)
OPERATING INSTRUCTIONS
• Connect the hydraulic ram, hose and pump unit together, ensure
that you have securely fastened the couplers before pumping (as
shown in Figures 1 and 2).
• Open the breather valve (PO9).
• Firmly close the release valve (P15) by turning it clockwise.
• Adjust the ram slowly to make the load coaxial with the ram.
• Pump the handle (P39) up and down to supply pressure.
• When work is done, SLOWLY and CAREFULLY turn the
release valve counter-clockwise (never more than one turn)
to release the pressure until ram retracts to desired position.
• Close the breather valve.
WARNING!
Inspect before each use. Do not use if bent,
broken, leaking, damaged components or
any suspect parts are noted and/or it has
been subjected to a shock load.
NOTE: The pump can be used in any position from horizontal
to vertical. Always keep the hose end of the pump
downward when it is not horizontal.
En

MAINTENANCE
• When not in use, store the equipment in a dry location with
the pump piston (P34) and the ram fully retracted.
• Periodically check the ram and pump piston for signs of rust or
corrosion. Clean exposed areas with a clean oiled cloth.
• A coating of light lubricating oil to pivot points, axles and
hinges will help to prevent rust and assure that pump
assemblies move freely. Periodically lubricate the pivot points,
axles and hinges with a light lubricating oil as needed.
• With ram fully lowered, set pump unit in its normal, level
position. Remove the oil ller screw (PO7) to check the
hydraulic oil level. If it is not adequate, add high quality
hydraulic jack oil as necessary.
• To ensure best performance and longer equipment life,
replace the complete hydraulic oil at least once a year. With
ram fully lowered, remove the oil ller screw (PO?) and drain
the oil into a suitable container. Ensure that no dirt gets into
the system. Set the pump in its normal level position, ll with
approved hydraulic jack oil, then replace the oil ller screw
(PO7).
• When equipment eciency drops, purge air from hydraulic
system: Turn the release valve counter-clockwise 1 1/2 turns.
When fully retracted and release valve open, pump the handle
rapidly 10-20 times.
• It is recommended that an annual inspection be done by
qualied technicians.
TROUBLESHOOTING
WARNING!
Never use sandpaper or abrasive
materialon these surfaces!
DO NOT use brake uid or any other
improper uid and avoid mixing dierent
types of oil when adding hydraulic oil.
NOTE: Dispose of hydraulic oil in accordance
with local regulation.
ENVIRONMENTAL CONCERNS
Dispose of hydraulic oil in accordance with
local regulations. Pouring oil onto the ground
or into storm drains, or tossing it into trash cans,
even in a sealed container, is illegal and can
contaminate and pollute the environment.
The materials are recyclable. By recycling,
material recycling or other forms of reutilization,
you are making an important contribution
towards protecting our environment.
Symptom Possible Causes Corrective Action
Ram won’t lift load Release valve not tightly closed
Overload condition
Air trapped in system
Firmly close release valve
Remedy overload condition
Purge away air from system
Ram won’t maintain load Release valve not tightly closed
Hydraulic unit malfunction
Firmly close release valve
Remplace ram and/or pump
Ram won’t lower after unloading Reservoir overlled
Linkages binding
Drain oil to proper level
Clean N lubricate moving parts
Ram won’t extend to full stroke Oil level low Add hydraulic oil
Roor performance Oil level low
Air trapped in system
Add hydraulic oil
Purge away air from system
En

No. Description Qty
01 Case 1
02 Tube 5
03 Flat base 1
04 Ram toe 1
05 Plunger toe 1
06 Wedge head 1
07 V-base 1
08 Male connector 1
09 Serrated saddle 1
10 Rubber head 1
P01 Valve block 1
P02 Oil lter 1
P03 O-ring 2
P04 Reservoir 1
P05 Tie rod 1
P06 Nylon ring 1
P07 Oil lter screw 1
P08 Sealing 1
P09 Breather valve 1
P10 Screw 1
P11 O-ring 3
P12 Pump foot 1
P13 Ball 2
P14 O-ring 1
P15 Release valve 1
P16 Hydraulic hose 1
P17 Coupler 1
P18 Hose dust cover 1
No. Description Qty
P19 Ball 1
P20 Ball cap 1
P21 Spring 1
P22 Screw 1
P23 O-ring 2
P24 Screw 1
P25 Screw protector 1
P26 Screw 1
P27 Nylon ring 1
P28 Sealing ring 1
P29 O-ring 1
P30 Nylon ring 1
P31 Screw 1
P32 O-ring 1
P33 Nylon ring 1
P34 Piston 1
P35 Pin 1
P36 Retaining ring 2
P37 Pin 1
P38 Handle socket 1
P39 Handle 1
P40 Handle sleeve 1
P41 Screw 1
P42 Nylon ring 1
P43 Spring 1
P44 Ball 1
P45 Screw 1
No. Description Qty
R01 Cover 1
R02 Cir clip 1
R03 Piston rod 1
R04 Cir clip 1
R05 Bushing 1
R06 Nylon ring 1
R07 Sealing ring 1
R08 Cir clip 1
R09 Nut 1
R10 Spring 1
R11 Screw 1
R12 Protection cap 1
R13 Riing for ram 1
R14 Cylinder 1
R15 Screw 1
S1 Pin 1
S2 Cir clip 2
S3 Movable jaw 1
S4 Spring 1
S5 Fixed jaw 1
S6 Piston 1
S7 Cup seal 1
S8 O-ring 1
S9 End cap 1
S10 Coupling ring 2
S11 Coupling bolt 2
S12 Dust cap 2
PART LIST
01
03 04 05 06 07 08 09 10
02
9078
En

P40
P39
P41
P23
P43
P44
P03
P04
P05
P09
P10 P11 P12
P08
P07
P06
P02
P01 P13
P14
P15
P36
P38 P36
P35
P32 P25
P17
P18
P16
P24
P23
P22
P21
P20
P19
P30
P28
P26
P45
P34
P33
P31
P29
P27
P13
P42
P37
R12
R09
R01
R02
R03
R04
R05
R06
R06
R06
R10
R11
R13
R14
R15
S10
S11
P11
S12
S4
S3
S5
S2
S6
S7
S8
S9
S10
S12
P11
S11
9078
PUMP
RAM
SPREADER
En

Longueuil (Qc) Canada
[e-mail] | 1 800 361-7956
www.pro-tek.ca
www.pro-teksprayequipment.com