10 TON HYDRAULIC BODY & FRAME REPAIR KIT 95925 OPERATING INSTRUCTIONS

95925

Due to continuing improvements, actual product may differ slightly from the product described herein.

TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE. ®

3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our Web site at http://www.harborfreight.com Copyright © 2007 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools.

SKU 95925

For technical questions, please call 1-800-444-3353.

Page 1

SPECIFICATIONS ITEM

DESCRIPTION

Weight

67 Lbs.

Contents

Hydraulic Pump Hydraulic Spreader Hydraulic Ram (4) Extension Tubes Male Connector Serrated Cap Wedge Head Flat Base 900 V-Base Rubber Head - Round Spreader Ram Toe Spreader Plunger Toe End Caps Plastic Case High Pressure Hydraulic Hose

Hydraulic Pump Capacity

10-Tons

Pump Capacity With Extensions

5 Tons with one extension tube 2.5 Tons with two extension tubes 1.25 Tons with three extension tubes 0.625 Tons with four extension tubes

Cylinder Ram Travel

6-1/4”

Hydraulic Spreader Capacity

1/2-Ton

Spreader Maximum Jaw Opening

3-1/2”

Hose Length

61”

Hose Maximum PSI / Fitting

10,000 / 1/4” NPT (Both Ends)

Combined Extension Tube Length

50”

SAVE THIS MANUAL You will need the manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep the manual and invoice in a safe and dry place for future reference. WARNING! READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in serious injury. SAVE THESE INSTRUCTIONS 07c SKU 95925

For technical questions, please call 1-800-444-3353.

Page 2

GENERAL SAFETY WARNINGS AND PRECAUTIONS 1.

STORE IDLE EQUIPMENT. When not in use, tools and equipment should be stored in a dry location to inhibit rust. Always lock up tools and equipment and keep out of reach of children.

2.

DO NOT USE THIS PRODUCT 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 use this tool.

3.

USE EYE AND HAND PROTECTION. Wear ANSI-approved safety impact eye glasses and heavy duty gloves when working with this tool. ANSI approved safety impact eye glasses and heavy duty gloves are available from Harbor Freight Tools.

4.

DRESS SAFELY. Non-skid footwear or safety shoes should be used when working with this product. Do not wear loose clothing or jewelry as they can become caught in moving parts. Wear a protective hair covering to prevent long hair from becoming caught in moving parts. If wearing a long-sleeve shirt, roll sleeves up above elbows.

5.

INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.

6.

DO NOT OVERREACH. Keep proper footing and balance at all times to prevent tripping, falling, back injury, etcetera.

7.

STAY ALERT. Watch what you are doing at all times. Use common sense. Do not use this tool when you are tired or distracted from the job at hand.

8.

CHECK FOR DAMAGED PARTS. Before using this product, carefully check that this tool and its accessories will operate properly and perform its intended function. Check for damaged parts and any other conditions that may affect the operation of this tool. Replace or repair damaged or worn parts immediately.

9.

REPLACEMENT PARTS AND ACCESSORIES. When servicing, use only identical replacement parts. Only use accessories intended for use with this product. Approved accessories are available from Harbor Freight Tools.

SKU 95925

For technical questions, please call 1-800-444-3353.

Page 3

10.

MAINTAIN THIS PRODUCT WITH CARE. Keep this tool and its accessories clean, dry, and free of oil and grease.

11.

KEEP WORK AREA CLEAN AND DRY. Cluttered, damp or wet work areas invite injuries.

12.

KEEP CHILDREN AWAY FROM WORK AREA. Do not allow children to handle this product.

SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS 1.

MAINTAIN A SAFE WORK ENVIRONMENT. Keep work area well lit. Make sure there is adequate surrounding work space.

2.

DO NOT FORCE THE TOOL. This product will do the work better and safer at the capacity for which it was designed.

3.

KEEP COUPLER VALVES PROTECTED WHEN NOT IN USE. Dust caps are included for all Coupler Valves and should be screwed in when not in use to keep the equipment clean.

4.

BEFORE WORKING ON A VEHICLE ALWAYS SET THE PARKING BRAKE AND BLOCK THE TIRES. Never attempt a repair while the engine is running or the vehicle is moving.

5.

DO NOT OVER EXTEND THE HYDRAULIC RAM. Over extending the Hydraulic Ram may force the plunger out of the top of the Hydraulic Ram, causing damage.

6.

AVOID OFF-CENTER LOADS. If the Pump seems unusually hard to pump, immediately stop the operation. Adjust the tool set to diminish an off-center load.

7.

PROTECT THE HOSE. Do not drop heavy objects on the Hose. Avoid sharp kinks in the Hose. Make sure there is proper clearance to avoid damage to the Hose and Couplers.

8.

KEEP THE PUMP UNIT PROPERLY FILLED WITH OIL. See page 10 for bleeding and filling instructions.

UNPACKING When unpacking, check to make sure the contents on page 12 are included. If any parts are missing or broken, please call Harbor Freight Tools at: 1-800-444-3353 as soon as possible. SKU 95925

For technical questions, please call 1-800-444-3353.

Page 4

OPERATION Product Overview: NOTE: See pages 12 and 15 to help identify the parts described below. This 10 Ton Hydraulic Body and Frame Repair kit is designed for bending frames and repairing dents in vehicle body panels. It will only be able to return vehicle body parts to their approximate, original position. Additional work will be required to completely repair the vehicle part. Included are two attachments for the Pump. The Hydraulic Ram is used in larger spaces where greater force is needed and where there is sufficient room. The Hydraulic Spreader is used in tighter spaces where the Hydraulic Ram will not fit. The Hydraulic Ram and the Spreader both require a solid, non-movable base directly across from the damaged area and in line with the damaged area that needs to be bent.

The Hydraulic Ram Attachments: The Hydraulic Ram comes with several different attachments that, depending on the damage, may be used to achieve the desired results. The Tubes (2) plug in together in different combinations to reach desired lengths. NOTE: When extension tubes and/or offset attachments are used, the rated capacity is always reduced by 50% for each tube or offset attachment connected. That means: 5 Tons with one Extension Tube, 2.5 Tons with two Extension Tubes, 1.25 Tons with three Extension Tubes, and .625 Tons with four Extension Tubes. The Serrated Saddle (9) is typically used on the pushing end in frame repair. The Serrated Saddle may be plugged into either end of the Ram or Tubes (2). The Rubber Head (10) is typically used for popping dents out of sheet metal such as doors or body panels. The Rubber Head may be plugged into either end of the Hydraulic Ram or Tubes (2). The Flat Base (3) is typically used on the stationary side to spread out the force of the Hydraulic Ram (5). The Base Plate may be plugged into either end of the Hydraulic Ram or Tubes (2). The Ram Toe (4) and Plunger Toe (5) are typically used for straightening the edges of metal such as fenders and bumpers. They may be attached to either the Ram or Tubes (2).

SKU 95925

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Page 5

. The V- base (7) is used to offset the force of the Ram when there is not a straight line between the stationary side and the damaged side. The “V” Base may be attached to the Ram or the Tubes (2). The Spreader is used to repair small dents and areas located in angles and tight spaces. The Spreader attaches to the hose that connects to the Pump . The Male Connector (8) is used with the Tubes (2) and other attachments. They plug into the female end of the Ram. CAUTION: When positioning the Hydraulic Ram, use a smaller attachment on the side that is to be bent (as opposed to the stationary side). If the stationary side is in danger of being bent or damaged, place a block of wood or other material behind the Flat Base (3) for protection and to spread the Ram pressure over a greater area.

Attaching The Pump To The Ram And Spreader: 1.

Unscrew and save the End Plugs (located on the ends of the Hose) and Ram .

2.

Securely screw the Hose into the Ram. (See Figure A.)

3.

Screw the Pump Handle (P39) into the Handle Bracket (P38) at the top of the Pump.

4.

To attach the Rubber Head (10), the Tubes (2), and the Flat Base (3) to the Ram (See Figure A.)

5.

To attach the Hydraulic Spreader to the Pump, ( See Figure B.)

6.

For other attachment combinations, see Figure C.

Flat Base (3)

Ram

Tubes (2) Rubber Head (10)

FIGURE A

07c SKU 95925

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Page 6

FIGURE B

Hydraulic Spreader

Hydraulic Pump

Male Connector (8)

FIGURE C

Hydraulic Ram Flat Base (3) Rubber Head (10)

Plunger Toe (5) Tubes (2)

Flat Base (3) Tubes (2)

Flat Base (3)

Rubber Head (10)

To Operate The Pump Unit: 1.

Position the Pump on a stable, flat and level surface close to the damaged area.

2.

Firmly close the Release Valve (P15) by turning it clockwise, and pump the Pump Handle (P40) to apply pressure.

3.

Turn the Release Valve (P15) counterclockwise to release the pressure.

4.

The Pump may be positioned horizontally or vertically. When using the Pump in a vertical position, always keep the Hose end of the Pump downward.

SKU 95925

For technical questions, please call 1-800-444-3353.

Page 7

To Repair Frame Damage: 1.

Determine which direction the frame needs to be bent.

2.

Remove any obstructions that could be damaged or are in the way.

3.

Connect the Flat Base (3) to the stationary side of the Ram, and connect the appropriate attachment to the pushing end of the Ram.

4.

Position the Ram so that the Flat Base (3) is resting against a frame member opposite the damaged area. It must also be in line with the direction in which the damaged area needs to be pushed.

5.

Aim the pushing end towards the area that needs to be repaired, and slowly apply pressure to the Pump.

6.

Once contact on either end has been made, step away as far as possible and continue to slowly apply pressure to the damaged area until the desired bend has been made.

WARNING: Keep hands away from contact areas and tight spaces. This tool may slip and cause injury. 7.

When the damaged area has been bent to the desired position, slowly turn the Release Valve (P15) on the Pump in a counterclockwise direction to release the Pump pressure and remove the Ram. (See Figure C, page 7.)

How To Repair Body Damage: 1.

Determine which direction the body panel should be moved.

2.

Remove any obstructions that could be damaged or are in the way.

3.

Connect the appropriate attachments to the Ram.

NOTE: When repairing larger body panel dents such as a dented door, fender or quarterpanel, the proper pushing attachment will be the Rubber Head (10). 4.

Position the Ram so that the Flat Base (3) is resting against a frame or a sturdy body part opposite the damaged area. It must also be in line with the direction in which the damaged area needs to be pushed. Make sure the body part is stronger than the area to be bent or it may be damaged. A block of wood or a towel may be used to protect the body part.

SKU 95925

For technical questions, please call 1-800-444-3353.

Page 8

5.

Aim the pushing end towards the area that needs to be repaired, and slowly apply pressure to the Pump.

6.

Once contact on either end has been made, step away as far as possible and continue to slowly apply pressure to the damaged area until the desired bend has been made.

7.

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 the hydraulic pressure and remove the Ram.

To Use The Spreader; 1. 2.

Determine which direction the body panel should be moved. Remove any obstructions that could be damaged or are in the way.

3.

Place the Spreader so that the hinged arm is resting against the part to be moved and the stationary arm is resting against a non-movable base. Hold the Hydraulic Spreader in position, then move the Hydraulic Pump Handle (P40) up and down.

4.

Once contact on either end has been made, step away as far as possible and continue to slowly apply pressure to the damaged area until the desired bend has been made.

WARNING: Keep hands away from contact areas and tight spaces. The Spreader may slip and cause injury. 5.

When the damaged area has been bent to the desired position, slowly turn the Release Valve (P15)) on the Pump in a counterclockwise direction to release the Pump pressure. Remove the Spreader.

CLEANING AND MAINTENANCE 1.

Keep this tool and its accessories free of oil or grease. Use only a mild detergent and damp cloth when cleaning. Do not use a flammable or combustible solvent to clean this tool or its accessories.

2.

Before each use, examine the general condition of the tool. Inspect the tool and its accessories for damage. Check for loose bolts, misalignment, binding of moving parts, broken parts and any other condition that may affect its safe operation. Do not use a damaged tool or its damaged accessories.

3.

When the Portable Puller is not in use, the Pump should be stored with the Release Valve (P15) open.

SKU 95925

For technical questions, please call 1-800-444-3353.

Page 9

4.

After extensive use, the hydraulic oil supply should be replaced to ensure longer equipment life.

How To check the oil level: Set Pump flat on a level surface. Remove the Oil Fill Screw (P07) with its attached dipstick. The oil level should be near the bottom of the opening. If required, add a high grade hydraulic oil. Replace the Oil Fill Screw (P07).

How To bleed the pump:

1.

Firmly turn the Release Valve (P15) clockwise utill it stops turning.

2.

To bleed the pump, press the tip of the Coupling (P17) against a hard surface and pump the pump handle.

2.

Continue pumping until the hydraulic fluid that comes out the end of the coupler tip is free of air bubbles.

3.

Turn the Release Valve (P15) counterclockwise to release the pressure in the pump and hose.

NOTE: There will be oil pouring out the tip. Place a shop towel or rag under the Coupler Tip to catch the oil. Properly dispose of hydraulic fluid. Never pour used oil down storm drains.

TROUBLESHOOTING Sympton Ram will not lift load

Possible Cause Release valve not tightly closed Overload condition Air trapped in system

Ram will not lower after unloading

Release valve not tightly closed Hydraulic unit malfunction Reservoir overfilled Linkages binding

Ram will not lower after unloading Ram will not extend to full stroke Poor performance

SKU 95925

Oil level low Oil level low Air trapped in system

Corrective Action Firmly close release valve Remedy overload condition Purge away air from system Firmly close release valve Replace ram and/or pump Drain oil to proper level Clean and lubricate moving parts Add hydraulic oil Add hydraulic oil Purge away air from system

For technical questions, please call 1-800-444-3353.

Page 10

PARTS LIST

*

Screw (safety valve)

Plastic cap

NOTE: When ordering part #2 see diagram on page 12 for reference. SKU 95925

For technical questions, please call 1-800-444-3353.

07c Page 11

ASSEMBLY DIAGRAM

Hydraulic Pump

Hydraulic Spreader

Hydraulic Ram 2.1

2.2

2.3

2.4

1

3

SKU 95925

4

5

6

7

8

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9

10

Page 12

PUMP ASSEMBLY DIAGRAM

SKU 95925

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Page 13

HYDRAULIC RAM ASSEMBLY DIAGRAM

HYDRAULIC SPREADER ASSEMBLY DIAGRAM

SKU 95925

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Page 14

LIMITED 1 YEAR / 90 DAY WARRANTY Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that for a period of ninety days from date of purchase that the engine is free of defects in materials and workmanship. Harbor Freight Tools also warrants to the original purchaser, for a period of one year from date of purchase, that all other parts and components of the product are free from defects in materials and workmanship (90 days if used by a professional contractor or if used as rental equipment). This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, 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. To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. 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. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. 3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353

PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER 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 RISKS 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.

SKU 95925

For technical questions, please call 1-800-444-3353.

Page 15