10 TON HYDRAULIC BODY & FRAME REPAIR KITimages.harborfreight.com/manuals/95000-95999/95925.pdf ·...

SKU 95925 For technical questions, please call 1-800-444-3353.

3491 Mission Oaks Blvd., Camarillo, CA 93011Visit our Web site at http://www.harborfreight.com

BODY & FRAME REPAIR KIT

Copyright © 2007 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artworkcontained herein may be reproduced in any shape or form without the express written consent of HarborFreight Tools.

OPERATING INSTRUCTIONS

95925

TO PREVENT SERIOUS INJURY, READ AND UNDERSTANDALL WARNINGS AND INSTRUCTIONS BEFORE USE.

10 TON HYDRAULIC

®

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

95925


Weight

Contents

Hydraulic Pump Capacity

Pump Capacity With Extensions

Cylinder Ram Travel

Hydraulic Spreader Capacity

Spreader Maximum Jaw Opening

Hose Length

Hose Maximum PSI / Fitting

SPECIFICATIONS

ITEM DESCRIPTION

67 Lbs.

Hydraulic PumpHydraulic SpreaderHydraulic Ram(4) Extension TubesMale ConnectorSerrated CapWedge HeadFlat Base900 V-BaseRubber Head - RoundSpreader Ram ToeSpreader Plunger ToeEnd CapsPlastic CaseHigh Pressure Hydraulic Hose

10-Tons

5 Tons with one extension tube2.5 Tons with two extension tubes1.25 Tons with three extension tubes0.625 Tons with four extension tubes

6-1/4”

1/2-Ton

3-1/2”

61”

10,000 / 1/4” NPT (Both Ends)

SAVE THIS MANUAL

You will need the manual for the safety warnings and precautions, assemblyinstructions, operating and maintenance procedures, parts list and diagram. Keepyour invoice with this manual. Write the invoice number on the inside of the frontcover. Keep the manual and invoice in a safe and dry place for future reference.

WARNING!READ AND UNDERSTAND ALL INSTRUCTIONSFailure to follow all instructions listed below may

result in serious injury.SAVE THESE INSTRUCTIONS

Combined Extension Tube Length 50”

07c


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

2. DO NOT USE THIS PRODUCT IF UNDER THE INFLUENCE OF ALCOHOL ORDRUGS. Read warning labels on prescriptions to determine if your judgment orreflexes are impaired while taking drugs. If there is any doubt, do not attempt touse this tool.

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

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

5. INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.

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

7. STAY ALERT. Watch what you are doing at all times. Use common sense. Donot 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 thatthis tool and its accessories will operate properly and perform its intendedfunction. Check for damaged parts and any other conditions that may affect theoperation of this tool. Replace or repair damaged or worn parts immediately.

9. REPLACEMENT PARTS AND ACCESSORIES. When servicing, use onlyidentical replacement parts. Only use accessories intended for use with thisproduct. Approved accessories are available from Harbor Freight Tools.

GENERAL SAFETY WARNINGS AND PRECAUTIONS


SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS

1. MAINTAIN A SAFE WORK ENVIRONMENT. Keep work area well lit. Make surethere 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 areincluded for all Coupler Valves and should be screwed in when not in use to keepthe equipment clean.

4. BEFORE WORKING ON A VEHICLE ALWAYS SET THE PARKING BRAKEANDBLOCK THE TIRES. Never attempt a repair while the engine is running or the ve-hicle is moving.

5. DO NOT OVER EXTEND THE HYDRAULIC RAM. Over extending the HydraulicRam 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 sharpkinks in the Hose. Make sure there is proper clearance to avoid damage to theHose and Couplers.

8. KEEP THE PUMP UNIT PROPERLY FILLED WITH OIL. See page 10 forbleeding and filling instructions.

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 inviteinjuries.

12. KEEP CHILDREN AWAY FROM WORK AREA. Do not allow children to handlethis product.

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

UNPACKING


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 andrepairing dents in vehicle body panels. It will only be able to return vehicle body parts totheir approximate, original position. Additional work will be required to completely repairthe vehicle part.

Included are two attachments for the Pump. The Hydraulic Ram is used in larger spaceswhere greater force is needed and where there is sufficient room. The HydraulicSpreader 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 directlyacross 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 thedamage, 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 isalways reduced by 50% for each tube or offset attachment connected. That means: 5Tons with one Extension Tube, 2.5 Tons with two Extension Tubes, 1.25 Tons with threeExtension Tubes, and .625 Tons with four Extension Tubes.

The Serrated Saddle (9) is typically used on the pushing end in frame repair. TheSerrated 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 asdoors or body panels. The Rubber Head may be plugged into either end of theHydraulic Ram or Tubes (2).

The Flat Base (3) is typically used on the stationary side to spread out the force of theHydraulic Ram (5). The Base Plate may be plugged into either end of theHydraulic Ram or Tubes (2).

The Ram Toe (4) and Plunger Toe (5) are typically used for straightening the edgesof metal such as fenders and bumpers. They may be attached to either the Ram orTubes (2).

OPERATION


.The V- base (7) is used to offset the force of the Ram when there is not a straight linebetween the stationary side and the damaged side. The “V” Base may be attached tothe Ram or the Tubes (2).

The Spreader is used to repair small dents and areas located in angles and tightspaces. 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 pluginto the female end of the Ram.

CAUTION: When positioning the Hydraulic Ram, use a smaller attachment on theside that is to be bent (as opposed to the stationary side). If the stationary side is indanger of being bent or damaged, place a block of wood or other material behind theFlat Base (3) for protection and to spread the Ram pressure over a greater area.

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 thePump.

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.

FIGURE ARubber Head (10)

Ram

Tubes (2)

Flat Base (3)

Attaching The Pump To The Ram And Spreader:

07c


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 PumpHandle (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 avertical position, always keep the Hose end of the Pump downward.

FIGURE B

Hydraulic SpreaderHydraulic Pump

FIGURE C Hydraulic Ram

Rubber Head (10)

Flat Base (3)

Flat Base (3)

Plunger Toe (5)

Tubes (2)

Male Connector (8)

Rubber Head (10)

Tubes (2)

Flat Base (3)


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 theappropriate attachment to the pushing end of the Ram.

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

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

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

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

7. When the damaged area has been bent to the desired position, slowly turn theRelease Valve (P15) on the Pump in a counterclockwise direction to release thePump 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 orquarterpanel, 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 sturdybody part opposite the damaged area. It must also be in line with the directionin which the damaged area needs to be pushed. Make sure the body part isstronger than the area to be bent or it may be damaged. A block of wood or atowel may be used to protect the body part.


To Use The Spreader;

1. Determine which direction the body panel should be moved.2. 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 movedand the stationary arm is resting against a non-movable base. Hold the HydraulicSpreader 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 con-tinue to slowly apply pressure to the damaged area until the desired bend hasbeen made.

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

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

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

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

7. When the damaged area has been bent to the desired position, slowly turn theRelease Valve on the Pump in a counterclockwise direction to release the hydraulicpressure and remove the Ram.

CLEANING AND MAINTENANCE

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

2. Before each use, examine the general condition of the tool. Inspect the tool anditsaccessories for damage. Check for loose bolts, misalignment, binding of movingparts, broken parts and any other condition that may affect its safe operation. Donot use a damaged tool or its damaged accessories.

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


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 dip-stick. The oil level should be near the bottom of the opening. If required, add a highgrade 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 andpump the pump handle.

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

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

TROUBLESHOOTING

Sympton Possible Cause Corrective Action Ram will not 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 will not lower after unloading

Release valve not tightly closed Hydraulic unit malfunction

Firmly close release valve Replace ram and/or pump

Ram will not lower after unloading

Reservoir overfilled Linkages binding

Drain oil to proper level Clean and lubricate moving parts

Ram will not extend to full stroke

Oil level low Add hydraulic oil

Poor performance Oil level low Air trapped in system

Add hydraulic oil Purge away air from system

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

PARTS LIST

*

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

Screw (safety valve)

SKU 95925 For technical questions, please call 1-800-444-3353. 07c

Plastic cap


ASSEMBLY DIAGRAM

HydraulicPump

HydraulicSpreader Hydraulic

Ram

1

3 4 5 6 7 8 9 10

2.1

2.2

2.3

2.4


PUMP ASSEMBLY DIAGRAM


HYDRAULIC RAM ASSEMBLY DIAGRAM

HYDRAULIC SPREADER ASSEMBLY DIAGRAM


3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353

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.

LIMITED 1 YEAR / 90 DAY WARRANTY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTSLIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOLONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REP-RESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE ORSHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT,THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THATALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BYCERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THEBUYER ASSUMES ALL RISKS AND LIABILITY ARISING OUT OF HIS OR HERREPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO,OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTSTHERETO.

PLEASE READ THE FOLLOWING CAREFULLY

10 TON HYDRAULIC BODY & FRAME REPAIR KITimages.harborfreight.com/manuals/95000-95999/95925.pdf ·...

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