Matco Tools BRK4T Manuals

BRK4T BRK10T Body Repair Kits Model Capacity BRK4T 4 Ton BRK10T 10 Ton Printed in China BRK4T-M0_072017 Read this manual and follow all the Safety Rules and Operating Instructions before using this product. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. ! ⒀⑾⑥⑾⒀⒆⑩㈢          㙀䴷঻࣋㺘 03D          㙀䴷঻࣋㺘 03D © July 2017 Operating Instructions & Parts Manual MATCO TOOLS http://www.matcotools.com Figure 1 - BRK4T and BRK10T Components 2 Oil Filler Screw Handle Release Valve Plunger Hose Hose Coupler Ram Coupler Ram Dust Cover Gauge SAFETY AND GENERAL INFORMATION Save these instructions. For your safety, read, understand, and follow the information provided with and on this device before using. The owner and/or operator shall have an understanding of the device, its operating characteristics and safety operating instructions before operating the equipment. The owner and/or operator shall be aware that use and repair of this product may require special skills and knowledge. Instructions and safety information shall be read to and discussed with the operator in the operator's native language, making sure that the operator comprehends their contents, before use of this equipment is authorized. If any doubt exists as to the safe and proper use of this device, remove from service immediately. Inspect before each use. Do not use if abnormal conditions such as cracked welds, damaged, loose or missing parts are noted. Any equipment that appears damaged in any way, is found to be worn, or operates abnormally shall be removed from service until repaired. If the equipment has been or is suspected to have been subjected to an abnormal load or shock, immediately discontinue use until inspected by a factory authorized repair facility (contact distributor or manufacturer for list of authorized repair facilities). It is recommended that an annual inspection be made by an authorized repair facility. Labels and Operator's Manuals are available from the manufacturer. PRODUCT DESCRIPTION Matco Tools Body Repair Kits are designed to be used for pushing, spreading, and pressing of vehicle body panels as well as various component parts and assemblies. A variety of attachments are included. SPECIFICATIONS Model Pump Capacity Ram Capacity Ram Number of Attachments Closed Height Extended Height BRK4T 8,000 psi 4 Ton 10-3/4” 15-5/8” 14 BRK10T 10,000 psi 10 Ton 13-3/4” 19-3/4” 13 When using extension tubes and/or offset attachments, reduce rated capacity by 50% for each tube or offset attachment connected. See Replacement PartsVHFWLRQRQSDJHV IRULGHQWL¿FDWLRQRIRIIVHW attachments. WARNING ! 3 ‡6WXG\XQGHUVWDQGDQGIROORZDOOLQVWUXFWLRQVEHIRUHRSHUDWLQJWKLVGHYLFH ‡:HDUH\HSURWHFWLYHWKDWPHHWV$16,=DQG26+$VWDQGDUGV ‡'RQRWH[FHHGWKHUDWHGFDSDFLW\ ‡8VHDSUHVVXUHJDXJHWKDWLQGLFDWHVSRXQGVRIIRUFHDSSOLHG ‡:KHQXVLQJH[WHQVLRQWXEHVSRVLWLRQWKHVKRUWHVWWXEHIDUWKHVWIURPWKHF\OLQGHU ‡'RQRWVXEMHFWWKHKRVHWRH[WUHPHFROGKHDWVKDUSVXUIDFHVDEUDVLRQRULPSDFW ‡'RQRWDOORZWKHKRVHWRNLQNWZLVWFXUORUEHQGVRWLJKWO\WKDWLWUHVWULFWVÀXLGÀRZ ‡0DNHVXUHVHWXSLVVWDEOHDQGVHFXUHEHIRUHSHUIRUPLQJDQ\ZRUN ‡1RDOWHUDWLRQVRUPRGL¿FDWLRQVVKDOOEHPDGHWRWKLVSURGXFW ‡2QO\FRPSRQHQWVVXSSOLHGZLWKWKLVNLWVKDOOEHXVHGZLWKWKLVNLW ‡)DLOXUHWRKHHGWKHVHPDUNLQJVPD\UHVXOWLQSHUVRQDOLQMXU\DQGRUSURSHUW\GDPDJH ADDITIONAL SAFETY MESSAGES ‡$YRLGVKRUWUXQVRIVWUDLJKWOLQHWXELQJ6WUDLJKWOLQHUXQVGRQRWSURYLGHIRUH[SDQVLRQDQGFRQWUDFWLRQGXHWR pressure and/or temperature changes. ‡/RQJWXELQJUXQVVKRXOGEHVXSSRUWHGE\EUDFNHWVRUFOLSV%HIRUHRSHUDWLQJWKHSXPSDOOKRVHFRQQHFWLRQV PXVWEHWLJKWHQHGZLWKWKHSURSHUWRROV'RQRWRYHUWLJKWHQ&RQQHFWLRQVVKRXOGRQO\EHWLJKWHQHGVHFXUHO\DQG OHDNIUHH2YHUWLJKWHQLQJFDQFDXVHSUHPDWXUHWKUHDGIDLOXUHRUKLJKSUHVVXUH¿WWLQJVWREXUVW ‡6KRXOGDK\GUDXOLFKRVHUXSWXUHEXUVWRUQHHGWREHGLVFRQQHFWHGLPPHGLDWHO\VKXWRIIWKHSXPSDQGUHOHDVH   DOO SUHVVXUH 1HYHU DWWHPSW WR JUDVS D OHDNLQJ SUHVVXUL]HG KRVH ZLWK \RXU KDQGV 7KH IRUFH RI HVFDSLQJ K\GUDXOLFÀXLGLVXQGHUKLJKSUHVVXUHDQGFDQLQÀLFWLQMXU\ ‡'RQRWSXOOSRVLWLRQRUPRYHVHWXSE\WKHKRVH'RLQJVRFDQGDPDJHWKHKRVH ‡ +RVHVDOVRPXVWQRWFRPHLQFRQWDFWZLWKFRUURVLYHPDWHULDOVVXFKDVEDWWHU\DFLGFUHRVRWHLPSUHJQDWHG REMHFWVDQGZHWSDLQW1HYHUSDLQWDFRXSOHURUKRVH ‡ ,QVSHFWHDFKUDPDQGFRXSOHUEHIRUHHDFKXVHWRSUHYHQWXQVDIHFRQGLWLRQVIURPGHYHORSLQJ,QVSHFWWKHKRVH for wear. ‡ 'RQRWXVHUDPVLIWKH\DUHGDPDJHGDOWHUHGRULQSRRUFRQGLWLRQ ‡ 'RQRWXVHUDPVZLWKEHQWRUGDPDJHGFRXSOHURUGDPDJHGWKUHDGV ‡ 8QGHUFHUWDLQFRQGLWLRQVWKHXVHRIDQH[WHQVLRQZLWKDK\GUDXOLFUDPPD\QRWEHDGYLVDEOHDQGFRXOGSUHVHQW a dangerous condition. ‡ $YRLGSLQFKSRLQWVRUFUXVKSRLQWVWKDWFDQEHFUHDWHGE\WKHORDGRUSDUWVRIUDP ‡ 7RKHOSSUHYHQWPDWHULDOIDWLJXHLIWKHUDPLVWREHXVHGLQDFRQWLQXRXVDSSOLFDWLRQWKHORDGVKRXOGQRWH[FHHG 85% of the rated capacity. ‡ 5DPPXVWEHRQDVWDEOHEDVHFDSDEOHRIVXSSRUWLQJWKHORDGZKLOHSXVKLQJRUOLIWLQJ ‡ (QVXUHUDPLVIXOO\HQJDJHGLQWRRQWRDGDSWHUVH[WHQVLRQDFFHVVRULHV ‡ 8VHVKLPVIULFWLRQPDWHULDORUFRQVWUDLQWVWRSUHYHQWVOLSSDJHRIWKHEDVHRUORDG ‡ 'RQRWRIIFHQWHUORDGVRQDUDP7KHORDGFDQWLSRUWKHUDPFDQ³NLFNRXW´DQGFDXVHSHUVRQDOLQMXU\ ‡ 1HYHUWU\WRGLVDVVHPEOHDK\GUDXOLFF\OLQGHU5HIHUUHSDLUVWRTXDOL¿HGDXWKRUL]HGSHUVRQQHO ‡.HHSUDPFOHDQDWDOOWLPHV ‡:KHQQRWLVXVHNHHSUDPIXOO\UHWUDFWHG ‡8VHDQDSSURYHGKLJKJUDGHSLSHWKUHDGVHDODQWWRVHDODOOK\GUDXOLFFRQQHFWLRQV7HÀRQWDSHFDQEHXVHG LIRQO\RQHOD\HURIWDSHLVXVHGDQGLWLVDSSOLHGFDUHIXOO\WZRWKUHDGVEDFNWRSUHYHQWWKHWDSHIURPEHLQJ LQWURGXFHGLQWRK\GUDXOLFV\VWHP$SLHFHRIWDSHFRXOGWUDYHOWKURXJKWKHV\VWHPDQGREVWUXFWWKHÀRZRIÀXLG and adversely affect function. WARNING ! WARNING ! BEFORE USE 1. Before using this product, read the owner's manual completely and familiarize yourself thoroughly with the product, its components and recognize the hazards associated with its use. 2. Inspect before each use. Do not use if bent, broken, leaking or damaged components are noted. 3. Ensure all parts of your kit are included (ref. illustrations and parts list). 4. Remove dust caps and plugs from hose coupler and ram coupler. &RQQHFWKRVHFRXSOHUWRUDPFRXSOHUHQVXULQJWKHUHDUHQRÀXLGOHDNV 6. Locate and open release valve. Close release valve clockwise and pump handle until ram is fully extended, then open release valve counter-clockwise until ram has fully retracted. :LWKUDPIXOO\UHWUDFWHGDQGUHOHDVHYDOYHRSHQSODFHSXPSLQKRUL]RQWDOSRVLWLRQ2SHQRLO¿OOHUVFUHZORFDWHG RQUHVHUYRLUERG\7KLVZLOOUHOHDVHDLUWUDSSHGZLWKLQWKHUHVHUYRLU5HLQVWDOORLO¿OOHUVFUHZ Bleeding Air from System 1. Bleed air from ram: Place pump at a higher elevation than the hose and ram as shown in Figure 2. With the objective being to force air up stream to the reservoir, close valve and extend ram as fast as possible. Open valve fully allowing oil and air to return to reservoir. Repeat procedure two or three times. %OHHGDLUIURPSXPS:LWKUDPIXOO\UHWUDFWHGUHPRYHRLO¿OOHUVFUHZWROHW SUHVVXUL]HGDLUHVFDSHWKHQUHLQVWDOORLO¿OOHUVFUHZ General Instruction 1. Pump may be used in horizontal or vertical position as illustrated (ref. Figure. 3). 2. Attachments must be fully engaged before applying load. 3. Ensure load is centrally applied to attachment or ram saddle. Do not attempt off-center loading. 4. Always monitor the force applied to work piece by using a load cell and indi- cator, or monitor pressure developed in the ram by using an in-line pressure gauge, then calculate the applied force using the formula: F = P x A, where F = lbs force, P = pressure in psi, and A = effective ram area in in2. Ram Area of Model BRK4T is: 0.998 in2 Ram Area of Model BRK10T is: 2.411 in2 (ref. Load-Pressure Correlation chart on page 10) 5. If bowing or bending of ram or any attachment occurs during use, STOP IMMEDIATELY, release pressure and reconsider application. Application may require higher capacity ram kit. Basic Setup 7KHFDSDFLW\RIWKHERG\UHSDLUNLWFDQEHVLJQL¿FDQWO\DIIHFWHGE\WKHQXPEHURIDWWDFKPHQWVXVHGDQGWKHW\SH of load applied. The approximate load capacity of each function setup is illustrated on page 5. When two or more extension tubes are used together, be sure to position the shorter tube furthest from the ram. OPERATION Applying Pressure to Work Piece: /RFDWHDQGFORVHUHOHDVHYDOYHE\WXUQLQJLWFORFNZLVHXQWLO¿UPO\FORVHG'RQRWRYHUWLJKWHQ 2SHUDWHE\SXPSLQJKDQGOH7KLVZLOOVHQGÀXLGIURPWKHSXPSUHVHUYRLULQWRWKHKLJKSUHVVXUHKRVHDVVHPEO\ and into the ram assembly. 3. Continue pumping until ram reaches desired position or overpressure situation is reached. 4 Figure 3 - Variable Position Figure 2 - Pump/ram air bleed When using extension tubes and/or offset attachments, reduce rated capacity by 50% for each tube or offset attachment connected. See Replacement PartsVHFWLRQRQSDJHV IRULGHQWL¿FDWLRQRIRIIVHW attachments. WARNING !