Clarke STRONG-ARM CS4BRK Instruction Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0520 - rev3

BODY REPAIR KIT

MODEL NO: CS4BRK, CS10BRK & CS10SBRK

PART NO: 7617000, 7617005 & 7617010

INTRODUCTION

Thank you for purchasing this CLARKE Body Repair Kit. This manual covers the

compact 4 Tonne Kit and the larger 10 Tonne kits, the CS10SBRK featuring a

faster acting hydraulic pump.

Before attempting to use this product, please read this manual thoroughly and

follow the instructions carefully. In doing so you will ensure the safety of yourself

and that of others around you, and you can look forward to your purchase

giving you long and satisfactory service.

GUARANTEE

This product is guaranteed against faulty manufacture for a period of 12

months from the date of purchase. Please keep your receipt which will be

required as proof of purchase.

This guarantee is invalid if the product is found to have been abused or

tampered with in any way, or not used for the purpose for which it was

intended.

Faulty goods should be returned to their place of purchase, no product can

be returned to us without prior permission.

This guarantee does not effect your statutory rights.

SPECIFICATIONS

SAFETY PRECAUTIONS

WORK AREA

1. Keep the work area clean and well lit. Cluttered and dark areas invite

accidents.

2. Keep children and bystanders away while working. Distractions can cause

you to lose control and bystanders should be kept at a safe distance from

the working area especially when work is in progress.

PERSONAL SAFETY

1. Stay alert, watch what you are doing and use common sense when using

this equipment. Do not operate this equipment when you are tired, ill or

under the influence of alcohol, drugs or medication.

2. Do not over-reach. Keep your proper footing and balance at all times. This

enables better control of the equipment in unexpected situations.

3. Concentrate on the job in hand, no matter how trivial it may seem. Be

aware that accidents are caused by carelessness due to familiarity.

4. Do not wear loose clothing or jewelry which may get caught in moving

parts. Wear protective hair covering to contain long hair. For best footing,

wear rubber soled footwear. Keep floor clear of oil, scrap wood, etc.

5. Before working on a vehicle with this repair kit, ensure the vehicle is well

supported and completely stable.

6. 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.

7. Never use an additional extension handle to operate the pump.

8. Never modify this equipment in any way.

9. Check the equipment for damage before use. Any damaged part should

be discarded and replaced. Check for alignment of parts, breakage of

parts, and any other condition that may affect the operation. Any

damage should be properly repaired or the part replaced. If in doubt, DO

NOT use. Consult your local Clarke dealer.

10. Store out of the reach of children and do not allow persons unfamiliar with

these instructions to use this product.

WARNING: THE OPERATOR MUST FOLLOW ALL INSTRUCTIONS WITHIN THIS

INSTRUCTION BOOKLET

UNPACKING

This complete kit contains the heavy duty hydraulic equipment needed for

lifting, pushing, pulling, straightening and spreading.

When unpacking, check for damage or shortages etc. Any found should be

reported to your CLARKE dealer where the product was originally purchased.

This Body Repair Kit is supplied with the following components:

1 Hydraulic Spreader Wedge 7 Plate Head

2 Pump Assembly with Hose 8 Wedge Head

3 Hydraulic Ram 9 Male Connector

4 Flat Base 10 Angled Toe

5 Rubber Head 11 Serrated Cap

6 Square V-Head 12 4 x Extension Tubes

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.

• 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.

• 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.

•TheFlat 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.

•TheRubber 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.

•TheSquare 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.

•TheWedge Head is used to repair small dents and areas located in

angles and tight spaces and attaches to the Hydraulic Ram or

Extension Tubes.

•TheMale Connector plugs into the female end of the Hydraulic Ram.

•TheAngled 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.

•TheSerrated Cap is used for pushing during frame repair. It may be

plugged into either end of the Hydraulic Ram or Extension Tubes.

•TheExtension Tubes plug together in different combinations to reach

the desired length.

•TheHydraulic 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.

• 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.

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.

• The pump may be positioned horizontally or vertically. When using

the Hydraulic Ram in a vertical position, always keep the hose end

facing downward.

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 in which direction 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.

• Use soft pads or wooden supports where necessary to protect the

body.

CAUTION: NOTE THAT WHEN ADDING FURTHER EXTENSION TUBES, THE

MAXIMUM RATED LOAD IS REDUCED. (SEE WARNING LABEL)

CAUTION: NEVER OVERLOAD THE RAM BEYOND ITS CAPACITY. ENSURE

THE BEARING POINT IS STABLE AND PROPERLY CENTRED ABOVE THE

RAM. NEVER OVERLOAD THE ATTACHED COMPONENTS BEYOND THEIR

RATED CAPACITIES AS STATED IN THE SPECIFICATION.

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 as well clear 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 in which direction 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 as well clear 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 Clarke

Hydraulic Oil. (part no. 3050830 for 1 litre).

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.

• CS4BRK - 250 ml + 5ml

• CS10BRK/CS10SBRK - 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 case in a

clean, dry environment protected

from the weather.

ENVIRONMENTAL PROTECTION

One of the most damaging sources of environmental pollution is oil products.

Never throw away used hydraulic oil with domestic refuse or flush it down a

sink or drain. Collect any hydraulic oil in a leak proof container and take it to

your local waste disposal site.

If disposing of this product or any damaged components, do not dispose of

with general waste. This product contains valuable raw materials and should

be taken to your local civic amenity site for recycling of metal products.

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