Matco Tools BRK10T, BRK4T Operating Instructions & Parts Manual
Matco Tools BRK4T is a versatile body repair kit designed for pushing, spreading, and pressing tasks on vehicle body panels and various components. It features a powerful 8,000 psi pump with a 4-ton capacity and a durable ram with a 10-3/4" closed height and a 15-5/8" extended height. The kit includes a range of attachments, including a serrated saddle, flat base, male connector, ram, rubber head, and combination head, providing the flexibility to handle a variety of applications.
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Operating Instructions & Parts Manual
Body Repair Kits
Model
BRK4T
BRK10T
Capacity
4 Ton
10 Ton
BRK4T
㙀䴷࣋㺘
03D
⑩㈢
BRK10T
!
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.
MATCO TOOLS
http://www.matcotools.com
Read this manual and follow all the Safety Rules and Operating Instructions before using this product.
© July 2017
Printed in China
BRK4T-M0_072017
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.
!
WARNING
When using extension tubes and/or offset attachments, reduce rated capacity by 50% for each tube or offset attachment connected. See Replacement Parts
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SPECIFICATIONS
Model
Pump
Capacity
BRK4T 8,000 psi
BRK10T 10,000 psi
Ram
Capacity
4 Ton
10 Ton
Ram
Closed Height Extended Height
10-3/4”
13-3/4”
15-5/8”
19-3/4”
Number of
Attachments
14
13
Handle
Gauge
Hose
Hose
Coupler
Dust Cover
Plunger
Oil Filler
Screw
Release Valve
Ram Coupler
Ram
Figure 1 - BRK4T and BRK10T Components
2
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WARNING
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WARNING
ADDITIONAL SAFETY MESSAGES
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,QVSHFWHDFKUDPDQGFRXSOHUEHIRUHHDFKXVHWRSUHYHQWXQVDIHFRQGLWLRQVIURPGHYHORSLQJ,QVSHFWWKHKRVH for wear.
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8QGHUFHUWDLQFRQGLWLRQVWKHXVHRIDQH[WHQVLRQZLWKDK\GUDXOLFUDPPD\QRWEHDGYLVDEOHDQGFRXOGSUHVHQW a dangerous condition.
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85% of the rated capacity.
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and adversely affect function.
3
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.
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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.
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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.
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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 indicator, or monitor pressure developed in the ram by using an in-line pressure
Figure 2 - Pump/ram air bleed 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 in 2 .
Ram Area of Model BRK4T is: 0.998 in 2
Ram Area of Model BRK10T is: 2.411 in 2 Figure 3 - Variable Position
(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.
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WARNING
When using extension tubes and/or offset attachments, reduce rated capacity by 50% for each tube or offset attachment connected. See Replacement Parts
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Basic Setup
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OPERATION
Applying Pressure to Work Piece:
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2SHUDWHE\SXPSLQJKDQGOH7KLVZLOOVHQGÀXLGIURPWKHSXPSUHVHUYRLULQWRWKHKLJKSUHVVXUHKRVHDVVHPEO\ and into the ram assembly.
3. Continue pumping until ram reaches desired position or overpressure situation is reached.
4
Releasing Pressure on Work Piece:
Slowly, carefully turn the release valve counter-clockwise until ram retracts to desired position. Never turn release valve more than 1/2 of a full turn. The ram return system is spring loaded and the release valve system is metered, allowing controlled retraction of the ram.
A. Pushing
Serrated Saddle
Ram
100%
Flat Base
Male Connector
Ram
Male Connector
Flat Base
(i) Vertical Push
Extension Tube Male Connector Ram
100%
Head (90 0 )
25%
(iii) Horizontal Push with Extension
B. Spreading
Ram
Ram Toe
Extension Tube
Flat Base
(i) Vertical Spread
Ram
(ii) Horizontal Spread
Plunger Toe
0.5 Ton
(iii) Hydraulic Spreader
5
MAINTENANCE
NOTICE:
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Adding oil
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Changing oil
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NOTICE:
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3. Set pump in its level upright position.
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5. Perform Bleeding/Air from System
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Lubrication
A coating of light lubricating oil to pivot points and hinges will help to prevent rust and assure that pump assemblies move freely.
Cleaning
Periodically check the pump piston and ram for signs of rust or corrosion. Clean as needed and wipe with an oily cloth.
NOTICE:
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Storage
When not in use, store with the pump piston and ram fully retracted.
6
TROUBLESHOOTING GUIDE
The following information is intended as an aid in determining if problem exists. For repair service, contact Matco
Tools service center in your area.
Symptom
Ram will not extend, or respond to
SUHVVXUL]HGÀXLG
Ram responds to pressurized
ÀXLGEXWV\VWHPGRHVQRWPDLQWDLQ pressure
Possible Causes
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Ram will not fully extend (cylinder or spreader)
Poor performance
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Corrective Action
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Service Center
Secure load by other means. Open release valve, depressurize pump and hose, remove application and replace coupler
6HFXUHORDGE\RWKHUPHDQVRSHQ release valve, depressurize pump and hose, remove application, then
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6HFXUHORDGE\RWKHUPHDQVRSHQ release valve, depressurize pump and hose, remove application, then
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Bleeding Air from System procedure (page 4)
7
REPLACEMENT PARTS
Not all components of the jack are replacement items, but are illustrated as a convenient reference of location and position in the assembly sequence. When ordering parts, give Model number, serial number and description below.
Call or write for current pricing: Matco Tools 4403 Allen Road, Stow, OH 44224-1096, U.S.A.
Tel:(866)BUY-TOOL Matco Tools Website: http://www.matcotools.com
Model BRK4T
Item
-
-
20
21
22
23
24
-
14
15
16
17
18
19
9
10
11
6
7
8
12
13
3
4
5
1
2
Part No.
Description
F040-90211-K01 Pump Assembly
F040-90009-K06 Ram Assembly
F040-22000-000 Hose Assembly (with coupler)
F040-00001-000 Blow Molded Case
F040-42000-000 Hydraulic Spreader (1000 lb. capacity)
F040-40002-000 Combination Head
F040-43000-000 Rubber Head
F040-40004-000 Ram Toe
F040-40005-000 Plunger Toe
F040-44000-000 Flat Base
F040-40003-000 Serrated Saddle
F040-40001-000 Wedge Head
F040-41600-000 Male connector
F040-41400-000 Extension Tube (3")
F040-41300-000 Extension Tube (6-1/8")
F040-41200-000 Extension Tube (8-1/2")
F040-41100-000 Extension Tube (16-1/2")
F040-41500-000 Extension Tube (19-1/2")
F040-22200-000 Release Valve Knob
F040-90009-K04 Ram Coupler Assy, Female
F040-20012-000 Dust Cover - Hose
F040-90009-K03 Pump Handle
F040-90107-K02 Oil Filler Screw
F100-80001-000 Gauge
F0400S-85 Repair Kit
BRK4T-L0
BRK4T-M0
Label
Manual
Qty
1
1
-
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
24
22
7
5
23
10
12
6 11
8 9
3
19
21
1
18
17 16 15
14 13
20
2
4
Figure 4 - Replacement Parts Illustration for Model BRK4T
8
Model BRK10T
Item
15
16
17
18
19
20
10
11
12
13
14
-
-
-
21
22
23
7
8
9
4
5
6
1
2
3
Part No.
Description
F100-90211-K01 Pump Assembly
F100-30000-000 Ram Assembly
F040-22000-000 Hose Assembly
F100-00004-000 Blow Molded Case
F040-42000-000 Hydraulic Spreader (1000 lb. capacity)
F100-40003-000 Combination Head (90 o )
F100-42000-000 Rubber Head
F100-40005-000 Ram Toe (offset)
F100-40006-000 Plunger Toe (offset)
F100-40001-000 Flat Base
F100-40004-000 Serrated Saddle
F100-40002-000 Wedge Head (offset)
F100-41500-000 Male Connector
F100-41400-000 Extension Tube (4")
F100-41300-000 Extension Tube (10")
F100-41200-000 Extension Tube (18")
F100-41100-000 Extension Tube (27")
F040-90107-K02 Oil Filler Screw
F040-90009-K05 Hose Coupler, Male
F040-90009-K04 Ram Coupler Assy, Female
F040-20012-000 Dust Cover - Hose
F100-90009-K01 Pump Handle
F100-80001-000 Gauge
F1000S-85
BRK10T-L0
BRK4T-M0
Repair Kit
Label ( not shown)
Manual
Qty
1
1
1
1
1
1
1
1
1
1
1
-
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
3
20
23
22
19
21
1
5
⒀⒆⑩㈢
⒀⑾⑥⑾
18
7
10 12
6 11
8
9
17
16 15 14 13
Figure 5 - Replacement Parts Illustration for Model BRK10T
9
LOAD - PRESSURE CORRELATION CHART
Models BRK4T & BRK10T
Always monitor the force applied to work piece by using a load cell and indicator or you may 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 = Force/ Load (lbs)
P = Hydraulic Working Pressure (psi) and
A = Ram Effective Area (in²)*
7,000
8,000
9,000
10,000
11,000
12,000
13,000
14,000
Load
(lbs)
1,000
2,000
3,000
4,000
5,000
6,000
15,000
16,000
17,000
18,000
19,000
20,000
Pressure (psi) of 4 Ton
Ram, where A = 0.998 in
2
1,002
2,004
3,006
4,008
5,010
6,012
7,014
8,016
Pressure (psi) of 10 Ton
Ram, where A = 2.411 in
2
415
830
1,244
1,659
2,074
2,489
2,903
3,318
3,733
4,148
4,562
4,977
5,392
5,807
6,221
6,636
7,051
7,466
7,881
8,295
*For Model BRK4T, A = 0.998 in²; For Model BRK10T, A = 2.411 in²
Example 1
Model BRK4T exerting 5,000 lbs of force will require what pressure?
Pressure = Force / Ram Effective Area = 5,000 lbs / 0.998 in² = 5,010 psi
Example 2
Model BRK10T operating at 6,000 psi will generate what force?
Force = Pressure x Ram Effective Area = 6,000 psi x 2.411 in 2 = 14,466 lbs
10
11
Matco Tools
4403, Allen Road, Stow, OH 44224-1096, U.S.A.
Tel: (866) BUY-TOOL
Matco Website: http://www.matcotools.com
ONE YEAR LIMITED WARRANTY
For a period of one (1) year from date of purchase, Matco Tools will repair or replace, at its option, without charge, any of its products, which fails due to a defect in material or workmanship under normal usage. This limited warranty is a consumer's exclusive remedy.
Performance of any obligation under this warranty may be obtained by returning the warranted product, freight prepaid, to Matco Tools Warranty Service Department, 4403 Allen Road, Stow, OH 44224-1096.
([FHSW ZKHUH VXFK OLPLWDWLRQV DQG H[FOXVLRQV DUH VSHFL¿FDOO\ SURKLELWHG E\ DSSOLFDEOH ODZ 7+(
CONSUMER'S SOLE AND EXCLUSIVE REMEDY SHALL BE THE REPAIR OR REPLACEMENT OF DEFECTIVE
PRODUCTS AS DESCRIBED ABOVE. (2) Matco Tools SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL
OR INCIDENTAL DAMAGE OR LOSS WHATSOEVER. (3) ANY IMPLIED WARRANTIES, INCLUDING WITHOUT
LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, SHALL BE LIMITED TO ONE YEAR, OTHERWISE THE REPAIR, REPLACEMENT OR REFUND AS
PROVIDED UNDER THIS EXPRESS LIMITED WARRANTY IS THE EXCLUSIVE REMEDY OF THE CONSUMER,
AND IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED. (4) ANY MODIFICATION,
ALTERATION, ABUSE, UNAUTHORIZED SERVICE OR ORNAMENTAL DESIGN VOIDS THIS WARRANTY AND
IS NOT COVERED BY THIS WARRANTY.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
DERYHOLPLWDWLRQRUH[FOXVLRQPD\QRWDSSO\WR\RX7KLVZDUUDQW\JLYHV\RXVSHFL¿FOHJDOULJKWVDQG\RXPD\DOVR have other rights, which vary from state to state.
12
Matco Tools
4403, Allen Road, Stow, OH 44224-1096, U.S.A.
Tel: (866) BUY-TOOL
Matco Website: http://www.matcotools.com
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