ATD Tools Atd-5810 Automobile Parts User Manual
Contents
1. lifted load before it is properly supported by appropriate mechanical means such as jack stands Never rely on hydraulic pressure alone to support load Wear protective clothing and safety goggles to reduce the risk of injection e All WARNING statements must be carefully observed to help prevent personal injury e Do not exceed rated capacity e Use only on hard level surfaces capable of sustaining rated capacity loads e Do not open oil filler screw unless ram is fully retracted Do not wear sandals and jewelry when operating this equipment e Do not use as a vehicle lifting device or vehicle support e Any attachment that is not loaded centrally as through the centerline of the ram is considered to be offset When extension tubes and or offset attachments are used the rated capacity is always reduced by 50 for each tube or attacment connected e Monitor pressure and load at all times e Always verify load with calibrated load cell and indicator known good pressure gauge or equivalent devices e Do not modify this device e Failure to heed these markings may result in personal injury and or property damage Hydraulic Hoses and Fluid Transmission Lines e Avoid short runs of straight line tubing Straight line runs do not provide for expansion and contraction due to pressure and or temperature changes Reduce stress in tube lines Long tubing runs should be supported by brackets or clips Before oper2. 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 above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Atd Tools Inc 160 Enterprise Drive Wentzville MO 63385 Tel 636 327 9050 Fax 636 327 9046 www atdtools com 10 Notes Atd Tools Inc 160 Enterprise Drive Wentzville MO 63385 Tel 636 327 9050 Fax 636 327 9046 www atdtools com Notes Atd Tools Inc 160 Enterprise Drive Wentzville MO 63385 Tel 636 327 9050 Fax 636 327 9046 www atdtools com
3. replaced with factory authorized replacement parts only Any component of this Body Repair Kit that appears to be damaged in any way is worn or operates abnormally shall be removed from service immediately until such time as it can be repaired replaced Labels and Operator s Manuals are available from the manufacturer see Replacement Parts pages 7 amp 8 PRODUCT DESCRIPTION Atd Tools Hydraulic 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 extension tubes and or offset attachments are used the rated capacity is always reduced by 50 for each tube or offset attachment connected See Parts Section on page 7 amp 8 for identification of offset attachments SPECIFICATIONS dl Pump Rm Number of Capacity di Closed Height Extended Height Attachments Atd 5800 8 000 psi 10 3 4 15 5 8 NES Atd 5810 10 000 psi 13 3 4 19 3 4 AGE USE Before using this product read the owner s manual completely and familiarize yourself thoroughly with pump handle release valve 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 oil filler 3 Check to ensure that all parts of your kit are included screw see illustration and parts list 4 Carefully re
4. Hydraulic Body Repair Kits Operating Instructions amp Parts Manual Model Number Capacity Atd 5800 4 Ton Atd 5810 10 Ton Atd Tools Inc 160 Enterprise Drive Wentzville MO 63385 OIPM 5800 0309 Printed in China Save these instructions For your safety read and understand the information contained within The owner and operator shall have an understanding of this product and safe operating procedures before attempting to use this product Instructions and Safety information shall be conveyed in the operators native language before use of this product is authorized Make certain that the operator thoroughly understands the inherent dangers associated with the use and misuse of the product If any doubt exists as to the safe and proper use of this product as outlined in this factory authorized manual remove from service Inspect before each use Do not use if broken bent cracked or otherwise damaged parts are noted If any component of this product has been or suspected to have been subjected to a shock load a load dropped suddenly unexpectedly upon it discontinue use until checked out by an Atd Tools authorized service center Owners and operators of this equipment shall be aware that the use and subsequent repair of this equipment may require special training and knowledge It is recommended that an annual inspection be done by qualified personnel and that any missing or damaged parts decals warning safety labels or signs be
5. ating the pump all hose connections must be tightened with the proper tools Do not overtighten Connections should only betightened securely and leak free Overtightening can cause premature thread failure or high pressure fittings to burst Should a hydraulic hose ever rupture burst or need to be disconnected immediately shut off the pump and release all pressure Never attempt to grasp a leaking pressurized hose with your hands The force of escaping hydraulic fluid can inflict injury Do not subject the hose to potential hazard such as fire sharp objects extreme heat or cold or heavy impact Do not allow the hose to kink twist curl crush cut or bend so tightly that the fluid flow within the hose is blocked or reduced Periodically inspect the hose for wear because any of these conditions can damage the hose and possibly result in personal injury Do not pull position or move setup by the hose Doing so can damage the hose and possibly cause personal injury Hose material and coupler seals must be compatible with hydraulic fluid used Hoses also must not come in contact with corrosive materials such as battery acid creosote impregnated objects and wet paint Hose deterioration due to corrosive material can result in personal injury Never paint a coupler or hose The user must be a qualified operator familiar with the correct operation maintenance and use of rams Lack of knowledge in any of these areas can lead to per
6. en ordering parts Not all components of this kit are replace ment 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 Atd Tools Inc 160 Enterprise Drive Wentzville MO 63385 Tel 636 327 9050 Fax 636 327 9046 ONE YEAR LIMITED WARRANTY For a period of one 1 year from date of purchase Atd Tools Inc will repair or replace at its option without charge any of its products which fails due to a defect in material or workmanship or which fails to conform to any implied warranty not excluded hereby Performance of any obligation under this warranty may be obtained by returning the warranted product freight prepaid to Atd Tools Inc Warranty Service Department 160 Enterprise Drive Wentzville MO 63385 Except where such limitations and exclusions are specifically prohibited by applicable law 1 the CONSUMER S SOLE AND EXCLUSIVE REMEDY SHALL BE THE REPAIR OR REPLACEMENT OF DEFECTIVE PRODUCTS AS DESCRIBED ABOVE and 2 Atd Tools Inc SHALL NOT BE LIABLE FORANY CONSEQUENTIAL OR INCIDEN TAL DAMAGE OR LOSS WHATSOEVER and 3 THE DURATION OF ANY AND ALL EXPRESSED AND IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO A PERIOD OF ONE 1 YEAR FROM DATE OF PURCHASE Some states do not allow limitations
7. er try to disassemble a hydraulic cylinder Refer repairs to qualified authorized personnel IMPORTANT Keep ram clean at all times When the ram is not is use keep the piston s fully retracted Use an approved high grade pipe thread sealant to seal all hydraulic connections Teflon tape can be used if only one layer of tape is used and it is applied carefully two threads back to prevent the tape from being introduced into hydraulic system A piece of tape could travel through the system and obstruct the flow of fluid and adversely affect function Never attach ANY component not authorized by manufacturer Never use other than factory provided and or authorized fasteners KNOW YOUR SYSTEM Your ram hose s couplings and pump all must be rated for the same maximum operating pressure correctly connected and compatible with the hydraulic fluid used An improperly matched system can cause the system to fail and possibly cause serious injury If you are in doubt consult your nearest Atd Tools Dealer Basic Setup The capacity of the body repair kit can be significantly affected by the number of attachments used and the type of load applied The approximate load capacity of each function setup is illustrated below When two or more extension tubes are used together be sure to position the shortest tube further away from the ram A Push Serrated Saddle Ram Male Connector Flat Base l i Vertical Push Flat Base E
8. her means Open release valve depressurize pump and hose remove application then add fluid to proper level Poor performance e Fluid level low e Ensure proper fluid level e Air trapped in system Vent the sytem refer to figure 3 How to bleed air from system 1 Bleed air from ram Place pump at a higher elevation than the hose and ram as shown in figure 3 below The objective is to float the air bubbles up hill and back to the reservoir where they belong Close valve and extend ram as fas as possible Open valve fully allowing oil and air to return to reservoir Repeat this procedure two or three times will do the trick 2 Bleed air from pump With ram fully retracted remove oil filler screw to let pressurized air escape then reinstall oil filler screw Figure 3 Pump and ram illustration to bleed air Model No Atd 5800 1 xtension Tube 19 1 2 xtension Tube 16 1 2 xtension Tube 8 1 2 xtension Tube 6 1 8 5 xtension Tube 3 Male connector 7 Wedge Head Serrated Saddle Flat Base 10 Plunger Toe Ram Toe Rubber Head ombination Head draulic Spreader 1000 Ib capacit ust Cover Hose Dust Cover Ram Hose Coupler Male Ram Coupler Assy Female Ram Assembl Release Valve Knob Pump Handle Hose Assembly with coupler Oil Filler Screw ump Assembl O F040 00001 000 low Molded Case I Atd 5800 L0 abel not shown csi di 5800 0309 anual Figure 3 Replacement Parts Ill
9. move the dust caps and plugs from hose coupler and ram coupler ram plunger 5 Connect hose coupler to ram coupler ensure that there are no fluid leaks 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 7 With ram fully retracted and release valve open place pump in horizontal position Locate and open oil filler ose coupler screw on reservoir body near the back This will release air trapped within the reservoir Retighten the oil filler screw Figure 1 Atd 5800 and Atd 5810 Nomenclature 8 If using with air actuated units an air source of at least 7 8 CFM 90 PSI is required dust cover GENERAL SAFETY INFORMATION 1 Ensure that attachments are fully engaged before applying load 2 Ensure that load is centrally applied to attachment or ram saddle Do not load off center 3 Always monitor the force applied to workpiece by using a load cell and indicator or you may monitor pressure developed in the ram by using an inline pressure gauge then calculate the applied force using the formula F P xA where F lbs force P pressure in PSI and A effective ram area in in Ram Area of Model 50040 is 0 998 in Ram Area of Model 50100 is 2 411 in You can refer to Load Pressure correlation chart on page 9 4 If bowing or bending of ram or any attachment occurs during use STOP
10. release pressure immediately and reconsider application Application may not be compatible with product a ram kit with a higher capacity may be needed OPERATION Note Inspect before each use for evidence of fluid leaks damaged hydraulic fittings bent or broken attachments and missing parts 1 Locate and close release valve by turning it clockwise until firmly closed Do not over tighten 2 Operate by pumping handle This will send fluid from the pump reservoir into the high pressure hose assembly and into the ram assembly 3 Continue pumping until ram reaches desired position Note Pump may be used in horizontal and vertical position as illustrated See figure 2 Figure 2 Horizontal and Vertical position To Release 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 DANGER If oil leakage is detected discontinue use of the ram immediately and contact your nearest Omega authorized Service Center The ram could develop excessive pressure and cause the ram hose or coupler to burst which could cause serious injury or death To avoid crushing and related injuries NEVER work on under or around a
11. s 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 TROUBLESHOOTING GUIDE Note Never use sandpaper or abrasive material on these surfaces Storage When not in use store with the pump piston and ram fully retracted The following information is intended as an aid in determining if problem exists For repair service contact Atd Tools service center in your area Symptom Possible Causes Corrective Action Ram will not extend or respond e Overload condition e Remedy overload condition to pressurized fluid Release valve not closed e Ensure release valve closed Ram responds to pressurized fluid but system does not maintain pressure Ram will not return fluid to pump Reservoir overfilled Ram will not fully extend e Fluid level low cylinder or spreader e Overload condition Release valve not closed e Hydraulic unit malfunction e Malfunctioning coupler damaged application e Remedy overload condition e Ensure release valve closed e Contact Service Center e Secure load by other means Open release valve depressurize pump and hose remove application and replace coupler e Secure load by other means Open release valve depressurize pump and hose remove application then drain fluid to proper level e Secure load by ot
12. sonal injury Use only approved accessories and approved hydraulic fluid Do not exceed the rated capacity of the ram Inspect each ram and coupler before each use to prevent unsafe conditions from developing Do not use rams ifthey are damaged altered or in poor condition Do not use rams with bent or damaged coupler or damaged threads Under certain conditions the use of an extension with a hydraulic ram may not be advisable and could present a dangerous condition Avoid pinch points or crush points that can be created by the load or parts of ram To help prevent material fatigue ifthe ram is to be used in a continuous application the load should not exceed 85 of the rated capacity Ram must be on a stable base which is able to support the load while pushing or lifting Ensure ram is fully engaged into onto adapters extension accessories To help prevent personal injury use shims friction material or constraints to prevent slippage of the base or load Do not off center loads on a ram The load can tip or the ram can kick out and cause personal injury 7 Center loads on ram As the load is lifted use blocking and cribbing to guard against a falling load Never allow personnel to work on under or around a load before it is properly supported by appropriate mechanical means Never rely on hydraulic pressure alone to support load All personnel must be clear before lowering Nev
13. ustration for Model Atd 5800 7 Model No Atd 5810 Extension Tube 27 e F10040002 000 _ Wedge Head os DL F100 40001 000 Flat Base e FatBas o F100 40006 000 _ Plunger Toe ofiss TT F100 42000 100 17 18 79 5800 0309 lt Figure 4 Replacement Parts Illustration for Model Atd 5810 8 Load Pressure Correlation For Model Atd 5800 amp Atd 5810 Always monitor the force applied to workpiece by using a load cell and indicator or you may monitor pressure developed in the ram by using an inline pressure gauge then calculate the applied force using the formula where F Force Load Ibs F PxA P Hydraulic working pressure psi and A Ram effective area in For model Atd 5800 A 0 998 in For model Atd 5810 A 2 411 in Example1 Example2 Model Atd 5800 lifting 5 000 lbs will require what Model Atd 5810 operating at 6 000 psi will gener presure ate what force Pressure 5 000 Ibs 0 998 in 5 010 psi Force 6 000 psi x 2 411 in 14 466 Ibs Load Pressure of 4 Ton Ram Pressure of 10 Ton Ram where A 0 998 in where A 2 411 in Ibs psi psi 415 830 1 244 1 659 2 074 a 000 e 000 1 452 12 4 000 na 14 1400 5 5807 000 5 221 a 000 n 636 17 an 7 a 18000 000 T 7a Sl 000 Li 5 Se 000 4 295 REPLACEMENT PARTS Available Parts Please refer to the Parts drawing wh
14. xtension Tube Male Connector Ram Flat Base Male Connector Rubber Head m 100 ii Horizontal Push Combination Head 90 B Spread Ram Toe Extension Tube Flat Base 2 i Vertical Spread MAINTENANCE Important Use only a good grade hydraulic jack oil Avoid mixing different types of fluid and Never use brake fluid turbine oil transmission fluid motor oil or glycerin Improper fluid can cause premature failure of the ram and the potential for sudden and immediate loss of load We recommend Mobil DTE 13M or equivalent Adding oil 1 With ram fully lowered set pump unit in its normal level position Locate and remove oil filler screw 2 Fill until oil is within 3 8 of the oil filler screw hole opening re install oil filler screw ii Horizontal Spread Hydraulic Spreader iii Hydraulic Spreader Changing oil For best performance and increased system life replace the complete fluid supply at least once per year 1 With ram fully lowered remove the oil filler screw from the pump reservoir as above 2 Lay the pump on its side and drain the fluid into a suitable container Note Dispose of hydraulic fluid in accordance with local regulations 3 Set pump in its level upright position 4 Fill with good quality jack oil to within 3 8 of the oil filler screw hole opening Reinstall oil filler screw Lubrication A coating of light lubricating oil to pivot point
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