INSTRUCTIONS FOR:
SUPERSNAP® BODY REPAIR KIT
MODEL NO: RE83/4.V2
Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these
instructions and maintained properly, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE THE PRODUCT
CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL
INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.
Refer to Instruction
Manual
Wear eye
protection
Wear protective
gloves
Keep people
away
Warning! Crushing
of Hands
1. SAFETY
p WARNING! Ensure Health & Safety, local authority and general workshop practice regulations are adhered to when using this equipment.
3 Familiarise yourself with product application and limitations, as well as the specific potential hazards peculiar to the repair kit.
p WARNING! No part of this unit or any accessory relating to the repair kit is designed for lifting loads. It is intended only as a
pushing device and must be used as such, with care.
p WARNING! Disconnect the repair kit from the hydraulic pump before servicing or performing any maintenance on the unit.
3 Maintain repair kit in good order. Replace/repair with genuine parts only. Non-genuine parts may be dangerous and will invalidate the warranty.
3 Use qualified person to lubricate and maintain the hydraulic pump. DO NOT use brake fluid to top up hydraulic unit. Use Sealey hydraulic oil only.
3 Keep the repair kit clean for best and safest performance.
p WARNING! Ensure you know how much load you are pushing. Never exceed the maximum pushing capacity.
3 Use only with the supplied Sealey hydraulic pump and accessories. Wrong equipment may damage unit and invalidate your warranty.
3 The kit accessories may be used with other popular makes of kit.
3 Ensure there is positive engagement of repair kit accessories to the vehicle body before pushing.
3 Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
3 If working on an ‘off centre’ load, pump with care. If you feel undue resistance, stop and re-adjust the set-up.
p WARNING! Keep your hands, body and clothing away from the repair kit and accessories when in use. Take any necessary
precautions to protect your personal safety whilst using the repair kit.
3 Ensure the hydraulic hose is not bent or kinked but laid out correctly.
3 Keep non-essential persons away from the operating area. Be aware of the locations of other persons assisting you.
3 When releasing tension from the load be sure to undo the hydraulic valve VERY slowly.
7 DO NOT operate the repair kit if any parts are damaged or missing as this may cause failure and/or personal injury.
7 DO NOT use for any purpose other than for which it is designed.
7 DO NOT over extend the ram as the plunger may be forced out of the ram end.
7 DO NOT heat accessories as this may weaken them.
7 DO NOT modify accessories for use with this kit.
3 When not in use, place dust cap in end of hydraulic hose and store the kit, in the case, in a safe, dry, childproof location.
2. INTRODUCTION
SuperSnap® kits feature snap-together pipework for speed and threaded attachments for strength. Connecting parts are zinc or cad plated for
long, rust-free life. Components are manufactured from high quality steel and finished with red supergloss paint. All attachments interchange with
other popular makes so you can use your existing equipment with the SuperSnap® range. Supplied in robust composite storage/carry-case.
IMPORTANT:
Only fully trained and qualified persons should use this equipment. It is very important that the user understands the applications, limitations and
specific potential hazards of the product.
3. CONTENTS
ITEM PART NO. DESCRIPTION
RE83/4 4 ton capacity kit
© Jack Sealey Limited
Original Language Version
1 604/1 METAL BOX
A2 604/A2 21” SUPERSNAP
A3 604/A3 18” SUPERSNAP® TUBING
A4 604/A4 10” SUPERSNAP® TUBING
A5 604/A5 6-1/2” SUPERSNAP® TUBING
A6 604/A6 3-1/4” TUBE ADAPTOR
7 604/7 SERRATED SADDLE
8 604/8 MALE CONNECTOR
A9 604/A9 MALE ADAPTOR
A10 604/A10 FEMALE ADAPTOR
11 604/11 SPREADER RAM
12 604/12 2-3/4” RUBBER HEAD
13 604/13 FLAT BASE
14 604/14 SPREADER RAM TOE
15 604/15 SPREADER PLUNGER TOE
16 604/16 WEDGE HEAD
17 604/17 90
40 604/40 10 TON HYDRAULIC UNIT
41 604/41 RAM
42 604/42 HOSE
O
V-BASE
®
TUBING
RE83/4.V2 Issue: 5(L) - 06/01/17
4. ATTACHMENTS
4.1 Hydraulic Ram
(Item 41) For use in large spaces and where a large amount of force is required. Supplied with several attachments.
4.2 Extension Bars
(Items A2, A3, A4, A5) Plug into the hydraulic ram in different combinations in order to obtain the required length.
4.3 Serrated Saddle
(Item 7) Typically used on the pushing end in frame repair. Suitable for attachment to either end of the hydraulic ram or extension bars.
4.4 Rubber Head
(Item 12) This is used for popping dents out of doors and/or body panels. Suitable for attachment to either end of the hydraulic ram or
extension bars.
4.5 Flat Base
(Item13) This is used on the stationary side to spread the force of the hydraulic ram. Suitable for attachment to either end of the hydraulic
ram or extension bars.
4.6 Spreader Ram Toe and Spreader Plunger Toe
(Items 14, 15) Typically used for straightening the edges of metal e.g. bumpers. Suitable for attachment to either end of the hydraulic ram
or extension bars.
4.7 90º V Base
(Item 17) This is used to offset the force of the hydraulic ram when there is no straight line between the stationary and damaged sides.
Suitable for attachment to either end of the hydraulic ram or extension bars.
4.8 Spreading Ram
(Item 11) This is used to repair minor dents and damage located in angles and tight spaces. Attaches directly to the pump unit.
4.9 Male Connector
(Item 8) This is used with the extension bars and other attachments that may be connected to the hydraulic ram. Plugs into the female
end of the hydraulic ram.
When positioning the hydraulic ram, it is necessary wherever possible to use a smaller attachment on the side that is to be bent/reshaped.
To further reduce the danger of the stationary side being damaged, place a block of wood or other suitable material (e.g. dense rubber) behind
the base plate, in order to cushion the stationary side and spread the pressure exerted by the hydraulic ram.
5. ASSEMBLY
5.1 Unscrew the end plugs from the hose and hydraulic ram. Retain end caps for use when storing the kit.
5.2 Screw the hose into the hydraulic ram. Ensure the hose is secure but DO NOT overtighten.
5.3 Fit the pump handle to the pump unit - DO NOT overtighten.
To provide maximum versatility a combination of pump accessories may be used.
5.4 Tousetherubberhead,baseplateandextensionbarswiththehydraulicram,seeg1.
6. OPERATION
To provide maximum versatility a combination of pump accessories may be used.
Illustrated below are the main attachment variations
Ensure the task you are undertaking falls within the capacity of the pump and accessories you are using.
© Jack Sealey Limited
Original Language Version
RE83/4.V2 Issue: 5(L) - 06/01/17
p WARNING! Ensure you have read and understood section 1 safety instructions.
Note: These instructions are intended to provide a guide to the basic operation of the body repair kit and are in no way intended to
replacetheadvice/instructionofaqualiedmechanic/carbodyrepairspecialist.Onlyfullytrainedpersonsshouldusethisequipment.
6.1 The pump may be used in any position from horizontal to vertical. When not horizontal ensure the hose end of the pump is down.
6.2 Tousethepump,closevalve(g1.A)byturningtheknobclockwiseandpumpthethehandleup and down to apply the load.
6.3 To release pump pressure, turn knob anti-clockwise (B).
6.4 REPAIRING FRAME DAMAGE
6.4.1 Determine the direction in which the frame needs to be bent.
6.4.2 Carefully remove any obstructions and items that may be damaged in the bending process.
6.4.3 Attach the base plate to the stationary side of the hydraulic ram.
6.4.4 Attach the appropriate attachment/combination of attachments to the pushing end of the hydraulic ram.
fig 1
A
6.4.5 Position the assembled kit appropriately i.e. with the base plate resting against a frame member opposite
the damaged area and in line with the direction in which the damaged area needs to be pushed.
6.4.6 Slowly extend the ram, being sure to direct the moving end of the ram toward the area in need of repair
B
until contact is made.
6.4.7 Move as far away as possible and continue to slowly operate the pump, applying pressure until the desired bend has been made.
6.4.8 When operation is complete, slowly turn the release valve anti-clockwise. Remove the hydraulic ram.
6.5 REPAIRING BODY DAMAGE
6.5.1 Determine the direction in which the body panel needs to be moved.
6.5.2 Carefully remove any obstructions and items that may be damaged in the bending process.
6.5.3 Attach the base plate to the stationary side of the hydraulic ram.
6.5.4 Attach the appropriate attachment/combination of attachments to the pushing end of the hydraulic ram.
6.5.5 Position the assembled kit appropriately i.e. with the base plate resting against a frame/robust body part opposite the damaged area and
in line with the direction in which the damaged area needs to be pushed. Be sure that the stationary frame/body part is stronger than the
area to be bent (a block of wood or rubber may be used to protect the stationary part).
6.5.6 Slowly extend the ram, being sure to direct the moving end toward the area in need of repair until contact is made.
6.5.7 Move as far away as possible and continue to slowly operate the pump, applying pressure until the desired bend has been made.
6.5.8 When operation is complete, slowly turn the release valve anti-clockwise. Remove the hydraulic ram.
6.6 USING THE SPREADER RAM
6.6.1 Determine the direction in which the body panel needs to be moved.
6.6.2 Carefully remove any obstructions and items that may be damaged in the bending process.
6.6.3 Place the spreader ram such that the hinged arm is resting against the part to be moved and the stationary arm is resting against a
strongxedbase.Holdingthespreaderraminposition,operatethepumpuntilcontactismade.
6.6.4 Move as far away as possible and continue to slowly operate the pump, applying pressure until the desired bend has been made.
6.6.5 When operation is complete, slowly turn the release valve anti-clockwise. Remove the spreader ram.
IMPORTANT: Always store the ram with the piston fully retracted to help prevent corrosion. Rams with signs of rust on the main piston
cannot be replaced under warranty.
Rams with signs of damage to the piston or the cylinder and/or with damaged hydraulic couplings cannot be accepted under warranty.
Due to the severe abuse required to cause damage to the pump piston or arm hinge mechanism, these can not be accepted under warranty.
7. MAINTENANCE
IMPORTANT: Only fully qualified personnel should attempt maintenance or repair to the hydraulic system.
5.1. Pump oil level
Release pressure and disconnect the ram from the pump.
Hold pump in an upright position.
Remove filler plug and add hydraulic oil until it is level with the full mark (fig 2).
p WARNING: DO NOT use brake fluid, or any fluid other than hydraulic jack fluid, as this may cause serious damage to the pump/ram
and will invalidate the warranty! Use only Sealey hydraulic oil.
5.2. General
Before each use check for broken, cracked, bent, or loose parts, or any visible damage to welds, ram, pump, hose and accessories.
If any suspect item is found remove from service and take necessary action to remedy the problem.
Replace/repair with genuine parts only. Non-genuine parts may be dangerous and will invalidate the warranty.
Keep all parts of the kit clean. use only a mild detergent and a damp cloth. DO NOT use solvent or abrasive cleaners.
Note: A small amount of oil around ram seal is normal - a thicker layer of oil may be deposited onto the ram initially, due to the ram
seals bedding in.
Hydraulic couplings will weep a small amount of oil, particularly if ram is under pressure when coupling is released - this is normal.
IMPORTANT: NO RESPONSIBILITY IS ACCEPTED FOR INCORRECT USE OF THE PUMP AND/OR RAM.
Owing to their size and weight, hydraulic products should ideally be repaired by local service agents. We have service / repair agents in
most parts of the UK. Before returning your product please call our technical helpline on 01284 757505 for advice and trouble shooting
guidance.
If the jack is under guarantee please contact your stockist..
a recycling centre and disposed of in a manner which is compatible with the environment. When the product becomes completely
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to
Environmental Protection
unserviceable and requires disposal, drain off any fluids (if applicable) into approved containers and dispose of the product and the
fluids according to local regulation
s.
NOTE: It is our policy to improve products continually and as such we reserve the right to alter data, specifications and component parts without
prior notice.
IMPORTANT: No liability is accepted for incorrect use of this product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
fig.2
© Jack Sealey Limited
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk,
IP32 7AR
Original Language Version
01284 757500
01284 703534
www.sealey.co.uk
sales@sealey.co.uk
RE83/4.V2 Issue: 5(L) - 06/01/17
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