INSTRUCTIONS FOR:
HYDRAULIC BODY REPAIR KIT 4TONNE SNAP
TYPE
MODEL No: RE97/4.V3
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
1.1 GENERAL SAFETY
p WARNING! Ensure Health & Safety, local authority and general workshop practice regulations are adhered to when using this equipment.
3 Only fully trained and qualified persons should use this equipment. Familiarise yourself with the application and limitations, as well as the
specific potential hazards, of 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. Unauthorised 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. Other equipment may damage unit and will 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 with 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 and that of others whilst using the repair kit.
3 Ensure the hydraulic hose is not bent or kinked.
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.
p WARNING! DO NOT use repair kit as a lifting device of any type. 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 cylinder.
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 on end of hydraulic hose and store the kit, in the case, in a safe, dry, childproof location.
2. INTRODUCTION
Heavy gauge snap-together pipework and cast snap-together attachments compatible with most leading makes of snap-together equipment.
Supplied with hand pump, hose, hydraulic ram and storage/carry-case.
3. CONTENTS
Fig.1
Sited on pump
© Jack Sealey Limited
15
11
16
10
13
Original Language Version
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18
14
1
12
9
3
2
RE97/4.V3 Issue: 2 (L) - 11/01/17
Item Component Description
1 RE97.4-01 Pump assembly
2 RE97.4-02 Ram assembly
3 RE97.4-03 Hose assembly
4 RE97.4-A14 Ext. tube 19-1/2"
5 RE97.4-A01 Ext. tube 16-1/2"
6 RE97.4-A02 Ext. tube 8-1/2"
7 RE97.4-A03 Ext. tube 5"
8 RE97.4-A04 Ext. tube 3-1/4"
9 RE97.4-A05 Male connector
10 RE97.4-A06 Serrated saddle
19
11 RE97.4-A07 Wedge head
12 RE97.4-A08 Flat base
13 RE97.4-A09 90° Combination head
14 RE97.4-A10 Rubber head
15 RE97.4-A11 Ram toe
16 RE97.4-A12 Plunger toe
17 RE97.4-A13 Hydraulic spreader
18 RE97.4-H1-2 Handle with grip
19 Moulded case
(For spare parts of pump, ram and hose etc. see
Parts Support).
4. ASSEMBLY
4.1. Unscrew the end plugs from the hose and hydraulic ram. Retain end caps for use when storing the kit.
4.2. Screw the hose into the hydraulic ram. Ensure the hose is secure but DO NOT overtighten.
4.3. Fit the pump handle to the pump unit - DO NOT overtighten.
To provide maximum versatility a combination of pump accessories may be used.
4.4. To use the flat base plate (item 12) and snap tubing sections (items 4-8) with the hydraulic ram, see Fig.3.
Fig.2
Close
Release
Pump
Ram
Snap tubing sections
(extension tubes)
Typical arrangement with
base plate attachment.
Flat base plate
(item 12)
Fig.3
5. OPERATION
p WARNING! Ensure you have read and understand Section 1 Safety Instructions.
5.1. When using to repair vehicle damage an assessment must be made of all vehicle parts and bodywork distortions. Measurements
should be taken and compared with original manufacturer's specifications. Stored energy (memory) in the areas of damage could
result in sudden stored energy release, causing body shell movements other than the predicted hydraulic ram stroke.
5.2. DO NOT commence operation of ram until you are sure of total deflection requirement. Comprehensive planning for all operations is
essential. Ensure the task undertaken falls within the capacity of the pump and any attachment (items 9,10 & 11).
5.3. The pump may be used in any position from horizontal to vertical. When not horizontal ensure the hose end of the pump is down.
5.4. To use the pump, close valve (Fig.1 and Fig.2) by turning the knob clockwise and pump the handle up and down to apply the load.
5.5. To release pump pressure, turn knob anti-clockwise.
6. ATTACHMENTS
6.1. Hydraulic Ram- For use in large spaces and where a large amount of force is required. Comes with several attachments.
6.2. Snap Tubing- Plug into the hydraulic ram in different combinations in order to obtain the required length.
6.3. Serrated Saddle, Combi, Rubber, Wedge Heads, Ram and Plunger Toes- Typically used on the pushing end in frame repair. Can
be attached to either end of the hydraulic ram or extension bars.
6.4. Flat Base- This is used on the stationary side to spread the force of the hydraulic ram. Can be attached to either end of the
hydraulic ram or extension bars.
6.5. Adaptor- This is used with the extension bars and other attachments that may be connected to the hydraulic ram. Plugs into
either end of the hydraulic ram.
NOTE! When positioning the hydraulic ram, it is necessary wherever possible to use a smaller attachment on the side that is to be bent or
shaped. To further reduce the danger of the stationary side being damaged, place a block of wood or dense hard rubber behind the flat base
plate (item 12) in order to cushion the stationary side and spread the pressure exerted by the hydraulic ram.
7. MAINTENANCE
IMPORTANT: Only fully qualified personnel should attempt maintenance or repair of the hydraulic system.
7.1. Pump oil level
Release pressure and disconnect the ram from the pump.
Hold pump in an upright position.
Ensure the hydraulic ram is fully retracted. Remove the oil reservoir plug (opposite valve) and top up using Sealey hydraulic jack oil
(Sealey Part Nos HJO500MLS/HJO5LS). DO NOT use brake fluid. After filling, purge the system in order to eliminate any air. Open
the release valve (Fig.1.) and pump the handle several times (suggested 20 times). Close the valve and replace the oil reservoir
plug. Should the system fail at any time, repeating this process may resolve the problem.
7.2. General
Before each use check for broken, cracked, bent, loose parts, or any visible damage to welds, ram, pump, hose or accessories.
Suspect items to be removed from service and repaired or replaced. Repair or replace with genuine parts only. Unauthorised repairs
or parts may be dangerous and will invalidate the warranty.
7.3. De-commissioning hydraulic pump/ram
Should the pump or ram become unserviceable, draw off the oil into an approved container and dispose of the product and the oil in
accordance with local authority regulations.
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..
© Jack Sealey Limited
Original Language Version
RE97/4.V3 Issue: 2 (L) - 11/01/17
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