Sealey DZRE21 User manual

STRAIGHTENER KIT WITH VARIABLE UPRIGHT
MODEL NO: DZRE21
Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these instructions,
and properly maintained, 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 INJURYAND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.
1. SAFETY
HSE WARNING! WHEN USING THIS OR ANY TOOLS OR EQUIPMENT INA COMMERCIAL OR PRIVATE WORKSHOP
ENVIRONMENT BEAWARE OF THE DANGERS AND YOUR RESPONSIBILITY TO OTHERS. WE RECOMMEND YOUAND
YOUR COLLEAGUES READ THE FOLLOWING UK GOVERNMENT PUBLICATIONS, AND OTHERS THAT MAY BE AVAILABLE,AND
TAKE HEED OF ALL WARNINGS AND PRECAUTIONS:
( AVAILABLE FREE ON LINE OR AVAILABLE AT A COST IN BOOK FORM.) https://www.hse.gov.uk/pUbns/priced/hsg261.pdf
THIS EQUIPMENT IS DESIGNED FOR PROFESSIONAL USE AND IS INTENDED TO BE EMPLOYED IN COMMERCIAL
WORKSHOPS BY FULLY TRAINED AND QUALIFIED OPERATIVES. FOR THIS REASON WE DO NOT PROVIDE DETAILED
INSTRUCTIONS FOR APPLICATIONS FOR THE PRODUCT. ENSURE THAT ONLY FULLY TRAINEDAND EXPERIENCED
OPERATIVES ARE ALLOWEDACCESS AND THAT THEYARE FULLY INFORMED OF REPAIR TECHNIQUES FOR THE BRAND
AND MODEL OF VEHICLE TO BE REPAIRED.
WARNING! Ensure health & safety, local authority, and general workshop practice regulations are adhered to when using
this equipment.
9Familiarise yourself with product application and limitations, as well as the specific potential hazards peculiar to the straightener.
IMPORTANT. THE RATED CAPACITY OF THE HYDRAULICS SUPPLIED WITH THIS KIT IS 10 TONNES. OTHER COMPONENTS
POTENTIALLY HAVE ADIFFERENT CAPACITY RATING. PLEASE SEE BELOW FOR DETAILS.
CAPACITY OF THE PULL CLAMPS IS 3TONNE. PUMP & RAM - MAX 10TONNE CAPACITY, CHAIN - MAX 10TONNE CAPACITY,
HOOK - MAX 3TONNE CAPACITY.
IF USED WITH A STRAIGHT PUSH BETWEEN 2 POINTS THE MAXIMUM FORCE EXERTED CAN BE 10 TONNES PER SQUARE
INCH. HOWEVER WHEN USED IN THE STRAIGHTENER KIT THE ACTUAL FORCE EXERTED WILL BE VARIABLE DEPENDING
ON THEANGLESAND THE PRESSUREAPPLIED. TAKE GREAT CARE WHEN ATTACHING CLAMPS AND HEED THE WARNING
TO COVER CHAINSAND CLAMPS WITH TARPAULIN OR SIMILAR UNDER LOAD TO MINIMISE RISK FROM WHIPLASHAND
MOVEMENT CAUSED BYANY SLIPPING OR LOOSENING OF CLAMPS/HOOKS WHICH MAY OCCUR.
PLEASE NOTE THAT THE FUNCTION OF THE TWO STANDS SUPPLIED WITH THIS KIT IS ONLY TO SUPPORT THE
CARRIAGE ANCHORAGE TUBE WHICH IS USED AS A RESISTANCE FOR PULLING. AS SUCH THE STANDS DO NOT HAVE
A VEHICULAR RATED CAPACITY AND SHOULD NEVER BE USED TO SUPPORTA VEHICLE AT ANY TIME AND SHOULD
NEVER BE ALTERED TO DO SO.
WARNING! No part of this unit or any accessory relating to the straightener is designed for lifting loads. It is intended only as
a pulling device and must be used as such with care.
WARNING! Disconnect the straightener from the hydraulic pump before servicing or performing any maintenance on the unit.
9Maintain straightener in good order. Replace/repair with genuine parts only. Non genuine parts may be dangerous and will invalidate
the warranty.
9Use qualified person to lubricate and maintain the hydraulic pump. DO NOT use brake fluid to top up hydraulic unit. Use Sealey hydraulic
oil only.
9Keep the straightener clean for best and safest performance.
WARNING! Use straightener on level & solid ground, preferably concrete. Avoid tarmacadam since the equipment may sink into the
surface.
9Keep area clean & tidy and free from unrelated materials. Ensure there is adequate lighting.
WARNING! Ensure you know how much load you are pulling. Never exceed the maximum pulling capacity.
8DO NOT attempt to increase pressure by increasing pump leverage through putting an extension on the handle of the pump.
9Ensure the hydraulic hose is not bent or kinked.
9Use in conjunction with Sealey hydraulic pump, chains, hooks, etc only. DO NOT use pumps or accessories other than those supplied
with kit, or contact your local agent for details of Sealey hydraulic pumps and pulling accessories. Non-genuine items may damage unit and
void warranty.
9Ensure there is positive engagement of straightener chains, claws, hooks, links etc to the chassis or vehicle body before pulling. Get a
colleague to double check the all the clamps are fully tightened and chains firmly located before using the pump to start a pull.
9Place tarpaulin or heavy cover over chains to minimise backlash etc should chains, clamps other accessory work loose or whiplash for
any reason.
9Should jacks be employed in the operation, ensure they are of the appropriate type and capacity, are in good condition and that you
follow any instructions relating to the jack. Also ensure correct stress supports are used between the jack and jacking surfaces.
9Maintain correct balance and footing. Ensure the floor is not slippery and wear non slip shoes.
9DO BE CERTAIN THAT THE VEHICLE BEING WORKED ON IS PROPERLY PREPARED AND SECURED.
DZRE21 Issue 1 05/08/21
Original Language Version
© Jack Sealey Limited
Wear head
protection Wear eye protection
Wear protective
gloves
Refer to
instructions

When pressure is applied there exists the possibility of body parts giving way suddenly and the vehicle moving in what could
be a dangerous way.
WARNING! Keep your hands, body and clothing away from the chassis and straightener accessories in use.
Take any necessary precautions to protect your personal safety whilst using the straightener.
9Keep non essential persons away from the operating area. Be aware of the location of other persons assisting you.
9When releasing tension from the load be sure to undo the hydraulic valve VERY slowly.
8DO NOT operate the straightener if any parts are damaged or missing as this may cause failure or possible personal injury.
WARNING! DO NOT use straightener as a lifting device of any type. DO NOT use for any purpose other than for which it is designed.
8DO NOT pull chains or cables over or around sharp corners.
8DO NOT heat chains or accessories as this may weaken them.
8DO NOT bolt links together.
2. INTRODUCTION
Heavy duty repair kit for straightening bent chassis and body damage. Variable position upright allows six pre-set angles of pull plus a seventh
upright position. Supplied as standard with manual hydraulic pump and ram.
3. CONTENTS
Unpack the product and check contents. Should there be any damaged or missing parts contact your supplier immediately.
Each straightener kit should consist of:
Chassis Frame.....................................................................1
SuperSnap® Hydraulic Pump & Ram...................................1
Pull Clamp ...........................................................................2
Sill Clamp.............................................................................2
4. ASSEMBLY
4.1. Assemble the unit using the parts list as your guide. When connecting the hydraulic pump ensure you retain the dust caps for
future use.
4.2. To use the hydraulic pump, turn the release valve clockwise to close (fig 1). To release the hydraulic pressure, slowly turn the valve
anti-clockwise.
NOTE: To achieve adequate locking of the anchor post, some adjustment of the angle and setup will be required.
4.3. BEFORE FIRST USE
Before using the pump for the first time, purge hydraulic circuit in order to eliminate any possible air that may have accumulated during
transit. To do so, connect the pump and ram. Put the pump on a the floor and fully pump out ram. Turn ram upside down open valve,
close ram and pump 8-10 times with the valve open.
5. MAINTENANCE
IMPORTANT: Only fully qualified personnel should attempt maintenance or repair to the hydraulic system.
5.1. PUMP OIL LEVEL
5.1.1. Release pressure and disconnect the ram from the pump.
5.1.2. Hold pump in an upright position.
5.1.3. Remove filler plug and add hydraulic oil until it is level with the full mark on the pump stem.
WARNING: DO NOT use brake fluid, or any fluid other than hydraulic jack fluid as this may cause serious damage to the product and
will invalidate the warranty! Use only Sealey hydraulic oil (Sealey Part Number: HJO500MLS/HJO5LS)
5.2. GENERAL
5.2.1. Before each use check for broken, cracked, bent, or loose parts, or any visible damage to welds, ram, pump and hose, nuts, bolts,
pins, jaws, clamps, beam, stands, chains, hooks and other fasteners. If any suspect item is found remove from service and
take necessary action to remedy the problem.
5.2.2. Replace/repair with genuine parts only. Non genuine parts may be dangerous and will invalidate the warranty.
5.2.3. Keep all parts of the unit clean, oil wheels every three months.
IMPORTANT: NO RESPONSIBILITY IS ACCEPTED FOR INCORRECT USE OF THE PUMP.
Hydraulic products are only repaired by local service agents. We have service/repair agents in all parts of the UK.
DO NOT RETURN PUMP TO US. Please telephone us on 01284 757500 to obtain the address and phone number of your local
agent. If product is under guarantee please contact your Sealey Stockist.
5.3. DE-COMMISSIONING HYDRAULIC PUMP
Should the pump become completely unserviceable and require disposal, draw off the oil into an approved container and dispose of
the product and the oil according to local regulations.
Original Language Version
© Jack Sealey Limited
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 01284 703534 [e-mail] www.sealey.co.uk
ENVIRONMENT PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to
a recycling centre and disposed of in a manner which is compatible with the environment. When the product becomes completely
unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and dispose of the product and fluids
according to local regulations.
Note: It is our policy to continually improve products 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 is required for any claim.
g.1
DZRE21 Issue 1 05/08/21
Chain ...................................................................................2
Chain Hook..........................................................................2
Carriage Anchorage Tube ....................................................1
Tube Stand ..........................................................................2