Sealey RE97/4 User manual

INSTRUCTIONS FOR:
SNAP BODY REPAIR KITS
Models: RE97/4 & RE97/10C
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.
1. SAFETY INSTRUCTIONS
2. CONTENT
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. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
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WARNING! Ensure Health & Safety, local authority and general workshop practice regulations are adhered to when using this equipment.
3Familiarise yourself with the application and limitations, as well as the specific potential hazards, of the repair kit.
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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.
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WARNING! Disconnect the repair kit from the hydraulic pump before servicing or performing any maintenance on the unit.
3Maintain repair kit in good order. Replace/repair with genuine parts only. Unauthorised parts may be dangerous and will invalidate the warranty.
3Use qualified person to lubricate and maintain the hydraulic pump. DO NOT use brake fluid to top up hydraulic unit. Use Sealey hydraulic oil only.
3Keep the repair kit clean for best and safest performance.
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WARNING! Ensure you know how much load you are pushing. Never exceed the maximum pushing capacity.
3Use only with the supplied Sealey hydraulic pump and accessories. Other equipment may damage unit and will invalidate your warranty.
3The kit accessories may be used with other popular makes of kit.
3Ensure there is positive engagement of repair kit accessories with the vehicle body before pushing.
3Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
3If working on an off centre load, pump with care. If you feel undue resistance, stop and re-adjust the set-up.
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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.
3Ensure the hydraulic hose is not bent or kinked.
3Keep non-essential persons away from the operating area. Be aware of the locations of other persons assisting you.
3When releasing tension from the load be sure to undo the hydraulic valve VERY slowly.
7DO NOT operate the repair kit if any parts are damaged or missing as this may cause failure and/or personal injury.
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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.
7DO NOT over extend the ram as the plunger may be forced out of the cylinder.
7DO NOT heat accessories as this may weaken them.
7DO NOT modify accessories for use with this kit.
3When not in use, place dust cap on end of hydraulic hose and store the kit, in the case, in a safe, dry, childproof location.
Only fully trained and qualified persons should use this equipment. These instructions are not a substitute for user receiving full
supervised training by a qualified person. It is important the user understands the applications, limitations and potential hazards of the product.
ITEM PART NO. DESCRIPTION
1RE97.4-01 Pump assembly
2 RE97.4-02 Ram assembly
3RE97.4-03 Hose assembly
4 RE97.4-A14 Extension Tube, 19 1/2
5 RE97.4-A01 Extension Tube, 16 1/2
6RE97.4-A02 Extension Tube, 8 1/2
7 RE97.4-A03 Extension Tube, 5
8 RE97.4-A04 Extension Tube, 3 1/4
9RE97.4-A05 Male connector
10 RE97.4-A06 Serrated sadle
11 RE97.4-A07 Wedge head
12 RE97.4-A08 Flat base
13 RE97.4-A09 90º Combination head
14 RE97.4-A10 Rubber head
15 RE97.4-A11Ram toe
16 RE97.4-A12 Plunger toe
17 RE97.4-A13 Hydraulic spreader
ITEM PART NO. DESCRIPTION
1 RE97.10C-40 Pump assembly
2RE97.10C-41 Ram assembly
3RE97.10C-42 Hose assembly
4 RE97.10C-A02 Extension Tube, 27
5RE97.10C-A03 Extension Tube, 18
6RE97.10C-A04 Extension Tube, 10
7 RE97.10C-A05 Extension Tube, 5
8RE97.10C-18 Male connector
9RE97.10C-07 Serrated sadle
10 RE97.10C-16 Wedge head
11 RE97.10C-13 Flat base
12 RE97.10C-17 90º Combination head
13 RE97.10C-12 Rubber head
14 RE97.10C-14 Ram toe
15 RE97.10C-15 Plunger toe
16 RE97.10C-11 Hydraulic spreader
17 RE97.10C-01 Metal Box
RE97/4, RE97/10C - 1 - 060802
RE97/4
RE97/10C

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WARNING! Ensure you have read and understand Section 1 Safety Instructions.
4.1. The pump may be used in any position from horizontal to vertical. When not horizontal ensure the hose
end of the pump is down.
4.2. To use the pump, close valve (fig. 1.A) by turning the knob clockwise and pump the the handle up and
down to apply the load.
4.3. To release pump pressure, turn knob anti-clockwise (B).
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.
To provide maximum versatility a combination of ram accessories may be used.
3. INTRODUCTION
4. INSTRUCTIONS FOR USE
IMPORTANT: NO RESPONSIBILITY IS ACCEPTED FOR INCORRECT USE OF THE PUMP AND/OR RAM.
Hydraulic products are only repaired by local service agents. We have service/repair agents in all parts of the UK.
DO NOT RETURN PUMP OR RAM TO US. Please call us on 01284 757500 to obtain the address and telephone number of your local agent.
If product is under guarantee please contact your dealer.
5. MAINTENANCE
IMPORTANT:Only fully qualified personnel should attempt maintenance or repair of 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).
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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. Unauthorised parts may be dangerous and will invalidate the warranty.
Keep all parts of the kit clean.
5.3. De-commissioning hydraulic pump/ram
Should the pump or ram become completely unserviceable draw off the oil into an approved container and dispose of the product and the
oil according to local regulations.
Declaration of Conformity We, the sole importer into the UK, declare that the product listed below is in conformity with the following standards and directives.
S S N N A A P P
BODY REPAIR KITS
Models: RE97/4 & RE97/10C
98/37/EC Machinery Directive 4th November 2000Signed by Mark Sweetman
The construction file for this product is held by the Manufacturer and may be inspected, by a national
authority, upon request to Jack Sealey Ltd.
For Jack Sealey Ltd. Sole importer into
the UK of Sealey Power Products.
Sole UK Distributor,
Sealey Group,
Bury St. Edmunds, Suffolk. 01284 757500 E-mail: [e-mail]
Web: www.sealey.co.uk
01284 703534
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 will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
RE97/4, RE97/10C - 1 - 060802
Kit features heavy gauge snap-together pipe-work and cast snap-together attachments compatible with most leading makes of snap-together
equipment. Hydraulic rams are capable of a thrust of 4 tons and 10 tons respectively.
IMPORTANT:
Only fully trained and qualified persons should use this equipment. It is important that the user understands the applications, limitations and
potential hazards of the equipment.
VEHICLE DAMAGE INTRODUCTION
Before using the repair kit, you must determine the extent of vehicle damage. Check all parts and determine whether there are any broken, torn,
crumpled, wrinkled, crushed, twisted or bent metallic parts. Measurements should be taken to see how far the vehicle is out of alignment. It is
important to determine correct dimensions by referring to the manufacturers frame dimension charts and specifications. Remember, do not
commence pushing until you are sure when to stop. Take time to examine and determine damage correctly. Comprehensive planning will save
you time when using the equipment.
A
fig. 1
fig. 2
B