SEALEY RE97-10.V3 Hydraulic Body Repair Kit Instructions

SEALEY RE97-10.V3 Hydraulic Body Repair Kit

Specifications:

• Product: 10 Tonne Snap Hydraulic Body Repair Kit
• Model No: RE97/10.V3

Product Usage Instructions

Safety Precautions:

• Wear eye protection and protective gloves.
• Keep people away to avoid crushing of hands.
• Ensure adherence to Health & Safety regulations and workshop practices.
• Only trained individuals should operate the equipment.

Proper Operation:

• Repair kit is for pushing, not lifting. Disconnect from hydraulic pump before maintenance.
• Maintain kit with genuine parts and Sealey hydraulic oil only.Keep it clean for optimal performance.
• Do not exceed maximum pushing capacity. Use only with supplied Sealey pump and accessories.
• Engage accessories with vehicle body before pushing. Maintain balance and non-slip footing.

Safety Measures During Use:

• Avoid contact with kit and accessories when in use. Protect hands, body, and clothing.
• Ensure hydraulic hose is not bent or kinked.
• Keep non-essential persons away from the operating area and be cautious of surroundings.
• Release tension slowly and do not operate if any parts are damaged or missing.

Avoidance of Common Mistakes:

• Do not use the repair kit as a lifting device or for purposes other than intended.
• Avoid overextending the ram to prevent plunger displacement.
• Avoid heating accessories as it may weaken them.

FAQ:

Q: Can I use the repair kit with equipment from other brands?
A: Yes, the kit accessories may be compatible with other popular makes of kits.

Q: What type of fluid should I use to top up the hydraulic unit?
A: Use Sealey hydraulic oil only. Do not use brake fluid for topping up.

Q: How should I release tension from the load?
A: Undo the hydraulic valve very slowly to release tension safely.

10 TONNE SNAP HYDRAULIC BODY REPAIR KIT
MODEL NO: RE97/10.V3

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 INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.

SAFETY

GENERAL SAFETY

• WARNING! Ensure Health & Safety, local authority and general workshop practice regulations are adhered to when using this equipment.
• 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.
• 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.
• WARNING! Disconnect the repair kit from the hydraulic pump before servicing or performing any maintenance on the unit.
• Maintain repair kit in good order. Replace/repair with genuine parts only. Unauthorised parts may be dangerous and will invalidate the warranty.
• 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.
• Keep the repair kit clean for best and safest performance.
• WARNING! Ensure you know how much load you are pushing. Never exceed the maximum pushing capacity.
• Use only with the supplied Sealey hydraulic pump and accessories. Other equipment may damage unit and will invalidate your warranty.
• The kit accessories may be used with other popular makes of kit.
• Ensure there is positive engagement of repair kit accessories with the vehicle body before pushing.
• Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
• If working on an off centre load, pump with care. If you feel undue resistance, stop and re-adjust the set-up.
• 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.
• Ensure the hydraulic hose is not bent or kinked.
• Keep non-essential persons away from the operating area. Be aware of the locations of other persons assisting you.
• When releasing tension from the load be sure to undo the hydraulic valve VERY slowly.
• DO NOT operate the repair kit if any parts are damaged or missing as this may cause failure and/or personal injury.
• 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.
• DO NOT over extend the ram as the plunger may be forced out of the cylinder.
• DO NOT heat accessories as this may weaken them.
• DO NOT modify accessories for use with this kit.
• 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.

INTRODUCTION

Heavy gauge snap-together pipework and cast snap-together attachments compatible with most leading makes of snap-together equipment. Supplied with 10 Tonne hand-operated pump, hose, hydraulic ram and storage case.

CONTENTS

ASSEMBLY

1. Unscrew the end plugs from the hose and hydraulic ram. Retain end caps for use when storing the kit.
2. Screw the hose into the hydraulic ram. Ensure the hose is secure but DO NOT overtighten.
3. Fit the pump handle to the pump unit – DO NOT overtighten.
4. To provide maximum versatility a combination of pump accessories may be used.
5. To use the flat base plate (item 11) and snap tubing sections (items 4-7) with the hydraulic ram, see Fig.3.

OPERATION

WARNING! Ensure you have read and understand Section 1 Safety Instructions.

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.
   • DO NOT commence operation of ram until you are sure of total deflection requirement.
2. Comprehensive planning for all operations is essential. Ensure the task undertaken falls within the capacity of the pump and any attachment.
3. The pump may be used in any position from horizontal to vertical. When not horizontal ensure the hose end of the pump is downwards.
4. To use the pump, close valve (Fig.1) by turning the knob clockwise and open the breather valve (which must be closed when not in use), pump the handle up and down to apply the load.
5. To release pump pressure, turn knob anti-clockwise.

ATTACHMENTS

1. Hydraulic Ram- For use in large spaces and where a large amount of force is required. Comes with several attachments.
2. Snap Tubing- Plug into the hydraulic ram in different combinations in order to obtain the required length.
3. Serrated Saddle and Wedge Head- Typically used on the pushing end in frame repair. Can be attached to either the hydraulic ram or extension bars.
4. Flat Base- This is used on the stationary side to spread the force of the hydraulic ram. Can be attached to either the hydraulic ram or extension bars.
5. Male Connector- This is used with the extension bars and other attachments that may be connected to 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 11) in order to cushion the stationary side and spread the pressure exerted by the hydraulic ram.

MAINTENANCE

IMPORTANT: Only fully qualified personnel should attempt maintenance or repair of the hydraulic system.

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.

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.

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.

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. Please note that other versions of this product are available. If you require documentation for alternative versions, please email or call our technical team on technical@sealey.co.uk or 01284 757505.

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.

Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR

01284 757500
sales@sealey.co.uk
www.sealey.co.uk

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