SEALEY DZRE21 Straightener Kit with Variable Upright Instructions
- June 3, 2024
- SEALEY
Table of Contents
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 INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.
Refer to instructions Wear protective gloves
Wear head protection Wear eye protection
1. SAFETY
HSE WARNING! WHEN USING THIS OR ANY TOOLS OR EQUIPMENT IN A COMMERCIAL OR
PRIVATE WORKSHOP ENVIRONMENT BE AWARE OF THE DANGERS AND YOUR RESPONSIBILITY
TO OTHERS. WE RECOMMEND YOU AND 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 TRAINED AND EXPERIENCED OPERATIVES ARE ALLOWED
ACCESS AND THAT THEY ARE 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.
** Familiarise 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 A DIFFERENT CAPACITY RATING.
PLEASE SEE BELOW FOR DETAILS.
CAPACITY OF THE PULL CLAMPS IS 3.5 TONNE.
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 THE ANGLES AND THE PRESSURE
APPLIED. TAKE GREAT CARE WHEN ATTACHING CLAMPS AND HEED THE WARNING TO COVER
CHAINS AND CLAMPS WITH TARPAULIN OR SIMILAR UNDER LOAD TO MINIMISE RISK FROM
WHIPLASH AND MOVEMENT CAUSED BY ANY 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 SUPPORT A 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.
Maintain straightener in good order. Replace/repair with genuine parts
only. Non genuine 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 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.
** Keep 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.
DO NOT attempt to increase pressure by increasing pump leverage through
putting an extension on the handle of the pump.
Ensure the hydraulic hose is not bent or kinked.
Use 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.
Ensure 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.
Place tarpaulin or heavy cover over chains to minimise backlash etc
should chains, clamps other accessory work loose or whiplash for any reason.
Should 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.
Maintain correct balance and footing. Ensure the floor is not slippery
and wear non slip shoes.
DO BE CERTAIN THAT THE VEHICLE BEING WORKED ON IS PROPERLY PREPARED AND
SECURED. 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.
Keep non essential persons away from the operating area. Be aware of
the location of other persons assisting you.
When releasing tension from the load be sure to undo the hydraulic valve
VERY slowly.
DO 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.
DO NOT pull chains or cables over or around sharp corners.
DO NOT heat chains or accessories as this may weaken them.
DO 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
Chain ……………………………………………………… 2
SuperSnap® Hydraulic Pump & Ram ……..1
Chain Hook …………………………………………… 2
Pull Clamp …………………………………………….. 2
Carriage Anchorage Tube ……………………… 1
Sill Clamp ……………………………………………… 2
Tube Stand ……………………………………………. 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.
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.
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 01284 703534sales@sealey.co.uk www.sealey.co.uk
© Jack Sealey Limited Original Language Version DZRE21 Issue 1 26/07/21