RE2000 Issue 2 29/01/25
Original Language Version
© Jack Sealey Limited
BODY REPAIR KIT, 20 TONNE
MODEL NO: RE2000
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
instruction
manual
Wear eye
protection
1. SAFETY
WARNING! Ensure Health & Safety, local authority and general workshop practice regulations are adhered to when using this
equipment.
9 Only fully trained and qualied persons should use this equipment. Familiarise yourself with the application and limitations, as well
as the specic 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! Keep children and unauthorised persons away from the work area.
WARNING! The maximum ram capacity is 20 Tonne. DO NOT exceed this rated capacity.
WARNING! When extension tubes are used, the rated capacity is always reduced by 50% for each tube connected.
WARNING! Disconnect the repair kit from the hydraulic pump before servicing or performing any maintenance on the unit.
9 Maintain repair kit in good order. Replace/repair with genuine parts only. Unauthorised parts may be dangerous and will invalidate
the warranty.
9 Use qualied person to lubricate and maintain the hydraulic pump. DO NOT use brake uid to top up hydraulic unit. Use Sealey
hydraulic oil only.
9 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.
WARNING! Only use this equipment on a surface that is stable, level, dry and not slippery, and capable of sustaining the load.
Keep the surface clean, tidy and free from unrelated materials and ensure that there is adequate lighting.
9 Use only with the supplied Sealey hydraulic pump and accessories. Other equipment may damage unit and will invalidate your
warranty.
9 The kit accessories may be used with other popular makes of kit.
9 Ensure there is positive engagement of repair kit accessories with the vehicle body before pushing.
9 If working on an o 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.
9 Ensure the hydraulic hose is not bent or kinked.
9 Keep non-essential persons away from the operating area. Be aware of the locations of other persons assisting you.
9 When releasing tension from the load be sure to undo the hydraulic valve VERY slowly.
8 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.
8 DO NOT over extend the ram as the plunger may be forced out of the cylinder.
8 DO NOT heat accessories as this may weaken them.
8 DO NOT modify accessories for use with this kit.
8 DO NOT drop any heavy objects onto the hose and DO NOT twist the hose. Always keep the hose clean to avoid damage to the
hose and couplers.
8 DO NOT operate this equipment when you are tired or under the inuence of alcohol, drugs or any intoxicating medication
9 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.
9 Keep the equipment away from heat or re, as this may cause damage or weaken the seals.
2. INTRODUCTION
Equipped with threaded attachments for increased durability and superior performance in auto repair tasks. Steel construction
ensures long-lasting strength and reliability, perfect for demanding pushing, pulling and spreading applications. Complete kit
includes two cases which feature hydraulic equipment and various attachments to accommodate multiple repair functions,
oering exibility for dierent requirements. Designed for easy operation and portability, ensuring ecient use in dierent work
environments. Supplied with a 20 Tonne hand-operated pump, hose, hydraulic ram and metal storage cases for easy set-up,
transport and storage.
Wear safety
footwear
Wear
protective
gloves
Wear
protective
clothing
Wear safety
footwear
IMPORTANT:
Only fully trained and qualified persons should use this equipment. It is very important that the user understands the applications,
limitations and specific hazards of the product.
VEHICLE DAMAGE INTRODUCTION
Before using the repair kit, you must determine the extent of vehicle damage. The technician will check all parts and determine if there
is any broken, torn, crumpled, wrinkled, crushed, twisted or bent metallic parts. Measurements should be taken to see how far out
of alignment the vehicle may be. 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 you are actually using this equipment.
3. SPECIFICATION
4. CONTENTS
5. ASSEMBLY
5.1. Unscrew the end plugs from the hose and hydraulic ram. Retain end caps for use when storing the kit.
5.2. Screw the hose into the hydraulic ram. Ensure the hose is secure but DO NOT overtighten.
5.3. Fit the pump handle to the pump unit - DO NOT overtighten. To provide maximum versatility a combination of pump accessories may
be used.
6. INSTRUCTIONS
WARNING! Ensure you have read and understood chapter 1 safety instructions.
NOTE: These instructions are intended to provide a guide to the basic operation of the body repair kit and are in no way intended to
replace the advice/instruction of a qualified mechanic/car body repair specialist. Only fully trained persons should use this equipment.
6.1. The pump may be used in any position from horizontal to vertical. When not horizontal ensure the hose end of the pump is down.
6.2. To use the pump, see parts list for reference, close relieve valve (P-32) by turning the knob clockwise and pump the handle up and
down to apply the load.
6.3. To release pump pressure, turn knob anti-clockwise.
RE2000 Issue 2 29/01/25
Original Language Version
© Jack Sealey Limited
Model: RE2000
Nett Weight: 61kg
RE2000
20 Tonne Auto
repair kit
1
2
14
10
9
9
10
10
9
8
7
6
5
15
4
3
13
12
11
16
ITEM PART NO. DESCRIPTION QTY
1 RE2000-01 Pump & Hose Assembly 1
2 RE2000-02 Ram Assembly 1
3 RE2000-03 Hex Key 1
4 RE2000-04 Base 1
5 RE2000-05 Ram Toe 1
6 RE2000-06 V Base 1
7 RE2000-07 Wedge Toe 1
8 Plunger Toe Plunger Toe 1
9 RE2000-09 Extension Tube (72mm - 3") 3
10 RE2000-10 Connection Tube 3
11 RE2000-11 Extension Tube (127mm - 5") 1
12 RE2000-12 Extension Tube (255mm - 10") 1
13 RE2000-13 Extension Tube (508mm - 20") 1
14 RE2000-14 Extension Tube (700mm - 28") 1
15 RE2000-15 Steel Storage Case (A) 1
16 RE2000-16 Steel Storage Case (B) 1
Oil Capacity: 700ml
6.4. REPAIRING FRAME DAMAGE
6.4.1. Determine the direction in which the frame needs to be bent.
6.4.2. Carefully remove any obstructions and items that may be damaged in the bending process.
6.4.3. Attach the base plate to the stationary side of the hydraulic ram.
6.4.4. Attach the appropriate attachment/combination of attachments to the pushing end of the hydraulic ram.
6.4.5. Position the assembled kit appropriately i.e. With the base plate resting against a frame member opposite the damaged area and in
line with the direction in which the damaged area needs to be pushed.
6.4.6. Slowly extend the ram, being sure to direct the moving end of the ram toward the area in need of repair until contact is made.
6.4.7. Move as far away as possible and continue to slowly operate the pump, applying pressure until the desired bend has been made.
6.4.8. When operation is complete, slowly turn the release valve anti-clockwise. Remove the hydraulic ram.
6.5. REPAIRING BODY DAMAGE
6.5.1. Determine the direction in which the body panel needs to be moved.
6.5.2. Carefully remove any obstructions and items that may be damaged in the bending process.
6.5.3. Attach the base plate to the stationary side of the hydraulic ram.
6.5.4. Attach the appropriate attachment/combination of attachments to the pushing end of the hydraulic ram.
6.5.5. Position the assembled kit appropriately i.e. With the base plate resting against a frame/robust body part opposite the damaged area
and in line with the direction in which the damaged area needs to be pushed. Be sure that the stationary frame/body part is stronger
than the area to be bent (a block of wood or rubber may be used to protect the stationary part).
6.5.6. Slowly extend the ram, being sure to direct the moving end toward the area in need of repair until contact is made.
6.5.7. Move as far away as possible and continue to slowly operate the pump, applying pressure until the desired bend has been made.
6.5.8. When operation is complete, slowly turn the release valve anti-clockwise. Remove the hydraulic ram.
6.6. USING THE SPREADER RAM
6.6.1. Determine the direction in which the body panel needs to be moved.
6.6.2. Carefully remove any obstructions and items that may be damaged in the bending process.
6.6.3. Place the spreader ram such that the hinged arm is resting against the part to be moved and the stationary arm is resting against a
strong fixed base. Holding the spreader ram in position, operate the pump until contact is made.
6.6.4. Move as far away as possible and continue to slowly operate the pump, applying pressure until the desired bend has been made.
6.6.5. When operation is complete, slowly turn the release valve anti-clockwise. Remove the spreader ram.
IMPORTANT: Always store the ram with the piston fully retracted to help prevent corrosion. Rams with signs of rust on the main piston
cannot be replaced under warranty.
6.6.6. Rams with signs of damage to the piston or the cylinder and/or with damaged hydraulic couplings cannot be accepted under warranty.
Due to the severe abuse required to cause damage to the pump piston or arm hinge mechanism, these cannot be accepted under
warranty.
7. MAINTENANCE
IMPORTANT: Only fully qualified personnel should attempt maintenance or repair to the hydraulic system.
7.1. PUMP OIL LEVEL
With ram fully lowered, set pump unit in its normal, level position. Remove the oil filler screw (P05) to check the hydraulic oil level. If it
is not adequate, add high quality hydraulic jack oil as necessary.
To ensure best performance and longer equipment life, replace the complete hydraulic oil at least once a year. With ram fully lowered,
remove the oil filler screw (P05) and drain the oil into a suitable container. Ensure that no dirt gets into the system. Set the pump in its
normal level position, fill with approved hydraulic jack oil, then replace the oil filler screw (P05).
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.
7.2. 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 - use only a mild detergent and a damp cloth. DO NOT use solvents.
NOTE: A coating of light lubricating oil to pivot points, axles and hinges will help to prevent rust and assure that pump assemblies
move freely. Periodically lubricate the pivot points, axles and hinges with a light lubricating oil as needed.
7.2.1. When equipment efficiency drops, purge away air from hydraulic system: Turn the release valve counterclockwise by 1-1/2 turns, with
ram fully retracted and release valve open, pump the handle rapidly for 10-20 times.
NOTE: It is recommended that an annual inspection be done by qualified technicians.
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 telephone us on 01284 757505 to obtain the address and ‘phone number of your
local agent.
If product is under guarantee please contact your dealer.
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.
RE2000 Issue 2 29/01/25
Original Language Version
© Jack Sealey Limited
8. TROUBLESHOOTING
RE2000 Issue 2 29/01/25
Original Language Version
© Jack Sealey Limited
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
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 uids (if applicable) into
approved containers and dispose of the product and uids according to local regulations.
REGISTER YOUR
PURCHASE HERE
Symptom Possible Causes Corrective Action
Ram won't lift load Release valve not tightly closed.
Overload condition.
Air trapped in system.
Firmly close release valve.
Remedy overload condition.
Purge away air from system.
Ram won't maintain load Release valve not lightly closed.
Hydraulic unit malfunction.
Firmly close release valve.
Replace ram and/or pump.
Ram won't lower after unloading Reservoir overlled.
Linkages binding.
Drain oil to proper level.
Clean and lubricate moving parts.
Ram won't extend to full stroke Oil level low. Add hydraulic oil.
Poor performance Oil level low.
Air trapped in system.
Add hydraulic oil.
Purge away air from system.
