SEALEY SA36.V2 Air Punch or Flange Tool Instructions

SEALEY SA36.V2 Air Punch or Flange Tool

Product Information

• Product Name: Air Punch/Flange Tool
• Model Number: SA36.V2
• Manufacturer: Sealey

Introduction:
The Air Punch/Flange Tool is designed for heavy bodyshop use. It features an aluminum alloy body with a steel punch and dies. This tool is capable of putting a 10mm flange onto a car-panel-thickness sheet for lap jointing and creating 6mm holes in panels for mig spot welding.

Specification: Original Language Version SA36.V2 Issue: 3(SP) – 05/09/13

Product Usage Instructions

Safety Instructions

• Follow all workshop Health & Safety rules, regulations, and conditions when using this tool.
• WARNING! Disconnect from the air supply before servicing.
• Maintain the tool in good condition and replace any damaged or worn parts. Use genuine parts only. Unauthorized parts may be dangerous and will invalidate the warranty.
• WARNING! Check correct air pressure is maintained and not exceeded. We recommend 90psi.
• Keep the air hose away from heat, oil, and sharp edges. Check the air hose for wear before each use.

Preparing for Use

Air Supply

• Ensure that the tool air valve is in the Off position before connecting to the air supply.
• WARNING! Ensure the air supply is clean and does not exceed 90 psi (6.2 bar) while in use.

Operation

• WARNING! Ensure that you read, understand, and apply the safety instructions.
• Connect the tool to the air supply.
• To start the tool, hold it firmly and squeeze the throttle lever. The clamp will move down, punching a hole/forming a flange, as required.
• Release the lever, and the clamp will rise, allowing the tool to be positioned for the next operation.
• After use, disconnect the tool from the air supply, clean it, and store it in a safe, dry, childproof location.

Maintenance

Note: Numbers/letters in brackets refer to those on the parts diagram.

• WARNING! Disconnect the tool from the air supply before changing accessories, servicing, or performing maintenance.
• If the tool does not operate correctly, it may be due to a blockage or kink in the air hose connectors. To remedy this, check the air supply and follow the instructions in Section 3.
• Grit or gum deposits in the tool may also reduce performance. If your model has an air filter, refer to the user manual for cleaning instructions.
• 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 catalog and promotions, call us on 01284 757525 and leave your full name and address, including postcode.
• Sole UK Distributor: Sealey Group, Kempson Way, Suffolk Business Park, Bury St. Edmunds, Suffolk, IP32 7AR

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 AND CAUTIONS. USE THIS 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.

SAFETY INSTRUCTIONS

• Follow all workshop Health & Safety rules, regulations, and conditions when using this tool.
• WARNING! Disconnect from the air supply before servicing.
• Maintain the tool in good condition and replace any damaged or worn parts. Use genuine parts only. Unauthorized parts may be dangerous and will invalidate the warranty.
• WARNING! Check correct air pressure is maintained and not exceeded. We recommend 90psi.
• Keep the air hose away from heat, oil, and sharp edges. Check the air hose for wear before each use and ensure that all connections are secure.
• WARNING! Always wear approved eye and face protection when operating the tool.
• Wear ear defenders and gloves if necessary.
• Keep hands and body clear of the workpiece when operating the tool.
• Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
• Secure an unstable workpiece with a clamp, vice, or other adequate holding device.
• Keep children and non-essential persons away from the work area.
• DO NOT get the tool wet or use it in damp or wet locations.
• DO NOT hold the workpiece by hand. Use clamps or a vice to secure the workpiece.
• DO NOT use the tool for a task it is not designed to perform.
• WARNING! DO NOT use the tool if damaged or faulty. Contact your local service agent.
• DO NOT use the tool unless you have been instructed in its use by a qualified person.
• DO NOT carry the tool by the air hose, or yank the hose from the air supply.
• DO NOT direct air from the air hose at yourself or others.
• DO NOT operate the tool if you are tired or under the influence of alcohol, drugs, or intoxicating medication.
• When not in use, disconnect it from the air supply and store it in a safe, dry, childproof location.

INTRODUCTION & SPECIFICATION

Introduction
Suitable for heavy bodyshop use. Aluminum alloy body with steel punch and die. Puts a 10mm flange onto a car-panel-thickness sheet for lap jointing and puts 6mm holes in panels for mig spot welding.

Specification

• Operating Pressure:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90psi (6.2 bar)
• Air Inlet: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ¼”BSP
• Weight:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3kg
• Vibration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8m/s²
• Uncertainty: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.57m/s²
• Noise Power: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85dB(A)
• Noise Pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74dB(A)
• Spare Punch: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA36.V2-06
• Spare Die: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA36.V2-03

PREPARING FOR USE

Air Supply

• Ensure that the tool air valve is in the “Off” position before connecting to the air supply.
• WARNING! Ensure the air supply is clean and does not exceed 90 psi (6.2 bar) while operating the tool. Too high air pressure and/or unclean air will shorten the life of the tool due to excessive wear and may be dangerous causing damage and/or personal injury.
• Drain the compressor air tank daily. Water in the airline will damage the tool.
• Clean the compressor air inlet filter weekly. Recommended hook-up is shown in Fig. 1.
• Line pressure should be increased to compensate for unusually long air hoses (over 8 meters). The minimum hose bore should be 3/8” and fittings must have the same inside dimensions.
• Keep the hose away from heat, oil, and sharp edges. Check the hose for wear, and make certain that all connections are secure.

Couplings
Vibration may cause failure if a quick change coupling is connected directly to the tool. To overcome this, connect a leader hose to the tool. A quick change coupling may then be used to connect the leader hose to the air line recoil hose. See figs. 1 & 2.

OPERATION

WARNING! Ensure that you read, understand, and apply the safety instructions.

• Connect the tool to the air supply.
• To start the tool, hold it firmly and squeeze the throttle lever. The clamp will move down, punching a hole/forming a flange, as required.
• Release the lever and the clamp will rise allowing the tool to be positioned for the next operation.
• After use, disconnect the tool from the air supply, clean and store it in a safe, dry, childproof location.

MAINTENANCE

Note: Numbers/letters in brackets refer to those on the parts diagram.

WARNING!
Disconnect the tool from the air supply before changing accessories, servicing, or performing maintenance. Replace or repair damaged parts. Use genuine parts only. Unauthorized parts may be dangerous and will invalidate the warranty.

• If the compressed air system does not have an integral oiler then lubricate the tool daily with a few drops of Sealey air tool oil dripped into the air inlet.
• Regularly check the oil, and top-up if necessary, via the oil plug (13). Use Sealey Hydraulic Jack Oil, Part No. HJO/500ML, HJO/5L or HJO/25L.
• Clean the tool after use.
• Loss of power or erratic action may be due to the following:
  • Excessive drain on the airline. Moisture or restriction in the air pipe. Incorrect size or type of hose connectors. To remedy this, check the air supply and follow the instructions in Section 3.
  • Grit or gum deposits in the tool may also reduce performance. If your model has an air strainer (located in the area of the air inlet), remove the strainer and clean it. Flush out the tool with gum solvent oil or an equal mixture of SAE 10 oil and paraffin. Allow to dry before use.
• For a full service contact your local Sealey service agent.
• To remove and replace the punch (6) and/or die (3) proceed as follows:
  1. Remove screws (7) and slide off the cover plate (8).
  2. Slacken set screw (2) and strike the rear edge of clamp (1) with a soft-headed hammer in order to unscrew it from the shaft of the hydraulic piston (31). If necessary the shaft may be locked by removing the oil plug (13) and inserting a suitable rod into a hole in the shaft.
  3. Fully unscrew the clamp (1) and anvil (9) assembly from the shaft.
  4. Separate the anvil (9) and the clamp (1) to replace the punch (6) and/or die. The die (3) is a push fit in the clamp (1) and can be tapped out via the waste bore (A). Push/tap in the replacement.
  5. Reassemble the anvil (9), clamp (1), and replacement punch (6) and screw them onto the shaft. Tap with a soft-headed hammer to ensure tightness and lock with the set screw (2).
  6. Refit the cover plate (8) and retain it with screws (7).
• 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 catalog and promotions call us at 01284 757525 and leave your full name and address, including your postcode.

WARNING! – Risk of Hand Arm Vibration Injury.
This tool may cause Hand Arm Vibration Syndrome if its use is not managed adequately. This tool is to be operated in accordance with these instructions.

• Measured vibration emission value (a): . . . . . . . . . . . . . . . . . . 0.8m/s²
• Uncertainty value (k):. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.57m/s²
• Please note that the application of the tool to a sole specialist task may produce a different average vibration emission.
• We recommend that a specific evaluation of the vibration emission is conducted prior to commencing with a specialist task.

A health and safety assessment by the user (or employer) will need to be carried out to determine the suitable duration of use for each tool.

• NB: Stated Vibration Emission values are type-test values and are intended to be typical.
• Whilst in use, the actual value will vary considerably from and depend on many factors.
• Such factors include; the operator, the task and the inserted tool or consumable.
• NB: ensure that the length of leader hoses is sufficient to allow unrestricted use, as this also helps to reduce vibration.

The state of maintenance of the tool itself is also an important factor, a poorly maintained tool will also increase the risk of Hand Arm Vibration Syndrome.

PREPARING FOR USE

Air Supply

WARNING!

• Ensure the air supply is clean and does not exceed 90psi while operating the tool.
• Too high air pressure and unclean air will shorten the product life due to excessive wear and may cause damage and/or personal injury.
• Ensure that the tool air valve (or trigger) is in the “off” position before connecting to the air supply.
• Monitor the compressor daily to ensure that moisture is not present in the compressed air. Water in the airline will damage the tool.
• Line pressure should be increased to compensate for unusually long air hoses (over 8 meters).
• The minimum hose diameter should be ¼” internal diameter. Fittings must have compatible inside dimensions.
• Keep hoses away from heat, oil, and sharp edges. Check hoses for wear and ensure that all connections are secure.

Couplings

• Vibration may cause failure if a quick change coupling is connected directly to the tool.
• To overcome this, connect a leader hose to the tool (Sealey ref: AH2R or AH2R/38).
• A quick change coupling may then be used to connect the leader hose to the airline recoil hose.

CORRECT USE.
Vibration emission is closely linked to the operating pressure in the air supply. The user should ensure that the pressure is set in accordance with our recommendations to assure optimum efficiency and minimize vibration exposure.

• Ensure that the tool is correctly aligned with the work. Misalignment increases the risk of vibration injury.
• Ensure that consumables are selected, maintained, and replaced in accordance with Sealey Instructions.
• Sleeve fittings must be used where possible.
• Always support the tool in a stand or on a balancer or a tension device where possible.
• Ensure that the operator is sufficiently experienced in order to be able to handle and operate the tool correctly.
• Ensure that the tool is held with a light but secure grip. Avoid excessive grip force as this will increase the risk of vibration injury.

MAINTENANCE

• If the air system does not have an oiler, lubricate the air tool daily with a few drops of Sealey air tool oil dripped into the air inlet.
• Clean the tool after use.
• DO NOT use worn or damaged grinding discs (if applicable).

Loss of power or erratic action may be due to the following:

• Excessive drain on the airline. Moisture or restriction in the air pipe. Incorrect size or type of hose connectors. To remedy this, check the air supply and follow the instructions in the PREPARING FOR USE section.
• Grit, residual deposits (gum) in the tool may also reduce performance.
• Remove the strainer. Clean the strainer and flush the tool out with gum solvent oil or an equal mixture of SAE No: 10 oil and paraffin.
• Allow the tool and strainer to dry then lubricate before use.
• For a full service, contact your local Sealey service agent.
• When not in use, disconnect the tool from the air supply, clean the tool, and store the tool in a safe, childproof, location.

Health surveillance.
We recommend a program of health surveillance to detect early symptoms of vibration injury so that management procedures can be modified accordingly.

Personal protective equipment.
We are not aware of any personal protective equipment (PPE) that provides protection against vibration injury that may result from the uncontrolled use of this tool. We recommend a sufficient supply of clothing (including gloves) to enable the operator to remain warm and dry and maintain good blood circulation in fingers etc. Please note that the most effective protection is prevention, please refer to the Correct Use and Maintenance section in these instructions. Guidance relating to the management of hand-arm vibration can be found on the HSC website www.hse.gov.uk – Hand-Arm Vibration at Work.

© Jack Sealey Limited.

• Sole UK Distributor, Sealey Group, Kempson Way, Suffolk Business Park, Bury St. Edmunds, Suffolk, IP32 7AR.
• Phone: 01284 757500
• Fax: 01284 703534
• www.sealey.co.uk
• sales@sealey.co.uk.

References

• HSE: Information about health and safety at work

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