SEALEY AK450DP Pump Away Station Air Powered Instructions

AK450DP Pump Away Station Air Powered
Instructions

SEALEY AK450DP Pump

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.

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Refer to the instruction manual| Wear eye protection| Wear protective clothing| Wear protective gloves**

SAFETY

• WARNING! Ensure Health & Safety, local authority, and general workshop practice regulations are adhered to when using this equipment.
• WARNING! DO NOT pollute the environment by allowing uncontrolled discharge of waste oil. Dispose of waste oil in accordance with local authority regulations.
• WARNING! Turn off the air supply and de-pressurize the output line before removing the pump unit from any installation or mobile system. Failure to comply with this instruction may damage the unit and will invalidate the warranty.
• WARNING! Disconnect the pump from the air supply before changing accessories, servicing, or performing any maintenance.
• WARNING! Ensure correct air pressure is maintained and not exceeded.
• Familiarise yourself with the application and limitations of the product as well as the potential hazards.
• Install the pump in an appropriate working area. Keep the area clean and tidy, free from unrelated materials, and ensure there is adequate lighting.
• Maintain the pump in good condition (use an authorized service agent).
• Replace or repair damaged parts. Use genuine parts only. Unauthorized parts may be dangerous and will invalidate the warranty.
• When not in use ensure the air supply is turned off.
• Keep the pump clean for the best and safest performance.
• Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
• Keep children and unauthorized persons away from the working area.
• Keep 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.
• DO NOT allow unauthorized persons to operate the pump.
• DO NOT operate the drainer if any parts are damaged or missing as this may cause failure and/or personal injury.
• DO NOT point the airline at yourself, other persons, or animals.
• WARNING! DO NOT tamper with, or open, the pump unit. To do so will invalidate the warranty.
• DO NOT use the pump to draw off any other liquids other than oils.
• DO NOT force the pump to achieve a task it was not designed to perform.
• DO NOT allow untrained persons to operate the pump
• DO NOT operate the pump when you are tired or under the influence of alcohol, drugs, or intoxicating medication.
• DO NOT leave the pump operating unattended.

INTRODUCTION

Air-operated 1:1 oil pump, suitable for use with Model No’s AK450DX and AK468DX oil drain units. Supplied with a wall mounting bracket, 2m flexible hose with dry-fit male and female quick couplings to attach it to the drain unit. A 2m flexible air supply hose with filter, lubricator, and regulator assembly is also included. The pump can be plumbed into a run of pipework to a waste oil storage point sited out of the workshop.

SPECIFICATION

Model no …………………………………………………………..AK450DP
Air consumption ……………………………………………………..8.8cfm
Min/max air pressure …………………………………………. 30/120psi
Oil delivery @90psi ………………………………………………60L/min

CONTENTS

1. Pump
2. Filter-regulator
3. Lubricator
4. Pressure gauge
5. Mounting bracket, filter-regulator
6. Air inlet hose and fitting
7. Suction hose and fittings
8. Wall bracket, pump
9. Hex plug, regulator
10. Fitting, air system – 2 off

ASSEMBLY

5.1. The air control unit items (fig.1. 2 & 3) have polycarbonate bowls and must not be installed where the bowls may be exposed to materials incompatible with polycarbonate such as certain solvents and chemicals, or where fumes can weaken the bowls. If this is unavoidable, an extension air line hose may be placed between the pump unit and the air control unit, but should not exceed 2 metres (6½ft) in length. Note that a mounting bracket (fig.1.5) is supplied to provide support for the remote-positioned air control unit.

• WARNING! Clean new air lines ensuring all metal shavings have been removed before connecting the pump and control unit. Any dirt in the inlet lines could damage the unit and may invalidate the warranty.

5.2. Connect filter-regulator to lubricator using one of the fittings (10). Note the airflow direction arrows on each unit and that lubricator must be between the pump and filter-regulator. Using the second fitting (10) connect the lubricator outlet to the pump air inlet.
5.3. Screw gauge (4) into filter-regulator port, choosing the port which will provide the easiest gauge visibility in the final installed position. Plug the remaining gauge port with plug (9).
5.4. Screw air hose (6) into the filter-regulator inlet port. Secure all connections (but do not over-tighten).

INSTALLATION

• DO NOT install the unit where it may be damaged by moving apparatus, or may endanger personal safety.

6.1. Secure wall mounting bracket (fig.1.8) to a wall, as shown in fig.3, ensuring the wall and attaching screws are adequate to take the weight of the pump and the pull of the suction and output hoses.
6.2. Remove the knurled mounting ring from the pump body and pass the pump unit through the mounting bracket and secure it with the knurled ring, (fig.3).
6.3. Attach the suction hose (fig.2.7) to the inlet at the base of the pump unit. Attach output line (¾” bore – not supplied, (see fig.2) to the pump output port.
6.4. The bowl of the filter-regulator (fig.2.2) is fitted with an automatic drain valve the outlet of which may be piped away using a suitably sized flexible tube.
6.5. Remove lubricator (fig.2.3) oil filler plug and fill with good quality air tool oil (Sealey ATO/500 500ml size or ATO/1000 1L size) checking the maximum level marked on the side of the unit.
Note: The installation of a wall bracket next to the pump, to support the suction hose when not in use, is recommended.
Use PTFE tape or similar on all connections to ensure leak-free joints.

OPERATION

7.1. The regulator should be set at 6 bar/90psi. It is important to maintain the correct operating pressure to ensure that the control valves and connectors are not damaged and to prevent leakage in the delivery lines.
7.2. Connect the suction hose (fig.2.7) to the oil drain unit and ensure the outlet hose will dispose of the waste in accordance with local authority regulations. DO NOT pollute the environment by the uncontrolled discharge of waste products.

• WARNING! DO NOT operate pump dry – suction line must be connected to drainer before turning on.

7.3. Before turning on the air supply for the first time ensure that the pressure regulator knob (fig.4.A) is unwound (anticlockwise) so that there is no load on the regulator spring. Turn on the air supply. The regulator output gauge (fig.2.4) should show zero. Turn the regulator knob clockwise, slowly, until the gauge shows 6 bar (90psi) – pump will start at approx. 2 bar. Lock knob with locking ring (fig.4.B) to prevent accidental movement.
Note: When resetting the regulated pressure always start from below the new required pressure and adjust up.
7.4. Check that there are no leaks from any of the hoses or fittings.
7.5. When pumping is complete turn the airline of. Disconnect the suction hose from the drain unit and store it. Wipe up any spillage.
Note: Waste oil will not pump if its viscosity is too high.

MAINTENANCE

• WARNING! Ensure that the pump is disconnected from the air line and that there is no pressure in the output line before attempting any service or maintenance.

Note: It is essential that dirt and moisture are kept out of the air supply to the pump. Drain the air supply system and clean filters regularly.
8.1. AIR LINE LUBRICATOR AND WATER TRAP (FIG.2.3)
8.1.1. This unit is designed to automatically lubricate the pump via the air supply. The unit must be kept topped up with good quality air tool oil (Sealey reference: ATO/500 – 500ml size or ATO/1000 – 1L size). To adjust the oil flow turn the oil regulator on the top of the unit. Turn the screw anticlockwise to increase the flow and clockwise to decrease flow – set to minimum flow for this application.
At regular intervals check that water is draining from the filter regulator since it is essential that water does not enter the pump.
8.2. CLEANING
8.2.1. Clean pump and air units with a clean damp cloth. Mild detergents may be used to remove oil.

• DO NOT use solvents or abrasives and do not get the pump or air units wet.

TROUBLESHOOTING

Muffler is blocked
Internal defect
Muffler is blocked| Adjust air pressure to above 2 bar/30psi
Contact service agent
Contact service agent
Poor performance| Waste fluid to be pumped is below 15°C
Viscosity is too high for the pump| Contact service agent
Increase oil temperature by moving the drain unit to a warmer area
Check viscosity of waste oil
| WEEE REGULATIONS
Dispose of this product at the end of its working life in compliance with the EU Directive on Waste Electrical and Electronic Equipment (WEEE). When the product is no longer required, it must be disposed of in an environmentally protective way. Contact your local solid waste authority for recycling information.
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**| ENVIRONMENT PROTECTION**
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories, and packaging should be sorted, taken to a recycling center, and disposed of in a manner that 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: The guarantee is 12 months from the 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 703534
sales@sealey.co.uk
www.sealey.co.uk
© Jack Sealey Limited
AK450DP Issue:3 (H, F) 11/6/21

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