SEALEY YK209F.V3 Premier Heavy Duty Floor Type Hydraulic Press Instruction Manual

20 TONNE PREMIER HEAVY-DUTY FLOOR
TYPE HYDRAULIC PRESS
MODEL NO: YK209F.V3

YK209F.V3 Premier Heavy Duty Floor Type Hydraulic Press

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

1.1. GENERAL SAFETY
Familiarise yourself with the applications, limitations, and hazards peculiar to the press.
Maintain the press in good condition (use an authorised service agent).
Replace or repair damaged parts. Use recommended parts only. Unauthorised parts may be dangerous and will invalidate the warranty.
Keep the press clean for best and safest performance.
Locate the press in an adequate working area for its function, keep area clean and tidy and free from unrelated materials and ensure there is adequate lighting.
Ensure the workpiece is correctly secured before operating the press.
Ensure that all fittings are tight before each use.
Remove ill fitting clothing. Remove ties, watches, rings, loose jewellery and contain long hair.
Keep hands and body clear of the work table when operating the press.
Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip footware.
Keep children and unauthorised persons away from the working area.
 Securely attach the press to a flat, firm, level surface capable of supporting the weight of press and any workpiece taking into account clearance for workpieces.
**When not in use, release pressure from the hydraulic unit and clean the press. Stand or store the V blocks in a safe location.
X DO NOT operate the press if any parts are missing as this may cause failure and/or possible personal injury.
X DO NOT use the press for a task it is not designed to perform.
X DO NOT make any modifications to the press.
X DO NOT adjust or tamper with the safety valve.
X DO NOT exceed the rated capacity of the press.
X DO NOT apply off-centre loads.
X DO NOT allow the workpiece or the press plates to fall from the work table.
X DO NOT get the press wet or use in damp or wet locations or areas where there is condensation.
X DO NOT operate the press when you are tired or under the influence of alcohol, drugs or intoxicating medication.
X DO NOT climb upon the press.
X DO NOT use to compress a spring or any other item that could disengage and cause a potential hazard including personal injury.
X DO NOT stand directly in front of the loaded press and never leave a loaded press unattended.
X DO NOT allow untrained persons to operate the press. from your Sealey stockist.
X DO NOT top up hydraulic unit with brake fluid, or any other fluid other than a good quality hydraulic oil (Sealey Part Number: HJO500MLS/ HJO5LS) as this may cause serious damage to the hydraulic unit and will invalidate the warranty.
WARNING! Always position the press against a wall. If the press is situated in the open workshop, it is essential that a guard be placed at the rear of the unit. This will prevent injury to bystanders in the event of the workpiece ejecting suddenly.
WARNING! The warnings, cautions and instructions in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be applied by the operator.
▲ DANGER!** The press is top heavy. If it requires moving after assembly or for relocation, use suitable slings around the top crossbeam, or lift direct with a forklift with the forks located under the top crossbeam. DO NOT use a pallet truck.

INTRODUCTION

Made from a high quality steel with a powder coated paint finish to help corrosion resistance. Fully Welded frame. Sliding hydraulic ram assembly giving 176mm of lateral travel for off-centre pressing applications. Frame head fitted with ram pressure gauge.  Supplied with flat pressing plate/V-blocks.

SPECIFICATION

Model No:…………………………………………….. YK209F.V3
Capacity: …………………………………………………. 20 Tonne
Floor Mounting:…………………………………………………. Yes
Gauge Included:……………………………………………….. Yes
Lateral Ram Travel: ……………………………………… 176mm
Maximum Height – Ram to Table: …………………… 918mm
Minimum Height – Ram to Table: ……………………… 38mm
Optional Accessories:……………. YKSG20 – Safety Guard
……………………………………………. YKPP8 – Press Pin Set
Overall Height: ………………………………………….. 1625mm
Overall Width: …………………………………………….. 975mm
Ram Diameter: …………………………………………… Ø48mm
Ram Stroke: ……………………………………………….. 187mm
Table Aperture:……………………………………………. 152mm
Type: ………………………………………………………. Hydraulic
Working Table Depth:…………………………………… 172mm
Working Table Width: …………………………………… 510mm

ASSEMBLY

Unpack the product and check contents. Should there be any damaged or missing parts contact your supplier immediately. Take care to ensure safety when moving main frame from packing as the unit is very heavy.
Refer to attached parts list.
Seek assistance from another person on assembly of heavy parts.
Assemble press, if possible, in close proximity to where the press will be located.
4.1. FRAME ASSEMBLY
4.1.1. Attach load slings around the top cross member of the main frame (#15) and using a suitable hoist or gantry, slowly, and in a controlled manner lift the frame up and out of the transportation crate, into an upright position.
4.1.2. Keep the frame assembly in an upright position, held safely by the load slings.
▲ DANGER! DO NOT allow the main frame to fall over.
4.1.3. Position base section (#11) and secure with hex head set screw M10 x 30 (#9), M10 flat washer (#12), M10 spring washer (#13) and M10 nut (#14) loosely.
4.1.4. Repeat for other side base section (#11).
4.1.5. Position the supports (#10) to base section (#11) and main frame (#15) and secure with hex head set screw M10 x 30 (#9), M10 flat washer (#12), M10 spring washer (#13) and M10 nut (#14) loosely.
4.1.6. Repeat for other side supports (#10).
4.1.7. On a flat level floor, level the frame using a good quality spirit level. Fully tighten all fixings.
4.1.8. Remove the load slings and store in a safe and secure location.
WARNING! Take care and seek assistance from another person when lowering and levelling the frame assembly onto the floor.
4.2. ATTACH PUMP
4.2.1. Transfer the pump (#44) from its transport position by firstly removing the fixings, hex head set screw M10 x 20 (#17) and M10 flat washer (#16). Retain the fixings.
4.2.2. Move the pump to the outside, right hand side of the main frame (#15) and secure with the retained fixings.
4.2.3. Attach the pump oil hose (#43) and o-ring (#34) to the joint (#42) after removing the metal dust bungs. DO NOT discard.
4.2.4. ATTACH BED FRAME
4.2.5. Pass the table support pins (#8) through the holes on the press main frame assembly uprights (#15) at the desired height.
4.2.6. Fit the retaining clips (#7) to the table support pins.
X NOTE: The retaining clips should be spaced equidistant from the press frame sides to allow for ease of bed frame (#6) assembly.
4.2.7. Taking firm hold of the bed frame (#6), tip it into a diagonal position so that it can be introduced between the mainframe uprights, and then carefully lower it back to a horizontal position to rest on the table support pins (#8), between the retaining clips (#7).
WARNING! Take care not to allow the bed frame to drop onto the table support pins and ensure your hands and fingers are clear of the
bed frame when lowering.
WARNING! Seek assistance from another person with this task as the bed frame is heavy.
4.2.8. Place the V-blocks (#4), in the required orientation, onto the bed frame (#6).
4.3. PRESSURE GAUGE
4.3.1. Remove the dust cap hex bolt from the pressure gauge (#27) and pressure gauge fitting (#29). DO NOT discard.
4.3.2. Screw the pressure gauge (#27) and nylon ring (#28) into the pressure gauge fitting (#29) until tight.
X DO NOT over-tighten.
4.4. ATTACH HANDLE TO RAM PLATE
4.4.1. Secure the handle for ram plate (#15) with screws (#14) to ram plate (#16).
4.5. Push fit pump handle (#52) into pump assembly (#48).

INSTALLATION

▲ DANGER! Models are purpose designed to withstand greater loads than the hydraulic units can develop. For safety reasons, always ensure the workpiece and press tools are secured on the table and will not flex or suddenly “give way” causing danger to  operator or the component.
5.1. SECURE PRESS TO THE FLOOR
8 DO NOT attempt to move assembled press manually. When moving the press follow the instructions as detailed in Section 1.
5.1.1. Move the press to the mounting location, and spot mark through fixing holes in base section (#11) onto the floor.
5.1.2. Check for any hidden wiring or cables, if needed change the location for the holes.
5.1.3. Temporarily move the press to the side.
5.1.4. Use a masonry drill bit to drill the four holes about 3” to 4” deep into the concrete or wood, as necessary.
5.1.5. Clean out the drilled holes.
5.1.6. Position the press and align the holes in the base section with the holes in the floor.
5.1.7. Use four concrete anchor bolts or lag bolts for wooden floors, (not included), to secure to the floor.
WARNING! To prevent serious injury DO NOT use damaged equipment. If abnormal noise or vibration occurs have the problem corrected.
WARNING! Ensuree the mounting surface is capable of withstanding the weight of the press and the workpiece.
5.2. BEFORE FIRST USE
5.2.1. Before operating the press, purge the hydraulic system in order to eliminate any air that may have built up during transit. Open the release valve and pump the handle several times and close the release valve. Should the system malfunction at any time, repeating this process may resolve the problem.
▲ DANGER! Models are purpose designed to withstand greater loads than the hydraulic units can develop. For safety reasons, always ensure the workpiece and press tools are secured on the table and will not flex or suddenly “give way” causing danger to operator or the component. Also ensure you have read and understood section 1 Safety Instructions.

OPERATION

6.2.1. Check that release valve on the hydraulic unit is fully closed, ready for operating.
6.2.2. Position the table at the required operating height by inserting the pins into the appropriate holes in the frame.
6.2.3. Position the V-block (#4) or press tools to be used onto the table and align beneath the ram. Place workpiece onto the table or V-blocks and align beneath the ram as required.
NOTE: Care must be taken to ensure a V-block does not fall from the press table. If necessary hold the configuration in position with clamps (not supplied).
‰ WARNING! DO NOT apply off centre loads.
‰ WARNING! Monitor the pressure gauge during operation to ensure that the rated capacity of the press is not exceeded.
6.2.4. When the operation is complete turn the release valve anti-clockwise to release the pressure. The piston and the ram head will retract automatically.
NOTE: Always keep the piston retracted after use to avoid corrosion.

MAINTENANCE

NOTE: Maintenance and repair must be carried out by qualified person. Contact your Sealey stockist for details.
7.1. Check all fittings are tight before each use.
7.2. Lubricate all moving parts at regular intervals.
7.3. Always keep the press clean, dry, and protect from harsh conditions.
7.4. Should you need to replace the oil ensure the piston is fully retracted. An excess of oil will render the press inoperative.
Use only appropriate Sealey hydraulic jack oil. DO NOT use brake fluid. Contact your local Sealey stockist for details. Purge the system to remove any air.
7.5. Check your model parts information for spares.
IMPORTANT: NO RESPONSIBILITY IS ACCEPTED FOR INCORRECT USE OF THE MACHINE.
Hydraulic products are only repaired by local service agents. We have service/repair agents in all parts of the UK.
DO NOT RETURN PRODUCT TO US. Please telephone us on 01284 757500 to obtain the address and phone number of your local agent.
If the product is under guarantee please contact your stockist.
De-commissioning Product
Should the product 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. 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 5 years from purchase date, proof of which is required for any claim.
REGISTER YOUR PURCHASE HERE**https://qrco.de/bcy2E9

Sealey Group, Kempson Way, Suffolk
Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500
sales@sealey.co.uk
www.sealey.co.uk
© Jack Sealey Limited
Original Language Version
YK209F.V3 Issue 3 (2,F) 05/10/23

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