sealey YK309FAH.V2 30TONNE FLOOR TYPE AIR/HYDRAULIC PRESS WITH FOOT PEDAL User Guide

sealey YK309FAH.V2 30TONNE FLOOR TYPE AIR/HYDRAULIC PRESS WITH FOOT PEDAL

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

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.
• DO NOT operate the press if any parts are missing as this may cause failure and/or possible personal injury.
• DO NOT use the press for a task it is not designed to perform.
• DO NOT make any modifications to the press.
• DO NOT adjust or tamper with the safety valve.
• DO NOT exceed the rated capacity of the press.
• DO NOT apply off-centre loads.
• DO NOT allow the workpiece or the press plates to fall from the work table.
• DO NOT get the press wet or use in damp or wet locations or areas where there is condensation.
• DO NOT operate the press when you are tired or under the influence of alcohol, drugs or intoxicating medication.
• DO NOT climb upon the press.
• DO NOT use to compress a spring or any other item that could disengage and cause a potential hazard including personal injury.
• DO NOT stand directly in front of the loaded press and never leave a loaded press unattended.
• DO NOT allow untrained persons to operate the press.
• WARNING! Always wear approved eye or face protection when operating the press. A full range of personal safety equipment is available from your Sealey stockist.
• 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

Steel frame construction. Side mounted, air motor powering hydraulic pump unit with 2-speed manual operation. Sliding hydraulic ram assembly giving 200mm of lateral travel for off -centre pressing applications. Fitted with ram pressure gauge and supplied with fl at pressing plate/V-blocks.

SPECIFICATION

• Model No: ………………………………………………. YK309FAH.V2
• Air Consumption: ………………………………………………….. 9cfm
• Bench or Floor Mounting: ………………………………………..Floor
• Capacity: …………………………………………………………. 30tonne
• Lateral Ram Travel: ……………………………………………. 200mm
• Maximum Height – Ram to Table: ……………………….. 1030mm
• Minimum Height – Ram to Table: ………………………….. 150mm
• Optional Accessories: …………………. YKSG30 – Safety Guard
• Optional Accessories: ……………………YKPP8 – Press Pin Set
• Overall Height: ………………………………………………… 1801mm
• Ram Diameter: …………………………………………………. Ø70mm
• Ram Stroke: ……………………………………………………… 150mm
• Table Aperture: ………………………………………………….. 164mm
• Type: …………………………………………………………Air/Hydraulic
• Working Pressure:………………………………………… 108-123psi
• Working Table Depth: …………………………………………. 184mm
• Working Table Width: …………………………………………. 695mm

ASSEMBLY

Unpack the product and check the 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 the attached parts list.
Seek assistance from another person on the assembly of heavy parts. Assemble the press, if possible, in close proximity to where the press will be located.
FRAME ASSEMBLY

1. Attach load slings around the top cross member of the frame (#17) 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.
   • WARNING! Take care when lifting the frame not to damage the pre-assembled ram assembly (#14).
2. Keep the frame assembly in an upright position, held safely by the load slings.
   • DANGER! DO NOT allow the frame to fall over.

ATTACH BASE SECTION
NOTE: The base section (#10), supports (#9), hex head screw M10 x 25 (#8), fl at washer M10 (#7), spring washer M10 (#6) and nut M10 (#5) are supplied pre- assembled.

1. Remove the central fixings only, hex head screw M10 x 25 (#8), fl at washer M10 (#7), spring washer M10 (#6), and nut M10 (#5) from the base section (#10).
2. Position the base section (#10) onto the frame (#17) and secure with a hex head screw M10 x 25 (#8), fl at washer M10 (#7), spring washer M10 (#6), and nut M10 (#5) loosely.
3. Remove the top fixings only, hex head screw M10 x 25 (#8), fl at washer M10 (#7), spring washer M10 (#6), and nut M10 (#5) from one of the supports (#9).
4. Position the support (#9) onto the frame (#17) and secure with a hex head screw M10 x 25 (#8), fl at washer M10 (#7), spring washer M10 (#6), and nut M10 (#5) loosely.
5. Follow section 4.2.4 to attach the other support (#9).
6. Repeat sections 4.2.1 to 4.2.5 to attach the other base assembly.
7. On a flat level fl oor, level the frame using a good quality spirit level. Fully tighten all fi xings.
8. Remove the load slings and store them in a safe and secure location.
   • WARNING! Take care and seek assistance from another person when lowering and leveling the frame assembly onto the floor.

ATTACH THE PUMP ASSEMBLY
NOTE: The pump assembly (#32), oil hose (1) (#29), oil hose (2) (#23), air hose (#33), foot pedal (#34), air hose (#35) and quick coupler (male) (#36) are supplied pre-assembled.

1. Transfer the pump assembly (#32) from its transport location by firstly removing the fixings, hex head screw M10 (#24), and flat washer M10 (#7). Retain the fixings.
2. Attach the pump assembly (#32) into position at the top, right-hand side of the frame (#17) and secure with the retained fixings.
   • WARNING! Seek assistance from another person with this task as the pump assembly is heavy.

ATTACH BED FRAME
WARNING! Seek assistance from another person with this task as the bed frame is heavy.

1. Pass the lower bed frame pins (#4) through the holes on the press frame assembly uprights (#17) at the desired height.
2. Fit the circlips (#3) to the table support pins.
   • NOTE: The circlips should be spaced equidistant from the press frame sides to allow for ease of bed frame assembly (#2).
3. Taking fi rm hold of the bed frame (#2), 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 lower bed frame pins (#4), between the circlips (#3).
   • WARNING! Take care not to allow the bed frame to drop onto the bed frame pins and ensure your hands and fi ngers are clear of the bed frame when lowering.
4. Pass the upper bed frame pins (#4) through the bed frame (#2) and the press frame assembly uprights (#17).
5. Fit the circlips (#3) to the table support pins.
6. Place the V-blocks (#1), in the required orientation, onto the bed frame (#2).

ATTACH HANDLES

1. Fit handle (#11) into handle recess C on pump assembly and secure with fl at washer M8 (#38) and hex head screw M8 x 20 (#37).
2. Fit handle (#39) into handle recess D on pump assembly and secure with fl at washer M8 (#38) and hex head screw M8 x 20(#37).

PRESSURE GAUGE

1. Remove the dust cap hex bolt from the pressure gauge fi tting (#25). DO NOT discard.
2. Screw the pressure gauge (#25) and nylon ring (#26) into the pressure gauge fi tting (#27) until tight.
   • DO NOT over-tighten.

CONNECT OIL HOSE (1)

1. Remove the blanking plug from the oil hose (1) (#29). DO NOT discard.
2. Connect oil hose (1) (#29) to gauge fitting (#27).
3. CONNECT OIL HOSE (2)
4. Remove the blanking plug from oil hose (2) (#23). DO NOT discard.
5. Remove the blanking plug from the elbow fitting (#31). DO NOT discard.
6. Connect oil hose (2) (#23) to elbow fitting (#31).

ATTACH CARRY HANDLE

1. Secure the carry handle (#40) to the upper plate (#15) with a screw for the carrying handle (#41).

AIR SUPPLY

1. Connect a compressed air supply hose (fi g 1) to the quick coupler (male) (#36).
2. The recommended working air supply is pressure is between 108-123psi.

OPERATION

1. Connect the air supply to the foot pedal (#34).

2. Check that the release valve on the hydraulic unit is fully closed, ready for operating.

3. Position the bed frame at the required operating height by inserting the bed frame pins into the appropriate holes in the frame.

4. Position the V-block plates or press tools to be used onto the bed frame and align beneath the ram. Place workpiece onto the bed frame 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 bed frame. If necessary hold the configuration in position with clamps (not supplied).

   • WARNING! DO NOT apply off centre loads.

5. Use either of the handles or the foot pedal to lower the ram to the workpiece.

6. WARNING! Monitor the pressure gauge during operation to ensure that the rated capacity of the press is not exceeded.

7. When the operation is complete turn the release valve anti-clockwise to release the pressure. The piston and the ram head will retract automatically.

8. Disconnect the air supply.
   NOTE: Always keep the piston retracted after use to avoid corrosion

MAINTENANCE

NOTE: Maintenance and repair must be carried out by a qualified person. Contact your Sealey stockist for details.

1. Check all fittings are tight before each use.
2. Lubricate all moving parts at regular intervals.
3. Always keep the press clean, dry, and protect from harsh conditions.
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.
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 THE 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 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. Please note that other versions of this product are available. If you require documentation for alternative versions, please email or call our technical team at technical@sealey.co.uk or 01284 757505.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 24 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 703534 sales@sealey.co.uk www.sealey.co.uk

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