SEALEY YK509FAH Air Hydraulic Press 50tonne Floor Type Instruction Manual

SEALEY YK509FAH Air Hydraulic Press 50tonne Floor Type

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 with side mounted air motor powering hydraulic pump unit. 2-speed manual operation and sliding hydraulic ram assembly giving 245mm of lateral travel for off -centre pressing applications. Fitted with ram pressure gauge and supplied with table winch and fl at pressing plate/V-blocks.

SPECIFICATION

• Model No: ………………………………………………. YK509FAH.V2
• Air Consumption: ………………………………………………….. 7cfm
• Bench or Floor Mounting: ………………………………………..Floor
• Capacity: …………………………………………………………. 50tonne
• Gauge Included: ……………………………………………………… Yes
• Lateral Ram Travel: ……………………………………………. 245mm
• Maximum Height – Ram to Table: ……………………….. 1047mm
• Minimum Height – Ram to Table: ……………………………. 67mm
• Optional Accessories: …………………. YKSG50 – Safety Guard
• Optional Accessories: ……………………YKPP8 – Press Pin Set
• Overall Height: ………………………………………………… 1877mm
• Ram Diameter: …………………………………………………. Ø75mm
• Ram Stroke: ……………………………………………………… 200mm
• Table Aperture: ………………………………………………….. 235mm
• Type: …………………………………………………………Air/Hydraulic
• Working Pressure:………………………………………… 108-123psi
• Working Table Depth: …………………………………………. 259mm
• Working Table Width: …………………………………………. 910mm

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.

FRAME ASSEMBLY
Attach load slings around the top cross member of the frame (#71) 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 (#39).

1. Keep the frame assembly in an upright position, held safely by the load slings.

2. ATTACH BASE SECTION NOTE: The base section (#70), supports (#69), hex head screw M12 x 35 (#24), fl at washer M12 (#35), spring washer M12 (#36) and nut M12 (#37) are supplied pre-assembled.

3. Remove the central fi xings only, hex head screw M12 x 35 (#24), fl at washer M12 (#35), spring washer M12 (#36) and nut M12 (#37) from the base section (#70).

4. Position the base section (#70) onto the frame (#71) and secure with hex head screw M12 x 35 (#24), fl at washer M12 (#35),
   spring washer M12 (#36) and nut M12 (#37) loosely.

5. Remove the top fi xings only, hex head screw M12 x 35 (#24), fl at washer M12 (#35), spring washer M12 (#36) and nut M12 (#37) from one of the supports (#69).

6. Position the support (#69) onto the frame (#71) and secure with hex head screw M12 x 35 (#24), fl at washer M12 (#35), spring washer M12 (#36) and nut M12 (#37) loosely.

7. Follow section 4.2.4 to attach the other support (#69).

8. Repeat sections 4.2.1 to 4.2.5 to attach the other base assembly.

9. On a fl at level fl oor, level the frame using a good quality spirit level. Fully tighten all fixings.

10. Remove the load slings and store them in a safe and secure location.

11. WARNING! Take care and seek assistance from another person when lowering and leveling the frame assembly onto the floor.

12. ATTACH THE WINCH ASSEMBLY

13. WARNING! Seek assistance from another person with this task as the hand winch assembly is heavy.

14. Transfer the hand winch assembly (#21) from its transport location by firstly removing the fixings M12 x 35 hex head screw (#24),
    M12 fl at washer (#35), M12 spring washer (#36) and M12 nut (#37) from hand winch plate (#77). Retain the fixings.

15. Move the hand winch assembly (#21) to the outside of the left hand post (position A on the parts diagram) and secure with the retained fixings, loosely.

16.  Ensure that the cables are located correctly in the rollers prior to fully tightening fixings.

17.  ATTACH THE PUMP ASSEMBLY

18. WARNING! Seek assistance from another person with this task as the pump assembly is heavy.

19. NOTE: The pump assembly (#64), air hose (#78), foot pedal (#79), air hose (#80) and quick coupler (male) (#81) are supplied pre-assembled.

20. Transfer the pump assembly (#64) from its transport location by firstly removing the fi xings, screw (#62) and fl t washer M10 (#63). Retain the fixings.

21. Attach the pump assembly (#64) into position at the top, right hand side of frame (#71) and secure with the retained fixings.

22. CONNECT THE OIL HOSE

23. Remove the blanking plug from elbow fitting (#45) located on the pump assembly (#64). DO NOT discard.

24. Remove the blanking plug from the end of oil hose (#60). DO NOT discard.

25. Connect oil hose (#60) to the pump assembly elbow fitting (#45).

26. CONNECT THE AIR HOSE

27. Undo nut and remove blanking plug from end of air pipe (#61). DO NOT discard.

28. Place nut over pipe and push air pipe onto connector located on top of pump assembly and tighten nut.

29. IMPORTANT : Open transit plug, for use, located on top of pump assembly.

30. PRESSURE GAUGE

31. Remove the dust cap hex bolt from the pressure gauge (#58) and gauge fi tting (#57). DO NOT discard.

32. Screw the pressure gauge (#58) and nylon ring (#56) into the pressure gauge fi tting (#57) until tight.

33. DO NOT over-tighten.

34. ATTACH HANDLE TO RAM

35. Fit handle F (#65) into handle recess F on pump assembly and secure with washer M8 (#65) and hex head screw M8x 20 (#59).

36. Fit handle G (#67) into handle recess G on pump assembly and secure with washer M8 (#65) and hex head screw M8x 20 (#59).

37. ATTACH CARRY HANDLE

38. Secure the carry handle (#76) to under plate (#41) with screw for carry handle (#75).

39. Place the V-blocks (#4), in the required orientation, onto the bed frame (#28).

40. WARNING! The V-blocks are heavy.

41. AIR SUPPLY

42. Connect a compressed air supply hose (fi g 1) to the quick coupler (male) (#81).

43. The recommended working air supply is a pressure is between 108-123psi.

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.

SECURE PRESS TO THE FLOOR
DO NOT attempt to move assembled press manually. When moving the press follow the instructions as detailed in Section 1.

1. Move the press to the mounting location, and spot mark through fi xing holes in base section (#70) onto the floor.
2. Check for any hidden wiring or cables, if needed change the location for the holes.
3. Temporarily move the press to the side.
4. Use a masonry drill bit to drill the four holes about 3” to 4” (75 to 100mm) deep into the concrete or wood, as necessary.
5. Clean out the drilled holes.
6. Position the press and align the holes in the base section with the holes in the floor.
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! Ensure the mounting surface is capable of withstanding the weight of the press and workpieces.

BEFORE FIRST USE
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 fl ex or suddenly “give way” causing danger to operator or the component. Also ensure you have read and understood section 1 Safety Instructions.

OPERATION

1. SETTING THE BED FRAME HEIGHT
2.  Turn the hand winch handle (#21) until the cables just takes the weight of the bed frame (#28).
3. Remove the retaining clips (#26) from the back of the pins (#27) and withdraw the pins, store in a secure location.
4. Use the hand winch handle (#21) to raise or lower the bed frame (#28) to the desired height.
5. Re-insert the pins (#27) and the retaining clips (#26).
6. Slacken off the hand winch (#21) so that the pins (#27) are taking the full weight of the bed frame (#28).
7.  Check that the release valve on the hydraulic unit is fully closed, ready for operating.
8.  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.
9. 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).
10. WARNING! DO NOT apply off centre loads.
11. Connect the air supply to the foot pedal (#79) quick coupler (male) (#81).
12. Use either of the handles or the foot pedal to lower the ram to the workpiece.
13. WARNING! Monitor the pressure gauge during operation to ensure that the rated capacity of the press is not exceeded.
14. When the operation is complete turn the release valve anti-clockwise to release the pressure. The piston and the ram head will retract automatically.
15. Disconnect the air supply.
16. 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.

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 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 24 months from purchase date, proof of which is required for any claim.

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