Sealey RE300.V2 User manual

COIL SPRING COMPRESSOR
MODEL NO: RE300.V2
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.
1. SAFETY
1.1. GENERAL SAFETY.
WARNING! Ensure Health & Safety, local authority, and general workshop practice regulations are adhered to when using this equipment.
WARNING! Wear approved safety hand and eye protection (standard spectacles are not adequate).
WARNING! TRAPPING DANGER – Keep hands and fingers away from the spring and compressing jaws in use.
9Keep the work area clean, uncluttered and ensure there is adequate lighting.
9Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
9Remove ill-fitting clothes. Remove ties, watches, rings, other loose jewellery. Contain and/or tie back long hair.
9Wear appropriate protective clothing.
9Familiarise yourself with the applications, limitations and potential hazards of the spring compressor.
8DO NOT use the spring compressor for a task it was not designed to perform.
8DO NOT allow untrained persons to use the spring compressor.
1.2. PRE-OPERATIONAL SAFETY.
9Apply a little transmission oil to the front and rear faces of the main upright to assist the smooth action of the compressor.
8DO NOT operate compressor if parts are damaged or missing as this may cause failure and/or personal injury.
9Before commencing compression, make a visual inspection of machine to ensure pins are securely positioned and that there is no sign
of wear or fatigue – if found, DO NOT use and refer to your local Sealey stockist for advice and replacement parts.
9Ensure jaw locating pins are properly positioned and safety clips are attached correctly.
9Before commencing compression of spring, ensure coils of the spring are seated securely in the yokes of the compressor and cannot slide out
during compression.
9ALWAYS ensure that the safety guard locks in place, use the chain to secure the spring safely and attach the gate safety chain.
1.3. OPERATIONAL SAFETY.
9When applying compression to the spring, always stand to one side of the compressor.
▲DANGER! Stop compressing the spring before the coils touch / bind.
▲DANGER! Before attempting to remove top cap nut, always use a tool or similar to test if the compression has been relieved, DO NOT
use your hands / fingers.
9We recommend the use of purpose made strut tools to remove the top-nut from the shock piston.
9Once compressed, and the strut removed, we recommend releasing the tension on the spring. DO NOT leave the spring under
compression in the machine unattended and DO NOT leave in compression for prolonged periods, i.e. overnight.
9Before releasing the compression ensure that the top strut-nut is securely tightened to the manufacturer’s tolerance.
9Release the compression slowly keeping your hands and fingers away from the spring assembly.
9Be sure that the tension on the spring is fully controlled by the strut assembly before removing it from the yokes of the compressor.
1.4. POST OPERATIONAL SAFETY.
9When not in use, clean and store the spring compressor in a safe, dry, childproof location.
9Maintain the spring compressor in good condition. Replace or repair damaged parts. Use genuine parts only.
9Unauthorised parts may be dangerous and will invalidate the warranty.
2. INTRODUCTION
Fast and safe compression of road springs. 1000kg air operated unit with safety locking guard. Supplied with two interchangeable coated lower
yokes and a suspension strut clamp. Fits a wide range of spring congurations and diameters. Also features a strut locating platform for easy
movement of the suspension strut to avoid unnecessary lifting.
3. SPECIFICATION
Model no. ...............................................................RE300.V2
Maximum Load .......................................................... 1000kg
Upper Clamp travel .................................................... 420mm
Spring Diameter .................................................. 102-165mm
Actuation...............................................................Foot Pedal
Maximum Air pressure ....................................... 116psi(8bar)
Refer to
instructions
Wear eye
protection
Wear protective
gloves
Beware
coil binding
RE300.V2 Issue 2 (4, 5, 6, 7) 01/11/18
Original Language Version
© Jack Sealey Limited

4. ASSEMBLY
4.1. Unpack the spring compressor carefully, it will be necessary for two people to do this. (Refer to included Parts diagram).
4.2. Assemble the spring compressor as follows:
4.2.1. Lay out all of the parts ready for assembly.
4.2.2. There are pre-drilled holes in the feet if the unit needs to be bolted to the floor permanently.
4.2.3. Fit the two feet to the bottom of the frame with the wheels facing rearwards. Use four allen bolts, flat washers, spring washers and domed
nuts, to secure in place.
NOTE: the one longer bolt is fitted in position as shown in fig.1.
4.2.4. Using two people, stand the unit onto it’s feet, taking care when the wheels come into contact with the floor as the unit’s weight might
become unstable.
4.2.5. Fix the guard lock assembly (part K21) to the front of the unit using four cross headed bolts, see fig.2 for positioning.
4.2.6. Fit the guard by dropping it onto the bottom pivot, and then fit the large pin and spring into the top pivot holes and secure using a nyloc
nut (fig.3). Some pressure will be needed to push down on the pin to allow the nut to be fitted.
4.2.7. Fit the chain (part K15) to the left hand side using nut, bolt and washer to fix in place. Remove the clip from the end of the chain and clip it
onto the hook on the other side of the compressor frame, the chain can then be fixed to the clip at the appropriate link as required (fig.4).
4.2.8. Fit the locating plate (part K42) by threading it onto the long metal rod (part K41) and secure it by fitting and tightening knob (part B08).
The top of the rod fits through the hole in the frame and is held in place using a domed nut and washer. The bottom of the rod is secured
by attaching the metal arm to it and securing with a nut. Then undo the domed nut previously fitted (fig.1), and fit the metal arm over the
bolt and refit the domed nut. Tighten all nuts in turn ensuring that the metal rod hangs vertically from the frame and also squarely to the
metal arm (see fig.5).
4.2.9. Fit the handle to the top of the unit using two domed nuts, spring washers and washers to secure in place.
4.2.10. Hang two of the yokes not being used to the sides of the frame and locate the third yoke onto the compressor using the locking pin to
hold it in position (fig.6).
4.2.11. Position the unit in a suitable location near an air line feed.
5. AIR SUPPLY
WARNING! Ensure the air supply is always clean and does not
exceed 116psi (8bar) whilst operating the compressor. Too high an
air pressure and unclean air will shorten the product life due to
excessive wear, and may be dangerous causing damage and/or
personal injury.
5.1. A maximum air pressure of 116psi (8bar) is required to operate at
full capacity.
5.2. Ensure foot control lever is in the ‘O󰀨’ position before connecting
to the air supply.
5.3. Drain the air supply water seperator daily to avoid water in the
air line which may damage the ram.
g.1
g.3
g.5
RE300.V2 Issue 2 (4, 5, 6, 7) 01/11/18
Original Language Version
© Jack Sealey Limited
g.2
g.4

6. OPERATION
6.1. Compressing a strut spring.
Note! Before removing the strut from the vehicle it is recommended that the upper strut locking plate nut is loosened a quarter turn. DO
NOT loosen more than a quarter turn.
6.1.1. With the strut and spring removed from the vehicle, select the most suitably sized yoke or the strut clamp (parts K12, K13, 24) according
to the size of the spring and fit it onto the compressor using the locking pin to hold it in position (fig.6).
6.1.2. Position the lowest coil of the spring in the lower yoke and rotate the strut and spring so that the coil is held as low as possible (fig.7)
6.1.3. Swing the upper arms (parts K51) into position and locate the upper clamps on the uppermost available coil (fig.8). Ensure that the coil is
placed inside the recesses of the clamp to ensure that the coil will not break free under compression.
6.1.4. Having correctly positioned the spring on the lower and upper yokes, tighten both of the locking knobs (fig.9).
6.1.5. Position the locating plate so that it is just underneath the bottom of the strut and secure it in place.
6.1.6. Use the chain (part K15) to secure the spring by pulling it across the spring and hooking it onto the clip (fig.4).
6.1.7. Shut the safety guard ensuring that it locks in place (fig.2). Use the shorter chain (K58) to lock the guard in place (fig.10).
▲DANGER! Stop compressing the spring before the coil windings touch/bind
WARNING! If the spring/strut is not located correctly in the jaws, it is possible that the strut top retaining cap could be subject
to sideways forces. Watch closely as the spring reaches it’s final phase of compression and ensure the top cap assembly
rotates freely before attempting to remove it.
WARNING! Keep hands away from the spring whilst compressing.
6.1.8. Check to make sure that the spring is safely secured and then gradually press the pedal to start to compress the spring coils. Ensure the
spring is securely held.
6.1.9. When the strut is loose within the spring, unscrew the strut top plate nut and remove the plate from the top of the strut.
Gradually discharge the pressure on the spring by operating the foot control pedal. When all the pressure has been released,
take care to support the strut and spring when they become loose. Move the locating plate and withdraw the strut from the compressor.
Release the spring from the upper retaining clamps and remove from the compressor.
g.6 g.7
RE300.V2 Issue 2 (4, 5, 6, 7) 01/11/18
Original Language Version
© Jack Sealey Limited
g.8 g.9

6.2. Fitting a strut spring.
6.2.1. Offer the new strut spring up to the compressor’s yokes and fit it in the same position as that of the old spring.
Position the lowest coil of the spring in the lower yoke and rotate the spring, so that the coil is held as low as possible. Swing the
small upper arms into position and locate the upper clamps on the uppermost available coil. Ensure that the coil is placed inside the
recesses of the yokes to ensure that the coil will not break free under compression. Tighten the locking knobs (fig.9).
NOTE: There must be coils free at either end to allow them to seat on the strut plates, without the strut and compressor yokes
interfering.
6.2.2. Insert the strut up inside the spring, and move the locating plate just underneath the bottom of the strut to support it and secure the plate
in place by tightening the knob.
6.2.3. Use the chain to secure the spring by pulling it across and hooking it onto the side frame clip. Shut the safety guard, ensuring that it locks in place
and fit safety chain (fig.10).
▲DANGER! Stop compressing the spring before the coil windings touch or bind.
WARNING! Keep hands away from spring.
6.2.4. Compress the spring using the correct pedal on the foot control unit, ensuring that the spring is securely held in place within the clamp
recesses at all times. When the spring is compressed sufficiently, fit the strut top plate to the strut, and using a new nut, secure
it in position.
6.2.5. Decompress the spring carefully and slowly, using the pedal on the foot control unit, ensuring the spring is located correctly into the strut
top plate.
6.2.6. Remove complete strut carefully from the spring compressor.
6.2.7. When re-fitting the strut to the vehicle, the locking plate nut will need to be fully tightened using a torque wrench, to a setting in
accordance with the vehicle manufacturer’s specification.
6.2.8.
6.2.9.
6.2.10.
6.2.11.
6.2.12.
6.2.13.
6.2.14.
6.2.15.
6.2.16.
6.2.17.
6.2.18.
6.2.19.
6.2.20.
6.2.21.
7. MAINTENANCE
7.1. Before each use, check the spring compressor to ensure it is not damaged or worn. If in any doubt DO NOT use the
spring compressor. Remove it from service immediately and contact your local Sealey stockist for advice and/or repairs.
7.2. Periodically clean the sliding columns and wipe over using a little transmission oil.
7.3. Any other maintenance required should be carried out by an authorised service agent.
7.4. If the spring compressor is not being used for a considerable length of time, disconnect the air supply and discharge any air in
the cylinder by depressing the foot control lever. Drop a little Sealey air tool oil into the air inlet and cover to prevent the ingress of any
foreign matter.
g.10
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 01284 703534 [e-mail] www.sealey.co.uk
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.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.
RE300.V2 Issue 2 (4, 5, 6, 7) 01/11/18
Original Language Version
© Jack Sealey Limited