Sealey SA5040 User manual

Refer to instruction
manual
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protection Wear ear
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Warning:
hot surface
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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.
SA5040 SA5055 Issue:3(HF) - 04/04/18
Original Language Version
© Jack Sealey Limited
COMPRESSOR 50LTR BELT DRIVE PETROL
ENGINE 4.0HP, 5.5HP
MODEL No: SA5040, SA5055
1. SAFETY
 Familiarise yourself with the application and limitations of the compressor.
 Ensure that the compressor is in good order and condition before use. If in any doubt do not use the unit and contact a service agent.
WARNING! Compressor must only be serviced by an authorised agent. DO NOT tamper with, or attempt to adjust the pressure
switch or the safety valve.
 Before moving or maintaining the compressorensure that the air tank pressure has been vented.
 Only use recommended attachments and parts. Using unapproved items may be dangerous and will invalidate the warranty.
 Read the instructions for any accessory used with the compressor. Ensure that the safe working pressure of any air appliance used,
exceeds the output pressure of the compressor. If using a spray gun, check that the area selected for spraying is provided with an air
change system or adequate ventilation.
 Ensure that the air supply valve is turned off before disconnecting the air supply hose.
 To move the compressor use the front roll bar. Lift the compressor so that the front legs have enough clearance for manoeuvring but
maintain the centre of gravity in front of the wheels. DO NOT attempt to lift or move the compressor by any other means.
 Use the compressor in a well ventilated area and ensure it is placed on a firm surface. Remember that the compressor engine
produces harmful exhaust fumes.
 Keep tools and other items away from the compressor when it is in use, and keep work area clean.
 Ensure that air hoses are not tangled, twisted or pinched.
 Keep children and unauthorised persons away from the work area.
 DO NOT dismantle the compressor for any reason if you are not qualified to do so. The unit must be checked by qualified personnel only.
 DO NOT operate the compressor within the vicinity of flammable liquids, gases or solids.
 DO NOT touch compressor cylinder, cylinder head or pipe from head to tank as these may be hot and will remain so for some time
after shutdown.
 DO NOT operate the compressor without all safety guards in place.
 DO NOT attempt to move the compressor by pulling the air tool hose.
 DO NOT use the compressor for a task for which it is not designed.
 DO NOT deface the certification plate attached to the compressor tank.
DANGER! DO NOT direct the output jet of air towards people or animals.
 DO NOT operate the compressor without an air filter.
 DO NOT allow anyone to operate the compressor unless they have received full instructions.
For safety instructions relative to the maintenance and use of the petrol engine - refer to the engine manufacturer’s handbook supplied.
DO NOT check the ignition system by removing the spark plug or spark plug lead. Use specific tester or contact service agent.
 WARNING! DO NOT touch the spark plug or plug lead whilst the engine is running - severe, potentially fatal, electric shock
may result.
Ensure that engine fuel is stored in an approved container. For long term storage ensure that the fuel tank is drained and that the
compressor is adequately protected.
DO NOT smoke or have any naked flames nearby whilst re-fuelling.
DO NOT leave the compressor operating unattended.
 DO NOT remove the fuel cap, or try to refuel whilst the engine is running. Stop the engine and allow it to cool for two minutes before
attempting to refuel.
DO NOT refuel in a closed or poorly ventilated environment as there is a danger of explosion or fire. Refuel outdoors.
DO NOT operate the compressor if there is a fuel leak. Move the unit to a safe area, where there is no risk of ignition, until the leak has
been rectified and the machine is dry.
DO NOT start the engine if there are any flammable materials near the exhaust system or in the path of the exhaust gases.
DO NOT block the engine ventilation grilles.
 DO NOT cover the compressor or restrict air flow around the machine whilst it is operating.
 WARNING! The air tank is a pressure vessel and the following safety measures apply:
DO NOT tamper with the safety valve and DO NOT modify or alter the tank in any way and DO NOT strap anything to the tank.
DO NOT subject the tank to impacts, vibration or to heat and DO NOT allow contact with abrasive or corrosive materials.
DO drain condensation from tank daily and inspect inside walls for corrosion every 12 months.
The tank shell must not fall below the certified thickness at any point.
 When not in use, store the compressor carefully in a safe, dry, childproof location.

2. INTRODUCTION
Fully mobile compressors tted with Honda power unit coupled to heavy-duty, twin piston, cast iron pump. Fitted heavy-duty rubber transport
wheels and protected by 360° roll cage. Heavy-duty drive guard protects belt and ywheel that is designed to also force air over the pump to aid
cooling. Features twin gauges and air outlet regulator. Both models run on unleaded fuel.
3. SPECIFICATION
Model no: .................................................... SA5040 .....................................................................SA5055
Motor Type: .................................................. Honda GC135 Petrol.............................Honda GX160 Petrol
Motor Output: ............................................... 4HP ..............................................................................5.5HP
Receiver Capacity:....................................... 50ltr................................................................................ 50ltr
Air Displacement cfm(ltr/min): ...................... 10.7(303)................................................................ 15.8(447)
Maximum Free Air Delivery cfm(ltr/min): ...... 7.8(220).................................................................. 11.5(326)
Maximum Pressure: ..................................... 145psi(10bar) ...................................................145psi(10bar)
Size (W x D x H):.......................................... 970 x 470 x 730mm................................ 970 x 470 x 760mm
Noise Level: ................................................. 97dB(A).................................................................... 97dB(A)
Outlet: .......................................................... 1/2”BSP Female Tap .............................1/2”BSP Female Tap
4. PREPARATION
4.1. Remove compressor from packaging and inspect for any missing parts or damage. If anything is found to be missing or damaged
contact your supplier.
4.2. Save the packing material for future transportation of the compressor. It is recommended to store the packing in a safe location, at
least for the period of the guarantee. Then, if necessary, it will be easier to send the compressor to the service centre.
4.3. If not already fitted, fit the wheels and rubber feet to the compressor with the nuts, washers etc. supplied.
4.4. The compressor should be located in a position that allows good air circulation around the unit and where there is good ventilation.
Remember that the compressor engine produces harmful exhaust fumes.
5. OPERATIONer
 WARNING! Ensure that you read, understand and apply Section 1 Safety Instructions.
5.1. STARTING
IMPORTANT! Always check and, if necessary, top-up the engine oil and the pump oil before starting. Severe engine and/or
pump damage may otherwise result.
5.1.1. Check that the air outlet valves - one on the tank end-plate (fig.1.A) and one on the regulator (fig.3.6) - are closed.
5.1.2. Start the compressor engine, following the procedure detailed in the manufacturer’s handbook supplied.
5.1.3. When the engine is running smoothly, the compressor will operate automatically, building up the pressure in the tank, which is shown on
the pressure gauge (fig.3.2), to the maximum setting (factory set). When the maximum tank pressure is reached, the relief valve (fig.2)
will automatically vent the pump output. When the tank pressure falls below the minimum threshold (approx.2 bar/29psi less
than the maximum pressure), the relief valve will automatically close, and the tank pressure will increase back to it’s maximum.
Note: a) If the relief valve does not cut in and out, but is continuously closed whilst using an air appliance, the capacity of the compressor
may be too small for the equipment or tool.
b) The larger gauge (fig.3.2) indicates the pressure inside the tank, NOT the pressure supplied to the air equipment. If the pressure in
the tank exceeds the relief valve maximum, a safety valve (fig.3.1) will open.
WARNING! For this reason DO NOT tamper with, or adjust, the relief valve or the safety valve.
5.2. STOPPING.
5.2.1. To stop the compressor turn the engine ignition switch (fig.4) to Off (O). See the engine manufacturer’s handbook for the complete
engine shutdown procedure.
5.3. CONNECTING AIR POWERED EQUIPMENT.
5.3.1. After fitting the desired coupling to the outlet valve (fig.3.6), connect the air hose and equipment.
5.3.2. Adjust the regulator valve to the required output pressure (in accordance with the air equipment instructions) by turning the regulator
knob (fig.3.4) and locking it in position with the locking ring (fig.3.5), at the required pressure (see output gauge, fig.3.3). Turn on outlet
valve (fig.3.6).
Note: To determine the correct working pressure and air flow requirements for any piece of equipment check the corresponding manual. Be
aware that the air flow figure stated on tools and accessories refers to ‘Free Air Delivery’ and not the piston displacement of the
compressor. When adjusting the regulator, always adjust up to the required pressure.
5.3.3. To disconnect equipment, turn the regulator knob anti-clockwise to ‘zero’ (0) bar. Operate the equipment to depressurise the air line
and then disconnect from the compressor.
fig.1 fig.2 fig.3
SA5040 SA5055 Issue:3(HF) - 04/04/18
Original Language Version
© Jack Sealey Limited

5.4. WHEN WORK IS COMPLETE.
At the end of each working day, drain any moisture from the main tank. Place a container
under the drain plug and then carefully unscrew it (fig.5). DO NOT allow moisture to
accumulate in the tank as this will corrode the inside of the tank and affect the pressure.
WARNING! Wear safety goggles when performing this task.
6. MAINTENANCE
In order to keep the compressor in good working condition, periodic maintenance is essential.
IMPORTANT Failure to carry out maintenance tasks may invalidate the warranty on your compressor.
WARNING Service and maintenance must be performed by an authorised agent. DO NOT tamper with, or attempt to adjust, the pressure
switch or safety valve. Before moving, or carrying out any maintenance on the compressor, ensure that the ignition switch is ‘off’, that the
air tank pressure has been vented and the compressor has been allowed to cool down for a period of time.
6.1. ENGINE.
For all engine maintenance, please refer to the engine manufacturer’s handbook (supplied) for the full schedule.
6.2. COMPRESSOR.
6.2.1. Operations to be carried out after the first 50 working hours:
a) Check that all bolts/nuts are tight, particularly those retaining the crank case and cylinder head.
b) Replace the lubricating oil - see section 6.2.5.
6.2.2. Operations to be carried out daily:
a) Drain condensation by opening the valve (fig.5) located under the tank.
b) Check oil level (fig.6.B) and, if necessary, top-up.
c) Check guards/covers are secure.
d) Check for oil leaks.
e) Check for unusual noises or vibrations.
f) Check for air leaks.
6.2.3. Operations to be carried out weekly:
a) (or more frequently, if the compressor operates in a very dusty atmosphere):
Remove the air filter element by undoing the screw (fig.7.A) and removing the filter cover. Clean the filter by
blowing through from the clean side, with an air line at low pressure. Replace filter, cover and screw. DO NOT operate
compressor without filter as foreign bodies or dust could damage the pump.
WARNING: Wear safety goggles when performing this task.
b) Clean compressor.
c) Check the automatic cut-out operation at maximum pressure and the automatic cut-in at 2 bar below.
6.2.4. Operations to be carried out monthly:
a) Check belt tension. A weight of 3kg applied at the belt mid-point should give a deflection of approximately
10mm (fig.8). If adjustment is required, maintain the alignment of the two pulleys (fig.8). Adjust by repositioning the
engine, using the screw adjuster provided in the base plate.
6.2.5. Operations to be carried out every 200 working hours:
a) Change air filter element.
b) Replace the lubricating oil. For oil specifications see 6.4
Remove the oil filler cap (fig.6.A) and (after placing a suitable container under it) the oil drainer (fig.6.B). Drain
when the compressor has been recently run, so that the oil drains rapidly and completely. Replace the oil drainer and
refill through the filler aperture. DO NOT overfill. Replace the oil filler cap.
  WARNING! Never mix different oils and do not use non-detergent/low quality oils as the compressor may
be damaged.
  WARNING! Dispose of waste oil only in accordance with local authority requirements.
c) Check all tube fittings and electrical connections.
d) Inspect pressure tank inside and out for damage or corrosion.
It is recommended that every two years (or approximately every 1600 working hours), the compressor is returned to
an authorised dealer for a complete inspection.
fig.4
fig.5
fig.9
ALIGNMENT
fig.6 fig.8
fig.7
SA5040 SA5055 Issue:3(HF) - 04/04/18
Original Language Version
© Jack Sealey Limited

5.3. SCHEDULED MAINTENANCE TABLE (NOT ENGINE)
7. tTROUBLESHOOTING
5.4. RECOMMENDED OILS
Recommended oil for compressors:
- for ambient temperatures ranging from +5°C to +25°C.
SEALEY CPO (or equivalent) SAE 40 compressor oil.
- for ambient temperature below +5°C:
SAE 20 compressor oil.
Maintenance
Operations. After Use. Weekly.Daily. Monthly. 200 hrs.
Drain condensation. • •
Check oil level. •
Check guards/covers. •
Check for oil leaks. •
Replace air filter.
Check fittings.
Inspect Pressure Tank.
Change pump oil.
Check belt tension.
Clean air filter.
Check safety relief valve.
Clean compressor.
Check for air leaks.
Check for noise or
vibration.
•
•
•
•
•
•
•
•
•
•
Fault Possible Cause Remedy
Pressure drop in the tank. Air leaks at connections.
Run compressor to max. pressure, switch off.
Brush soap solution over connections and look for
bubbles. Tighten connections showing leaks.
If problem persists contact Authorised Service
Agent.
Compressor does not achieve maxiumum
pressure and overheats.
Relief valve does not open when maximum
pressure is reached, safety valve operates.
Engine stops and does not restart.
Engine and pump run, but no air produced.
Pressure drops when compressor is idle.
Head gasket or valve fault.
Valve failure or valve incorrectly set.
Out of fuel or engine fault.
Valves leaking or head gasket damaged.
Non-return valve seal defective.
Contact Authorised Service Agent.
Contact Authorised Service Agent.
Contact Authorised Service Agent.
Check fuel. If OK, contact Authorised Service Agent.
Check for leaks, or Contact Authorised Service
Agent.
Empty air tank, remove the relief/non-return valve
(fig.2 & fig.9) and clean the seat ‘D’.
If necessary replace the seal ‘E’.
Compressor makes metallic rattle. Bearing or piston fault. Contact Authorised Service Agent.
Safety valve operates below max pressure. Faulty valve.
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 01284 703534 [e-mail] www.sealey.co.uk
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.
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.
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.
SA5040 SA5055 Issue:3(HF) - 04/04/18
Original Language Version
© Jack Sealey Limited