Sealey Quality MACHINERY YAJ15-30 User manual

INSTRUCTIONS FOR :
AIR OPERATED JACKS
TELESCOPIC
IMPORTANT: READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND CAUTIONS.
USE THIS JACK 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. RETAIN THESE INSTRUCTIONS FOR FUTURE USE.
Thank you for purchasing a Sealey jack. Manufactured to a high standard this product will, if used according to these instructions and properly
maintained, give you years of trouble free performance.
1. SAFETY INSTRUCTIONS 2. SPECIFICATIONS
Note: The maximum heights shown may be extended by use of the
extension pins
MODEL No's YAJ15-30 YAJ15-30DC YAJ20-40 YAJ20-40DC YAJ20-40LR
 Disconnect jack from air supply before changing parts, servicing
or performing any maintenance.
WARNING! Ensure correct air pressure is maintained and not
exceeded. Recommended pressure 116-145psi or 174psi for
YAJ20-40LR. Required air flow 10.5cfm or 11.5cfm for
YAJ20-40LR.
Keep air hose away from heat, oil and sharp edges. Check air
hose for wear before each use, and ensure that all connections
are secure.
Ensure Jack is kept clean and in good working order. Immediately
repair or replace damaged parts.
Use recommended parts only. Incorrect parts may be dangerous
and will invalidate the warranty.
Use a qualified person to lubricate and maintain the jack.
DO NOT use brake fluid to top up system. Use Sealey hydraulic
oil only.
Locate jack in a suitable, well lit work area. Keep area clean and
tidy and free from unrelated materials.
Use jack on level & solid ground, preferably concrete. Avoid
tarmacadam since jack may sink in.
Place wedges under wheels of vehicle (but ensure wheels of jack
can freely move).
Ensure the vehicle handbrake is engaged (or in “PARKED”
mode), and switch the engine off.
Ensure minimum distance of 0.5m between vehicle tilt & static
objects such as doors, walls, etc.
Ensure all non essential persons keep a safe distance and that
there are no passengers in the vehicle to be jacked up.
Place jack under vehicle manufacturer’s recommended jacking
points (see vehicle handbook).
Check that the jacking point is stable and centred on the jack
saddle and is free from grease or oil.
Ensure jack wheels are free to move and that there are no
obstructions.
 DANGER: Use jack for lifting only, NOT for supporting the raised
load. Use correctly rated axle stands under vehicle before
proceeding with task.
 DO NOT apply your body weight to the handle during jacking.
The handle is only for moving the jack to and from the lifting
location.
 DO NOT operate the jack if parts are missing or damaged.
 DO NOT exceed the rated capacity of the jack.
 DO NOT allow the vehicle to move during lifting and do not use
the jack to move the vehicle.
 DO NOT jack a vehicle which may result in the spillage of fuel,
battery acid, or dangerous substances.
 DO NOT work under the vehicle until Axle Stands have been
correctly positioned.
DO NOT use the jack for purposes other that than which it is
designed for.
 DO NOT adjust the safety overload valve.
 DO NOT yank the hose from the air supply, and DO NOT direct
air from the air hose at yourself or others.
 Ensure there are no persons or obstructions beneath the vehicle
before lowering.
When not in use disconnect jack from the air supply, and store in
the lowered position in a safe, dry, childproof area.
 WARNING! Turn off air supply and de-pressurise the control
nozzle before removing the pump unit from any installation or
mobile system.
Failure to comply with this instruction may damage the unit and
will invalidate your warranty.
Original Language Version YAJ15-30, YAJ15-30DC, YAJ20-40,
YAJ20-40DC, YAJ20-40LR Issue 2 - 13/03/12
3.1. Ideal for workshop or roadside use, these jacks take the effort
out of lifting heavy plant, tractors and commercial vehicles.
Models feature dead man's control for extra safety
(detachable on Model No's YAJ15-30DC and YAJ20-40DC
making these models extremely portable) and multi-position
locking handles. Each jack is supplied with a 45mm and
75mm extension to help close the gap between the saddle of
the jack and the jacking point. Model No. YAJ20-40LR also
offers a long reach chassis, ideal for accessing deep set
jacking points.
3. INTRODUCTION
Model No YAJ15-30 YAJ15-30DC YAJ20-40 YAJ20-40DC YAJ20-40LR
Maximum
Capacity 30Tonne 30Tonne 40Tonne 40Tonne 40Tonne
Minimum
Height 175mm 150mm 175mm 150mm 190mm
Maximum Height/Capacity (mm/Tonne)
Stage 1 472/15 409/15 472/20 409/20 504/20
Stage 2 393/30 343/30 393/40 343/40 416/40
Extension 45/75mm 45/75mm 45/75mm 45/75mm 45/75mm
Chassis
Length 480mm 430mm 480mm 430mm 770mm
Length inc. Handle
Position 1 460mm 1280mm 460mm 1280mm 820mm
Position 2 1380mm 1600mm 1380mm 1600mm 1770mm
Position 3 1700mm - 1700mm - 2100mm
Width 290mm 290mm 290mm 290mm 282mm
Working
Pressure
116-
145psi
116-
145psi
116-
145psi
116-
145psi
116-
174psi
Air Flow 10.5cfm 10.5cfm 10.5cfm 10.5cfm 11.5cfm
Weight 39kg 31kg 41kg 33kg 62kg
4. ASSEMBLY
4.1. Attaching the Handle - YAJ15-30, YAJ20-40, YAJ20-40LR
4.1.1. Remove a circlip from either side of the large pin (fig.1A).
4.1.2. Slide out the pin and place the handle into the opening. Slide
the pin back through the jack, lining up the handle and
through the other side. Secure with circlips.
4.2. Air Hoses - YAJ15-30, YAJ20-40, YAJ20-40LR
4.2.1. Screw in the two air hoses from the handle into the jack.
4.2.2. The hose marked orange must be screwed into the left-hand
side. The hose marked black or clear into the right-hand side.
(fig.1).
4.2.3. Ensure the hoses are tight and do not obstruct the movement
of the handle.

5.1. Ensure that the jack pneumatic switch is in the "off" position
before connecting to the air supply.
5.2. You will require an air pressure of at least 116psi (max 145psi
or 174psi for YAJ20-40LR) and an air flow of 10.5cfm or
11.5cfm for YAJ20-40LR to get the best performance from this
jack.
5.3. WARNING! Ensure the air supply does not exceed 145psi
or 174psi for YAJ20-40LR while operating the jack.
Too high an air pressure and unclean air will shorten the
products life due to excessive wear, and may be dangerous
causing possible damage and personal injury.
5.4. Drain the air tank daily. Water in the air line will damage the
jack.
5.5. Clean the air inlet filter screen weekly.
5.6. Keep the air hose between the compressor and the air jack as
short as possible, and install an air filter and oiler (fig.2).
5.7. Line pressure should be increased to compensate for
unusually long air hoses (over 8 metres). The minimum hose
diameter should be 3/8" I.D. and fittings must have the same
inside dimensions.
5.8. Keep hose away from heat, oil and sharp edges. Check hoses
for wear, and make certain that all connections are secure.
5. AIR SUPPLY
Original Language Version YAJ15-30, YAJ15-30DC, YAJ20-40,
YAJ20-40DC, YAJ20-40LR Issue 2 - 13/03/12
6.1. Preparation - YAJ15-30, YAJ20-40, YAJ20-40LR
6.1.1. You will require an air pressure of at least 116psi (max
145psi or 174psi for YAJ20-40LR) and an air flow of 10.5cfm
or 11.5cfm for YAJ20-40LR to get the best performance from
the jack.
6.1.2. Connect the air supply to the connector (fig.3B).
6.1.3. Set the handle to the required angle using the handle release
lever shown in fig.3A. Pull the lever upwards towards the
main handle. Move the handle to the required position and
release the lever to lock it into position.
6.2. Preparation - YAJ15-30DC, YAJ20-40DC
6.2.1. Connect the air supply to the connector (fig.4A).
6.2.2 To change the handle position on the "DC" models turn the
handle (fig.4D) anti-clockwise then pull out of socket, insert
into the other handle socket and turn clockwise to secure.
6.2.3 On the "DC" models the controls (fig.4B) are detachable, lift
and slide off the handle before putting the jack under the
vehicle.
fig.2
6. OPERATION
fig.1
6.3. Purge the System - YAJ15-30, YAJ20-40, YAJ20-40LR
Before using the jack, purge the hydraulic circuit in order to
eliminate any possible air that may have entered the system
during transit.
6.3.1. Push the control lever (fig.5A) to the ‘down’ position and hold
it there for several seconds. Release the lever to the centre
‘hold’ position.
6.3.2. Now push the lever to the ‘up’ position and hold it there until
the jack is fully extended. Push the lever to the ‘down’
position and watch the jack as it retracts. The lowering
movement should be smooth and without irregular stops.
6.3.3. Repeat the raising and lowering cycle until the movement is
smooth. Once this has been achieved this indicates that all
air has been expelled.
6.4. Purge the System - YAJ15-30DC, YAJ20-40DC
Before using the jack, purge the hydraulic circuit in order to
eliminate any possible air that may have entered the system
during transit.
6.4.1. Push the down button (fig.6B) and hold it there for several
seconds. Release the button.
6.4.2. Now push the 'up' button and hold it there until the jack is
fully extended. Push the 'down' button and watch the jack as
it retracts. The lowering movement should be smooth and
without irregular stops.
6.4.3. Repeat the raising and lowering cycle until the movement is
smooth. Once this has been achieved this indicates that all
air has been expelled.
6.5. Using the Jack - YAJ15-30, YAJ20-40, YAJ20-40LR
WARNING! ensure you have read and understood the
safety instructions in chapter 1 before commencing work.
6.5.1. Position the Jack under the vehicle manufacturer’s
recommended jacking point (see vehicle hand book).
Note: Use the extension pins (fig.3D) to get the jack closer
to the jacking point before engaging the jack. See
specification for capacity when using the extension pins.
6.5.2. Whilst holding the main jack handle lifting is achieved by
pushing the control lever to the 'up' position (fig.5B).
6.5.3. When the vehicle has reached the desired height release the
control lever which will automatically return to the middle
hold position stopping any further air flow holding the jack at
the height to which it has been raised.
6.5.4. Place axle stands correctly in position and ensure chapter 1
safety instructions are strictly applied before performing any
task.
fig.3 fig.4

IMPORTANT: Only fully qualified personnel should
attempt maintenance or repair.
 WARNING! Disconnect jack from air supply before changing
parts, servicing or performing any maintenance.
7.1. When the jack is not in use, the piston must be in the lowest
position to minimise corrosion.
7.2. Keep the jack clean and lubricate all moving parts, and the
air intake connector with air tool oil on a regular basis.
7.3. To check oil level, fully lower jack. Remove the filler plug
(located next to the piston or for YAJ20-40LR it is located on
the side of the jack). The oil level should be level with the
indicator inside the filler hole, for YAJ20-40LR, it should be
level with the bottom of the filler hole.
Top up the oil level if necessary but do not overfill as the jack
will become inoperative. If inadvertently overfilled the excess
oil should be poured off. After topping up or pouring off
excess oil it may become necessary to purge air from the
unit. See section 6.3 / 6.4.
NOTE: Use a good quality Jack oil, such a SEALEY HYDRAULIC
JACK OIL.
7. MAINTENANCE
8. TROUBLESHOOTING
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 will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
01284 757500
01284 703534
[e-mail]
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk,
IP32 7AR
www.sealey.co.uk
Web
email
Original Language Version YAJ15-30, YAJ15-30DC, YAJ20-40,
YAJ20-40DC, YAJ20-40LR Issue 2 - 13/03/12
PROBLEM POSSIBLE CAUSE REMEDY
Jack does not lift
but pump is ok.
1. Oil Exhausted.
2. Air in hydraulic
system.
3. Defective suction or
delivery valves.
4. Defective packing or
O-ring.
5. Poor quality oil.
1. Supply oil.
2. Drain air by.
opening cap plug
of suction and
delivery valves.
3. Clean clogged
valve.
4. Replace.
5. Replace oil.
Air pump does
not operate.
1. Insufcient
compressor power.
2. Pump oil used up.
1. Use a larger
compressor.
2. Find leak and
rectify, rell with
oil. Rebuild and
lubricate air valve.
Jack stops before
end of travel.
1. Hydraulic oil is
insufcient.
1. Supply oil.
Jack Lowers or
does not hold
in the raised
position.
1. Defective suction
delivery, release or
safety valve.
2. Defective piston
packing.
1. Clean and adjust
valve.
2. Replace packing.
Lifting is slow. 1. Air leakage due to
worn servo-valve.
1. Replace servo-
valve.
Pump continues
to operate when
the air valves
are closed
1. Air valve will not close. 1. Replace Valve.
WARNING! DO NOT use brake fluid, or any fluid other
than hydraulic jack fluid as this may cause serious damage to
the Jack and will invalidate the warranty!
7.4. Ensure the air filter located in the air valve is clean.
7.5. Should the piston not rise and the oil level is correct, this may
indicate a problem with air seeping into the hydraulic valve
passage. Purge any air from the system. See 6.3 / 6.4.
7.6. Confirm that the piston can rise to the highest position.
7.7. Before each use check for broken, cracked, bent, or loose
parts. Or any visible damage to welds, piston, pump, saddle,
air connector, levers, frame and all parts including nuts, bolts,
pins and other fasteners. If any suspect item is found, remove
jack from service and take necessary action to fix the problem.
DO NOT use the jack if believed to have been subjected to
abnormal load or shock. Inspect and take appropriate action.
7.8. Every three months remove the locking rings on the caster
wheels and lubricate the ball bearings with grease.
7.9. After a year of extensive use, the oil should be replaced in
order to extend the life of the jack. To drain the oil, remove
the filler plug and valve. Make sure that no dirt is allowed to
enter the hydraulic system See 7.3. for refilling instructions.
7.10. Periodically check the pump piston and piston rod for signs of
corrosion. Clean exposed areas with a clean oiled cloth.
IMPORTANT: NO RESPONSIBILITY IS ACCEPTED FOR INCORRECT USE OF
THE MACHINE.
Air / Hydraulic products are only repaired by local service agents. We have
service/repair agents in all parts of the UK. DO NOT RETURN JACKS TO US.
Please telephone us on 01284 757500 to obtain the address and phone number
of your local agent. If jack is under guarantee please contact your dealer.
De-commissioning the Jack
Should the jack become completely unserviceable and require disposal, draw off
the oil into an approved container and dispose of the jack and the oil according to
local regulations.
fig.5
6.6. Using the Jack - YAJ15-30DC, YAJ20-40DC
WARNING! ensure you have read and understood the safety
instructions in chapter 1 before commencing work.
6.6.1. Position the Jack under the vehicle
manufacturer’s recommended
jacking point (see vehicle hand book).
Note: Use the extension pins (fig.3D/fig.4C)
to get the jack closer to the jacking
point before engaging the jack. See
specification for capacity when using
the extension pins.
6.6.2. Whilst holding the main jack handle
lifting is achieved by pushing the 'up'
button (fig.6A).
6.6.3. When the vehicle has reached the
desired height release the 'up' button,
stopping any further air flow holding
the jack at the height to which it has
been raised.
6.6.4. Place axle stands correctly in position
and ensure chapter 1 safety
instructions are strictly applied before
performing any task.
6.7. Lowering the Jack
6.7.1. Ensure there are no persons or obstruction beneath the
vehicle before lowering, and remove any axle stands.
6.7.2. Whilst holding the main jack handle lowering is achieved by
pushing the control lever/button to down (fig.5A/fig.6B), and
the jack will lower in a controlled manner.
6.7.3. Once completely lowered releasing the control lever will
return it to the middle hold position. Remove the jack from
under the vehicle. If you have finished using the jack, turn the
air pressure supply off and disconnect the jack from the air
line and store the jack and air line accordingly.
fig.6
Parts support is available for this product. To obtain a parts listing and/or diagram, please log on to www.sealey.co.uk,
email [e-mail] or phone [phone].