Sealey AK452X User manual

INSTRUCTIONS FOR:
AIR OPERATED GREASE GUNS
Models No: AK452X &AK453X
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.
1. SAFETY INSTRUCTIONS
2.1. Description.
These units of well proven design have a highly efficient trouble free 50:1 air motor. Supplied with safety regulator to prevent over pressure in the
pump unit. The units are also fitted with a follower plate to prevent cavitation of grease and insure a smooth flow. Both models include
SAE100R2AT rated grease hose Z-swivel, hand-gun and bucket trolley.
2.2. Application.
The AK452X and AK453X are designed for use with most popular multipurpose greases to NLGI No.2 specification made with light to
medium base oil viscosities. The flow rate (delivery) performance will vary dependant upon the lubricant viscosity, temperature, and
additives, and on the pipelines used.
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IMPORTANT: For effective and extended operating life of the unit an air regulator (air line oiler and moisture separator) is included
with your grease gun. The regulator must be connected to the unit as described in the assembly instructions. The operating pressure
may vary between 3.5bar minimum to 8.5bar maximum. We recommend that the operating pressure is set to 7.6BAR/115psi to avoid
damaging unit & to prevent any leakage in the delivery lines. Ensure only air operated grease flexi hoses are used with this equipment.
IMPORTANT
PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND CAUTIONS. USE
THIS PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE
DAMAGE, OR PERSONAL INJURY, AND WILL INVALIDATE THE WARRANTY. RETAIN THESE INSTRUCTIONS FOR FUTURE USE.
3. SPECIFICATIONS
AK452X & AK453X Common features
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . .50:1
Maximum air pressure . . . . . .8.2bar (120psi)
Operating air pressure . . . . .7.9bar ( 115psi)
Minimum air pressure . . . . . . .3.5bar ( 50psi)
Delivery pressure . . . . . . . . .400bar(5800psi)
Delivery performance . . . .500g/minute
Air inlet . . . . . . . . . . .1/4 Female BSP
Material outlet . . . . . .1/4 Female BSP
Shank length . . . . . . . . . . . . . . . .38cm
External shank DIA . . . . . . . . .28mmØ
Bucket Capacity: AK452X...12.5kg AK453X...50kg
AK452X & AK453X - 0444 -(2) - 140700
fig 1.
2. DESCRIPTION & APPLICATION
pWARNING! Disconnect the grease gun from the air supply before changing accessories, servicing or performing any maintenance.
pWARNING! ensure correct air pressure is maintained and not exceeded. Recommended pressure 6bar/90psi.
3Maintain pump in good condition (use an authorised service agent).
3Replace or repair damaged parts. Check the grease bucket to ensure it is not damaged. A damaged bucket will
cause the follower plate to jam. Use recommended parts only. Non authorised parts
may be dangerous and will invalidate the warranty.
3Wear appropriate protective clothing. When handling lubricants refer to manufacturers
instructions and conform to local regulations.
3Use the pump in an appropriate working area for its function. Keep area clean and tidy
and free from unrelated materials and ensure there is adequate lighting.
3Keep air hose away from heat, oil and sharp edges. Check air hose for wear before
each use, and ensure that all connections are secure.
3Maintain correct balance & footing. Ensure floor is not slippery, wear non slip shoes.
3Keep children and unauthorised persons away from the working area.
3Dispose of waste grease in accordance with local authority regulations.
pWARNING! 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.
3When not in use ensure the air supply is turned off.
7DO NOT allow unauthorised persons to operate the pump.
pWARNING! DO NOT tamper with or open pump unit. To do so will invalidate your warranty.
7DO NOT point grease gun at yourself or other persons or animals.
7DO NOT pull the grease gun unit by the hoses, or yank the hose from the air supply.
7DO NOT force the pump to achieve a task it was not designed to perform.
7DO NOT operate the pump when you are tired, under the influence of alcohol, drugs or intoxicating medication.
3When not in use, disconnect the unit from the air supply. Clean the unit and store in a dry, safe, childproof area.

AK452X & AK453X - 0444 - (2) - 140700
p p
WARNING! Ensure the pump is disconnected from the air line before attempting any service or maintenance.
6.1. Air line lubricator (fig 3. item A).
This unit is designed to automatically lubricate the pump by the air intake. The unit must be kept topped up with good quality air oil
(our reference: ATO/500 500ml size or ATO/1000 1ltr size). To adjust the oil flow turn the oil regulator on the top of the unit. Turn screw
towards marking (+) will to increase the flow and towards (-) will to decrease flow. To change and clean the oil unit unscrew the bowl
and be careful to keep the sealing ring safe. Empty, clean and re-fill to maximum line and replace ensuring the sealing ring correctly.
Finger tighten only. Contact your Sealey dealer for parts and information.
6.2. Cleaning.
Clean pump and air units with clean damp cloth. Mild detergents may be used to remove grease.
DO NOT use solvents or abrasives and do not get the pump or air units wet.
6. MAINTENANCE
Air regulator
Set the air regulator (fig 3. item A) at 7.9bar/115psi. It is important to maintain the correct operating pressure
to ensure that the control valves and connectors are not damaged, and to prevent leakage in the delivery lines.
5.1. If you need to adjust the air pressure identify the tap on top of unit (fig 3. item D & fig 4). Pull tap up (fig 4)
and turn whilst monitoring the pressure gauge (fig 3. item C).
pWARNING! When exchanging a polycarbonate bowl ensure the suction tube is protected to avoid dirt particles being
transmitted to a new bowel. Always clean new delivery lines ensuring all metal shavings have been removed before
connecting the pump and control valves. Failing to do so may damage the unit and will invalidate your warranty.
5.2. Turn the air pressure on and check to ensure there are not leaks in the system.
5.3. Prime unit by operating grease control valve (fig 2. item 9) until lubricant emerges from end of the gun. The unit is now ready for use.
5.4. When not in use, turn the air supply off and disconnect the unit from the air supply. Store the grease unit in a safe, clean, dry, childproof area.
5. OPERATING INSTRUCTIONS
4.2. Installation.
pWARNING! Clean new delivery lines ensuring all metal shavings have been removed before
connecting the pump and control valves. Any dirt in the inlet hoses will damage the unit
and may invalidate your warranty.
4.2.1. Fit the follower plat (fig 2 item 1) in the the grease bucket (2).
4.2.2. Fit the lid (3) to the pump shaft (4).
4.2.3. Attached the grease hose assembly (5) to the grease outlet (6) at the base of the pump body (7).
4.2.4. Screw the large 1/4bsp fitting (E1) into the air pump inlet (F).
4.2.5. Connect the two parts of the air regulator system together by using the small 1/4bsp fitting (fig 4. E2).
Screw the air regulator system (fig 3. A) to the pump fitting (E1) ensuring that the lubrication bowl (B)
is nearest to the pump head. Ensure the air flow arrows on each part of the air regulator are pointing
in the same direction, and that the unit is installed with the arrows pointing toward the pump inlet.
4.2.6. Screw the pressure dial (C) into the side of the air regulator that is appropriate for you to read.
4.2.7. Connect the external air line system to the regulator inlet (G) and set the dial (C) to 90psi.
4.2.8. To adjust the pressure raise the control knob (D) (see chapter 5).
4.2.9. The air regulator oil supply required to lubricate the pump is minimal. Turn adjusting screw (fig 4.H)
fully home and then open by 1/4 of a turn.
Note: We recommend that PTFE sealing tape is used on all connections.
fig 4.
4. ASSEMBLY & INSTALLATION
4.1. Contents: Remove items from carton. Identify (fig 2) and check pieces for damaged. Contact
supplier immediately if you experience a problem.
Fig 2.
1. Follower plate 2 Grease bucket 3. Dust cover 4. Pump shaft 5. Hose
6. Grease outlet 7. Pump 8. Z-swivel 9. Grease gun
Fig 3. item A.
Air regulator system with male air line fittings. & Trolley (not illustrated).
fig 2.
fig 3.
7. TROUBLE SHOOTING
THE PROBLEM THE CAUSE THE SOLUTION
1. Air motor does
not operate.
2. Air motor
operates but
the pump does
not.
3. Poor performance
1.1. Air pressure is too low.
1.2. Muffler is blocked.
2.1. Strainer tube blocked.
2.2. Temperature of grease too low.
2.3. Air pockets in grease container.
2.4. Grease container dented.
3.1. Muffler blocked.
3.2. Temp too low. Viscosity too high.
3.3. Distance between pump and control
discharge valve too long.
1.1. Adjust air pressure to Minimum 8bar 120psi.
1.2. Remove muffler clean and replace.
2.1. Clean strainer parts item
2.2. Remove drum to warmer area allow temp of grease to rise above 15OC
2.3. Viscosity too high. Temperature must be above 15OC. Then compact the grease
by pushing the follower plate down.
2.4. Push the follower plate down past the dented area of the container.
3.1. Clean muffler.
3.2. Increase grease temperature above 15OC by moving to warmer area.
3.3. Shorten hose.