Sealey AK452X.V2 User manual

INSTRUCTIONS FOR:
AIR OPERATED GREASE GUNS
Models No: AK452X.V2 &AK453X.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.
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 ensure a
smooth flow. Both models include SAE100R2AT rated grease hose, Z-swivel, hand-gun and bucket trolley.
2.2. Application. The AK452X.V2 and AK453X.V2 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.
!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 3.0bar minimum to 8.0bar maximum. We recommend that the operating pressure is set to 6.0BAR/90psi 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
4. CONTENTS
Ratio (AK452X.V2 & AK453X.V2) . . . .50:1
Maximum air pressure . . . . . . . . . . .150psi
Operating air pressure . . . . . . . . . . .120psi
Minimum air pressure . . . . . . . . . . .43.5psi
Max. delivery pressure . . . . . . . . . .6000psi
Air consumption . . . . . . . . . . . . .400ltr/min
Max. delivery performance . .1100g/minute
Air inlet . . . . . . . . . . . . . .1/4” Female BSP
Material outlet . . . . . . . . .1/4” Female BSP
Shank length AK452X.V2 . . . . . . . .450mm
Shank length AK453X.V2 . . . . . . . .700mm
External shank DIA . . . . . . . . . . . .35mmØ
Bucket capacity AK452X.V2 . . . . . .12.5kg
Bucket capacity AK453X.V2 . . . . . .50.0kg
AK452X.V2 & AK453X.V2 - 1076 -(2) - 171201
!WARNING! Disconnect the grease gun from the air supply before changing accessories, servicing or
performing and maintenance.
!WARNING! Ensure correct air pressure is maintained and not exceeded. Recommended pressure
6bar/90psi.
"Maintain pump in good condition (use an authorised service agent).
"Replace 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.
"Wear appropriate protective clothing. When handling lubricants refer to manufacturer’s instructions and
conform to local regulations.
"Use 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.
"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.
"Maintain correct balance & footing. Ensure floor is not slippery, wear non slip shoes.
"Keep children and unauthorised persons away from the working area.
"Dispose of waste grease in accordance with local authority regulations.
!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.
"When not in use ensure the air supply is turned off.
#DO NOT allow unauthorised persons to operate the pump.
!WARNING! DO NOT tamper with or open pump unit. To do so will invalidate your warranty.
#DO NOT point grease gun at yourself or other persons or animals.
#DO NOT pull the grease gun unit by the hoses, or yank the hose from the air supply.
#DO NOT force the pump to achieve a task it was not designed to perform.
#DO NOT operate the pump when you are tired, under the influence of alcohol, drugs
or intoxicating medication.
"When not in use, disconnect the unit from the air supply. Clean the unit and store in a dry, safe, childproof area.
fig.1 (AK452X.V2 illustrated)
4.1. Contents: Remove items from carton and identify pieces from contents list below and fig.2 overleaf. Contact your supplier immediately
if any pieces are missing or damaged.
2. DESCRIPTION & APPLICATION
(A) Follower plate
(B) Shaft guide
(C) Dust cover
(D) Pump shaft
(E) Grease hose
(G) Grease outlet
(H) 1/4 bsp male connector
(J) Air line connector.
(L) Pressure gauge.
(O) Air oiler
(P) Pump
(R) Air regulator
(X) Grease bucket (not included)
(Y) Grease gun
(Z) Z-swivel
Trolley (not illustrated).
01284 757500
01284 703534 [e-mail]
Sole UK Distributor
Sealey Group,
Bury St. Edmunds, Suffolk.
www.sealey.co.uk
Web
email

AK452X.V2 & AK453X.V2 - 1076 - (2) - 171201
!WARNING! Disconnect the pump from the air line before attempting any service or maintenance.
7.1. Air line lubricator (fig.2 item O). This unit is designed to automatically lubricate the pump through 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 screw on the top of the unit. Turn screw anticlockwise to increase the flow
and clockwise to decrease flow. The oil supply required to lubricate the pump is minimal. For an initial setting turn
adjusting screw on the top of the unit fully home and then open by 1/4 of a turn. To change and clean the oil unit
unscrew the bowl and retain the sealing ring. Empty, clean and re-fill to maximum line and replace ensuring the sealing ring is
fitted correctly. Do not over tighten the bowl. Contact your Sealey dealer for parts and information.
7.2. 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.
!WARNING! 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.
6.1 Turn the air pressure on and check to ensure there are no leaks in the system.
6.2 Adjust the air pressure using the knob on the top of the air regulator (fig 2. item R). Unlock the knob by pulling it
upwards and then turning it until the gauge indicates the recommended operating pressure of 6.0bar/87psi. Push the
knob down again to lock it. 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.
6.3 Prime unit by operating grease control valve (fig 2. item Y) until lubricant emerges from end of the gun. The unit is
now ready for use.
6.4 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.
5.0 Installation. ( Refer to fig.2 )
!WARNING! 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.
5.1 Place the grease bucket (X) onto the platform of the trolley and push it back until it touches the two stops
provided. Secure the container to the trolley using the straps provided. (see fig.1)
5.2 Remove the original lid supplied with the grease bucket and store it for future use.
5.3 Introduce the follower plate (A) into the top of the grease bucket (X) and settle it down onto the surface of
the grease.
5.4 Take the three legged shaft guide (B) and loosen all six butterfly nuts. Adjust the length of the
legs to suit the size of the grease bucket. Place the shaft guide onto the rim of the grease bucket
and align the central hole with the hole in the follower plate below. When aligned tighten all the butterfly nuts
ensuring that those at the end of the legs have caught under the rim of the bucket.
5.5 Slide the circular lid (C) onto the shaft of the pump as far as it will go.
5.6 Lift the pump and lid over the grease bucket and allow the shaft to pass through the shaft guide and follower plate
and sink down to the bottom of the bucket. Let the lid slide down the shaft to cover the top of the bucket.
5.7 Connect the in-line air regulator (R) and air oiler (O) together using the long bolts and nuts provided. (The nuts
slide into the recesses in the front and back of the regulator body.) Ensure that the air flow arrows moulded into the top
of each unit body are pointing in the same direction and that both arrows are pointing towards the pump air inlet. The air
oiler should be situated between the air regulator and the pump as indicated in fig.2.
5.8 Screw the circular pressure gauge (L) into whichever side of the air regulator is most convenient for reading. Seal
the unused mounting position using the blanking plug provided.
5.9. Connect the regulator assembly to the pump air inlet using the 1/4” bsp fitting provided (H).
5.10 Connect the ‘Z’ swivel assembly (Z) to the grease gun (Y) and connect the grease hose (E) to the ‘Z’ swivel.
Connect the other end of the grease hose to the grease outlet on the pump (G).
Note: We recommend that PTFE sealing tape is used on all connections.
5. ASSEMBLY & INSTALLATION fig 2.
THE PROBLEM THE CAUSE THE SOLUTION
1. Air motor runs slowly or
not at all
2. Air motor is running but
pump is too slow or not
working at all.
3. Air motor is running but
no pressure is generated.
4. Air escapes from the
muffler when the pump is
not operating
1.1. Air pressure is too low.
1.2. Muffler or filter is blocked or dirty.
2.1. Grease filter is blocked.
2.2. Grease is too stiff.
2.3. Air pockets in grease container.
2.4. Grease container dented.
3.1. ‘O’rings,washers or valves within pump
are damaged or dirty
4.1. The plunger is damaged.
4.2 The ‘O’ rings or the distributor seal are
damaged.
1.1. Adjust air pressure to a minimum of 3bar.
1.2. Remove muffler (part No.20) and/or filter (part No.11), clean and replace.
2.1. Remove and clean filter. (part No. 41)
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 or replace the relevant components. Servicing by an approved Sealey
dealer is recommended
4.1. Replace plunger. ( part No.5 ) Servicing by an approved Sealey
dealer is recommended.
4.2 Replace parts ( part No.19.6 ) using complete repair kit.
8. TROUBLE SHOOTING
6. OPERATING INSTRUCTIONS
7. MAINTENANCE
Declaration of Conformity We, the sole UK distributor, declare that the products listed below are in conformity with the following EEC standards and directives
The construction files for these products are held by the Manufacturer and may be inspected
by a national authority by contacting Jack Sealey Ltd
For Jack Sealey Ltd. Sole distributor in the UK of Sealey Power Products
Air Operated Grease Guns
Models AK452X.V2 & AK453X.V2
98/37/EC Machinery Directive 20th August 2001
Signed by Mark Sweetman