Sealey SA2004KIT.V2 User manual

INSTRUCTIONS FOR
AIR TOOL KIT 4PC WITH ACCESSORIES
MODEL NO: SA2004KIT.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
WARNING! Ensure that Health & Safety, local authority and general workshop practice regulations are adhered to when using this
equipment.
WARNING! Disconnect from the air supply before changing accessories, servicing or performing any maintenance.
9Maintain the tools in good condition (use an authorised service agent).
9Replace or repair damaged parts. Use genuine parts only. Unauthorised parts may be dangerous and will invalidate the warranty.
9Use in a suitable work area. Keep area free from unrelated materials and ensure that there is adequate lighting.
9Maintain correct balance and footing. DO NOT over reach, ensure the floor is not slippery and wear non-slip shoes.
WARNING! Always wear approved eye and hand protection when operating these tools.
9Use face, dust, or respiratory protection in accordance with COSHH regulations.
WARNING! Due to the possible presence of asbestos dust from brake linings, when working around vehicle brake systems we recommend that
suitable respiratory protection is worn.
9Depending on the task, the tool noise level may exceed 84dB in which case wear safety ear defenders.
9Remove ill fitting clothing. Remove ties, watches, rings and other loose jewellery and contain and/or tie back long hair.
9Wear appropriate protective clothing and keep hands and body clear of working parts.
9Keep children and unauthorised persons away from the work area.
9Ensure that the workpiece is secure before operating the tool. Never hold a workpiece by hand.
8DO NOT operate tool when you are tired or under the influence of alcohol, drugs or intoxicating medication.
WARNING! Ensure correct air pressure is maintained and not exceeded. Recommended pressure 90psi.
9Keep air hose away from heat, oil and sharp edges. Check air hose for wear before each use and ensure that all connections are secure.
9When not in use disconnect from air supply and store in a safe, dry, childproof location.
8DO NOT use tools for tasks that they are not designed to perform.
8DO NOT operate tools if any parts are damaged or missing as this may cause failure and/or personal injury.
8DO NOT carry the tool by the hose, or yank the hose from the air supply.
8DO NOT place air line attachments close to your face and do not point at other people or animals.
8DO NOT direct air from the air line at yourself or others.
8DO NOT operate tools unless you have been instructed in their use by a qualified person.
8DO NOT carry tools with your finger on the trigger and avoid unintentional starting.
8DO NOT drop, throw or abuse the tools as they are precision instruments.
8DO NOT leave the tools operating unattended.
8DO NOT get the tools wet or operate in damp or wet locations.
8DO NOT allow tools to free run for an extended period of time as this will shorten their life.
2. INTRODUCTION
Comprehensive air tool kit containing: medium stroke air hammer, air die grinder, 1/2” drive air impact wrench and 1/2” drive air ratchet wrench.
Includes a selection of WallDrive® sockets, extension bar, grinding points, chisels and many accessories. Suitable for workshop and bodyshop
applications. Supplied in carry case.
3. SPECIFICATION
All tools:
Max air consumption:..........................................................5cfm
Operating pressure: ...........................................................90psi
Air inlet size:.................................................................. 1/4”BSP
Total weight: ..........................................................................8kg
Ratchet wrench 1/2” sq. drive:
Maximum torque: ................................................45lb.ft, (61Nm)
Vibration: ...................................................................... 3.27m/s²
Uncertainty:.................................................................... 1.5m/s²
Noise power: .................................................................... 102dB
Noise pressure:.................................................................. 91dB
Refer to
instruction
manual
Wear ear
protection
Wear eye
protection
Wear protective
gloves
Wear a
mask
SA2004KIT.V2 | Issue 1 17/11/16
Original Language Version
© Jack Sealey Limited
Impact wrench 1/2” sq.drive:
Working/maximum torque: .......................200/230lb.ft, (312Nm)
Vibration: ...................................................................... 5.17m/s²
Uncertainty:.................................................................... 1.5m/s²
Noise power: .................................................................... 105dB
Noise pressure:.................................................................. 94dB
Air die grinder:
Chuck size:.......................................................................Ø6mm
Free speed:................................................................ 22000rpm
Vibration: ........................................................................ 1.6m/s²
Uncertainty:.................................................................... 0.8m/s²
Noise power: .................................................................... 100dB
Noise pressure:.................................................................. 89dB

Air hammer medium stroke:
Speed:.......................................................................... 4500rpm
Stroke:.............................................................................. 43mm
Chisel shank:............................................................ .401” round
Vibration: ........................................................................ 9.4m/s²
Uncertainty:.................................................................... 1.5m/s²
Noise power: ...................................................................... 96dB
Noise pressure:.................................................................. 85dB
4. PREPARATION FOR USE
4.1. Recommended hook-up is shown in fig.1.
WARNING! Ensure that the air supply is clean and does not exceed 90 psi while operating these tools. Too much air pressure and/or
unclean air will cause excessive wear and may be dangerous, causing damage and/or personal injury.
4.2. Ensure that the tool trigger is not depressed before connecting to the air supply.
4.3. You will require an air pressure of 90psi, and an air flow of 4cfm per tool.
4.4. Drain the air tank daily. Water in the air line will damage the tools and invalidate your warranty.
4.5. Clean the compressor air inlet filter weekly.
4.6. Line pressure should be increased to compensate for unusually long air hoses (over 8 metres). The minimum hose bore should be 1/4”
and fittings must have the same inside dimensions.
4.7. Keep hoses away from heat, oil and sharp edges. Check hoses for wear and make certain that all connections are secure.
4.8. Couplings - vibration may cause failure of a quick change coupling that is connected directly to the air tools.
4.8.1. To overcome this, connect a leader hose (Sealey model number AH2R) to the tools.
4.8.2. A quick change coupling may then be used to connect the leader hose to the air line recoil hose. See figs.1 & 2.
5. SA2 - AIR IMPACT WRENCH
Tough professional air impact wrench with fully polished alloy housing and rubber bumper. Through type forward/reverse control. 4 position
adjustable air/torque selection. Fitted with standard 1/2” square drive. Fitted with rocking-dog type clutch and hardened impact anvil. Suitable for
general garage use.
WARNING! Ensure that you read, understand and apply the safety instructions in Section 1 before use. Additionally the
 followingsafetyinstructionsarespecictothistool.
5.1. Use only impact sockets, since these are specifically designed for use with an impact wrench. Standard sockets may shatter.
8DO NOT use any additional force upon the wrench in order to tighten or remove a nut.
5.2. Take care not to over-tighten fixings.
5.3. Operation
5.3.1. Connect the wrench to the air supply as in Section 4.
5.3.2. Fit a socket onto the square drive and then place the socket over the nut. Squeeze the trigger to operate the wrench.
5.3.3. To change direction push the button at the top of the handle, direction “F” for forward and “R” for reverse.
5.3.4. Theowofair(torque)mayberegulatedbyadjustingowvalveatthebaseofthehandle,pushintheadjusterandturnclockwiseuntil
correct setting (1 to 4) is reached, then let adjuster click out to lock.
6. SA12/S - AIR HAMMER
The air hammer is designed primarily for use on vehicle bodywork. We do not recommend any other use.
WARNING! Ensure that you read, understand and apply the safety instructions in Section 1 before use. Additionally the
 followingsafetyinstructionsarespecictothistool.
6.1. Ensure chisels are correctly rated for the job. DO NOT use damaged or suspect chisels.
8DO NOT switch the hammer on whilst the chisel is in contact with the workpiece.
8DO NOT use hammer where there is flammable liquid, solids or gas such as paint solvent, including waste wiping or cleaning rags etc.
WARNING! DO NOT chisel any materials containing asbestos.
6.2. Operation
6.2.1. Insert the chisel shank into the gun cylinder (fig.3).
6.2.2. Place the retainer ring over the chisel (fig.3) and lower onto the hammer’s cylinder thread. Screw the retainer spring on to the cylinder
using a clockwise motion and using pressure on tag B until the spring is fully located (fig.4) and the chisel is retained by the spring retaining
tag (B).
6.2.3. Connect the hammer to the air supply as in Section 4.
6.2.4. To operate the hammer, squeeze the trigger, taking care that the chisel end is not in contact with the work-piece. The air regulator can be
adjusted by means of the knob at the base of the handle, use this as a means of throttle control.
Fig.1
Fig.2
SA2004KIT.V2 | Issue 1 17/11/16
Original Language Version
© Jack Sealey Limited
Sockets:
Sizes: ................................. 9, 10, 11, 13, 14, 17, 19, 22, 24, 27
Extension bar: .................................................................. 75mm
Adaptor:.................................................3/8”sq. (M) x 1/2”sq. (F)

6.2.5. To remove attachment, reverse procedures 6.1. and 6.2. using pressure on tag A.
7. SA21/S - AIR RATCHET WRENCHS
The air ratchet wrench has a hardened steel anvil with trigger operated power control, it is suitable for use in the engine bay where there is
limited space for hand operated ratchets.
WARNING! Ensure that you read, understand and apply the safety instructions in Section 1 before use. Additionally the
 followingsafetyinstructionsarespecictothistool.
8DO NOT use any additional force upon the wrench in order to remove or tighten a nut.
7.1.  Onlyusesocketsspecicallydesignedforusewitharatchetwrench.
7.2. Operation
7.3. Connect the wrench to the air supply as in Section 4.
7.4. Place the socket over the subject nut and depress the trigger to operate the wrench.
7.5. To change ratchet direction turn the switch on the tool head. F = Forward R = Reverse.
7.6.  Theowofair(torque)mayberegulatedbyturningthescrewabovethetrigger.
8. SA67 - AIR DIE GRINDER
One-handed straight type die grinder with aluminium body and trigger with safety catch. Chuck accepts grinding bits with Ø6mm
shanks.
WARNING! Ensure that you read, understand and apply the safety instructions in Section 1 before use. Additionally the
 followingsafetyinstructionsarespecictothistool.
WARNING! DO NOT grind any materials containing asbestos.
WARNING! Before each use check grinding bit is secure, and the bit is not worn or damaged, if damaged, replace immediately.
9Always use the correct grinding bit suitable for the material being ground. Ensure the maximum speed specification of the bit is higher
than that indicated on the machine data plate.
9Avoid subjecting grinding bit to excessive strain, hold grinder firmly and always ease grinding bit against workpiece (a harsh impact may
break the bit). Maintain a controlled progression.
8DO NOT turn the die grinder on whilst the grinding bit is in contact with the workpiece.
8DO NOT use die grinder where there are flammable liquids, solids or gases such as paint solvents, including waste wiping or cleaning
rags etc. as generated sparks may be dangerous.
8DO NOT touch the workpiece close to the ground surface as it will be very hot. Allow to cool. The workpiece may also be very sharp.
8.1. Operation
8.2. Check that grinding bits are not damaged in any way such as cracks, deformations or splinters etc. Damaged bits must not be used.
8.3. Use wrenches provided to loosen collet locking collar. Insert grinding bit and re-lock collar.
8.4. Connect the air die grinder to the air supply as in Section 4.
8.5. To start, hold firmly and push the trigger locking lever forward whilst depressing trigger.
8.6. The bit must be running at its maximum speed before attempting to grind the workpiece.
8.7. Slowly and smoothly bring the grinding stone toward the workpiece (avoid jerky movements).
8.8. Exert adequate pressure on the die grinder to grind according to the type and size of the material you are working with. Avoid subjecting
bit to excessive strain or harsh impacts.
9. MAINTENANCE
WARNING! Disconnect the tool from the air supply before changing accessories, servicing or performing maintenance.
9.1. Replace or repair damaged parts. Use genuine parts only. Unauthorised parts may be dangerous and will invalidate the warranty.
9.2. If the air supply does not have an oiler, lubricate the air tool daily with a few drops of Sealey air tool oil dripped into the air inlet to prolong its
life.
9.3. Clean the tool after use.
9.4. Loss of power or erratic action may be due to the following:
a) Excessive drain on the air line. Moisture or restriction in the air pipe. Incorrect size or type of hose connectors. To remedy check the
air supply and follow instructions in Section 4.
b) Grit or gum deposits in the wrench may also reduce performance. If your model has an air strainer (located in the area of the air
inlet), remove the strainer and clean it. Flush the wrench out with gum solvent oil or an equal mixture of SAE No 10 oil and paraffin.
Allow to dry before use.
9.5. For a full service contact your local Sealey service agent.
9.6. When not in use, disconnect from air supply, clean tool and store in a safe, dry, childproof location.
9.7. Impact Wrench only - Check and top up the gearbox oil by removing grub screw located on the right side, above the grip.
Fig.4
Fig.3
SA2004KIT.V2 | Issue 1 17/11/16
Original Language Version
© Jack Sealey Limited

NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specications 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.
Sole UK Distributor, Sealey Group.
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk.
IP32 7AR
www.sealey.co.uk
[e-mail]
01284 757500
01284 703534
Web
Environmental 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 off any fluids (if applicable)
into approved containers and dispose of the product and the fluids according to local regulations.
SA2004KIT.V2 | Issue 1 17/11/16
Original Language Version
© Jack Sealey Limited
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 telephone [phone].

WARNING! – Risk of Hand Arm Vibration Injury.
This tool may cause Hand Arm Vibration Syndrome if its use is not managed adequately.
This tool is subject to the vibration testing section of the Machinery Directive 2006/42/EC.
This tool is to be operated in accordance with these instructions.
Ratchet wrench:
Measured vibration emission value (a): 3.27m/s²
Uncertainty value (k): 1.5m/s²
Impact wrench:
Measured vibration emission value (a): 5.17m/s²
Uncertainty value (k): 1.5m/s²
Air die grinder:
Measured vibration emission value (a): 1.6m/s²
Uncertainty value (k): 0.8m/s²
Air hammer:
Measured vibration emission value (a): 9.4m/s²
Uncertainty value (k): 1.5m/s²
Please note that the application of the tool to a sole specialist task may produce a different average vibration emission. We recommend that a
specific evaluation of the vibration emission is conducted prior to commencing with a specialist task.
A health and safety assessment by the user (or employer) will need to be carried out to determine the suitable duration of use for each tool.
NB: Stated Vibration Emission values are type-test values and are intended to be typical.
Whilst in use, the actual value will vary considerably from and depend on many factors.
Such factors include; the operator, the task and the inserted tool or consumable.
NB: ensure that the length of leader hoses is sufficient to allow unrestricted use, as this also helps to reduce vibration.
The state of maintenance of the tool itself is also an important factor, a poorly maintained tool will also increase the risk of Hand Arm Vibration
Syndrome.
Health surveillance.
We recommend a programme of health surveillance to detect early symptoms of vibration injury so that management procedures can be modified
accordingly.
Personal protective equipment.
We are not aware of any personal protective equipment (PPE) that provides protection against vibration injury that may result from the
uncontrolled use of this tool. We recommend a sufficient supply of clothing (including gloves) to enable the operator to remain warm and dry and
maintain good blood circulation in fingers etc. Please note that the most effective protection is prevention, please refer to the Correct Use and
Maintenance section in these instructions. Guidance relating to the management of hand arm vibration can be found on the HSC website
www.hse.gov.uk - Hand-Arm Vibration at Work.