Sealey YAJ15-30.V2 User manual

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
Disconnect jack from air supply before changing parts, servicing or performing any maintenance.
RWARNING! Ensure correct air pressure is maintained and not exceeded. Recommended pressure 116-145psi or 174psi for
YAJ20-40LR. Required air ow 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 qualied person to lubricate and maintain the jack.
 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.
VDANGER: Use jack for lifting only, NOT for supporting the raised load. Use correctly rated axle stands under vehicle before
proceeding with task.
DO NOT use brake uid to top up system. Use Sealey hydraulic oil only.
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 pull 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.
RWARNING! 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.
2. INTRODUCTION
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.V2 and YAJ20-40DC.V2 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.
Refer to
Instruction
Manual
YAJ15-30.V2, YAJ15-30DC.V2,YAJ20-40.V2,
YAJ20-40DC.V2, YAJ20-40LR| Issue 2 (I) 28/04/15
Original Language Version
© Jack Sealey Limited
INSTRUCTIONS FOR :
AIR OPERATED JACKS TELESCOPIC
MODEL No's YAJ15-30.V2 YAJ15-30DC.V2 YAJ20-40.V2 YAJ20-40DC.V2 YAJ20-40LR

3. SPECIFICATION
Note: The maximum heights shown may be extended by use of the extension pins.
4. ASSEMBLY
4.1. Attaching the Handle - YAJ15-30.V2, YAJ20-40.V2, YAJ20-40LR
4.1.1. Remove a circlip from either side of the large pin (g.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.V2, YAJ20-40.V2, 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, (g.1).
4.2.3. Ensure the hoses are tight and do not obstruct the movement of the handle.
5. AIR SUPPLY
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 ow of 10.5cfm (or 11.5cfm for
YAJ20-40LR) to get the best performance from this jack.
RWARNING! 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.
5.3. Drain the air tank daily. Water in the air line will damage the jack.
5.4. Clean the air inlet lter screen weekly.
5.5. Keep the air hose between the compressor and the air jack as short as possible, and install an air lter and oiler (g.2).
5.6. 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 ttings must have the same inside dimensions.
5.7. Keep hose away from heat, oil and sharp edges. Check hoses for wear, and make certain that all connections are secure.
6. OPERATION
6.1. PREPARATION - YAJ15-30.V2, YAJ20-40.V2, 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 ow 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 (g.3B).
6.1.3. Set the handle to the required angle using the handle release lever shown in g.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.V2, YAJ20-40DC.V2
6.2.1. Connect the air supply to the connector (g.4A).
6.2.2. To change the handle position on the “DC” models turn the handle (g.4D) anti-clockwise then pull out of socket, insert into the
other handle socket and turn clockwise to secure.
6.3. PURGE THE SYSTEM - YAJ15-30.V2, YAJ20-40.V2 AND YAJ20-40LR
6.3.1. Before using the jack, purge the hydraulic circuit in order to eliminate any possible air that may have entered the system during
transit.
6.3.2. Push the control lever (g.5A) to the ‘down’ position and hold it there for several seconds.
Model No YAJ15-30.V2 YAJ15-30DC.V2 YAJ20-40.V2 YAJ20-40DC.V2 YAJ20-40LR
Maximum
Capacity 30Tonne 30Tonne 40Tonne 40Tonne 40Tonne
Minimum
Height 175mm 150mm 175mm 150mm 190mm
Maximum Height/Capacity (mm/Tonne)
Stage 1 393/30 343/30 393/40 343/40 416/40
Stage 2 472/15 409/15 472/20 409/20 504/20
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
fig.1
fig.2
YAJ15-30.V2, YAJ15-30DC.V2,YAJ20-40.V2,
YAJ20-40DC.V2, YAJ20-40LR| Issue 2 (I) 28/04/15
Original Language Version
© Jack Sealey Limited

6.3.3. Release the lever to the centre ‘hold’ position.
6.3.4. 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.
6.3.5. 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.V2, YAJ20-40DC.V2
6.4.1. Before using the jack, purge the hydraulic circuit in order to eliminate any possible air that may have entered the system during
transit.
6.4.2. Push the down button (g.6B) and hold it there for several seconds. Release the button.
6.4.3. 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.
6.4.4. 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.V2, YAJ20-40.V2, YAJ20-40LR
RWARNING! 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 handbook).
Note: Use the extension pins (g.3D) to get the jack closer to the jacking point before engaging the jack. See specication 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 (g.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 ow, 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 work on
the vehicle.
6.6. USING THE JACK - YAJ15-30DC.V2, YAJ20-40DC.V2
RWARNING! 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 handbook).
Note: Use the extension pins (g.3D/g.4C) to get the jack closer to the jacking point before engaging the jack. See specication
for capacity when using the extension pins.
6.6.2. Whilst holding the main jack handle lifting is achieved by pushing the ‘up’ button (g.6A).
6.6.3. When the vehicle has reached the desired height release the ‘up’ button, stopping any further air ow 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 (g.5A/g.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 nished 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.3 fig.4 fig.5
fig.6
YAJ15-30.V2, YAJ15-30DC.V2,YAJ20-40.V2,
YAJ20-40DC.V2, YAJ20-40LR| Issue 2 (I) 28/04/15
Original Language Version
© Jack Sealey Limited

7. MAINTENANCE
VIMPORTANT: Only fully qualied personnel should attempt maintenance or repair.
RWARNING! 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. CHECKING OIL LEVEL
7.3.1. Fully lower jack.
7.3.2. Remove the ller 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 ller hole, for YAJ20-40LR, it should be level with the bottom of the ller hole.
7.3.3. Top up the oil level if necessary but do not overll as the jack will become inoperative. If inadvertently overlled 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.
RWARNING! DO NOT use brake uid, or any uid other than hydraulic jack uid as this may cause serious damage to the jack and
will invalidate the warranty!
7.4. Ensure the air lter 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. Conrm 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 x the problem.
7.8. DO NOT use the jack if believed to have been subjected to abnormal load or shock. Inspect and take appropriate action.
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 ller plug
and valve. Make sure that no dirt is allowed to enter the hydraulic system See 7.3. for relling 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.
7.11.DECOMMISSIONING THE JACK
7.11.1. 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.
8. TROUBLESHOOTING
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.
YAJ15-30.V2, YAJ15-30DC.V2,YAJ20-40.V2,
YAJ20-40DC.V2, YAJ20-40LR| Issue 2 (I) 28/04/15
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 phone [phone].
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.
YAJ15-30.V2, YAJ15-30DC.V2,YAJ20-40.V2,
YAJ20-40DC.V2, YAJ20-40LR| Issue 2 (I) 28/04/15
Original Language Version
© Jack Sealey Limited