Sealey G3 Series User manual

1. SAFETY INSTRUCTIONS
 Follow all workshop Health & Safety rules, regulations, and conditions when using tool.
 WARNING! Disconnect from air supply before changing cutting disc or servicing.
 Maintain tool in good condition and replace any damaged or worn parts. Use
genuine parts only. Unauthorised parts may be dangerous and will invalidate the warranty.
WARNING! Check correct air pressure is maintained and not exceeded. We recommend 90psi.
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.
WARNING! Before each use check cutting disc is secure and the disc is not worn or
damaged. If damaged replace immediately.
Ensure replacement discs are not damaged in any way such as cracks, deformations or
splinters etc. Also check the mounting washer to ensure it is not deformed, burred or
notched. Damaged washer must not be used as it may cause irregular pressure on the disc
which may cause the disc to break. DO NOT over tighten a disc and never tamper with a disc
in order to adapt it to a different size holder.
Always use a disc suitable for the material being cut. Ensure the maximum speed
specification of the cutting disc is the same as or higher than that indicated on the machine data plate.
WARNING! Keep disc guard in place, tight and in good working order. The safety guard is a
mandatory fitting where the tool is used in premises covered by the Health & Safety at Work Act.
WARNING! Always wear approved eye or face protection when operating the tool.
Use breathing protection in accordance with COSHH regulations if fumes or dust pose a hazard.
Wear ear defenders and gloves if necessary.
Keep hands and body clear of the workpiece when operating the tool.
 Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
Secure non stable workpiece with a clamp, vice or other adequate holding device.
 Keep children and non essential persons away from the working area.
 Avoid subjecting disc to excessive strain, always ease disc down against workpiece (a harsh
impact may break the disc). Do not over press in order to cut workpiece. Maintain a controlled
adequate progression, which will emit a maximum of sparks.
DO NOT hold the workpiece by hand. Use clamps or a vice to secure the workpiece.
 DO NOT use the tool for a task it is not designed to perform.
WARNING! DO NOT use tool if damaged or faulty. Contact your local service agent.
 DO NOT use tool unless you have been instructed in its use by a qualified person.
 DO NOT position your body in line with the disc whilst cutting, and DO NOT remove
the safety guard whilst in use.
 DO NOT carry the tool by the air hose, or yank the hose from the air supply.
 DO NOT direct air from the air hose at yourself or others.
WARNING! DO NOT cut any materials containing asbestos.
 DO NOT switch the tool on whilst the disc is in contact with the workpiece.
 DO NOT allow workpiece to overheat. Periodically cool by immersing the workpiece in water.
 DO NOT use tool where there are flammable liquids, solids or gases such as paint solvents,
including waste wiping or cleaning rags etc as any sparks generated may be dangerous.
 DO 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.
 DO NOT operate tool if you are tired or under the influence of alcohol, drugs or intoxicating medication.
 When not in use disconnect from air supply and store in a safe, dry, childproof location.
INSTRUCTIONS FOR:
AIR CUT-OFF TOOL (G3)
MODEL No: GSA25
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 AND CAUTIONS. USE THIS 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. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
Original Language Version
GSA25 Issue: 3- 10/11/10

3.1 Air Supply
Recommended hook-up procedure is shown in fig 1.
3.1.1 Ensure tool air valve (or trigger) is in "off" position before connecting to the air supply.
3.1.2 You will require an air pressure of 90psi, and an air flow according to specification.
3.1.3 WARNING! Ensure the air supply is clean and does not exceed 90psi while operating the tool. Too
high an air pressure and unclean air will shorten the product life due to excessive wear, and may be
dangerous causing damage and/or personal injury.
3.1.4 Drain the compressor’s air tank daily. Water in the air line will damage the tool.
3.1.5 Clean the compressor’s air inlet filter weekly.
3.1.6 Line pressure should be increased to compensate for unusually long air hoses (over 8 metres). The
minimum hose diameter should be 1/4” I.D. and fittings must have the same inside dimensions.
3.1.7 Keep hose away from heat, oil and sharp edges. Check hose for wear, and make certain that all
connections are secure.
3.2 Couplings.
Vibration may cause failure if a quick change coupling is connected directly to the tool.
To overcome this, connect a leader hose to the tool. A quick change coupling may then be used to
connect the leader hose to the air line recoil hose. See fig 1 & 2.
3. PREPARING TOOL FOR USE
fig 1
fig 2
2. INTRODUCTION & SPECIFICATIONS
Sealey’s Generation or G3 series of air tools represents some of the best design innovations in air tools of recent
date. The tools feature contoured, soft-grip handles and housings which help reduce the effects of vibration and
chill – major contributors to circulatory and nerve problems such as white finger. The tools also include exhaust
systems designed to reduce noise levels by baffling the noise or directing it away from the operator’s environment.
Most of the tools include integral and adjustable air valves for precise control of output. The air wrenches are,
pound for pound, amongst the most powerful machines we have seen in the market and the materials and
manufacturing techniques used in the production of all the G3 series will ensure long and reliable service.
Disc Size: ......................Ø75 x 2 x 10mm
Free Speed: .........................20000rpm
Air Consumption: ......................... 4cfm
Operating Pressure: .......................90psi
Air Inlet Size: ..........................1/4"BSP
Weight: .................................0.9kg
Cutting Disc No: ..................Single: PTC/3C
. . . . . . . . . . . . . . . . . . . . . . . . . . . Pack of 5: PTC/3C5
Noise Pressure......................... 80dB.A
Risk of Hand Arm Vibration Injury
Air Cut-Off Tool Model No. GSA25 when operated in accordance with these instructions and tested in
accordance with EN 28662-2: 1994 results in the following vibration emission declared in accordance with
BS EN12096: 1996.
Measured vibration emission value: ...........3.9m/s²
Uncertainty: ..............................1.6m/s²
These values are suitable for comparison with emission levels of other tools that have been subject to
the same test.
This tool may cause hand-arm vibration syndrome if its use is inadequately managed.
Recommended Measures to reduce risk of hand-arm vibration syndrome:
This tool should not be used by an individual regularly for more than 402.5 minutes in any 8 hour period.
This duration of use should be reduced if the individual is exposed to hand-arm vibration from other sources.
Original Language Version
GSA25 Issue: 3- 10/11/10

 WARNING! Disconnect tool from air supply before changing accessories, servicing or performing
maintenance. Replace or repair damaged parts. Use genuine parts only. Unauthorised parts may be
dangerous and will invalidate the warranty.
5.1 If the air supply does not include 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.
5.2 Clean the tool after use.
5.3 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
chapter 3.
b) Grit or gum deposits in the tool 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 tool out with gum
solvent oil or an equal mixture of SAE No 10 oil and paraffin. Allow to dry before use.
5.4 For a full service contact your local Sealey service agent.
5.5 When not in use, disconnect from air supply, clean tool and store in a safe, dry,
childproof location.
5. MAINTENANCE
4. OPERATING INSTRUCTIONS
4.1 CHANGING THE CUTTING DISC
WARNING! Disconnect from the air supply before changing disc.
4.1.1 Use spanner to secure the shank and unscrew central hex screw with hex key.
4.1.2 Remove the washer and old disc, place the new cutting disc onto the spindle.
4.1.3 Replace the washer and secure with hex screw, but do not over tighten.
Check that replacement disc is not damaged (cracks, deformations or splinters etc).
Also check the mounting washer to ensure it is not deformed, burred or notched.
A damaged washer must not be used as it may cause irregular pressure on the disc which may cause
it to break. DO NOT tamper with a disc in order to adapt it to a different size holder.
4.2 OPERATING
 WARNING! Ensure you have read, understood and apply safety instructions.
4.2.1 Connect the tool to the air supply.
4.2.2 To start the tool, hold firmly and push the trigger locking lever forward whilst depressing
trigger.
4.2.3 The disc must be running at its maximum speed before attempting to cut the workpiece.
4.2.4 Slowly and smoothly bring the cutting disc toward the workpiece (avoid jerky movements).
4.2.5 Exert adequate pressure on the tool to allow cutting according to the type and size of the material you
are working with. Avoid subjecting disc to excessive strain, always hold tool firmly and ease disc
against workpiece (a harsh impact may break the disc). Maintain a controlled progression.
4.3 SAFETY
4.3.1 The G3 Air Cut-Off Tool has improved features including:
4.3.2 360° rotating metal guard, to protect the user from shards/debris during cutting.
4.3.3 360° rotating exhaust, this allows the user to direct airflow away from the body/hands. This is located at
the base of the tool’s handle
4.3.4 Variable air-valve, allows 4 different degrees of air pressure into the unit.
DO NOT allow tool to free run for an extended period of time as this will shorten its life.
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
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Original Language Version
GSA25 Issue: 3- 10/11/10