Sealey SA2501 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 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.
1. SAFETY INSTRUCTIONS
 WARNING! Ensure that Health & Safety, local authority, and general workshop practice regulations are
adhered to when using this equipment.
 WARNING!Disconnect from air supply before changing accessories or servicing.
 Maintain the cut-off tool in good condition (use an authorised service agent).
Replace or repair damaged parts. Use genuine parts only. Unauthorised parts may be dangerous and will
invalidate the warranty.
Use in a suitable work area. Keep area free from unrelated materials and ensure that there is adequate lighting.
Before each use check cutting disc for condition. If worn or damaged replace immediately.
Ensure that the speed rating (rpm) of the disc is the same as, or greater than, the speed rating of the cut off saw.
Ensure that there are no flammable or combustible materials near the work area.
WARNING! Always wear approved eye (or face) and hand protection when operating the cut-off tool.
 Use face, dust, or respiratory protection in accordance with COSHH regulations.
 Depending on the task, the cut-off tool noise level may exceed 98dB in which case wear safety ear defenders.
Remove ill fitting clothing. Remove ties, watches, rings and other loose jewellery and contain and/or tie back long
hair.
 Wear appropriate protective clothing and keep hands and body clear of working parts.
 Maintain correct balance and footing. Ensure that the floor is not slippery and wear non-slip shoes.
Keep children and unauthorised persons away from the work area.
 Check moving parts alignment on a regular basis.
Ensure that the workpiece is secure before operating the air cut-off tool. Never hold a workpiece by hand.
Check the workpiece to ensure there are no protruding screws, bolts, nuts etc.
 Avoid unintentional starting.
WARNING! Ensure correct air pressure is maintained and not exceeded. Recommended pressure 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.
Prolonged exposure to vibration from this tool poses a health risk. It is the owner’s responsibility to correctly
assess the potential hazard and issue guidelines for safe periods of use and offer suitable protective equipment.
 DO NOT use the cut-off tool for a task it is not designed to perform.
 DO NOT operate cut-off tool if any parts are damaged or missing as this may cause failure and/or personal injury.
WARNING! DO NOT grind any materials containing asbestos.
 DO NOT carry the cut-off tool by the hose, or yank the hose from the air supply.
 DO NOT force, or apply heavy pressure to, the cut-off tool, let the tool do the work.
 DO NOT place air line attachments close to your face and do not point them at other people or animals.
 DO NOT operate cut-off tool when you are tired or under the influence of alcohol, drugs or intoxicating medication.
 DO NOT use the cut-off tool where there are flammable liquids, solids or gases, such as paint solvents
and including waste wiping or cleaning rags etc.
 DO NOT carry the cut-off tool with your finger on the power lever.
 DO NOT direct air from the air line at yourself or others.
 When not in use disconnect from air supply and store in a safe, dry, childproof location.
DANGER OF FIRE/EXPLOSION HAZARD
 WARNING! The cutting process can produce streams of sparks which are a potential source of
ignition especially when cutting metal.
 DO NOT use the cut-off tool where there are flammable liquids, solids or gases.
 DO NOT allow cut-off tool sparks to make contact with the operator’s clothing or any other fabric
such as cleaning rags. Fabrics contaminated with inflammable materials such as petrol, oil, grease,
paint and solvents are a particular fire hazard.
 To reduce the risk of clothing catching fire the operator should wear wool or cotton outer garments
treated with a fire retardant in preference to man-made fibres.
Original Language Version SA2501 Issue: 1 - 14/05/13
INSTRUCTIONS FOR:
AIR CUT-OFF 75mm LONG REACH
MODEL No: SA2501
© Jack Sealey Limited 2013

2. INTRODUCTION & SPECIFICATION
3.1. Air Supply - Recommended hook-up is shown in fig 2.
3.1.1. Ensure that the cut-off tool air valve (or throttle) is in the "off" position before connecting to the air
supply.
3.1.2. You will require an air pressure between 70-90psi, and an air flow according to the specification above.
3.1.3. Ensure the air supply is clean and does not exceed 90psi while operating the cut-off tool.
Too high an air pressure and/or unclean air will cause excessive wear, and may be dangerous,
causing damage and/or personal injury.
3.1.4. Drain the air tank daily. Water in the air line will damage the cut-off tool and invalidate your warranty.
3.1.5. Clean 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 hoses 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 cut-off tool. To
prevent this, connect a leader hose - Sealey model number AH2R or AH2R/38 - to the cut-off tool. A
quick change coupling may then be used to connect the leader hose to the air line recoil hose. See fig.1
and fig.2.
3. PREPARING CUT-OFF TOOL
1.2. LEAD PAINT WARNING!
Paint once contained lead as a traditional ingredient. Contact with the dust from the removal of such
paint is toxic and must therefore be avoided. The following action must be taken before using the cut-off tool.
1. User must determine potential hazard relating to age of paint to be removed (modern paints
do not have lead content).
2. DANGER! Keep all people and pets away from the working area. The following are particularly
vulnerable to the effects of lead paint dust: Pregnant women, babies and children.
3. We recommend personal protection by using the following safety items:
a) Paint Spray Respirator (Our ref SSP1699)
b) PE Coated Hooded Coverall (Our ref SSP265). c) Latex Gloves (Our ref SSP24).
4. Take adequate measures to contain the paint dust, flakes and scrapings.
5. Continue to wear safety equipment as in (3) above and thoroughly clean all areas when work
is complete. Ensure that paint waste is disposed of in sealed bags or containers according to
local regulations.
Disc Size: ................................. Ø75 x 2 x Ø10mm
Free Speed:............................................20000rpm
Operating Pressure:.......................................90psi
Air Consumption:........................................... 7cfm
Air Inlet:..................................................... 1/4”BSP
Weight:.......................................................... 0.8kg
Pressure Noise Level:............................ 97.6dB(A)
Power Noise Level:................................ 86.6dB(A)
Measured vibration emission value (a).......2.1m/s²
Uncertainty value (k).................................0.08m/s²
Extended reach cut-off tool is especially suitable for cutting off rear axle and exhaust tubes/brackets. Additionally
suited to cutting off side frames or door sills. Fitted with metal safety guard and throttle safety device to prevent
accidental operation. Cutting disc not included.
Original Language Version SA2501 Issue: 1 - 14/05/13
fig. 1
fig. 2
© Jack Sealey Limited 2013
Pressed steel spanner:...........................................
Allen key:........................................................5mm
Cutting disc:[not supplied] ............ (single) PTC/3C
Cutting discs:[not supplied]... (pack of 5) PTC/3C5

WARNING! Disconnect the tool from the air supply before changing the disc, 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. Lubricate the grinder daily with a few drops of good grade air tool oil, such as Sealey ATO/500 or
ATO/1000, dripped into the air inlet before use or dispensed automatically through an air system oiler,
such as Sealey model SA106L or SA2001/L.
5.2. Clean the tool after use and change the disc when worn or damaged.
5.3. Loss of power or erratic action may be due to the following:
a) Excessive drain on the air supply. Moisture or restriction in the air line. Incorrect size or type of hose
connectors. To remedy check the air supply and follow instructions in Section 3.
b) Grit or gum deposits in the tool may also reduce performance. Flush the tool with gum solvent
oil or an equal mixture of SAE No 10 oil and kerosene. Allow to dry before use.
If you continue to experience problems, contact your local Sealey service agent.
5.4. When not in use, disconnect from air supply, clean tool and store in a safe, dry, childproof location.
4. OPERATING INSTRUCTIONS
5. MAINTENANCE
WARNING! Ensure that you read, understand and apply the safety instructions before use.
4.1. Assembly
4.1.1. To attach the cutting disc you will need the supplied pressed steel spanner and 4mm allen key, the spanner to
hold the spindle and the allen key to loosen or tighten the socket head cap screw.
4.1.2. Fit the flange with the 11mm x 0.8mm milled slot on to the spindle, the slot registering with the spanner
flats of the spindle. Place the cutting disc on to the spindle. Place the second flange with the Ø14mm x
0.8mm counter bore on to the spindle with the counter bore adjacent to the cutter face. Hold the
spindle by placing the spanner on the spindle spanner flats. Screw the M6 socket head cap screw into the
spindle and tighten the disc between the flanges with the 5mm allen key (fig.3).
4.1.3. Connect a filtered, lubricated and regulated air supply (fig.2) to the cut-off tool and push down the
safety catch and grip the control valve lever to check that the tool is working correctly.
4.2. Operating
DO NOT apply excessive pressure, let the cutting disc do the work for you. Start the tool and bring the
disc to the surface to be cut evenly and slowly. Remove the cutting disc from the work surface before
stopping the tool. Regularly check the condition of the disc and always change if worn, cracked or
otherwise damaged.
DO NOT run the tool away from the workpiece for extended periods as this will shorten the life of the bearings.
WARNING! Use only discs with speed ratings equal to, or higher than, the speed rating of the tool.
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
email
Original Language Version SA2501 Issue: 1 - 14/05/13
Safety catch
Control valve lever
Throttle valve adjustment
Direction of rotation
fig. 3
Slotted ange
Counter bored ange
Cutting disc
Soc. head cap screw
Environmental Protection.
Recycle unwanted materials instead of disposing of them as waste.
All tools, accessories and packaging should be sorted, taken to a recycle
centre and disposed of in a manner which is compatible with the environment.
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].
© Jack Sealey Limited 2013

WARNING! – Risk of Hand Arm Vibration Injury.
This tool may cause Hand Arm Vibration Syndrome if its use is not adequately managed.
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.
This tool has been tested in accordance with: EN ISO 28927-1:2009 & BS EN ISO 15744:2008.
Declaration and verification of Vibration Emission figures are in accordance with EN 12096:1997
Measured vibration emission value (a): 2.1 m/s²
Uncertainty value(k): 0.08 m/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.
Original Language Version SA2501 Issue: 1 - 14/05/13
© Jack Sealey Limited 2013