Sealey SGA1.v3 Instructions Manual
INSTRUCTIONS FOR:
GAS WELDING/CUTTING KIT
MODEL NO:
SGA1.V3
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
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND 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. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
Contents
1) Torch Handle
2) Hose Check Valve, OXYGEN (normal R.H. thread)
3) Hose Check Valve, ACETYLENE (reverse L.H. thread)
4) Cutting Attachment
5) Cutting Nozzle 1/32”
6) Cutting Nozzle 3/64”
7) Cutting Nozzle 1/16”
8) Nozzle Cleaning Tools
9) Mixer Nozzle
10) Welding Nozzles No. 2, No. 5, No. 10
11) Spark Lighter
12) Regulator OXYGEN Twin Gauge Single Stage (BLUE code)
13) Flash Arrestor OXYGEN (BLUE code)
14) Regulator ACETYLENE Twin Gauge Single Stage (RED code)
15) Flash Arrestor ACETYLENE (RED code)
16) Hoses, 2, 3/8” x 1.5mtr, complete with fittings
(These are stored in the lid, not shown here)
Always have a fire extinguisher nearby.
Never use oxygen or fuel gas to blow soot or dirt from your clothes.
DO NOT wear ragged clothes, as sparks can ignite the ragged or
loose ends.
Always wear goggles or a helmet with the appropriate shade lens.
DO NOT use shaded safety spectacles or unshaded face shield
visors for cutting or welding. They DO NOT stop the harmful rays
which cause eye damage.
Use gauntlet type gloves made from heat resistant material.
Secure cylinders to a trolley, wall or post to prevent them from falling.
All cylinders should be used and stored in an upright position.
Never drop or strike a cylinder. DO NOT use cylinders that have
been dented.
Cylinder caps should be used when storing or moving cylinders.
Empty cylinders should be kept in specified areas and clearly
marked ‘EMPTY’.
Never use oil or grease on any inlet connections, outlet connections
or cylinder valves.
Examine hoses for cuts, burns or worn areas before each use.
Also inspect fittings for damage. If any damage is found, replace
immediately.
DO NOT repair hose with tape.
Always use reverse flow check valves on torch and flashback
arrestors on the regulator. This greatly reduces the possibility of
mixing gases in the regulator or hoses. Reverse flow check
valves are an important safety precaution.
Working pressure on the acetylene regulator should NEVER be
set above 15psi (1bar).
Keep all threads and unions clean and free from oil, dirt or grease.
Never apply oil or grease to any thread.
These instructions cover the use of the kit on mild steel. If
used on any other materials, extra precautions will have to
be taken.
Make sure that there is a good flow of air to the user and the tip, at all
times. Use a welding fume extractor if conditions are poor or space is
confined.
Never leave the gun alight and unattended.
For safety advice regarding gas bottles (oxygen and acetylene)
refer to the supplier of the bottles.
Make sure bottle keys are in place at all times so that in the event
of an emergency the valves can be turned off quickly.
Keep hoses away from flame at all times. Make sure that hoses
are laid flat where possible and not in a position where they can be
run over by vehicles, which would result in permanent damage.
LEAKING HOSES CAN KILL. Leak test all connections and
valves prior to each use of the equipment.
If hoses are not long enough, join them together with the
manufacturer’s couplings only.
DO NOT join damaged hoses, they must be replaced immediately.
Remember at all times BLUE = OXYGEN ‘O’
RED = ACETYLENE ‘A’
At no time may you interchange parts contained in this kit with those
of other manufacturers.
Only Sealey replacement items should be used.
Acetylene fittings have a left-handed thread and notches on hose
unions to indicate this.
The regulators in this kit have no user-serviceable parts. All
repairs/calibrations must only be undertaken by a BCGA
approved service agent.
2. CONTENTS
fig.1
© Jack Sealey Limited
Original Language Version
SGA1.V3 Issue: 1 - 27/09/13
3. ASSEMBLY
3.2 CONNECTING THE GAS REGULATORS TO THE CYLINDERS.
NOTE: Pressure regulators should be treated as precision instruments and should not be jarred or knocked.
3.2.1 Function of the regulators. Fitted to the outlets of the gas cylinder valves, the pressure regulators reduce the pressure of
the gas from cylinder pressure to the constant lower pressure required for the operation of the equipment. The left hand
gauge indicates the pressure in the cylinder. The right hand gauge indicates the pressure of the gas being delivered to the
torch. Pressure reduction within the regulator occurs in two stages.
3.2.2 Attach oxygen and acetylene regulators to the appropriate cylinders. On each gauge ensure the inlet filter is in place and
is not blocked or contaminated. If an '0' ring is fitted to the inlet, check for damage and replace if necessary with an '0' ring
recommended by the regulator manufacturer. Do not use any form of jointing paste or tape between regulators and
cylinder valves. Before attaching the gauges wipe the fittings with a clean dry cloth. Screw the union at the base of each
regulator to the appropriate cylinder by hand. Ensure that the guage is correctly orientated so as to be seen properly by
the operator in use. To tighten, turn CLOCKWISE for OXYGEN, and ANTI-CLOCKWISE for ACETYLENE. A wrench
should be used to ensure tight connections.
3.2.3 Close the regulators by turning the adjusting screws anti-clockwise to relieve the pressure on the diaphragm before
opening the cylinder valve. If this is not done, pressure from the cylinder can damage the diaphragm and render the
regulator inoperative.
3.2.4 The cylinder valve-to-regulator connection should be checked for leaks using an approved leak detection spray or soap
and water solution.
3.3 CONNECTING THE FLASH ARRESTORS AND HOSES TO THE GAS REGULATORS.
3.3.1 Connect the BLUE, OXYGEN flash arrestor to the outlet on the OXYGEN regulator. (As shown above, on the left).
3.3.2 Then, connect the BLUE hose to the BLUE, OXYGEN flash arrestor. (As shown above, on the left).
3.3.3 Connect the RED, ACETYLENE Flash arrestor to the outlet on the ACETYLENE regulator. (As shown above, on the
right).
3.3.4 Then, connect the RED hose to the RED, ACETYLENE flash arrestor.(As shown above, on the right).
3.3.5 Tighten all nuts securely with a wrench. If any sign of oil or grease is found on the flash arrestors or regulators discontinue
use immediately.
NOTE: New hoses contain a preservative powder which must be blown out before use.
3.3.6 Prior to attaching the torch, blow out both hoses to eliminate any particles or debris. Perform this on one hose at a time
and in a well ventilated area, otherwise you may create conditions for fire or explosion.
a. Turn the oxygen or acetylene regulator adjusting screw clockwise to allow 5psi to pass through hose.
b. Allow oxygen or acetylene to flow for approximately 10 seconds to purge each hose in turn.
3.4 ASSEMBLING THE TORCH FOR WELDING.
WARNING! The teflon seal on the welding attachment inlet must not be damaged or missing, otherwise gases will mix
inside the torch and result in flashbacks or backfires. Always inspect the seal, coupling nut and torch head for damage or
oil. If either is found, discontinue use and contact your supplier.
3.4.1 Screw the chosen welding nozzle into the welding attachment making sure that it is fully tightened down.
3.4.2 Screw the welding attachment with nozzle attached onto the torch handle as shown below. Before fully tightening the
ribbed nut, check that the orientation of the gas valve knobs suits your normal welding practice. Adjust if necessary and
fully tighten the ribbed nut
.
WARNING! Danger of explosion. All parts which come into contact with acetylene or oxygen, including hands and tools,
must be free from oil or grease. If grease or oil is found on a cylinder, discontinue its use immediately and contact your
gas supplier.
3.1 Preparing the cylinder. Make sure that the cylinder to be used is safe and properly secured as noted in
the safety
precautions.
3.1.2 Whilst standing on one side ‘crack’ each cylinder valve. ‘Cracking’ is to quickly open and close the valve allowing gas to
escape and clear the valve of any foreign bodies.
© Jack Sealey Limited
Original Language Version
SGA1.V3 Issue: 1 - 27/09/13
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