Sealey AK506 Pipe Flaring and Cutting Kit User Manual

1. Introduction

This manual provides comprehensive instructions for the safe and effective use of the Sealey AK506 Pipe Flaring and Cutting Kit. This kit is designed for precision cutting and flaring of copper, brass, and thin-walled aluminum pipes. Please read this manual thoroughly before operation and retain it for future reference.

2. Safety Information

Important Safety Instructions

• Always wear appropriate personal protective equipment, including safety glasses and gloves, when operating this kit.
• Ensure the workpiece is securely clamped before cutting or flaring to prevent movement and potential injury.
• Do not use this kit on steel pipes or other materials not specified, as this can damage the tools and cause injury.
• Keep hands and fingers clear of cutting blades and flaring dies during operation.
• Store the kit in its carry-case in a dry, secure location, out of reach of children.
• Inspect all components for damage before each use. Do not use damaged tools.

3. Package Contents

What's Included

The Sealey AK506 Pipe Flaring and Cutting Kit includes the following components, neatly organized in a durable carry-case:

• Screw-type Tube Cutter with integral de-burring tool.
• Two-piece Screw-type 45° Flare Press.
• Seven Double Flare Dies (various sizes).
• Durable Carry-case.

Figure 1: Overview of the Sealey AK506 Pipe Flaring and Cutting Kit, including the tube cutter, flare press, and various dies, all stored within the blue carry case.

4. Setup

Preparing for Use

1. Unpacking: Carefully remove all components from the carry-case.
2. Inspection: Visually inspect each tool for any signs of damage or manufacturing defects. If any damage is found, do not use the tool and contact customer support.
3. Work Area: Ensure your work area is clean, well-lit, and free from obstructions.
4. Material Selection: Confirm that the pipe material is copper, brass, or thin-walled aluminum. Do not use on steel pipe.

5. Operating Instructions

How to Use the Kit

5.1. Cutting the Pipe

1. Measure and Mark: Measure the desired length of the pipe and mark the cutting point clearly.
2. Position the Cutter: Open the tube cutter and place the pipe between the cutting wheel and the two rollers. Align the cutting wheel with the marked line.
3. Tighten and Rotate: Hand-tighten the adjustment knob until the cutting wheel makes light contact with the pipe. Rotate the cutter around the pipe, applying slight pressure with the adjustment knob after each full rotation.
4. Complete Cut: Continue rotating and tightening until the pipe is cleanly cut.
5. Deburr: Use the integral de-burring tool (located on the back of the cutter) to remove any sharp edges or burrs from the inside and outside of the cut pipe end. This ensures a smooth surface for flaring.

Figure 2: The red tube cutter with its adjustment knob and cutting wheel, alongside the flaring press.

5.2. Flaring the Pipe (45° Single Flare)

1. Select Die: Choose the appropriate size hole on the flaring bar that matches the outer diameter of your pipe.
2. Insert Pipe: Insert the deburred pipe end into the selected hole on the flaring bar.
3. Adjust Pipe Height: Position the pipe so that its end extends slightly above the surface of the flaring bar (approximately 1/16 inch or 1.5 mm).
4. Clamp Pipe: Tighten the wing nuts on the flaring bar to securely clamp the pipe in place.
5. Position Flare Press: Place the 45° flare press cone directly over the pipe end.
6. Apply Pressure: Turn the screw handle of the flare press clockwise, slowly and steadily, to push the cone into the pipe. Continue until the pipe forms a smooth, uniform 45° flare against the flaring bar. Do not overtighten.
7. Remove Flared Pipe: Loosen the flare press and the flaring bar wing nuts to remove the flared pipe.

5.3. Creating a Double Flare (for specific applications)

Double flares are typically used for brake lines and other high-pressure applications. This kit includes seven double flare dies for this purpose.

1. Prepare Pipe: Cut and deburr the pipe as described in Section 5.1.
2. Select Die and Adapter: Choose the correct size double flare die (adapter) that matches your pipe diameter.
3. Insert Pipe and Adapter: Insert the pipe into the appropriate hole on the flaring bar. Place the selected double flare die (adapter) into the pipe opening, ensuring it sits flush.
4. Clamp Pipe: Tighten the wing nuts on the flaring bar to secure the pipe and adapter. The pipe end should be flush with the top of the flaring bar.
5. First Stage (Forming the Bubble): Place the flare press cone over the adapter. Turn the screw handle clockwise to push the adapter into the pipe, forming a bubble or mushroom shape. Stop when the adapter bottoms out.
6. Remove Adapter: Loosen the flare press and remove the double flare die (adapter).
7. Second Stage (Finishing the Flare): Reposition the flare press cone directly over the formed bubble. Turn the screw handle clockwise again, slowly and steadily, to flatten the bubble against the flaring bar, creating the double flare. Do not overtighten.
8. Remove Flared Pipe: Loosen the flare press and the flaring bar wing nuts to remove the double-flared pipe.

Figure 3: The flaring bar with different pipe size openings and the set of double flare dies.

6. Maintenance

Care and Storage

• Cleaning: After each use, wipe down all tools with a clean, dry cloth to remove any debris or metal shavings.
• Lubrication: Periodically apply a light coat of machine oil to the screw threads of the tube cutter and flare press to ensure smooth operation and prevent corrosion.
• Inspection: Regularly check the cutting wheel of the tube cutter for sharpness and damage. Replace if dull or chipped. Inspect flaring dies for wear.
• Storage: Always return all components to their designated slots in the carry-case after use. Store the kit in a cool, dry place away from direct sunlight and moisture.

7. Troubleshooting

Common Issues and Solutions

• Issue: Uneven Cut:
  • Solution: Ensure the pipe is securely clamped in the cutter and that even pressure is applied while rotating. Check the cutting wheel for damage or dullness.
• Issue: Cracked or Split Flare:
  • Solution: This often occurs due to overtightening, incorrect pipe extension from the flaring bar, or using the kit on unsuitable materials (e.g., steel). Ensure the pipe extends only slightly (1/16 inch) and apply gradual pressure. Deburr the pipe thoroughly before flaring.
• Issue: Difficulty Turning Flare Press Screw:
  • Solution: The screw threads may be dry or dirty. Clean and lubricate the threads with machine oil. Ensure the pipe is properly aligned and not binding.

8. Specifications

Product Specifications

9. Warranty and Support

Warranty Information

For warranty details, technical support, or to purchase replacement parts, please refer to the official Sealey website or contact your authorized Sealey dealer. Keep your proof of purchase for warranty claims.

Website: www.sealey.co.uk

Contact: Refer to the contact section on the official Sealey website for regional support information.