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Back Harness Assembly: 

 

Clean with oil-free cloth/rags and oil-free brushes. If extremely dirty, 

clean with warm soapy water, rinse with clean fresh water, and air dry. 

Confirm the serviceability of the straps, buckles, and fasteners. 

 

 

SCUBA Backpack 

 

Check for wear and other damage. Inspect serviceability. 

 

Backpack Pad 

 

Inspect the serviceability / check for damage. 

 

Backpack Harness 

 

Ensure proper functioning of adjusters and snaps. Inspect for wear 

and/or other damage. 

 

Tank Strap / Keeper 

Strap 

 

Inspect for cuts, excessive wear, or any other damage. Ensure the 

serviceability of the buckle / tensioner. 

 

Rod Extender, 14" 

 

Ensure proper functioning. Inspect for bends, wear, and/or other 

damage. Check the serviceability of the collet, collet nut, and threading. 

 

Case 

 

Inspect for dents, cracks, holes, or other damage. Make sure all 

securing hasps/hardware functions properly. 

 

Rod Quiver 

 

Ensure functionality of all snaps, buckles, fasteners, and clips. Inspect 

the stitching, as well as for holes and other damage. 

 

Leather Striker Holder 

 

Check for wear and damage. Ensure the item is serviceable. 

 

Leather Shield 

 

Check for burns, holes, damage, and/or wear. Ensure the shield 

functions properly on torch. Replace as required. 

 

Leather Gloves 

 

Check for burns, tears, holes, and any other damage. Examine the 

stitching and inspect the overall serviceability. 

 

Safety Glasses, #5 Lens 

 

Inspect for cracks, scratches, or other damage. Check for overall 

serviceability. 

 

 

Summary of Contents for PRIME-CUT PC/MINI-TAC

Page 1: ...ITS PC TAC PC MINI TAC OPERATING INSTRUCTIONS MANUAL Broco Inc 8690 Red Oak St Rancho Cucamonga CA 91730 4819 Tel 909 483 3222 Fax 909 483 3233 Toll Free 800 845 7259 E mail Broco Worldnet att net www...

Page 2: ...ING TORCH SYSTEM Chapter 2 PREPARATION Section I SETUP PROCEDURES 2 1 PREPARING THE WORK AREA 2 2 PRE ASSEMBLY INSPECTION Section II PC TAC ASSEMBLY PROCEDURES 2 3 OXYGEN SYSTEM 2 4 IGNITION SYSTEM 2...

Page 3: ...g rod igniter Handheld configuration 3 4 3 Ignition using the RapidFire cutting rod igniter Conventional configuration 3 4 4 Ignition using the RapidFire cutting rod igniter Underwater 3 5 OPERATING T...

Page 4: ...3 COLLET PROBLEMS Section III VALVE STEM MALFUNCTIONS 5 4 BENT CONTROL VALVE WORN PARTS Chapter 6 CORRECTIVE MAINTENANCE Section I INTRODUCTION 6 1 GENERAL Section II ADJUSTMENTS ALIGNMENTS AND REPAIR...

Page 5: ...e the user to make the best decisions concerning the deployment of thermal breaching equipment and its subsequent use 1 2 PRIME CUT TACTICAL TORCH KITS Broco is the leading manufacturer of self contai...

Page 6: ...nders c The operator and all bystanders must always wear adequate protective flame and or spark resistant clothing footwear and gloves when using this system d Never operate this equipment without pro...

Page 7: ...lways ensure the correct over pressure safety relief device is installed in the high pressure cylinder valve Never use a safety relief device whose burst pressure is higher than that recommended by th...

Page 8: ...4 and one 3 8 collet b Cutting Rod The kit is designed to use either 1 4 or 3 8 cutting rods 3 16 and 1 2 diameter cutting rods are also available from Broco but are not appropriate for this kit Stan...

Page 9: ...n foot hose Both are fitted with brass quick connect ends The five foot hose enables the operator to freely use the torch system in the backpack configuration The additional hose may be combined if th...

Page 10: ...ong cable is fitted with a set of electrical quick connects allowing it to be shortened to 5 long for use in a back packed mode 3 Torch Power Cable The Torch Power cable has electrical quick connects...

Page 11: ...included with each kit consists of welder s gloves and two pairs of safety glasses with number 5 lenses WELDER S GLOVES SAFETY GLASSES PC LWB LIGHTWEIGHT BACKPACK Never operate this equipment without...

Page 12: ...er cutting rods are also available from Broco but are not appropriate for this kit Standard rod length is 18 inches The 3 8 rod is also available in a 36 length c Oxygen Supply System The Oxygen 02 Su...

Page 13: ...triker plate assembly A dead short spark is all that is necessary for igniting the cutting rod 2 Dual Pole Striker Plate Assembly The Dual Pole Striker Plate Assembly consists of a handle two copper g...

Page 14: ...of safety glasses with number 5 lenses WELDER S GLOVES TINTED SAFETY GLASSES Never operate this equipment without proper face and eye protection Always use a number 5 or 6 shade filter lens h Componen...

Page 15: ...know the material previously contained therein Always thoroughly purge pipelines and containers with an inert gas such as nitrogen or argon prior to cutting f Ensure that falling material molten meta...

Page 16: ...must undergo internal visual inspection annually and pass hydrostatic testing every three years Always ensure the cylinder to be used is marked with a sticker showing a valid inspection certification...

Page 17: ...grease oil or other contaminant on these items d Ensuring that the oxygen is turned off place the oxygen cylinder into the back harness assembly 1 The oxygen cylinder will be in an up right position...

Page 18: ...assembly to the oxygen hose by pushing the plug end oxygen quick connect on the torch into the oxygen quick connect coupler on the hose Turn the plug valve to the open position Regulators may fail whe...

Page 19: ...ontinuously contacts the work area Exercise caution to prevent complete discharge of the battery The battery should never be left in a total discharged state for an extended period of time Damage coul...

Page 20: ...these instances leave the torch power cable and striker plate cable at 15 feet Also join the 10 foot long oxygen hose to the 5 foot hose for a total of 15 feet 2 4 2 Battery Adapter Clamps The battery...

Page 21: ...ce only a direct short is required to ignite the rod a Connect the 15 foot power cable to the torch by firmly seating the black plug in the hole in the back of the torch assembly then twisting 1 4 tur...

Page 22: ...quired to comply with current inspection and testing requirements Cylinders must undergo internal visual inspection annually and pass hydrostatic testing every three years Always ensure the cylinder t...

Page 23: ...trol lever is positioned correctly i e short side contacting valve stem long side parallel to cylinder To change remove the quick release pin turn the lever around replace the pin Regulators may fail...

Page 24: ...gulator spring 4 Install the replacement regulator spring Place cap back into position and thread clockwise until hand tight Snug with a tool Be careful not to over tighten b Ensure that the oxygen is...

Page 25: ...n control lever on the torch assembly to verify proper functioning i e not sticking no obstructions etc j Close the oxygen cylinder valve 2 6 IGNITION SYSTEM PC Mini Tac Always use a 12 volt DC igniti...

Page 26: ...a Lightweight Battery The Lightweight Battery PC BISLW contains a rechargeable 12 volt sealed lead acid gel type battery It can be stored in any position b Dual Pole Striker Plate The battery provides...

Page 27: ...8 FANNY PACK PC Mini Tac The Fanny pack is used for carrying the PC Mini Tac in either handheld or conventional mode It is sized to accommodate the oxygen cylinder with the regulator attached A packet...

Page 28: ...he appropriate size to properly fit the rod being used To replace the collet remove the collet nut and collet from the rod extender Make sure the appropriate size collet washer is in place Insert the...

Page 29: ...erial be exposed to air the strips can be inerted by the application of water carbon dioxide CO2 or foam Material will self inert in air over a time of approximately 30 45 minutes b Packaging RapidFir...

Page 30: ...en the tip of the burning rod is held on or in close proximity to the target material and the appropriate technique is applied a cut or pierce will result Section II OPERATING PROCEDURES Never operate...

Page 31: ...ith either white washer or black washer b Ensure the plug valve is closed Loosen the collet nut one half turn Do not remove the collet nut c Insert the end of the cutting rod that has the recessed int...

Page 32: ...bar in concrete re bar All steel plate mild and high strength to 1 2 thick All steel plate mild and high strength over 1 2 thick to 2 thick All steel plate mild and high strength over 2 thick Aluminum...

Page 33: ...rol lever on the torch assembly d Bring the striker plate 2 into contact with the end of the rod 3 e While holding the rod at a 45 to 90 degree angle to the striker plate slowly and lightly pull the r...

Page 34: ...en flowing when the igniter seal is first broken Too rapid a reaction will result Do not raise the rod from the ignition point until complete ignition has been achieved Ignition is more efficient if a...

Page 35: ...the rod from the ignition point until ignition has been achieved Ignition is more efficient if a molten puddle is allowed to form around the tip of the rod When using a RapidFire cutting rod ignition...

Page 36: ...ten puddle which forms approximately 4 5 seconds Sparkling indicates rod ignition h Keeping the oxygen control lever depressed fully open the plug valve Raise the cutting rod to the work piece target...

Page 37: ...n contact with the side of the rod and the lower plate in contact with the tip of the cutting rod d Hold the rod at a 60 to 90 degree angle to the bottom plate and slowly rotate the rod against the pl...

Page 38: ...gnition has been achieved Ignition is more efficient if a molten puddle is allowed to form around the tip of the rod a Place the cutting rod igniter on the cutting rod and press gently until the rod i...

Page 39: ...cutting rod and press gently until the rod is seated within both igniter alignment bushings and is against the safety clip c Remove the safety clip by pulling on the attached cord d With the operator...

Page 40: ...the cutting rod and press gently until the rod is seated within both igniter alignment bushings and is against the safety clip b Remove the safety clip by pulling on the attached cord c Pace the botto...

Page 41: ...ercing Exercise extreme caution Never touch a used rod the target material or the work surface with a bare hand until it has cooled Always wear welding gloves a With the oxygen control lever slightly...

Page 42: ...he ignition of a cutting rod it is brought to the work surface that is to be cut The rod is dragged or pulled along the surface in the direction of the desired cut The operator should strive for a pro...

Page 43: ...PULL TO CUT MAINTAIN CONTACT BETWEEN ROD AND TARGET DRAG SLAG SPRAY ANGLE DURING CUTTING...

Page 44: ...od in the puddle d With the oxygen control lever fully depressed push the rod in the direction of the desired gouge Ensure the tip of the rod does not hang up and burrow into the target material as bl...

Page 45: ...lose the oxygen cylinder valve c Depress the oxygen control lever to relieve any pressure from the oxygen hose and the pressure gauge hose Always place a protective cap or piece of tape over the open...

Page 46: ...de Disconnect and remove the oxygen hose from the torch assembly at the quick disconnect fitting Disconnect and remove the oxygen hose from the regulator at the quick disconnect fitting e Handheld mod...

Page 47: ...use recharge at least every three months Do not leave the Lightweight Battery on charge for more than 72 hours Damage to the battery may result Battery chargers supplied with Broco Prime Cut Tactical...

Page 48: ...p oil and grease away from the torch oxygen cylinders valves regulators hoses and fittings Oxygen reacts explosively when mixed with oil or grease Never clean any internal part of the oxygen system Ne...

Page 49: ...counter clockwise allowing the transfill hose to pressurize Listen for oxygen leaks Pause for 10 seconds then continue slowly opening the valve all the way until it stops Turn the valve handle 1 4 tur...

Page 50: ...ed to wash components Never use compressed air to purge any part of the oxygen system as oil contamination may result Always use oxygen Always replace any worn or damaged parts with authorized replace...

Page 51: ...the striker plate cable assembly with a clean dry oil free cloth Inspect for damaged parts and replace or repair as necessary i Recharge the battery as needed j Oxygen cylinder maintenance 1 Inspect a...

Page 52: ...Regulator Body Adapters Check for nicks dents or other damage Soft Tip Nipple Check for nicks gouges excessive wear or other damage that may cause leaks Valve Nut Ensure proper functioning Hand tight...

Page 53: ...ge Replace o rings or plug insert as necessary Male Quick Connect Inspect for dents bends or other damage Check for correct seating and locking with the oxygen hose assemblies Cable Power 15 feet w Co...

Page 54: ...sure proper functioning Inspect for bends wear and or other damage Check the serviceability of the collet collet nut and threading Case Inspect for dents cracks holes or other damage Make sure all sec...

Page 55: ...worn c The valve stem washer is dirty or worn d The valve stem is worn Loosen the collet nut 1 2 turn CCW Firmly seat the rod and tighten the collet nut If the leak persists remove the collet nut coll...

Page 56: ...dirty or worn c The torch is dirty a Follow the flash arrestor inspection replacement procedures to remove the flash arrestor Clean or replace as needed b Remove the flash arrestor screen as describe...

Page 57: ...en control valve disassembly reassembly procedures to remove and replace the valve stem o ring Section lII CUTTING ROD MALFUNCTIONS 5 4 COLLET PROBLEMS Table 5 4 Troubleshooting Collet Cutting Rod Mal...

Page 58: ...perform work on high pressure oxygen cylinders and oxygen cylinder valves The composite cylinders included with these kits must be inspected and hydrostatic tested every three years The maximum servi...

Page 59: ...on 1 Inspect the collet nut collet torch assembly and collet washer for damage and or wear Repair or replace as required 2 Inspect the flash arrestor for damage wear and clogging of the ports Clean or...

Page 60: ...alve nut facing up The valve spring is under tension and may cause an uncontrolled separation of the control valve nut from the torch body Use caution to avoid damaging the valve nut gasket 3 Using a...

Page 61: ...alve stem 3 Press the valve stem assembly into the rear of the control valve nut with a rotating motion 4 Attach the valve stem spring to the rear of the valve stem 5 If the valve nut gasket is to be...

Page 62: ...valve d Depress and release the oxygen control lever three or four times Ensure the torch appears to be working correctly e Completely submerge the torch assembly in the water Inspect around the valv...

Page 63: ...1 Ensure the striker plate power cable is not connected to the battery 2 Using a flat tip screwdriver remove the two nylon screws from the striker plate handle 3 Grasp the copper striker plate and sl...

Page 64: ...the groove in the wooden insulator 2 Insert the copper striker plate into the groove in the wooden insulator taking care to overlap the wire terminal lug with the copper striker plate Align these par...

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