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INTRODUCTION:
These instructions are intended for experienced operators and those
working under the close supervision of skilled welders. Operation and
maintenance of welding and cutting equipment should conform to the
provisions of American National Standard Z49.1, “Safety in Welding and
Cutting”. American Welding Society Manual C4.2-78 “Operator’s Manual
for Oxy-Fuel Gas Cutting” deserves careful study.
Reference Publications
AWS C-4.2 “Recommended Practices for Safe Oxy-Fuel Gas Cutting Torch
Operation” - American Welding Society, 8669 NW 36th Street, #130,
Miami, FL 33166-6672
ANSI Z49.1 - “Safety in Welding and Cutting” - American National
Standards Institute, 25 West 43rd Street, 4th Floor, New York, NY 10036
Compressed Gas Association (CGA), 14501 George Carter Way, Suite 103,
Chantilly, VA 20151
· Safety Bulletin SB.8 - “Recommended Practices for Safe Oxy-Fuel Gas
Cutting Torch Operation.”
· Pamphlet E-1 - “Standard Connections for Regulator Outlets”
· CGA Standard V-1 - “Compressed Cylinder Valve Inlet and Outlet
Connections”
IMPORTANT SAFEGUARDS: Read all Instructions
Warning: When using welding and cutting torches, basic safety
precautions should always be followed to reduce the risk of fire and
personal injury, including the following:
1. Wear protective attire. Always wear welding goggles to protect eyes
from sparks and light rays. Use gloves, and protective clothing. Watch
for sparks in cuffs. Do not wear oily gloves. Do not carry lighters,
matches or other flammable objects in pockets when welding or
cutting.
2. Handle Cylinders with care. Chain or otherwise secure cylinders to
a permanent fixture. Take care when moving. To transport cylinders
(except when in cylinder carts), remove regulators and replace with
valve cap. Never use any cylinder in other than an upright position.
3. Use “Good Housekeeping” in work area. Keep sparks and flame away
from combustibles. Prepare your work area before welding or cutting.
4. Do not oil or grease equipment. The equipment does not require
lubrication. Oil or grease is easily ignited and burns violently in the
presence of oxygen.
5. “Crack” oxygen cylinder valve before installing regulator. Open valve
slightly and then close. This will clear valve of dust or dirt which
may be carried to regulator and cause damage or accident. Do not
discharge flow of gas at any person or flammable material.
6. Be sure all connections are tight. Don’t force connections. Never test
for leaks with a flame. Use a soapy water solution and check for
bubbles.
7. Purge oxygen and fuel gas passages separately before lighting torch.
This will aid in preventing improper mixing of gases.
8. Use recommended pressure settings. Improper pressures are
wasteful. Extreme pressure build up in regulators is a warning they
need repair.
9. Never use oxygen or fuel gas to blow off work, equipment or clothing.
Pure oxygen supports combustion and a spark can ignite oxygen-
saturated clothing.
10. Purge system after use. When shutting down, close cylinder valves,
then bleed system by emptying both hoses independently. First,
open torch oxygen “OX” needle valve, drain line until pressure is
zero, then close oxygen needle valve. Repeat process with torch fuel
“GAS” needle valve.
11. Do not work with damaged or leaking equipment. Use soapy water
when checking for leaks. Do not use frayed or damaged hose. Never
use torch as a hammer to knock slag from work.
12. Handle equipment with care. Its continued good service and your
safety depend upon it.
13. Keep work area well ventilated. Flammable materials burn violently
in an oxygen atmosphere. Flames and glowing materials (tobacco
smoking) must be avoided when using oxygen. See American
National Standard Z49.1, paragraph 8.1.2.
14. When working with acetylene. Never use at pressures over 15
PSIG (Pounds per Square Inch Gauge).
15. Do Not Force connectors and threads. The differences are intentional
for the various Gases.
16. Never light a torch with matches or a lighter. Always use a striker
17. Always be aware of others around you when using a torch.
18. Be careful not to let welding hoses come into contact with torch flame
sparks from cutting or hot metal.
Set-Up Instructions
Attaching Regulators, Hoses and Torch: (WRENCH NOT INCLUDED)
1. Secure gas cylinders, if used, in upright position.
Note: Check contents of the cylinders before startup to assure an
adequate supply for the intended operating cycle.
2. Open cylinder valve (Fig. 1) slightly to blow out dirt, the close.
DO NOT discharge flow of gas at any person or flammable material.
3. Attach regulators (Fig. 2 and 3) using standard CGA inlet connection
and tighten firmly.
4. Attach hoses to regulators (Fig. 4) and tighten.
Note: The fuel gas (red) hose connections are left hand threads and
the oxygen (green) hose connections are right hand threads.
5. Attach fuel gas hose to torch valve (Fig. 5) marked “Gas” (left hand
thread).
Figure 1.
Opening Oxygen
Cylinder Valve
Figure 2.
Attaching
Oxygen Regulator
Figure 3.
Attaching Fuel
Gas Regulator
Figure 4.
Attaching Hose
to Regulator
Figure 5.
Attaching Hose
to Torch
6. Attach oxygen hose to torch valve marked “OX” (right hand thread).
7. Install correct size tip (Figs. 6 and 7) for metal thickness to be welded
or cut. make sure the tip seat is free of nicks or burrs. Welding
tips should be hand-tightened only. Cutting tips should be wrench
tightened.
8. Close both valves on torch (clockwise) before opening cylinders.
Figure 6.
Installing Welding Tip
Figure 7.
Installing Cutting Tip
