INSTRUCTIONS for
F-14-253-B
January, 2001
C-84-42 OXY-FUEL CUTTING TORCH
Cutting Range using acetylene ......................................... up to 5
other fuel gases ....................... up to 12
Cutting Nozzles .......................................................... 4200 series
Torch-Hose Connection .................... Oxy.¾CGA-022 (9/16¾18)
F. G. ¾CGA-023 (9/16¾18LH)
Torch Overall Length ........................................................... 21-in.
Weight ................................................................................ 38 oz.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation
and safe practices for oxy-fuel gas equipment, we urge you to read our booklet Precautions and Safe Practices for
Gas Welding, Cutting & Heating, Form 2035. Do NOT permit untrained persons to install, operate, or maintain this
equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these
instructions. If you do not fully understand these instructions, contact your supplier for further information.
The cutting torches covered by these instructions are listed by Underwriters Laboratories only when using parts
manufactured by ESAB Welding & Cutting Products to the exact specifications on file with Underwriters Laboratories, Inc., and when they are used in the gas service for which they are designed and listed. The use of other parts
that cause damage or failure to the equipment will void the manufacturers warranty.
OPERATING INSTRUCTIONS
CONNECTING
1. Attach regulators to the oxygen and fuel gas cylinders. Follow all instructions supplied with the regulators.
2. Attach oxygen and fuel gas hoses to the regulators and to the torch, after making sure all metal
seating surfaces are clean. Tighten all connection
nuts with a wrench.
3. Attach nozzle to torch head, and tighten connection nut with a wrench.
4. Check throttle valve packing nuts for tightness.
Flashbacks can cause serious burns.
Be sure gas flow is sufficient for head or nozzle size.
Adjust regulators for proper psig pressures.
Adjust throttle valves properly.
Keep torch in good repair.
DO NOT throttle back gases to use large head or nozzle
on thin material.
TESTING FOR LEAKS
Every cutting outfit should be thoroughly tested for
leaks after it is first hooked up, and at regular intervals
thereafter. After all connections have been made, make
sure all valves on the torch handle are closed. Then turn
in the regulator pressure-adjusting screws until the
oxygen delivery-pressure gauge registers 60 psi and
the fuel gas delivery-pressure gauge registers 10 psi.
Using Leak Test Solution suitable for oxygen service,
such as P/N 998771 (8 oz. container), check for leaks
at the cylinder valves, the cylinder-to-regulator connections, the regulator-to-hose connections, and the hoseto-torch connections. If bubbling at any point indicates
leakage, tighten the connection. If this does not stop the
leakage, close the appropriate cylinder valve, open the
corresponding torch valve to remove all pressure from
the line, and finally release the regulator pressure
adjusting screw by turning it counterclockwise. Then
break the leaky connection, wipe metal seating surfaces with a clean dry cloth, and examine them for nicks
and scratches. Remake the connection(s) and retest.
Do not try to light the torch until you are satisfied that all
connections are gas-tight.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
SAFETY PRECAUTIONS
These Safety Precautions are for your protection. They summarize precautionary information from the references listed
in Additional Safety Information section. Before performing any
installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other
manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS - Some
welding, cutting and gouging processes are
noisy and require ear protection. Hot metal can
cause skin burns and heat rays may injure
eyes. Training in the proper use of the processes and equipment is essential to prevent
accidents. Also:
1. Always wear safety glasses with side shields in any work area,
even if welding helmets, face shields, or goggles are also required.
2. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt,
cuffless trousers, high-topped shoes, and a welding helmet or
cap for hair protection, to protect against hot sparks and hot
metal. A flameproof apron may also be desirable as protection
against radiated heat and sparks.
3. Hot sparks or metal can lodge in rolled up sleeves, trousers
cuffs, or pockets. Sleeves and collars should be kept buttoned,
and open pockets eliminated from the front of clothing.
4. Protect other personnel from hot sparks with a suitable nonflammable partition or curtains.
5. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can travel considerable distances. Bystanders should also wear goggles over safety
glasses.
FIRES AND EXPLOSIONS - Heat from a flame
can act as an ignition source. Hot slag or sparks
can also cause fires or explosions. Therefore:
1. Remove all combustible materials well away from the work
area or completely cover the materials with a protective nonflammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices in
floors or wall openings and cause a hidden smoldering fire on
the floor below. Make certain that such openings are protected
from hot sparks and metal.
3. Do not weld, cut, or perform any other hot work on materials,
containers, or piping until it has been completely cleaned so
that no substances on the material can produce flammable or
toxic vapors. Do not do hot work on closed containers. They
may explode.
4. Have fire extinguishing equipment handy for instant use, such
as a garden hose, a pail of water or sand, or portable fire
extinguisher. Be sure you are trained in its use.
5. After completing operations, inspect the work area to be sure
that there are no hot sparks or hot metal which could cause a
later fire. Use fire watchers when necessary.
6. For additional information, refer to NFPA Standard 51B, Fire
Prevention in Use of Cutting and Welding Processes, which
is available from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
FUMES AND GASES - Fumes and gases, particularly in confined spaces, can cause discomfort or injury. Do not breathe fumes or
gases from welding or cutting, Therefore:
1. Always provide adequate ventilation in the work area by natural or mechanical ventilation means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel, copper,
zinc, lead, beryllium, or cadmium unless positive mechanical
ventilation is provided. Do not breathe fumes and gases from
these materials.
2. If you develop momentary eye, nose, or throat irritation while
operating, this is an indication that ventilation is not adequate.
Stop work at once and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical
discomfort persists.
3. Refer to ANSI/ASC Standard Z49.1 listed below for specific
ventilation recommendations.
4. WARNING: This product, when used for welding or
1. Always have qualified personnel perform the installation,
troubleshooting, and maintenance work. Do not operate or
repair any equipment unless you are qualified to do so.
2. Keep all oxy-fuel equipment free of grease or oil. Grease, oil,
and other similar combustible materials, when ignited, can burn
violently in the presence of oxygen.
3. Do not abuse any equipment or accessories. Keep equipment
away from heat and wet conditions, oil or grease, corrosive
atmospheres and inclement weather.
4. Keep all safety devices in position and in good repair.
5. Use equipment for its intended purpose. Do not modify it in
any manner.
1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors to mount the regulator on the cylinder. Maintain hoses and fittings in good condition. Follow manufacturers operating instructions for mounting the regulator to the gas cylinder.
2. Always secure cylinders in an upright position by chain or strap
to suitable hand trucks, benches, walls, post, or racks. Never
secure cylinders to work tables or fixtures where they may
become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have the valve
protection cap in place on top of the cylinder if no regulators is
installed. Secure and move cylinders by using suitable hand
trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, or flame of a welding, cutting, or gouging operation. Never strike an arc on a
cylinder.
5. For additional information, refer to CGA Standard P-1, Precautions for Safe Handling of Compressed Gases in Cylinders:, which is available from the Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.
The following publications, which are available from the American
Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are
recommended to you:
1. ANSI/AWS Z49.1 - Safety in Welding and Cutting.
2. AWS F4.1 - Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That
Have Held Hazardous Substances/
3. AWS SP - Safe Practices - Reprint, Welding Handbook.
2
cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety Code §25249.5 et seq.)
EQUIPMENT MAINTENANCE - Faulty or improperly maintained equipment, such as torches, hoses
and regulators, can result in poor work, but even
more important, it can cause injury or death
through fires. Therefore:
GAS CYLINDER HANDLING - Gas cylinders, if mishandled, can rupture or explode violently. Sudden
rupture of a cylinder, valve or relief device can injure or kill you. Therefore:
ADDITIONAL SAFETY INFORMATION - For more
information on safe practices for oxy-fuel welding
and cutting equipment, ask your distributor for a
copy of Precautions and Safe Practices for Gas
Welding, Cutting, and Heating, Form 2035. Gas
apparatus safety guidelines are also available on
video cassettes from your distributor.
MEANING OF SYMBOLS - As used throughout
this manual: Means Attention! Be Alert! Your
safety is involved.
Means immediate hazards which, if not avoided,
will result in immediate, serious personal in-
jury or loss of life.
Means potential hazards which could result in
personal injury or loss of life.
Means hazards which could result in minor
personal injury.
SP-GA 10/98
ADJUSTING GAS PRESSURE
Fuel Gas: Open the fuel gas valve about one turn. Turn
in the pressure-adjusting screw on the fuel gas regulator until its delivery-pressure gauge registers the desired pressure (see cutting chart on page 4). Then
immediately close the fuel gas valve.
Oxygen: Open the cutting oxygen valve by depressing
its valve lever fully. Turn in the pressure-adjusting
screw on the oxygen regulator until its delivery-pressure gauge registers the desired pressure (see chart on
page 4). Then release the cutting oxygen lever.
NOTE: When gaugeless regulators are used, do not
open torch valves. Merely turn in the pressureadjusting screws to the desired pressures as
indicated on the scales of the regulator caps.
LIGHTING AND FLAME ADJUSTMENT
When using acetylene:
1. Open the fuel gas valve a fraction of a turn and light
the gas with a friction lighter. DO NOT USE MATCH.
Use of a match can seriously burn your hand.
2. Continue opening the fuel gas valve until only a
trace of carbon soot is visible. Then open the
preheat oxygen valve until a neutral flame is obtained.
3. Depress cutting oxygen valve lever and readjust
preheat flame to neutral by gradually opening the
preheat oxygen valve.
SHUTTING OFF
Release the cutting oxygen valve lever. Then close the
fuel gas valve, and finally the preheat oxygen valve.
If operations are to be stopped for a half-hour or more,
all pressure should be released from the torch, hoses,
and regulators by doing the following:
1. Close each cylinder or station valve.
2. Open torch valves.
3. After relieving the gases, back out the pressureadjusting screw of each regulator and close the
torch valves.
OPERATING PRECAUTIONS
Flow: There must be proper flow of gases for safe
operation and full performance. This requires the following three conditions: (1) the regulators that determine the inlet pressure to the hoses must be set to the
correct pressure: (2) the hoses and their connectors
must have adequate capacity for the job (hoses that
are too long, too small or have connectors with small
passageways can cause problems); and (3) the throttle
valves on the torch must be adjusted with the procedure shown in these instructions.
Note: Items (1) and (2) can be checked by measuring
the gas pressures at the torch. Gauge adaptors
are available for this purpose.
When using FG-2 or other fuel gases except acetylene:
1. Crack the fuel gas valve on the torch and light the
gas at the nozzle with a friction lighter. DO NOT
USE A MATCH. Use of a match could seriously
burn your hand.
2. Open fuel gas valve until flame just starts to leave
the end of the nozzle and then open the preheat
oxygen valve until the flames are at their shortest
length.
3. Depress the cutting oxygen valve lever and then
readjust the preheat flames to the shortest length
by opening the preheat oxygen valve gradually.
The above procedures usually provide adequate preheat for the nozzle in use. If desiring to change the
preheat flames, always hold the cutting oxygen valve
open while readjusting the preheat oxygen and fuel gas
valves.
Backfire: Improper operation of the torch may cause
the flames to go out with a loud pop. Such a back fire
may be caused by contact of nozzle with the work, by
spatter from the work, by the use of incorrect gas pressure, or by leakage at the cutting nozzle seats due to
dirt or nicks on seats or to a loose nozzle nut.
Flashback: Under certain circumstances, the flame
may not pop out (backfire) abut instead burn back
inside the torch with a shrill hissing or squeal. This is
called flashback. A flashback should never occur if
(1) the equipment is in good condition; (2) preheat ports
on cutting nozzles or welding tips are cleaned frequently; (3) operating pressures are correct; and (4)
throttle valves are adjusted properly. Should a flashback occur, IMMEDIATELY shut off the torch. Allow it
to cool off for at least a minute. Then check your nozzle
or tip, gas pressures, readjust regulators if necessary,
and relight the torch. If flashback recurs, send the cutting torch with nozzle to ESAB Remanufacturing Center, Ebenezer Road, Florence, SC 29501 or to your
distributor for repair.
3
OPERATING DATA
1. The tables show average values based on typical conditions. The type and quality of steel, its surface condition,
the purity of oxygen, etc. will always have a bearing on the end results.
2. If cutting up to 4-in. thick steel, 1/4-in. oxygen and fuel gas hoses up to 25-ft. long are suitable. For heavier cuts
or if longer hoses are required, 3/8-in. hoses are recommended.
4202 Series Acetylene General Purpose Nozzles
Nozzle Steel Gas Pressure, Gas Consumption, Cleaning Drill
Thickness, psig ft
3
/hr Size
Size Part No. in. Oxygen Acetylene Oxygen Acetylene Preheat Cutting
1/4 16K08 1/8-1/4 30 10 35-45 8-10 73 68
1/2 16K09 1/2-3/4 40 12 60-85 12-14 73 60
1-1/2 16K10 1-1-1/2 50 14 100-170 15-18 69 55
4 16K11 2-5 55 15 200-360 20-25 68 50
4217 Series Fuel Gas Two-Piece Cutting Nozzles
Nozzle Sleeve Steel Pressure, psig Gas Consumption, ft3/hr Cleaning
Nozzle (Internal) (External) Thickness, Fuel Gas Fuel Gas Drill Size
Size P/N P/N in. Oxygen FG-2 Propane Nat. Gas Oxygen FG-2 Propane Nat. Gas Cuttingl
1/4 19485 1/4 30 4 6 7 70 8 12 30 68
1/2 19486 19518 1/2 35 4 7 8 120 9 14 32 60
1 19487 1 40 4 8 9 180 10 15 35 53
2 19488 2 45 5 9 10 250 11 16 40 50
4 19489 4 40 4 8 10 370 12 18 45 43
6 19490 19519 6 50 5 12 13 520 14 20 50 39
8 19491 8 50 6 15 16 610 16 22 55 35
12 19492 12 75 8 18 20 860 20 30 85 31
l Use soft-bristled brush (750F99) to clean preheat slots of internal nozzles.
4216 Series Fuel Gas One-Piece Cutting Nozzles
Nozzle Steel Gas Pressure, Gas Consumption Cleaning Drill
Thickness, psig ft
3
/hr Size
Size Part No. In. Oxygen Fuel Gas Oxygen Fuel Gas Preheat Cutting
3 998589 1/8-1/4 25 4 50-60 5-6 67 68
4 998590 3/8-5/8 35 4 75-100 6-7 67 60
6 998591 3/4-1-1/2 45 5 175-190 7-8 64 53
8 998592 2-4 55 7 315-325 10-12 62 46
10 998593 6-8 65 10 650-690 12-15 59 39
12 998594 10-12 75 10 825-875 15-20 56 31
4
MAINTENANCE INSTRUCTIONS
For all repairs other than those covered below, send
the torch to an ESAB Remanufacturing Center,
Ebenezer Road, Florence, SC 29501, or to your
ESAB welding equipment distributor. Improperly
repaired apparatus is hazardous.
Preheat Valves: Leakage around either throttle valve
can almost always be corrected by tightening the pack-
ing nut slightly.
If either preheat valve will not shut off completely, loosen
the packing nut and remove the throttle assembly from
the body. Wipe the seat on the valve stem, and the
seating surface in the body, with a clean cloth. Then
reinstall the valve assembly and retighten the packing
nut. If the valve still leaks, install a new throttle valve
assembly. After you do so, tighten the packing nut until
you find it extremely difficult to turn the valve wheel.
Set the unit aside for a few hours to set the packing.
Then loosen the packing nut until the valve stem turns
readily.
If leakage though either preheat valve is still evident
after a new throttle valve assembly has been installed,
send the torch to your distributor for reseating.
Cutting Valve: If leakage is detected between the cut-
ting valve, or if the valve fails to shut off completely
when cutting oxygen valve lever is released, unscrew
the lock screw (see illustration) with a spanner wrench.
When the thread is fully disengaged, lift out the valve
assembly. Then tilt the torch and let the valve spring
drop out in your hand.
Now pull the lock screw off the valve stem and remove
seat and retainer from the stem. Examine the stem
carefully. If either the seating surface or the cylindrical
section that runs in the valve screw is marred, replace
the stem with a new part. Always replace the seat with
a new part. Replace the small O-ring in the lock screw
with a new part if there has been leakage around the
valve stem. Inspect the large O-ring and replace it if it
is not in excellent condition. Place new seat on stem,
slide on the retainer, and insert stem in lock screw (be
sure the lock screw has both O-rings in position). Finally, slide valve spring into body, insert valve assembly, and tighten lock screw.
Cleaning Cutting Nozzles: If the cutting nozzle does
not produce straight, uniform flames, or if any of the
nozzle orifices become clogged, clean them by hand
with the correct size twist drills shown in the table on
page 4, or with OXWELD tip cleaners. (The relationship between OXWELD tip cleaners and drill sizes is
shown on the tip cleaner case.)
To clean the preheat slots on internal nozzles, remove
the external sleeve and use a soft bristled brush
(750F99).
For longer life, nozzles should be cleaned periodically
in a solution of OXWELD Nozzle Cleaning Compound
(P/N 761F00) made up and used as directed on the jar
in which it is packed.
5
PARTS INFORMATION
All parts which can be replaced without breaking soldered or brazed joints are illustrated and listed below. When
ordering parts, please give both part number and description (including size where appropriate). Parts may be ordered from your ESAB welding equipment distributor or from ESAB Welding & Cutting Products, Customer Service
Department, Florence, SC.
BALL - 9232
SPRING - 28Z01
NUT - 802
LOCKSCREW - 57K02
NOTES:
1. Position slot of roll pin to face upwards.
2. Apply light coating of silicone grease P/N 17672 (1 oz.
tube) on O-rings before assembly.
3. Threads on throttle valves should be lubricated only with
KRYTOX 240 Compound, P/N 73585064 (2 oz. jar).
4. Apply one drop of Loctite Compound No. 271, P/N
73185271, on the second thread of the pipe thread part
of connection, and then assemble and tighten connec-
tion to body up to approx. 350 in-lbs.
LEVER - 19527
STEM - 18559
O-RING - 85W11
(See Note 2)
SPRING - 23K08
ROLL PIN - 5/32 DIA. X 3/4
(See Note 1)
OXY. CONNECTION - 3389
(See Note 4)
FG CONNECTION - 3390
(See Note 4)
THROTTLE VALVE ASSY. - 18255
(See Note 3)
O-RING - 14K07
(See Note 2)
RETAINER 57K03
SEAT - 32Z01
CUTTING OXY. VALVE ASSY
(Enlarged View)
C-84-42 Cutting Torch, 75° Head ........................... P/N 18261
C-84-42 Cutting Torch, 90° Head ........................... P/N 18260
6
7
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Order Entry Product Availability Pricing Delivery
Order Changes Saleable Goods Returns Shipping Information
Telephone: (800)362-7080 / Fax: (800) 634-7548
Telephone: (800)783-5360 / Fax: (800) 783-5362
Telephone: (800) 235-4012/ Fax: (888) 586-4670
B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693
Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations
D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548
E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 / Fax: (843) 664-4454 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
Eastern Distribution Center
Central Distribution Center
Western Distribution Center
Hours: 7:30 AM to 4:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com
F-14-253-B 01/2001 Printed in U.S.A.
Hours: 7:30 AM to 5:00 PM EST
®
1/19/01
1/24/01
70406260
Cynthia Gurley
MCD
44441
C-84-42 Oxy-Fuel Cutting Torch
F-14-253
B
8
3
x
x
x
x
Deliver the 3 copies to Cynthia Gurley. The Revision Letter remains B but the Date is now January, 2001. This was not a
revision change, but it was enough of a change to reprint and restock shelves. Thank you.
MCD-146
ESAB Welding &
Cutting Products
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