INSTRUCTIONS for
F-12-330-K
October, 2000
PREST-O-LITE
®
OXY-ACETYLENE KITS
Welding & Welding & General
Brazing Kit Cutting Kit Maintenance Kit
for for for for for for
Description of B Tank MC Tank B Tank MC Tank B Tank MC Tank
Kit Components 638593 639021 998138 998139 639103 639130
W-200 Welding Torch 999805 999805 999805
Welding Head 06L48 (No 4) 06L48 (No 4) 06L49 (No 6)
06L50 (No. 9) 06L49 (No 6)
06L50 (No. 9)
CW-200 Cutting Attachment 05L20 05L20
Cutting Nozzle (4202 Series) 16K09 (1/2") 16K09 (1/2")
POL Air-Acet. Torch Tip 10X23 (No. 3)
Adaptor (POL Tip to W-200) 639040
R-22-60-540A Oxy. Regulator 18564 18564 18564
R-22-15* Acet. Regulator 05X01 05X02 05X01 05X02 05X01 05X02
Fitted (A-A) Twin-Hose, 12-1/2-ft. 571F72 571F72 571F72
Goggles 17862 17862 17862
Friction Lighter 790F34 790F34 790F34
*R-22-15-520 (05X01) corrects to B acetylene tank. R-22-15-200 (05X02) to MC tank.
If you desire to extend the range of any kit listed above after welding heads (thin gauge to 3/8-in. thick steel) and cutting
nozzles (1/16-in. to 2-in. thick steel) are available for attachment to the W-200 welding torch and CW-200 cutting attachment
(see Tables). You may also use the PREST-O-LITE tips and attachment (such as SWIRLJET tips and halide leak detectors
with the W-200-to-POL Tip Adaptor) supplied with each General Maintenance kit, contact your Prest-O-Lite distributor for
additional information as well as available accessories.
ACCESSORIES: Reverse Flow Check Valves (A-size) - P/N 6271725 (Oxy.), P/N 6271726 (FG).
Attaches to torch hose fittings. Designed to provide certain measure of protection against back flow of one gas into hose of
other Nominal pressure drop with ample flow capacity for cutting up to 2-in. thick steel.
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
Welding, Cutting and 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 welding torch handle, cutting attachment and regulators covered by these instructions are listed by Underwriters
Laboratories only when used in combination with welding tips, cutting nozzles and parts manufactured by ESAB
Welding & Cutting Products, to the specifications on file with Underwriters Laboratories, Inc. and when they are
used in the gas service to which they are designed and listed. The use of other welding tips, cutting nozzles and
parts that cause damage or failure to the equipment will void the manufacturers warranty.
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.
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.
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SP-GA 10/98
OPERATING INSTRUCTIONS
CONNECTING:
1. Open each cylinder valve slightly, for an instant, to
blow out dust and dirt that may have collected in the
valve outlet. Be sure to keep your face away from
the valve outlet to protect your eyes from dust or
dirt.
Never crack a fuel gas valve near sparks, flames,
or any other possible source of ignition.
2. Attach the regulators to the oxygen and acetylene
cylinder valves. Tighten the connection nuts with a
wrench.
3. MAKE SURE each regulator pressure-adjusting
screw is released by turning it counterclockwise until
it turns freely.
4. Open the cylinder valves SLOWLY. Open acetylene
cylinder valve no more than 1-1/2 turns.
Never stand in front of or behind the regulator
when opening the valve. Always stand to one
side.
5. Attach the hose to the regulator outlet and to the
oxygen and acetylene connections on the torch
handle. Tighten all nuts firmly with a wrench. Acetylene hose connections have left-hand threads.
6. Using Welding Head: Remove welding head connection nut from the torch handle. Insert the welding head into handle using slight back and forth twisting motion as you push. Slip connection nut over
the head and hand-tighten to handle.
Using Cutting Attachment: Set the welding head
connection nut aside and insert the cutting attachment to the torch handle in the same manner as the
welding head. Remove nozzle nut and insert cutting
nozzle into the cutting attachment head. Slip nut over
the nozzle and tighten with a wrench.
7. 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 welding and 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 both valves on the torch handle are
closed. Then turn in the regulator pressure-adjusting
screws clockwise until the oxygen deliver-pressure
gauge registers 50 psi, the acetylene 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 hose-to-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 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.
ADJUSTING GAS PRESSURES:
Acetylene: Open the acetylene valve on the torch handle
about one turn. Turn the pressure-adjusting screw on
the acetylene regulator until its delivery-pressure gauge
indicates the desired pressure (see Table 1 or 2). Then
immediately close the torch acetylene valve.
Oxygen, Using Welding Head: Open the torch oxygen
valve WIDE (about 1-1/2 turns). Adjust oxygen pressure
at the regulator to the desired pressure (see Table 1),
and then close the torch oxygen valve.
Oxygen, Using Cutting Attachment: Open the torch
oxygen valve WIDE and leave the preheat oxygen valve
on the cutting attachment closed. Depress the cutting
oxygen valve lever on the cutting attachment. Adjust the
oxygen pressure at the regulator to the desired pressure (see Table 2). Shut off the oxygen flow by releasing
the cutting oxygen valve lever only.
LIGHTING & FLAME ADJUSTMENT:
CAUTION: Use friction lighter for lighting torch. Do NOT
use a match. Use of a match can seriously
burn your hand.
Welding or Heating Head
1. Open fuel gas valve about 1/2 turn and light the gas
at the tip.
2. Slowly close the fuel gas valve until the yellow flame
just starts to throw off smoke.
3. Open oxygen valve slowly until you have a neutral
flame.
4. If harsher or softer flame is desired, readjust the
two valves.
NOTE: When operating with a very soft flame, the weld-
ing head will tend to heat up and transfer some
of the heat back to the torch handle. This may
create some discomfort to the operator.
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