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INSTRUCTIONS for
SABRE "V" LIGHT-DUTY
WELDING AND CUTTING OUTFITS
F15-577
November, 2004
Brazing Outfit w/Tote, MC ............................. P/N 22552
Brazing Outfit w/Tote & Tanks, MC ..............
Brazing Outfits Include:
J28 Welding Torch .........................................
WJ-4 Welding Head .......................................
R-522-15-200A (MC) Acetylene Regulator ... P/N 22555
R-522-75-540 Oxygen Regulator ................. P/N 22554
Tote ................................................................
3/16" X 12' A-A Hose ..................................... P/N 591F72
Goggles ......................................................... P/N 17862
Friction Lighter ............................................. P/N 790F34
Check Valve (Oxy) ........................................ P/N 6271725
Check Valve (FG) ..........................................
If you desire to extend the range of this outfit, other welding heads (thin gauge to 3/4" thick steel) and cutting nozzles (1/8" to 3"
thick steel) are available for attachment to the QJ28 welding torch and QCA1260 cutting attachment (see tables).
J28 Welding Torch
P/N QJ28
Welding Range ..........................................
Length ..................................................................................6-in.
Weight ...............................................................................10 oz.
Torch-Hose Connections ...... Oxy (3/8" - 24RH) "A" Connection
F.G. (3/8" - 124LH) "A" Connection
Welding Nozzles ......................................................... WJ Series
Thin Gauge to 3/4-in.
P/N 22553
P/N QJ28
P/N QWJ-4
P/N 0558003632
P/N 6271726
Table 1 - Specifications
Welding & Cutting Outfit w/Tote, MC ........... P/N 22550
Welding & Cutting Outfit w/Tote & Tanks, MC
......................................................................... P/N 22551
Welding & Cutting Outfits Include in Addition to Brazing
Outfit Items:
CA1260 Cutting Attachment ........................
Q3-101 Series Cutting Nozzle ...................... P/N Q3-101-0
Outfits W/Tanks Include:
Tank "R" 20 cu.ft. - Oxygen .........................
Tank "MC" 10 cu.ft. - Acetylene ................... P/N 22456
CA1260 Cutting Attachment (90 deg. head)
P/N QCA1260
Cutting Range using acetylene ................................1/16 to 3-in.
Length ..................................................................................8-in.
Weight ...............................................................................12 oz.
Cutting Nozzles .................................................... 3 - 101 Series
P/N QCA1260
P/N 22457
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 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 instruc
tions, contact your supplier for further information.
The welding torch handle, cutting attachment and regulators covered by these instructions are listed by Underwriter’s 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 Underwriter’s Laboratories, Inc. and when they are used in the gas service for which they are
designed and listed. The use of other welding tips, nozzles and parts voids the manufacturer’s warranty.
For packing purposes, the pressure-adjusting screw of the regulator may be either turned in or packed separately. If installed in
regulator, back out screw (turn counterclockwise) until it turns freely. If packed separately, install the screw in the regulator cap
and turn it in (clockwise) only one or two turns.
Be sure this information reaches the operator. You
can get extra copies through your supplier.
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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 non-flammable 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.
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:
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.
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:
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 manufacturer’s 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.
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.
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.
This symbol appearing in this manual means Attention! Be Alert! Your safety is involved.
Used to call attention to immediate hazards
which, if not avoided, will result in immediate,
serious personal injury or loss of life.
Used to call attention to potential hazards
which could result in personal injury or loss
of life.
Used to call attention to hazards which could
result in minor personal injury.
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SP-GA 7/97
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OPERATING INSTRUCTIONS
CONNECTING
1. Attach regulators to the oxygen and fuel gas cylinders. Follow all instructions supplied with your
regulators.
2. Attach oxygen and fuel gas hoses (see Note 1 in
Operating Data section on pg. 4 for recommended
hose sizes) to the regulators and to the torch handle
after making sure all metal seating surfaces are
clean. Tighten all connection nuts with a wrench.
3. Using Welding or Heating Head: Remove welding head connection nut from torch handle. Insert
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.
4. Check all valve packing nuts for tightness.
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 delivery-pressure
gauge registers 50 psi, the fuel gas delivery-pressure
gauge registers 10 psi. Using Leak Test Solution suit
able 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 connections, 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.
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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.
ADJUSTING GAS PRESSURES
Fuel Gas: With oxygen valve closed, open the fuel
gas valve on the torch handle about one turn. Turn in
the pressure adjusting screw on the fuel gas regulator
until its delivery-pressure gauge indicates the desired
pressure (refer to operating charts on page 5). Then
immediately close the torch fuel gas valve.
Oxygen, Using Welding or Heating Head: Open the
torch oxygen valve at least 1-1/2 turns. Adjust oxygen
pressure at the regulator to the desired pressure (refer
to charts) 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
(refer to chart). 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 this heat back to the torch handle. This may
create some discomfort to the operator.
Cutting Attachment
1. Open the acetylene valve on the torch handle about
1/2 turn, and light the gas at the nozzle.
2. Slowly close the acetylene throttle valve until the
yellow flame just starts to throw off black smoke.
3. Slowly open preheat oxygen valve on cutting attachment until neutral flames are obtained.
4. Finally, open the cutting oxygen valve by depressing lever and readjust the neutral flames by turning
preheat oxygen valve.
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The flame now has the proper strength for any cutting
job. With this flame, acetylene is being consumed economically and the cutting attachment will be operating
at best resistance to flashback. If greater preheat flame
temperature is desired for faster starts or piercing, open
the cutting oxygen valve and adjust the preheat oxygen
valve until the flame inner cones shorten about 10 percent and become sharply pointed.
SHUTTING OFF
Close the fuel gas valve first, then the oxygen valve
whether you are using a welding head or cutting at
tachment. However, if the cutting attachment is to be
relighted within a half-hour, you may close the preheat
oxygen valve on the attachment instead of the oxygen
valve on the torch handle.
If operations are to be stopped for a half-hour or more,
you should release all pressure from regulators. To do
this, first close both cylinder valves. Then open the torch
valves. Finally, back out the regulator pressure-adjusting
screws until they turn freely.
OPERATING PRECAUTIONS
Flow: There must be proper flow of gases for safe op-
eration 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.
Backfire: Improper operation of the torch or cutting
attachment may cause the flame to go out with a loud
‘pop’. (If you are welding, the flame will often reignite
instantly). Such a backfire may be caused by contact of
tip or 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. After a backfire, you can normally re
light the flames immediately. However, if backfires occur
repeatedly, shut off the torch. Check the ‘O’-ring seals
between the welding head or cutting attachment and
the handle, and the nozzle seats (if cutting). Readjust
operating pressure and relight.
Flashback: Under certain circumstances, the flame
may not ‘pop’ out (backfire) but instead burn back inside
the torch with shrill hissing or squeal. This is called a
‘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
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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 torch handle and
welding head or cutting attachment to your distributor
for repair.
IMPORTANT OPERATING NOTES
1. Pressures given in the charts are measured at the
regulator using 25-ft. long hoses (1/4-in. I.D. up
through size No. 4 welding/heating head or for cut
ting up to 3-in. thick steel; 3/8-in. I.D. for larger heads
or cutting nozzles). If longer hoses re required, only
3/8-in. I.D. hoses should be used and pressure drop
between regulator and torch should be considered.
Use test gauge adaptors to check for proper pressure at torch if using long hose length, or if there are
doubts about the adequacy of gas flows. Do NOT
use hose line check valves when operating No. 5
and larger heads.
2. Correct pressure and flow must be maintained for
proper operation of a welding or heating head. If a
tip is “starved” due to insufficient flow of fuel gas, the
tip may overheat and cause backfire or flashback.
An acetylene cylinder has a limited capacity for
delivering fuel to the tip; therefore, it is extremely
important to manifold 2 or more cylinders when op
erating larger heads to assure adequate supply of
fuel gas to the tip. The rate of withdrawal depends on
type of fuel gas cylinder size, the contents remaining, and the outside temperature. Check with your
fuel gas supplier for recommended withdrawal rate
information.
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3. The tables show average values based on typical
conditions. The type and quality of steel, its surface
condition, and purity of oxygen, etc., will always
have a bearing on the end results.
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Tip Selection & Recommended Working Pressure of Regulators
Complete Welding Nozzle Assembly - Part # QWJ
Oxy-Acetylene Welding Tip Chart
Complete Assy.
Part No. Min. Max. Min. Max.
QWJ-000 up to 1/32" 000 1/2 2 1/2 2
QWJ-00 1/64" - 3/64" 00 1 2 1 2
QWJ-0 1/32" - 5/64" 0 1 3 1 3
QWJ-1 3-64" - 3/32" 1 1 4 1 4
QWJ-2 1/16" - 1/8" 2 2 5 2 5
QWJ-3 1/8" - 3/16" 3 3 7 3 7
QWJ-4 3/16" - 1/4" 4 4 10 4 10
QWJ-5 1/4" - 1/2" 5 5 12 5 15
QWJ-6 1/2" - 3/4" 6 6 14 6 15
Supplied with Sabre "V" Light-Duty Outfit.
*
*
*
Tip SizeMetal Thickness
Oxygen Pressure
P.S.I.G.
Acetylene Pressure
P.S.I.G.
Heating Nozzle Assembly - Part # QMFAJ
OXY-ACETYLENE MULTI-FLAME HEATING NOZZLES
Complete
Assembly
Part No. P.S.I.G. P.S.I.G. Min. Max. Min. Max.
Tip
Size
Acetylene
Pressure
Range
Oxygen
Pressure
Range
Acetylene
Cubic Feet
Per Hour
Oxygen
Cubic Feet
Per Hour
QMFAJ-2 2 4 - 8 4 - 8 3 9 3 10
QMFAJ-4 4 6 - 10 8 - 12 6 20 7 22
QMFAJ-6 6 8 - 11 10 - 14 14 40 15 44
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Cutting Nozzle - Part # Q3-101
Oxy-Acetylene Cutting Nozzle Chart
Complete Assy.
Part No. Min. Max. Min. Max.
Q3-101-000 1/8 000 20 25 3 5
Q3-101-00 1/4 00 20 25 3 5
Q3101-0 1/2 0 30 35 3 5
Q3-101-1 3/4 1 30 35 3 5
Q3-101-2 1-1/2 2 35 45 3 7
Q3-101-3 2-1/2 3 40 50 4 10
Q3-101-4 3 4 40 50 5 10
Supplied with Sabre "V" Light-Duty Welding & Cutting Outfit.
*
*
Inches
Tip SizeMetal Thickness
Oxygen Pressure
P.S.I.G.
Acetylene Pressure
P.S.I.G.
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MAINTENANCE
For all repairs, send the apparatus to ESAB Remanufacturing Center, 411 S. Ebenezer Road, Florence, SC 29501.
Improperly repaired apparatus is hazardous.
Replacement - Welding Torch and Cuttting Attachment Assemblies:
J28 Welding Torch - Part # QJ28
CA1260 Cutting Attachment 90° Head - Part # QCA1260
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SABRE is a registered trademark of ESAB Welding & Cutting Products.
F15-577 11 / 2004 Printed in U.S.A.
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