W-500 WELDING TORCH and
CW-500 CUTTING ATTACHMENT
Instruction Manual
F-12-837-F 05 / 2004 Vaild serial no. 150-xxx-xxxx
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with
the principles of operation and safe practices for arc welding and cutting equipment, we
urge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging," Form 52-529. 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. Be sure to read the Safety Precautions before
installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual
and accompanying labels and/or inserts when installed, operated, maintained and repaired in
accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing,
worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for
service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of
the manufacturer. The user of this equipment shall have the sole responsibility for any malfunc
tion which results from improper use, faulty maintenance, damage, improper repair or alteration
by anyone other than the manufacturer or a service facility designated by the manufacturer.
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TABLE OF CONTENTS
SECTION TITLE .........................................................................................................PAGE
SECTION 1 SAFETY ..............................................................................................................
English ................................................................................................................
Spanish ............................................................................................................... 7
French ................................................................................................................. 9
SECTION 2 DESCRIPTION .................................................................................................. 11
Sales Catalog Page
SECTION 3 OPERATION .....................................................................................................
SECTION 4 MAINTENANCE ................................................................................................
SECTION 5 REPLACEMENT PARTS ................................................................................... 21
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TABLE OF CONTENTS
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SECTION 1 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:
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.
als 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.
tion 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.
1. Always wear safety glasses with side shields in
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 materi-
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 ventila-
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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.
SECTION 1 SAFETY PRECAUTIONS
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