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OM-251341E
Processes
Oxy-Fuel Welding and Cutting
Description
Accessory
Oxy-Fuel Outfits
2022-01
Medium Duty (770502) And
Heavy Duty (770974)
www.HobartWelders.com
OWNER’S MANUAL
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From Hobart to You
Thank you and congratulations on choosing Hobart. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
This Owner’s Manual is designed to help you get the most out of your
Hobart products. Please take time to read the Safety Precautions.
They will help you protect yourself against potential hazards on the
worksite. We’ve made installation and operation quick and easy. With
Hobart, you can count on years of reliable service with proper
maintenance. And if for some reason the unit needs repair, there’s a
Troubleshooting section that will help you figure out what the problem
is. The parts list will then help you to decide the exact part you may
need to fix the problem. Warranty and service information for your
particular model are also provided.
Hobart Welders manufactures a full line of
welders and welding-related equipment. For
information on other quality Hobart products,
contact your local Hobart distributor to receive
the latest full line catalog or individual
specification sheets. To locate your nearest
distributor or service agency call
1-800-332-3281, or visit us at
www.HobartWelders.com on the web.
For Technical Help call 1-800-332-3281.
Register your product at www.HobartWelders.com
Hobart is registered to the ISO
9001 Quality System
Standard.
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TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2 Welding, Cutting, Brazing, And Heating Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3 California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4 Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-2 Soudage, coupage, brasage, risques de surchauffe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-3 Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-4 Principales normes de sécurité. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 3 – ADDITIONAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-1 Hazardous Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-2 Associated Hazards Of Recompressing Pure Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-3 Inspecting The Equipment Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 4 – SPECIFICATIONS . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-1 Equipment Included With Medium-Duty Outfit 770502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-2 Equipment Included With Heavy-Duty Outfit 770974 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-3 Equipment Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4 Cutting Tip And Gas Pressure Guide — Acetylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-5 Cutting Tip And Gas Pressure Guide — Propane And Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-6 Heating Nozzle And Gas Pressure Guide — Acetylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-7 Welding (Brazing) Nozzle And Gas Pressure Guide — Acetylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-8 Combination Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-9 Regulators — Single Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 5 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 13
5-1 Installing Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-2 Installing Regulators On Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-3 Connecting Hoses To Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-4 Replacing Torch Check Valves With Flashback Arrestors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-5 Connecting Hoses To Torch Check Valves Or Flashback Arrestors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-6 Installing Cutting Attachment On Torch Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-7 Installing Cutting Tip On Cutting Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-8 Installing Welding/Brazing Tip On Torch Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-9 Testing The System For Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 6 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-1 Purging Oxygen From The System And Adjusting Oxygen Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-2 Purging Fuel From The System And Adjusting Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-3 Lighting And Using The Cutting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-4 Lighting And Using The Brazing Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING
Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! – Indicates a hazardous situation which, if not
avoided, will result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained
in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in
the text.
NOTICE – Indicates statements not related to personal injury.
Indicates special instructions.
F
1-2. Welding, Cutting, Brazing, And Heating Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety
information found in the Principal Safety Standards. Read
and follow all Safety Standards.
Only qualified persons should install, operate, maintain,
and repair this equipment. A qualified person is defined as
one who, by possession of a recognized degree, certificate,
or professional standing, or who by extensive knowledge,
training and experience, has successfully demonstrated the
ability to solve or resolve problems relating to the subject
matter, the work, or the project and has received safety
training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children,
away.
Do not use this equipment unless you are trained in its
proper use or are under competent supervision. Follow the
procedures described in this manual every time you use the
equipment. Failure to follow these instructions can cause
fire, explosion, asphyxiation, property damage, or personal
injury. This equipment must be used in accordance with all
Federal, State, and local regulations as well as DOT (Department of Transportation) and CGA (Compressed Gas Association) regulations. Contact your gas supplier for more
information on the proper use of compressed gases.
In this document, the phrase "welding and cutting" also refers to
F
other oxy-fuel operations like brazing and heating.
READ INSTRUCTIONS.
l Read and follow all labels and the Owner’s Manual
carefully before installing, operating, or servicing
unit. Read the safety information at the beginning
of the manual and in each section.
l Use only genuine replacement parts from the manufacturer.
l Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and local codes.
HOT PARTS can burn.
l Do not touch hot parts bare handed.
l Allow cooling period before working on equipment.
l To handle hot parts, use proper tools and/or wear
prevent burns.
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heavy, insulated welding gloves and clothing to
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult
symbols and related instructions below for necessary actions to
avoid these hazards.
FUMES AND GASES can be
hazardous.
Welding and cutting produces fumes and gases.
Breathing these fumes and gases can be hazardous to your health.
l Keep your head out of the fumes. Do not breathe the fumes.
l Ventilate the work area and/or use local forced ventilation at the
flame to remove welding and cutting fumes and gases. Some
gases (natural gas and acetylene) are lighter than air and will collect in high areas. Other gases (propane and butane) are heavier
than air and will collect in low areas. Heavier-than-air gases are
more difficult to diffuse and are more likely to accumulate. The recommended way to determine adequate ventilation is to sample for
the composition and quantity of fumes and gases to which personnel are exposed.
l If ventilation is poor, wear an approved air-supplied respirator.
l Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
l Work in a confined space only if it is well ventilated, or while wear-
ing an air-supplied respirator. Always have a trained watchperson
nearby. Welding and cutting fumes and gases can displace air and
lower the oxygen level, causing injury or death. Be sure the
breathing air is safe. Test atmospheres in confined spaces for explosive and toxic gases before using oxy-fuel equipment.
l Do not weld or cut in locations near degreasing, cleaning, or
spraying operations. The heat from welding or cutting flame can
react with vapors to form highly toxic and irritating gases.
l Do not weld or cut on coated metals, such as galvanized, lead, or
cadmium-plated steel unless the coating is removed from the affected area, the area is well ventilated, and while wearing an airsupplied respirator. The coatings and any metals containing these
elements can give off toxic fumes if welded or cut.
l Do not weld or cut on sealed air conditioning or refrigeration sys-
tems unless all refrigerants have been removed from the system.
LIGHT RAYS can burn eyes and skin.
Light rays from the welding and cutting process
produce intense visible and invisible (ultraviolet
and infrared) rays that can burn eyes and skin.
Sparks fly off from the weld.
l Wear approved face protection fitted with a proper shade of filter
lenses to protect your face and eyes from light rays and sparks
when welding, cutting, or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
l Wear welding goggles, or wear welding helmet /welding faceshield
over approved goggles/safety glasses with side shields.
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l Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the welding or cutting.
l Wear body protection made from leather or flame-resistant cloth-
ing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
WELDING AND CUTTING can cause
fire or explosion.
Welding and cutting on closed containers, such as
tanks, drums, or pipes, can cause them to blow up.
Sparks can fly off from the welding or cutting operations. The torch flame, flying sparks, hot workpiece, and hot equipment can cause fires and burns. Check and be sure the area is safe
before doing any welding or cutting.
l Do not use this welding and cutting equipment with gases and
pressures other than those for which it is intended. Oxygen is not
flammable; however, the presence of pure oxygen will drastically
increase the speed and force with which burning takes place. Oxygen must never be allowed to contact grease, oil, or other petroleum-based substances; therefore, be sure there is no oil or grease
on the regulator, cylinder, valves, or equipment. Do not use petroleum-based pipe sealants. Do not use sealants on metal-to-metal
seals, such as hose and CGA cylinder connections; use PTFEbased sealant (PTFE tape) on pipe threads. Do not use or store
near excessive heat (above 125° F/51.5° C) or open flame. Do not
refer to oxygen as air and do not use oxygen as a substitute for
compressed air. Do not use oxygen to clean clothes or work area,
for ventilation, or to operate pneumatic tools. Open oxygen cylinder valves slowly. Be sure regulator adjusting handle is in the full
out (off) position before opening oxygen cylinder valve.
l Inspect all equipment before use. Do not use damaged, defective,
or improperly adjusted welding and cutting equipment. Make sure
levers and valves work properly, threads on equipment are clean
(no grease or oil) and not deformed, gauges are intact and easy to
read, regulator is clean and free of oil or dirt, and fittings are properly sized for the cylinder. Make sure hoses are clean (no grease
or oil) and ferrules are properly installed so the fitting does not slip
inside the hose. Be sure all connections are tight.
l It is recommended that a reverse-flow check valve or a flashback
arrestor be installed between the torch handle and the regulator.
Check valves do not prevent the propagation of a flame upstream
(flashback) but are designed to prevent the unintentional backflow
of gases into the cutting attachment, torch, hoses, or regulator
which could cause an explosion or fire. A flashback arrestor can
be installed on the torch handle instead of a check valve. Miller
flashback arrestors have a reverse flow check valve and prevent
the propagation of a flame upstream. If a flashback arrestor is installed, a check valve is not necessary. Using a flashback arrestor
and a check valve can reduce gas flow and affect torch operation.
To help prevent the reverse flow of gases, be sure the cylinders
contain enough gas to complete the work.
l Understand the properties and applications of a gas, and how to
safely use a gas, before placing it in service.
l Perform work only in an area with a fireproof floor (concrete). Do
not heat concrete because it can expand and explode violently.
l Perform work on a fireproof surface. Use heat resistant shields to
protect nearby walls and flooring.
l Do not use if grease or oil is present on equipment or if equipment
is damaged. Have equipment cleaned/repaired by a qualified
person.
l Do not open a cylinder valve quickly or the regulator can be dam-
aged and cause a fire.
l Do not open acetylene cylinder valve more than 1–1/2 turns. (For
all gases except acetylene, open cylinder valve fully to backseal
the cylinder valve.) Keep cylinder wrench on the cylinder for quick
shut-off.
l Do not slightly open or "crack" fuel cylinder valve to blow debris
from the valve outlet. Remove the debris using nitrogen, air, or a
clean, oil-free rag.
l Always purge gas from the system before lighting torch. Purge
gas in a well-ventilated area and away from flame or sparks.
l Keep torch flame or sparks away from cylinder, regulator, and gas
hose.
l Use only the gases recommended by the manufacturer of the oxy-
fuel equipment being used.
l Never light a torch with matches or a lighter. Always use a striker.
l Do not use acetylene above 15 psi (103 kPa) flowing. It is accept-
able to use acetylene regulators that indicate a static pressure up
to 22 psi (151 kPa).
l Do not withdraw acetylene from a cylinder at a rate exceeding 1/7
of the cylinder capacity per hour (50 SCFH for a 350 ft
Maximum withdrawal rate for a half-full 100 lb propane cylinder at
70°F is 75 SCFH (2124 lph).
l When required flows (SCFH) exceed the recommended with-
drawal rate from one cylinder, then additional cylinders must be
manifolded to provide safe and efficient operation.
l When using liquid oxygen, tips may require greater gas volume
than a single cylinder is capable of producing. External evaporators or manifolding multiple cylinders may be necessary to supply
sufficient gas flows.
l Do not use long gas hoses or hoses with multiple connections be-
cause they restrict gas flow and reduce gas pressure. These conditions can cause backfires and flashbacks, and reduce
equipment efficiency.
l Do not use torch if you smell gas. Check oxy-fuel system for leaks
with an approved leak detection solution or leak detector. Never
test for gas leaks with a flame.
l Remove all flammables within 35 ft (10.7 m) of the welding or cut-
ting operation. If this is not possible, tightly cover them with approved covers.
l Do not weld or cut where flying sparks can strike flammable
material.
l Protect yourself and others from flying sparks and hot metal.
l Be alert that welding and cutting sparks and hot materials from
welding and cutting can easily go through small cracks and openings to adjacent areas.
l Watch for fire, and keep a fire extinguisher nearby.
l Be aware that welding or cutting on a ceiling, floor, bulkhead, or
partition can cause fire on the hidden side.
l Do not cut or weld on tire rims or wheels. Tires can explode if
heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
l Do not weld or cut on containers that have held combustibles, or
on closed containers such as tanks, drums, or pipes unless they
are properly prepared according to AWS F4.1 (see Safety
Standards).
l Do not weld or cut where the atmosphere can contain flammable
dust, gas, or liquid vapors (such as gasoline).
l Wear body protection made from leather or flame-resistant cloth-
ing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
l Do not use fuel gases to clean clothes or work area.
l Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding or cutting.
l After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
l Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
3
cylinder).
CYLINDERS can explode if
damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
ing or cutting process, be sure to treat them carefully.
l Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, and sparks.
Since gas cylinders are normally part of the weld-
OM-251341 Page 2
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l Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping. Do not lay
acetylene cylinders on their sides or acetone will flow out of the
cylinder and damage the equipment.
l Keep cylinders away from any arc welding, cutting, or other electri-
cal circuits.
l Never drape a welding or cutting torch over a gas cylinder.
l Never weld or cut on a pressurized cylinder - explosion will result.
l Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition. Do not use compressed
gas cylinder unless an approved gas regulator is attached to the
gas valve.
l Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the
valve.
l Keep protective cap in place over valve except when cylinder is in
use or connected for use.
l Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
l Store compressed gas and oxygen cylinders in separate
locations.
l Store empty cylinders with valves closed and caps in place.
1-3. California Proposition 65 Warnings
WARNING – This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive harm.
l Do not modify or repair cylinders or valves. Store leaking acety-
lene cylinders outdoors in a safe area. Identify leaking cylinders
and return them to the supplier.
l Dispose of used disposable cylinders according to the manufac-
turer’s recommendations. Do not throw cylinders in fire.
l Follow instructions provided by the gas supplier and on com-
pressed gas cylinders, associated equipment, and in Compressed
Gas Association (CGA) publication P-1 listed in Safety Standards.
BUILDUP OF GAS can injure or kill.
l Shut off compressed gas supply when not in use.
l Always ventilate confined spaces or use approved
air-supplied respirator.
FLYING METAL or DIRTcan injure
eyes.
l Welding, cutting, chipping, wire brushing, and
grinding cause sparks and flying metal.
l Wear welding goggles, or wear welding helmet
/welding faceshield over approved goggles/safety glasses with
side shields.
For more information, go to www.P65Warnings.ca.gov.
1-4. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org.
Recommended Practices for Safe Oxyfuel Gas Cutting Torch Operation, American Welding Society Standard C4.2/C4.2M, and Recommended Practices for Safe Oxyfuel Gas Heating Torch Operation,
American Welding Society Standard C4.3/C4.3M. Website: http://
www.aws.org
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1 from Compressed Gas Association. Website: www.cganet.com.
Acetylene CGA Pamphlet G-1 from Compressed Gas Association.
Website:www.cganet.com.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.
csagroup.org.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards In-
stitute. Website: www.ansi.org.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:
www.osha.gov.
OSHA Important Note Regarding the ACGIH TLV, Policy Statement
on the Uses of TLVs and BEIs. Website: www.osha.gov.
Applications Manual for the Revised NIOSH Lifting Equation from the
National Institute for Occupational Safety and Health (NIOSH). Website: www.cdc.gov/NIOSH.
Oxy–Fuel 2022–01
OM-251341 Page 3
Page 7
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT
UTILISATION
Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! – Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les
dangers possibles sont montrés par les symboles joints
ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas peut
donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
AVIS – Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
F
2-2. Soudage, coupage, brasage, risques de surchauffe
Les symboles représentés ci-dessous sont utilisés dans ce
manuel pour attirer l’attention et identifier les dangers possibles. En présence de ce symbole, prendre garde et suivre
les instructions afférentes pour éviter tout risque. Les
consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les Normes de sécurité
principales. Lire et suivre toutes les Normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une personne qualifiée est définie comme celle qui, par la possession d’un diplôme reconnu, d’un certificat ou d’un statut
professionnel, ou qui, par une connaissance, une formation
et une expérience approfondies, a démontré avec succès sa
capacité à résoudre les problèmes liés à la tâche, le travail
ou le projet et a reçu une formation en sécurité afin de reconnaître et d’éviter les risques inhérents.
Au cours de l’utilisation, tenir toute personne à l’écart et
plus particulièrement les enfants.
Ne pas utiliser cet équipement à moins d’avoir été formé à
son usage adéquat ou d’être sous la supervision d’une personne qualifiée. Respecter les procédures décrites dans le
présent livret pour toute utilisation de l’équipement. Le nonrespect de ces procédures peut causer des risques d’incendie, d’explosion, d’asphyxie, de dommages matériels ou de
blessures. Cet équipement doit être utilisé dans le respect
de toutes les réglementations fédérales, provinciales et municipales, ainsi que celles du Ministère des Transports et de
l’association CGA (Compressed Gas Association). Pour
plus d’information sur l’utilisation adéquate de gaz
comprimé, communiquez avec votre fournisseur de gaz.
Dans ce document, l’expression « soudage et coupage » fait
F
également référence à d’autres opérations oxy-combustibles
comme le brasage et le chauffage.
LIRE LES INSTRUCTIONS.
l Lire et appliquer les instructions sur les étiquettes
et le Mode d’emploi avant l’installation, l’utilisation
ou l’entretien de l’appareil. Lire les informations de
section.
l N’utiliser que des pièces de remplacement provenant du fabricant.
l Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
sécurité au début du manuel et dans chaque
Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Reportez-vous aux symboles et aux directives cidessous afin de connaître les mesures à prendre pour éviter tout
danger.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
l Ne pas toucher des parties chaudes à mains nues.
l Prévoir une période de refroidissement avant de
travailler à l’équipement.
l Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage et le coupage produisent des vapeurs
et des gaz. Respirer ces fumées et ces gaz peut
être dangereux pour votre santé.
l Garder la tête à l’extérieur des vapeurs et des fumées et ne pas
les respirer.
l Ventiler le lieu de travail ou avoir recours à une ventilation aspi-
rante installée près de la flamme pour évacuer les vapeurs et les
gaz de soudage et de coupe. Certains gaz (gaz naturel et de l’acétylène) sont plus légers que l’air et s’accumulent en hauteur. D’autres gaz (propane et butane) sont plus lourds que l’air et
s’accumulent à un niveau inférieur. Les gaz plus lourds que l’air
sont plus difficiles à diffuser et sont plus susceptibles de s’accumuler. Pour déterminer la bonne ventilation, il est recommandé de
procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquels est exposé le personnel.
l Si la ventilation est médiocre, porter un respirateur à adduction
d’air approuvé.
l Lire et comprendre les fiches de données de sécurité et les ins-
tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.
l Ne travailler dans un espace confiné que s’il est bien ventilé, ou
en portant un appareil respiratoire à adduction d’air pur. Ne soudez pas ou ne coupez pas près de zones où sont effectuées des
opérations de dégraissage, nettoyage ou pulvérisation. Les vapeurs de soudage et de coupage peuvent déplacer de l’air et
abaisser le niveau d’oxygène, cause de lésion ou de mort. Assurez-vous que l’air ambiant est sain pour la santé. Tester les atmosphères dans les espaces clos pour les gaz explosifs et toxiques
avant d’utiliser l’équipement d’oxycoupage.
l Ne soudez pas ou ne coupez pas près de zones où sont effec-
tuées des opérations de dégraissage, nettoyage ou pulvérisation.
La chaleur et les rayons d’arc peuvent réagir avec les vapeurs et
former des gaz hautement toxiques et irritants.
OM-251341 Page 4
Page 8
l Ne soudez pas ou ne coupez pas des métaux enrobés tels que
des métaux galvanisés, contenant du plomb ou de l’acier plaqué
au cadmium, à moins que l’enrobage ne soit ôté de la surface de
soudage, que l’endroit où vous travaillez ne soit bien ventilé, ou, si
nécessaire, que vous ne portiez un respirateur alimenté en air.
Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.
l Ne pas souder ou couper sur des systèmes de climatisation ou de
réfrigération fermés à moins que tous les réfrigérants aient été retirés du système.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Les rayons d’arc issus des procédés de soudage
et de coupage produisent des rayons visibles et in-
visibles intenses (ultraviolets et infrarouges) qui peuvent entraîner
des brûlures aux yeux et à la peau. Des étincelles sont projetées pendant le soudage.
l Portez un casque de soudage approuvé muni de verres filtrants
appropriés pour protéger visage et yeux contre les rayons et les
étincelles d’arc pendant le soudage, le coupage ou la surveillance
(voir ANSI Z49.1 et Z87.1 énuméré dans les Normes de Sécurité).
l Porter des lunettes de soudage, ou porter un écran facial/casque
de soudage sur des lunettes/lunettes de sécurité approuvées avec
écrans de protection latéraux.
l Avoir recours à des écrans protecteurs ou à des rideaux pour pro-
téger les autres contre les rayonnements les éblouissements et
les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.
l Porter une protection corporelle en cuir ou des vêtements ignifu-
ges (FRC). La protection du corps comporte des vêtements sans
huile, comme des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.
Le SOUDAGE ET le COUPAGE
présentent un risque d’incendie ou
d’explosion.
Les récipients fermés, comme les réservoirs, les
fûts ou les tuyaux, peuvent éclater lorsqu’ils sont
soumis à des travaux de soudure ou de coupage. De tels travaux
peuvent produire des étincelles. La flamme de la torche, les étincelles, les pièces de travail chauffées, et les équipements chauds peuvent causer des brûlures et des incendies. S’assurer que le lieu ne
présente pas de danger avant d’effectuer le soudage ou la coupe.
l Ne pas utiliser cet équipement de soudage et de coupage avec
des gaz et des pressions autres que celles pour lesquelles il est
prévu. L'oxygène est pas inflammable, cependant, la présence
d'oxygène pur augmentera considérablement la vitesse et la force
avec laquelle la combustion a lieu. L'oxygène ne doit jamais être
autorisé à entrer en contact avec de la graisse, de l'huile ou d’autres substances à base de pétrole. Par conséquent, assurez-vous
qu'il n'y a pas d'huile ou de graisse sur le régulateur, le cylindre,
les valves ou l'équipement. Ne pas utiliser de produits d'étanchéité
de tuyaux à base de pétrole. Ne pas utiliser de produits d'étanchéité sur les joints métal-métal, tels que les raccords de tuyaux
et de cylindres CGA; utiliser un produit d'étanchéité à base de
PTFE (ruban PTFE) sur les filetages des tuyaux. Ne pas utiliser
ou entreposer à proximité d'une chaleur excessive (supérieure à
1255 F/ 51,55 C) ou d'une flamme ouverte. Ne pas appeler l'oxygène de l'air et ne pas utiliser l'oxygène comme un substitut à l'air
comprimé. Ne pas utiliser l'oxygène pour nettoyer les vêtements
ou la zone de travail, pour la ventilation, ou pour faire fonctionner
des outils pneumatiques. Ouvrir les valves de bouteille d'oxygène
lentement. Inspecter tous les équipements avant utilisation.
l Inspecter tous les équipements avant utilisation. Ne pas utiliser
des équipements de soudage et de coupage endommagés, défectueux ou mal réglés. S'assurer que les leviers et les robinets fonctionnent bien, que les filets d'équipements sont propres (aucune
graisse ou huile) et inaltérés, que les cadrans sont intacts et
OM-251341 Page 5
faciles à lire, que les régulateurs sont propres (sans saleté ou
huile), et que les raccords sont de bonne taille pour la bouteille.
S'assurer que les flexibles sont propres (sans graisse ou huile) et
que les bagues d'extrémité sont adéquatement installées pour
que les connecteurs ne glissent pas à l'intérieur des boyaux. S'assurer que tous les raccords sont serrés.
l L'installation d'un clapet anti-retour ou d'un intercepteur de rentrée
de flamme entre la poignée de la torche et le régulateur est recommandée. Les clapets anti-retour ne font pas obstacle à la propagation d'une flamme en amont (retour de flamme), mais sont conçus
pour empêcher le reflux non intentionnel des gaz dans l'équipement de coupe, torche, tuyaux ou un régulateur, qui pourrait provoquer une explosion ou d'incendie. Un intercepteur de rentrée de
flamme peut être installé sur la poignée de la torche au lieu d'un
clapet anti-retour. Les pare-flashback Miller ont un clapet anti-retour d'écoulement inverse et empêchent la propagation d'une
flamme en amont. Si un intercepteur de rentrée de flamme est installé, un clapet anti-retour n'est pas requis. L'utilisation d'un intercepteur de rentrée de flamme et d'un clapet antiretour peut
réduire le débit de gaz et affecter le fonctionnement de la torche.
Pour aider à prévenir le débit de gaz en sens inverse, s'assurer
que les bouteilles d'alimentation contiennent suffisamment de gaz
pour faire le travail au complet.
l Bien s'assurer de comprendre les propriétés et les applications
d'un gaz, et comment l'utiliser en toute sécurité avant de le mettre
en service.
l Ne travailler que dans des lieux où le plancher est à l'épreuve du
feu (béton). Ne pas chauffer le béton, car c'est un matériau expansible qui peut exploser violemment.
l Effectuer des travaux sur une surface anti-feu. Utiliser des bou-
cliers résistants à la chaleur pour protéger les murs et les planchers à proximité.
l Ne pas l'utiliser si de la graisse ou de l'huile est présente sur
l'équipement ou si l'équipement est endommagé. Faire nettoyer/
réparer l'équipement par une personne qualifiée.
l Ne pas ouvrir rapidement le robinet de bouteille sinon le régulateur
pourrait être endommagé et causer un incendie.
l Ne pas ouvrir la vanne de la bouteille d'acétylène plus de 1–1/2 de
tour. (Pour tous les gaz, à l'exception de l'acétylène, ouvrir la valve
de la bouteille entièrement). Garder la clé sur le cylindre pour une
fermeture rapide.
l Ne pas entrouvrir la valve de la bouteille de carburant pour souffler
les débris de la sortie de la valve. Retirer les débris à l'aide
d'azote, d'air ou d'un chiffon propre et exempt d'huile.
l Toujours purger le gaz du système avant d'allumer la torche. Pur-
ger le gaz dans un endroit bien aéré et à l'abri des flammes ou
des étincelles.
l Garder la flamme ou les étincelles de la torche à l'écart de la bou-
teille, du régulateur et du tuyau de gaz.
l Utiliser uniquement les gaz recommandés par le fabricant de
l'équipement d'oxycoupage utilisé.
l Ne jamais allumer une torche avec des allumettes ou un briquet.
Toujours utiliser un dispositif à friction.
l Ne pas utiliser de l'acétylène au-dessus de 15 psi (103 kPa). Il est
acceptable d'utiliser des régulateurs d'acétylène qui indiquent une
pression statique allant jusqu'à 22 psi (151 kPa).
l Ne pas retirer l'acétylène d'un cylindre à un taux supérieur à 1/7
de la capacité du cylindre par heure (50 SCFH pour un cylindre de
350 pi3). Le taux de prélèvement maximal pour un cylindre de propane à moitié plein de 100 lb à 70 °F est de 75 SCFH (2 124 l/h).
l Lorsque les débits requis (SCFH) dépassent le taux de prélève-
ment recommandé d'un cylindre, des cylindres supplémentaires
devront être raccordés pour assurer un fonctionnement sécuritaire
et efficace.
l Lors de l'utilisation d'oxygène liquide, les becs pourront nécessiter
un volume de gaz plus important qu'un seul cylindre n'est pas en
mesure de produire. Des évaporateurs externes ou des cylindres
multiples pourront être nécessaires pour fournir des débits de gaz
suffisants.
Page 9
l Ne pas utiliser de longs tuyaux de gaz ou des tuyaux à connexions
multiples, car ceux-ci limitent le débit de gaz et réduisent la pression de gaz. Ces conditions peuvent provoquer des retours de
flamme et des retours de courant de soudage, et réduire l’efficacité de l'équipement.
l S'il y a odeur de gaz, n'utilisez pas la torche. Contrôler le système
de gaz oxygéné pour détecter toute fuite à l'aide d'une solution de
détection de fuites ou d'un détecteur de fuites approuvé. Ne jamais tester les fuites de gaz avec une flamme.
l Écarter tout produit inflammable situé à moins de 35 pieds (10,7
m) de l'arc de soudage ou de coupage. Si cela n'est pas possible,
bien les recouvrir en utilisant des bâches approuvées.
l Ne soudez pas ou ne coupez pas dans un endroit où des étincel-
les pourraient atteindre des matières inflammables.
l Se protéger et d'autres personnes de la projection d'étincelles et
de métal chaud.
l Assurez-vous qu'aucune étincelle ni matière chaude provenant du
soudage ou du coupage ne peut se glisser dans de petites fissures ou tomber dans d'autres pièces contiguës.
l Afin d'éliminer tout risque de feu, soyez vigilant et gardez toujours
un extincteur à portée de main.
l Si vous soudez ou coupez sur un plafond, un plancher ou une cloi-
son, soyez conscient que cela peut entraîner un incendie de l'autre côté.
l Ne pas couper ni souder sur les jantes de pneus ou les roues. Les
pneus peuvent exploser s'ils sont chauffés. Les jantes et les roues
réparées peuvent avoir une défectuosité. Vous reporter à la liste
OSHA 29 CFR 1910.177 dans les normes de sécurité.
l N'effectuez pas de soudage ou de coupage sur des conteneurs
ayant stocké des combustibles ou sur des conteneurs fermés tels
que des réservoirs, tambours, ou conduites, à moins qu'ils n'aient
été préparés correctement conformément à AWS F4.1 (voir les
Normes de Sécurité).
l Ne soudez pas ou ne coupez pas si l'air ambiant est chargé de
particules, gaz, ou vapeurs inflammables (vapeur d'essence, par
exemple).
l Porter une protection corporelle en cuir ou des vêtements ignifu-
ges (FRC). La protection du corps comporte des vêtements sans
huile, comme des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.
l Ne pas utiliser de gaz carburant pour nettoyer les vêtements ou la
zone de travail.
l Avant le soudage ou coupage, retirez tout combustible de vos po-
ches, par exemple un briquet au butane ou des allumettes.
l Une fois le travail achevé, assurez-vous qu'il ne reste aucune
trace d'étincelles incandescentes ni de flammes.
l Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA
51B pour travaux de soudage et prévoir un détecteur d'incendie et
un extincteur à proximité.
l Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser. Ne pas poser les bouteilles d’acétylène sur le
côté, sinon de l’acétone coulera de la bouteille et endommagera
l’équipement.
l Les bouteilles ne doivent pas être près de la zone de soudage à
l’arc ou de coupage ni de tout autre circuit électrique.
l Ne placez jamais une torche de soudage ou de coupage sur une
bouteille de gaz.
l Ne soudez ou coupez jamais sur une bouteille pressurisée – une
explosion en résulterait.
l Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ;
les maintenir ainsi que les éléments associés en bon état. Ne pas
utiliser de bouteille de gaz comprimé, à moins qu’un régulateur de
gaz approuvé soit fixé à la valve de gaz.
l Ne pas tenir la tête en face de la sortie en ouvrant la soupape de
la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
l Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
l Utiliser le bon équipement, les bonnes procédures et suffisam-
ment de personnes pour soulever, déplacer et transporter les
bouteilles.
l Stocker les bouteilles de gaz et d’oxygène comprimé dans des en-
droits séparés.
l Stocker les bouteilles vides avec les valves fermées et les bou-
chons en place.
l Ne pas modifier ou réparer les bouteilles ou les valves. Stocker
les bouteilles d’acétylène qui fuient à l’extérieur dans une zone sûre. Identifier les bouteilles qui fuient et les retourner au
fournisseur.
l Éliminer les bouteilles à usage unique usagées selon les recom-
mandations du fabricant. Ne pas jeter les bouteilles dans le feu.
l Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de
sécurité.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
l Fermer l’alimentation du gaz comprimé en cas de
non utilisation.
l Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé sont sous haute
pression. Une bouteille endommagée peut explo-
ment partie du procédé de soudage, les manipuler avec précaution.
l Protégez les bouteilles de gaz comprimé contre la chaleur exces-
sive, les chocs, les dommages physiques, le laitier, les flammes
nues et les étincelles.
ser. Du fait que les bouteilles de gaz font normale-
des étincelles et des particules métalliques volantes.
l Porter des lunettes de soudage, ou porter un écran facial/casque
de soudage sur des lunettes/lunettes de sécurité approuvées avec
écrans de protection latéraux.
2-3. Proposition californienne 65 Avertissements
AVERTISSEMENT – Ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
l Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
OM-251341 Page 6
Page 10
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org.
Recommended Practices for Safe Oxyfuel Gas Cutting Torch Operation, American Welding Society Standard C4.2/C4.2M, and Recommended Practices for Safe Oxyfuel Gas Heating Torch Operation,
American Welding Society Standard C4.3/C4.3M. Website: http://
www.aws.org
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1 from Compressed Gas Association. Website: www.cganet.com.
Acetylene CGA Pamphlet G-1 from Compressed Gas Association.
Website:www.cganet.com.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.
csagroup.org.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards In-
stitute. Website: www.ansi.org.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:
www.osha.gov.
OSHA Important Note Regarding the ACGIH TLV, Policy Statement
on the Uses of TLVs and BEIs. Website: www.osha.gov.
Applications Manual for the Revised NIOSH Lifting Equation from the
National Institute for Occupational Safety and Health (NIOSH). Website: www.cdc.gov/NIOSH.
Oxy–Fuel 2022–01
OM-251341 Page 7
Page 11
SECTION 3 – ADDITIONAL SAFETY PRECAUTIONS
3-1. Hazardous Events
The following events are very hazardous and can occur in any oxy-fuel system. It is important to understand these hazards and know how to
prevent them.
Backfire: The return of the flame into the torch, usually accompanied by a popping sound. The flame may be extinguished or it may re-appear at the tip end.
Sustained Backfire: The return of the flame into the torch that continues to burn inside the torch with a hissing or squealing sound.
Flashback: The return of a flame into and through the torch or into the hose. In some instances it can reach the regulator and even enter the
cylinder. This is generally caused by the mixing of the oxygen and fuel gas in the system. This is a very dangerous situation that can cause
an explosion anywhere in the system. This is why purging is so important (see Sections 6-1 and 6-2).
3-2. Associated Hazards Of Recompressing Pure Oxygen
Open oxygen cylinder valves slowly. Opening an oxygen cylinder valve quickly can cause a fire or explosion. Be sure regulator adjusting handle is in the full out (off) position before opening an oxygen cylinder valve.
Recompressing high pressure oxygen in a low pressure cavity may create heat, resulting in combustion. For combustion to occur, oxygen,
fuel, and kindling temperatures must be present. All of these components may be present when oxygen is recompressed by opening the tank
valve too quickly.
Oxygen: High purity oxygen accelerates the rate of combustion, increases heat output, and lowers the combustible point at which various
materials will burn.
Fuel: The fuel for combustion may be the regulator itself if enough heat is produced to reach the kindling temperature of the regulator’s
components.
Kindling Temperatures: Enough heat may be generated to ignite the regulator components by the friction created when recompressing
high-pressure oxygen. This heat is known as the heat of recompression.
If an internal fire or flashback occurs (indicated by a whistling sound or inverted flame), do the following:
l Turn off the torch oxygen valve immediately.
l Turn off the torch fuel valve.
l Turn off the oxygen cylinder valve.
l Turn off the fuel gas cylinder valve.
Do not relight the torch until the equipment has cooled to the touch and the flashback cause has been determined and corrected.
3-3. Inspecting The Equipment Before Use
Inspect all equipment before use. Do not use damaged, defective, or improperly adjusted welding and cutting equipment.
Make sure levers and valves work properly, threads on equipment are clean (no grease or oil) and not deformed, gauges are
intact and easy to read, regulator is clean and free of oil or dirt, and fittings are properly sized for the cylinder. Make sure hoses are clean (no grease or oil) and ferrules are properly installed so the fitting does not slip inside the hose. Be sure all connections are tight and there are no leaks in the system.
This manual offers basic information regarding the Medium-Duty and Heavy-Duty Oxy-Acetylene Cutting and Welding Outfits. Given reasonable care, this equipment will provide trouble-free use for many years.
OM-251341 Page 8
Page 12
SECTION 4 – SPECIFICATIONS
1
161-135
2
3
4
5
6
7 8 9 10 11
12
1
2
3
4
161-136
5
6
7
8
9
10
11
12
13
4-1. Equipment Included With Medium-Duty Outfit 770502
Use only acetylene or propane gas
and oxygen with this equipment.
Check valves are factory installed
on the torch handle. Replace the
check valves with the supplied
flashback arrestors if the torch will
be used frequently or for long periods (see Section 5-4).
1 Regulator - Oxygen (Green)
2 Regulator - Fuel (Red)
3 Flip-Front Goggles
4 T-Grade Hose With Fittings, 3/16 in. ID,
20 Ft (6.1 m)
5 Cutting Attachment
6 Cutting Tip No. 0
7 Spark Lighter
8 Flashback Arrestors, Torch Mount
9 Torch Handle With Check Valves
10 Welding Tip No.0
11 Tank Wrench
12 Tip Cleaner
4-2. Equipment Included With Heavy-Duty Outfit 770974
Use only acetylene or propane gas
and oxygen with this equipment.
Check valves are factory installed
on the torch handle. Replace the
check valves with flashback arrestors if the torch will be used frequently or for long periods (see
Section 5-4).
1 Regulator - Oxygen (Green)
2 Regulator - Fuel (Red)
3 Torch Handle With Check Valves
4 Cutting Attachment
5 Heating Tip No. 8
6 Welding Tip No. 2
7 Cutting Tips, No. 0, No. 1, No. 2
8 Flip-Front Goggles
9 Stainless-Finish Carrying Case
10 Tip Cleaner
11 Spark Lighter
12 T-Grade Hose With Fittings, 1/4 in. ID, 20
Ft (6.1 m)
13 O-Ring Set, Cutting Attachment
Replacement
OM-251341 Page 9
Page 13
4-3. Equipment Specifications
Description Fuel Gas Cutting Capacity Heating Capacity Welding Capacity Accessories
770502
Medium-Duty Outfit
Cutting, Welding
770974
Heavy-Duty Outfit
Cutting, Heating,
Welding
Acetylene
(Tips In Outfit)
Propane
(Tips Optional)
Cuts Up To
1/2 in. (13 mm)
Metal Thickness
Cuts Up To
1-1/2 in. (38 mm)
Metal Thickness
Not Applicable
Heats up to 117600
BTU Per Hour
Welds Up To
5/64 in. (2 mm)
Metal Thickness
Welds Up To
1/8 in. (3 mm)
Metal Thickness
Goggle Flip Front
Shade No. 5
2 x 4.25 in.
(51 x 108 mm)
T-Grade All-Fuel Hose
20 ft (6 m)
Case (HD Only)
17 x 13.4 x 11.8 in.
(45 x 35 x 30 cm)
Max Load 50 lb (23 kg)
4-4. Cutting Tip And Gas Pressure Guide — Acetylene
Medium Duty Cutting – Acetylene
Hobart
770153 3-101 0 3/8 10 25 - 30 172 - 207 55 - 60 3 - 5 21 - 34 5 - 8 0.04 24 - 28 0.06
770153 3-101 0 1/2 13 30 - 35 207 - 241 60 - 65 3 - 5 21 - 34 6 - 10 0.04 20 - 24 0.06
770154 3-101 1 3/4 19 30 - 35 207 - 241 80 - 85 3 - 5 21 - 34 8 - 13 0.05 17 - 21 0.07
770155 3-101 2 1 25 35 - 40 241 - 276 140 - 150 3 - 6 21 - 41 10 - 16 0.06 15 - 19 0.09
770155 3-101 2 1-1/2 38 40 - 45 276 - 310 150 - 160 3 - 7 21 - 48 12 - 18 0.06 13 - 17 0.09
770993 3-101 3 2 51 40 - 45 276 - 310 210 - 225 4 - 9 28 - 55 14 - 22 0.07 12 - 15 0.11
770993 3-101 3 2-1/2 64 45 - 50 310 - 345 225 - 240 4 - 10 28 - 69 16 - 26 0.07 10 -13 0.11
Hobart
770975 1-101 0 3/8 10 25 - 30 172 - 207 55 - 60 3 - 5 21 - 34 5 - 8 0.04 24 - 28 0.06
770975 1-101 0 1/2 13 30 - 35 207 - 241 60 - 65 3 - 5 21 - 34 6 - 10 0.04 20 - 24 0.06
770163 1-101 1 3/4 19 30 - 35 207 - 241 80 -85 3 - 5 21 - 34 8 - 13 0.05 17 - 21 0.07
770164 1-101 2 1 25 40 - 45 276 - 310 150 - 160 3 - 7 21 - 48 12 - 18 0.06 13 - 17 0.09
770164 1-101 2 1-1/2 38 40 - 45 276 - 310 150 - 160 3 - 7 21 - 48 12 - 18 0.06 13 - 17 0.09
770165 1-101 3 2 51 40 - 45 276 - 310 210 - 225 4 - 9 28 - 55 14 - 22 0.07 12 - 15 0.11
770165 1-101 3 2-1/2 64 45 - 50 310 - 345 225 - 240 4 - 10 28 - 69 16 - 26 0.07 10 - 13 0.11
770994 1-101 4 3 76 40 - 50 276 - 345 270 - 320 5 - 10 34 - 69 18 - 30 0.08 9 - 12 0.12
No.
No.
Victor
Style
Victor
Style
Tip
Size
Tip
Size
Metal
Thickness
in. mm psig kPa SCFH psig kPa SCFH
Metal
Thickness
in. mm psig kPa SCFH psig kPa SCFH
Oxygen Pressure
Heavy Duty Cutting – Acetylene
Oxygen Pressure
Oxygen
Consum.
Oxygen
Consum.
Acet. Pressure
Acet. Pressure
Acet.
Cosum.
Acet.
Cosum.
Orifice
Size
Orifice
Size
Speed IPM
Speed IPM
Kerf
Width
Kerf
Width
4-5. Cutting Tip And Gas Pressure Guide — Propane And Natural Gas
Medium Duty Cutting – Propane And Natural Gas
Hobart
770162 3-GPN 2 1 25 35 - 40 241 - 276 115 - 125 4- 8 28 - 55 12 - 15 0.06 14 - 18 0.09
770162 3-GPN 2 1–1/2 38 40 - 45 276 - 310 115 - 125 5- 9 34 - 55 12 - 15 0.06 14 - 18 0.09
Hobart
770166 1-GPN 1 3/4 19 30 - 35 207 - 241 70 - 80 4- 6 28 - 41 10 - 12 0.05 15 - 20 0.08
770167 1-GPN 2 1 25 35- 40 241 - 276 115 - 125 4- 8 28 - 55 12 - 15 0.05 14 - 18 0.09
770167 1-GPN 2 1–1/2 38 40- 45 276 - 310 125 - 135 5- 9 34 - 55 12 - 15 0.05 14 - 18 0.09
No.
No.
Victor
Style
Victor
Style
Tip
Size
Tip
Size
Metal
Thickness
in. mm psig kPa SCFH psig kPa SCFH
Metal
Thickness
in. mm psig kPa SCFH psig kPa SCFH
Oxygen Pressure
Heavy Duty Cutting – Propane And Natural Gas
Oxygen Pressure
Oxygen
Consum.
Oxygen
Consum.
Propane
Pressure
Propane
Pressure
Propane
Consum.
Propane
Consum.
Orifice
Size
Orifice
Size
Speed IPM
Speed IPM
OM-251341 Page 10
Kerf
Width
Kerf
Width
Page 14
4-6. Heating Nozzle And Gas Pressure Guide — Acetylene
Medium Duty Heating — Acetylene
Hobart
No.
770169 MFA-1 6
Hobart
No.
770977 MFA 8
Victor
Style
Victor
Style
Size
Size
Tip
Tip
BTU Per
Hour
20580 -
58800 10 - 15 69 - 103 15 - 44 8 - 12 55 - 83 14 - 40 11 (279)
BTU Per
Hour
44100 117600 20 - 30 138 - 207 33 - 88 10 - 15 69 - 103 30 - 80 12.5 (318)
Oxygen Pressure
psig kPa SCFH psig kPa SCFH
Heavy Duty Heating — Acetylene
Oxygen Pressure
psig kPa SCFH psig kPa SCFH
Oxygen
Consumption
Oxygen
Consumption
Acetylene Pressure
Acetylene Pressure
Acetylene
Consumption
Acetylene
Consumption
Length in. (mm)
Length in. (mm)
4-7. Welding (Brazing) Nozzle And Gas Pressure Guide — Acetylene
Medium Duty Welding – Acetylene
Hobart
770149 W-1 2 1/8 3 3 - 5 21 - 34 6 - 11 3 - 5 21 - 34 5 - 10 0.05 6.6 (167) Long Cone
Hobart
770891 W 1 3/32 2 3 - 5 21 - 34 3 - 7 3 - 5 21 - 34 3 - 6 0.05 6.2 (156) Long Cone
770976 W 2 1/8 3 3 - 5 21 - 34 6 - 11 3 - 5 21 - 34 5 - 10 0.05 6.9 (175) Long Cone
770988 W 3 3/16 5 4 - 7 28 - 48 9 - 20 3 - 6 21 - 41 8 - 18 0.06 7.7 (195) Long Cone
Victor
No.
– W-1 0 5/64 2 3 - 5 21 - 34 2 - 4 3 - 5 21 - 34 2 - 4 0.04 5.1 (131) Long Cone
Victor
No.
Style
Style
Tip
Size
Tip
Size
Metal
Thickness
in. mm psig kPa SCFH psig kPa SCFH
Metal
Thickness
in. mm psig kPa SCFH psig kPa SCFH
Oxygen
Pressure
Oxygen
Pressure
Oxygen
Consum.
Heavy Duty Welding – Acetylene
Oxygen
Consum.
Acetylene
Pressure
Acetylene
Pressure
Acetylene
Consum.
Acetylene
Consum.
Orifice
Size
Orifice
Size
Length in.
(mm)
Length in.
(mm)
Flame Character
Flame Character
4-8. Combination Torch
Use the appropriate tip for the fuel gas.
F
Hobart
No.
770200 100 All Torch Handle
770201 100 All
Hobart
No.
770979 300 All Torch Handle
770978 300 All
Victor
Style
Victor
Style
Fuel
Gas
Fuel
Gas
Description Hose Connection
Cutting
Attachment
Description Hose Connection
Cutting
Attachment
Medium Duty Combination Torch
Weight
lb (kg)
9/16 -18 in.
B Size
0.96 (0.44) 8.59 (226) –
– 0.89 (0.40) 8.0 (203) 90°
Heavy Duty Combination Torch
Weight
lb (kg)
9/16 -18 in.
B Size
1.4 (0.64) 9.5 (240) –
– 1.9 (0.87) 10.5 (267) 90°
Length
in. (mm)
Length
in. (mm)
Head
Angle
Head
Angle
OM-251341 Page 11
Page 15
4-9. Regulators — Single Stage
Max
Inlet
Press.
Max
Inlet
Press.
Hobart
No.
770503
770504
Hobart
No.
770980
770981
Victor
Style
SR
250
SR
250
Victor
Style
SR
450
SR
450
Delivery
Fuel
Gas
Oxy. 145 1000 2900
Acet./
LP
Fuel
Gas
Oxy. 145 1000 2900
Acet./
LP
Pressure
psig kPa psig Outlet Inlet Outlet Inlet
14.5 100 220
Delivery
Pressure
psig kPa psig Outlet Inlet Outlet Inlet
14.5 100 220
Medium Duty Regulators
Connection Gauges (psig)
9/16 in.-RHCGA
9/16 in.
- LH
Heavy Duty Regulators
Connection Gauges (psig)
9/16 in.
- RH
9/16 in.
- LH
540
CGA
510
CGA
540
CGA
510
200 4000
30 400
200 4000
30 400
Design
in. (mm)
Steel
2 (51)
Steel
2 (51)
Design
in. (mm)
Steel
2.5 (63)
Steel
2.5 (63)
Diaphragm
in. (mm)
Neoprene
2.15 (55)
Neoprene
2.15 (55)
Diaphragm
in. (mm)
SST
3.38 (86)
SST
3.38 (86)
Weight
lb (kg)
2.9
(1.3)
2.9
(1.3)
Weight
lb (kg)
5.11
(2.3)
5.11
(2.3)
Dimension
WxHxD
in. (mm)
6.38 x 5 x
4.25
(162 x 127
x 108)
6.38 x 5 x
4.25
(162 x 127
x 108)
Dimension
WxHxD
in. (mm)
7.25 x 7 x
5.13
(184 x 178
x 130)
7.25 x 7 x
5.13
(184 x 178
x 130)
OM-251341 Page 12
Page 16
SECTION 5 – INSTALLATION
161-018
5-1. Installing Cylinders
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent
falling or tipping. Maintain a clear
path from the cylinders to the work
area.
Inspect equipment before use. Do
not use if grease or oil is present
on equipment or if equipment is
damaged. Have equipment
cleaned/repaired by a qualified
person.
Do not slightly open or "crack" fuel
cylinder valve to blow debris from
the valve outlet. Remove the debris
using nitrogen, air, or a clean, oilfree rag.
Remove the protective cap from the cylinder
valve.
Use nitrogen, air, or a clean oil-free rag to remove dust or debris from valve outlet. These
particles can damage regulators or cause a
fire or explosion.
OM-251341 Page 13
Page 17
5-2. Installing Regulators On Cylinders
2
1
3
4
C
161-027 / 029
NGO’s
tools/
helmet weldshield faceshield
ear plugs
Use only acetylene or propane gas
and oxygen with this equipment.
Do not slightly open or "crack" fuel
cylinder valve to blow debris from
the valve outlet. Remove the debris
using nitrogen, air, or a clean, oilfree rag.
Do not use pipe sealants on metal
to metal fittings, such as hose and
torch connections and CGA cylinder connections.
Do not handle oxygen regulators
with oily hands and never apply oil
to any part of an oxygen regulator.
Do not use cylinder adaptors to con-
F
nect regulators to cylinders. Regulators
have CGA connections (manufactured
to standards of the Compressed Gas
Association) which allow the regulator
to only be installed on the appropriate
cylinder valve for the intended gas.
1 Oxygen Regulator(Green Label)
2 Fuel Regulator(Red Label)
The hex nut on the fuel regulator has
F
notches on the corners. The hex nut
corners are smooth on the oxygen
regulator.
Install the two-piece fitting of the oxygen regulator (green) on the corresponding fitting on
the oxygen cylinder. The oxygen cylinder
has right-hand (clockwise) threads. Use a
wrench to tighten hex nut.
Install the two-piece fitting of the fuel regulator (red) on the fuel cylinder (acetylene or
propane only). The fuel cylinder has lefthand (counterclockwise) threads. Use a
wrench to tighten hex nut.
Contact the gas supplier if the regulator
F
fittings do not match the cylinder
fittings.
3 Working Pressure Gauge
4 Cylinder Pressure Gauge
Each regulator has two gauges. The gauge
closest to the cylinder shows the pressure in
the cylinder. The other gauge shows the outlet pressure going to the torch handle.
1 in.
OM-251341 Page 14
Page 18
5-3. Connecting Hoses To Regulators
1
2
3
161-030
NGO’s
tools/
helmet weldshield faceshield
ear plugs
11/16 in.
Use only industrial grade hose.
Grade T hose (supplied with outfits)
is acceptable for all fuel gases including acetylene. Grade R hose is
for acetylene only.
Replace hoses at the first sign of
any defects, flaws, or damage. The
hoses should otherwise be replaced
every four years. Inspect hoses for
damage or leaks before each operation. Do not allow hoses to come in
contact with hot metal, molten solder, or corrosive chemicals. Do not
expose hoses to fluxing agents as
these agents will deteriorate the
hose materials and cause them to
leak.
Do not splice or use damaged
hoses.
Do not use pipe sealants on metal to
metal fittings, such as hose and
torch connections and CGA cylinder
connections.
1 Regulator
2 Hose
3 Adjustment Handle
Connect green hose to the regulator on the
oxygen cylinder. Connect red hose to the
regulator on the fuel gas cylinder.
The fuel fittings have left-handed
F
threads.
Use a wrench to tighten fittings.
NOTICE – Before opening the cylinder
valves, turn regulator adjusting handles
counterclockwise to the off position and
there is no resistance on the adjusting handle. This action is necessary to release pressure on the regulator diaphragm. Pressure
may damage the regulators.
Stand with the oxygen cylinder valve between you and the regulator. Slowly open
the oxygen cylinder valve 1/4 turn until the
tank pressure stabilizes, then fully open the
oxygen valve to seat it in the open position.
Tighten the adjustment handle (on the regulator adjustment screw) to bring the pressure up to 5 psi (34 kPa). Allow oxygen to
flow through hose for about 10 seconds.
Stop oxygen flow by turning adjustment handle counterclockwise.
Stand with the fuel cylinder valve between
you and the regulator. Slowly open the fuel
cylinder valve 1/4 turn until the tank pressure stabilizes, then open the fuel valve to a
maximum of one full turn (acetylene) or fully
open (all other fuel gases).
Tighten the adjustment handle (on the regulator adjustment screw) to bring the pressure up to 5 psi (34 kPa). Allow fuel gas to
flow through hose for about 10 seconds.
Stop fuel gas flow by turning adjustment
handle counterclockwise.
Use the correct tip for the gas and metal
thickness. Do not exceed the recommended
pressures in the Tip and Gas Pressure
Guide tables (see Section 4).
OM-251341 Page 15
Page 19
5-4. Replacing Torch Check Valves With Flashback Arrestors
1
161-117 / 161 118
1
3
2
NGO’s
tools/
helmet weldshield faceshield
ear plugs
1
2
3
4
161-031
NGO’s
tools/
helmet weldshield faceshield
ear plugs
F
1 Torch Handle
2 Check Valves
3 Flashback Arrestors
Remove check valves from torch handle.
Install fuel flashback arrestor (red) in fuel fitting on torch handle. Install oxygen flashback
arrestor (blue) in oxygen fitting on torch
handle.
Remove the factory-installed
check valves from the torch handle
and replace them with the supplied
flashback arrestors.
Do not use pipe sealants on metal
to metal fittings, such as hose and
torch connections and CGA cylinder connections.
Check valves are designed to protect
against the reverse flow of gas into the
hose and regulator of the other gas
when there is sudden loss of pressure
on one of the gases.
Flashback Arrestors protect against reverse flow and flashback. Flashback
occurs when the flame travels upstream from the torch to the gas
source.
The oxygen check valve has right-hand
F
threads and the fuel check valve has
left-hand threads.
11/16 in.
5-5. Connecting Hoses To Torch Check Valves Or Flashback Arrestors
11/16 in.
The hex nut on the fuel hose has
F
notches on the corners. The hex nut
corners are smooth on the oxygen
hose.
1 Torch Handle
2 Fuel Hose (Red)
3 Oxygen Hose (Green)
4 Flashback Arrestors/Check Valves
Attach fuel hose (red) to fuel inlet fitting on
torch check valve or flashback arrestor. The
nut on the fuel hose has left-hand threads.
Attach oxygen hose (green) to oxygen inlet
fitting on torch check valve or flashback arrestor. The nut on the oxygen hose has right
hand threads.
Use a wrench to tighten connections.
Do not use pipe sealants on metal
to metal fittings, such as hose and
torch connections and CGA cylinder connections.
OM-251341 Page 16
Page 20
5-6. Installing Cutting Attachment On Torch Handle
1
2
161-032
NGO’s
tools/
helmet weldshield faceshield
ear plugs
1
2
161-033
NGO’s
tools/
helmet weldshield faceshield
ear plugs
Do not use cutting attachment if
the o-rings are missing or
damaged.
Do not use pipe sealants on metal
to metal fittings, such as hose and
torch connections and CGA cylinder connections.
See Section 5-8 for attaching brazing
F
tip to torch handle.
1 Cutting Attachment
2 Torch Handle
The cutting attachment uses two o-rings to
seal the connection to the torch handle. If replacing the cutting attachment, be sure the
o-rings are properly installed.
Attach cutting attachment to torch handle.
Use a wrench to tighten connections.
3/4 in.
5-7. Installing Cutting Tip On Cutting Attachment
Do not use pipe sealants on metal
to metal fittings, such as hose and
torch connections and CGA cylinder connections.
NOTICE – Do not drop or mishandle the cutting tip or the seating surface may be
damaged.
Cutting tips are available in different sizes to
accommodate various metal thicknesses.
Use the tables in Sections 4-4 and 4-5 to select the correct tip, and to determine the correct fuel and oxygen pressures.
Inspect cutting tips for damage and to ensure that the cutting orifice and preheat
holes are not blocked with dirt or slag.
A No. 0 cutting tip is already installed in
F
the cutting attachment with the Medium
Duty Outfit.
1 Cutting Tip
2 Cutting Attachment
1 in.
OM-251341 Page 17
Install correct cutting tip in cutting
attachment.
Use a wrench to tighten connections.
Page 21
5-8. Installing Welding/Brazing Tip On Torch Handle
1
2
161-034
NGO’s
tools/
helmet weldshield faceshield
ear plugs
Do not use pipe sealants on metal
to metal fittings, such as hose and
torch connections and CGA cylinder connections.
Welding/brazing tips are available in different
sizes to accommodate various metal thicknesses. Use the table in Section 4-7 to select
the correct tip, and to determine the correct
fuel and oxygen pressures.
A No. 0 welding/brazing tip with mixer
F
is supplied with the medium duty outfit.
A No. 2 welding/brazing tip with mixer
is supplied with the heavy duty outfit.
1 Welding/Brazing Tip With Mixer
2 Torch Handle
Attach welding/brazing tip to torch handle.
Use a wrench to tighten connections.
3/4 in.
OM-251341 Page 18
Page 22
5-9. Testing The System For Leaks
1
2
4
3
5
161-013 / 031 / 035 / 036
6
NGO’s
tools/
helmet weldshield faceshield
ear plugs
Leak test the system before lighting the torch. Repeat this procedure every time the equipment is
set up or a cylinder is changed.
Use an approved oil-free leak detection fluid or leak detector to locate possible leaks.
Do not stand in front of or behind
the regulator when opening the
cylinder valve. Never open a cylinder valve suddenly as this can
damage a regulator or cause an
oxygen regulator fire.
1 Fuel Regulator Adjustment Handle
2 Oxygen Regulator Adjustment Handle
3 Torch Handle Fuel Valve
4 Torch Handle Oxygen Valve
5 Oxygen Cylinder Valve (Fuel Cylinder
Valve Is Not Shown)
6 Checking System For Leaks
Step 1. Turn the fuel and oxygen regulator
adjustment handles to the Off position
(counterclockwise).
Step 2. Close the fuel and oxygen valves on
the torch handle.
Step 3. Slowly open the oxygen cylinder
valve one turn and adjust pressure to 20 psi
(138 kPa) by turning oxygen regulator adjustment handle clockwise.
Step 4. Slowly open the fuel cylinder valve
and adjust pressure to 10 psi (69 kPa) by
turning fuel regulator adjustment handle
clockwise.
Step 5. Check every connection and joint
from the cylinder valve to the torch tip with
an approved oil-free leak detection fluid or
leak detector. If leaks are detected, eliminate
them before proceeding. If leaks cannot be
eliminated, do not put the equipment into
service until it has been repaired or
replaced.
Step 6. Close cylinder valves.
OM-251341 Page 19
11/16, 3/4,1 in.
Page 23
SECTION 6 – OPERATION
1
4
2
3
161 032 / 036
NGO’s
tools/
helmet weldshield faceshield
ear plugs
6-1. Purging Oxygen From The System And Adjusting Oxygen Pressure
Inspect all equipment before use.
Do not use damaged, defective, or
improperly adjusted welding and
cutting equipment. Make sure levers and valves work properly,
threads on equipment are clean
(no grease or oil) and not deformed, gauges are intact and easy
to read, regulator is clean and free
of oil or dirt, and fittings are properly sized for the cylinder. Make
sure hoses are clean (no grease or
oil). Be sure all connections are
tight and there are no leaks in the
system.
Always purge gas from the system
before lighting torch to prevent a
possible mixed-gas explosion.
Purge gas in a well ventilated area
and away from flame or sparks.
See Section 4 for oxygen and fuel pres-
F
sure recommendations.
Purge fuel from the system according
F
to Section 6-2.
Purging Oxygen And Setting Oxygen
Pressure
1 Oxygen Cylinder Valve
2 Torch Handle Oxygen Valve
3 Preheat Oxygen Valve
4 Oxygen Regulator Adjustment Handle
Step 1. Slowly open the oxygen cylinder
valve until valve is fully open.
Step 2. Open oxygen valve on torch 1/4 turn
for five to ten seconds. (If using welding attachment, also open preheat oxygen valve.)
While the oxygen is flowing, turn the adjustment handle on the oxygen regulator to
achieve the desired working pressure.
Step 3. Close the oxygen valve and the preheat oxygen valve on the torch handle.
Step 4. Purge fuel from the system and adjust fuel pressure according to Section 6-2.
OM-251341 Page 20
Page 24
6-2. Purging Fuel From The System And Adjusting Fuel Pressure
4
1
2
3
NGO’s
tools/
helmet weldshield faceshield
ear plugs
Inspect all equipment before use.
Do not use damaged, defective, or
improperly adjusted welding and
cutting equipment. Make sure levers and valves work properly,
threads on equipment are clean
(no grease or oil) and not deformed, gauges are intact and easy
to read, regulator is clean and free
of oil or dirt, and fittings are properly sized for the cylinder. Make
sure hoses are clean (no grease or
oil). Be sure all connections are
tight and there are no leaks in the
system.
Always purge gas from the system
before lighting torch to prevent a
possible mixed-gas explosion.
Purge gas in a well ventilated area
and away from flame or sparks.
Do not use acetylene above 15 psi
(103 kPa) flowing.
See Section 4 for oxygen and fuel pres-
F
sure recommendations.
Purge oxygen from the system accord-
F
ing to Section 6-1.
Purging Fuel And Setting Fuel Pressure
1 Fuel Cylinder Valve
2 Torch Handle Fuel Valve
3 Preheat Oxygen Valve
4 Fuel Regulator Adjustment Handle
Step 1. Slowly open the fuel cylinder valve
one turn maximum (for acetylene). Fully
open fuel cylinder valve for all other fuel
gases.
Step 2. Open fuel valve on torch 1/4 turn for
five to ten seconds. (If using welding attachment, also open preheat oxygen valve.)
While the fuel is flowing, turn the adjustment
handle on the fuel regulator to achieve the
desired working pressure.
Step 3. Close the fuel valve and the preheat
oxygen valve on the torch handle.
OM-251341 Page 21
Page 25
6-3. Lighting And Using The Cutting Torch
1
23 45
6
NGO’s
tools/
helmet weldshield faceshield
ear plugs
NGO’s
tools/
Always purge gas from the system
before lighting torch to prevent a
possible mixed-gas explosion.
Purge gas in a well ventilated area
and away from flame or sparks. See
Sections 6-1 and 6-2.
Do not use matches or a cigarette
lighter to ignite the gas.
See Sections 6-1 and 6-2 for oxygen
F
and fuel pressure recommendations.
1 Spark Lighter
2 Oxygen Valve
3 Preheat Oxygen Valve
4 Fuel Valve
5 Cutting Lever
6 Neutral Flame — Even Mixture Of Fuel
And Oxygen
Lighting The Torch
Step 1. Hold the spark lighter near torch tip.
Step 2. Slowly open the fuel valve on the
torch handle 1/4 turn and quickly squeeze
the spark lighter to light the flame.
Step 3. Slowly open the oxygen valve on
the torch to the desired pressure.
Step 4. Continue to open the fuel valve until
the black sooty smoke disappears and the
flame begins to move away from the tip.
Failure to force a sufficient amount
of fuel gas through the tip will cause
the tip to overheat and may cause a
flashback or backfire.
Step 5. Slowly open the preheat oxygen
valve on the cutting attachment; a white-hot
feather (flame) appears.
Step 6. Slowly add oxygen until the feather
begins to disappear into the bright cone at
the end of the tip. This produces a neutral
flame (ratio of fuel to oxygen is 1:1).
Operating The Cutting Torch
Step 1. Hold the torch tip about 1/4 in. (6
mm) from the metal to be cut.
Step 2. Heat the metal until it is bright red
(about 1550° F or 843° C).
Step 3. Slowly depress the cutting lever on
the cutting attachment. Let the oxygen
stream burn through the metal, then completely depress the lever to begin the cutting
process.
When Finished Cutting
NOTICE – Shut down the torch in the correct
sequence or the torch may be damaged.
Oxygen must be released from the system
first or residual fuel in the handle or fuel
hose may burn. Fuel cannot burn without
oxygen.
Step 1. When finished cutting, release the
cutting lever. Close the oxygen preheat
valve on the torch handle first and then close
the fuel valve on the torch handle.
Step 2. Turn valves at fuel and oxygen cylinders clockwise to the closed position.
Step 3. Open the fuel valve on the torch
handle to relieve pressure; both gauges on
the fuel regulator should indicate zero (0)
pressure. Close the fuel valve on the torch
handle.
Step 4. Turn fuel regulator adjustment handle counterclockwise until there is no pressure on the regulator diaphragm.
Step 5. Open the preheat oxygen valve on
the torch handle to relieve pressure; both
gauges on the oxygen regulator should indicate zero (0) pressure. Close the preheat
oxygen valve and oxygen valve on the torch
handle.
Step 6. Turn oxygen regulator adjustment
handle counterclockwise until there is no
pressure on the regulator diaphragm.
OM-251341 Page 22
Page 26
6-4. Lighting And Using The Brazing Tip
1
2
3
161-039 / 040
NGO’s
tools/
helmet weldshield faceshield
ear plugs
NGO’s
tools/
Always purge gas from the system
before lighting torch to prevent a
possible mixed-gas explosion.
Purge gas in a well ventilated area
and away from flame or sparks. See
Sections 6-1 and 6-2.
Do not use matches or a cigarette
lighter to ignite the gas.
Do not allow the flame to touch the
brazing tip or allow the brazing tip to
overheat.
See Sections 6-1 and 6-2 for oxygen
F
and fuel pressure recommendations.
1 Spark Lighter
2 Oxygen Valve
3 Fuel Valve
Lighting The Torch
Step 1. Hold the spark lighter near torch tip.
Step 2. Slowly open the fuel valve on the
torch handle about 1/8 turn and quickly
squeeze the spark lighter to light the flame.
Step 3. Slowly open the oxygen valve on
the torch to neutralize the flame.
Step 4. Open the fuel valve on the torch
handle another 1/8 turn and then increase
the oxygen to neutralize the flame.
Step 5. Continue this procedure until the
maximum amount of fuel gas is used and
the desired flame is present.
When Finished Welding/Brazing
NOTICE – Shut down torch in correct sequence or the torch may be damaged. Oxygen must be released from the system first
or residual fuel in the handle or fuel hose
may burn. Fuel cannot burn without oxygen.
Step 1. When finished welding/brazing,
close the oxygen valve on the torch handle
first and then close the fuel valve on the
torch handle.
Step 2. Turn valves at fuel and oxygen cylinders clockwise to the closed position.
Step 3. Open the fuel valve on the torch
handle to relieve pressure; both gauges on
the fuel regulator should indicate zero (0)
pressure. Close the fuel valve on the torch
handle.
Step 4. Turn fuel regulator adjustment handle counterclockwise until there is no pressure on the regulator diaphragm.
Step 5. Open the oxygen valve on the torch
handle to relieve pressure; both gauges on
the oxygen regulator should indicate zero
(0) pressure. Close the oxygen valve on the
torch handle.
Step 6. Turn oxygen regulator adjustment
handle counterclockwise until there is no
pressure on the regulator diaphragm.
OM-251341 Page 23
Page 27
Effective January 1, 2022
5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial num-
ber preface of NC or newer.
This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or
warranties expressed or implied.
LIMITED WARRANTY - Subject to the terms and
conditions below, Miller Electric Mfg. LLC, dba Hobart Welding Products, Appleton, Wisconsin, warrants to its original retail purchaser that new
Hobart equipment sold after the effective date of
this limited warranty is free of defects in material
and workmanship at the time it is shipped. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING THE WARRANTIES OF MERCHANTABILITYAND FITNESS.
Within the warranty periods listed below, Hobart/
Miller will repair or replace any warranted parts or
components that fail due to such defects in material or workmanship. Hobart/Miller must be notified
in writing within thirty (30) days of such defect or
failure, at which time Hobart/Miller will provide instructions on the warranty claim procedures to be
followed. Notifications submitted as online warranty claims must provide detailed descriptions of
the fault and troubleshooting steps taken to diagnose failed parts. Warranty claims that lack the required information as defined in the Miller Service
Operation Guide (SOG) may be denied by Miller.
Hobart/Miller shall honor warranty claims on warranted equipment listed below in the event of a defect within the warranty coverage time periods
listed below. Warranty time periods start on the delivery date of the equipment to the original retail
purchaser, or 12 months after the equipment is
shipped to a US or Canada distributor, or 18
months after the equipment is shipped to an international distributor, whichever occurs first.
1 5 Years — Parts and Labor
l Original Main Power Rectifiers only to include
SCRs, diodes, and discrete rectifier modules
in non-inverter products
l Reactors
l Stabilizers
l Transformers
2 3 Years — Parts and Labor Unless Specified
l Drive Systems
l Idle Module
l PC Boards
l Rotors, Stators and Brushes
l Solenoid Valves
l Switches and Controls
3 1 Year — Parts and Labor Unless Specified(90
days for industrial use)
l Accessories (Kits)
l Field Options (NOTE: Field options are cov-
ered for the remaining warranty period of the
product they are installed in, or for a minimum
of one year — whichever is greater.)
l HF Units
l MIG Flowgauge Regulators (No Labor)
l MIG Guns/TIG Torches
l Plasma Cutting Torches
l Remote Controls
l Replacement Parts (No labor) - 90 days
l Running Gear/Trailers
l Spoolguns
4 6 Months — Parts
l 12 Volt Automotive-Style Batteries
5 Engines and tires are warranted separately by
the manufacturer.
Hobart’s 5/3/1 Limited Warranty shall not apply to:
1. Consumable components; such as contact
tips, cutting nozzles, contactors, brushes,
relays, work station table tops and welding
curtains, or parts that fail due to normal
wear. (Exception: brushes and relays are
covered on all engine-driven products.)
2. Items furnished by Hobart/Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the
manufacturer’s warranty, if any.
3. Equipment that has been modified by any party
other than Hobart/Miller, or equipment that has
been improperly installed, improperly operated
or misused based upon industry standards, or
equipment which has not had reasonable and
necessary maintenance, or equipment which
has been used for operation outside of the
specifications for the equipment.
4. Defects caused by accident, unauthorized repair, or improper testing.
HOBART PRODUCTS ARE INTENDED FOR
COMMERCIAL AND INDUSTRIAL USERS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
The exclusive remedies for warranty claims are, at
Hobart’s/Miller’s option, either: (1) repair; or (2) replacement; or, if approved in writing by Hobart/Miller, (3) the pre-approved cost of repair or
replacement at an authorized Hobart/Miller service
station; or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon
use). Products may not be returned without
Hobart’s/Miller’s written approval. Return shipment
shall be at customer’s risk and expense.
The above remedies are F.O. B. Appleton, WI, or
Hobart’s/Miller’s authorized service facility. Transportation and freight are the customer’s responsibility. TO THE EXTENT PERMITTED BY LAW,
THE REMEDIES HEREIN ARE THE SOLE AND
EXCLUSIVE REMEDIES REGARDLESS OF THE
LEGAL THEORY. IN NO EVENT SHALL HOBART/MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING
LOSS OF PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY,
GUARANTY, OR REPRESENTATION, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, ARE EXCLUDED AND DISCLAIMED
BY HOBART/MILLER.
Some US states do not allow limiting the duration
of an implied warranty or the exclusion of certain
damages, so the above limitations may not apply
to you. This warranty provides specific legal rights,
and other rights may be available depending on
your state. In Canada, some provinces provide additional warranties or remedies, and to the extent
the law prohibits their waiver, the limitations set out
above may not apply. This Limited Warranty provides specific legal rights, and other rights may be
available, but may vary by province.
Warranty Questions?
Call 1-800-332-3281
8 AM – 5 PM EST
Service
You always get the fast, reliable response you
need. Most replacement parts can be in your
hands in 24 hours.
Support
Need fast answers to the tough welding questions? Contact your distributor or call 1-800332-3281. The expertise of the distributor and
Hobart is there to help you, every step of the
way.
Assistance
Visit the Hobart website:
www.HobartWelders.com
Page 28
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date
Distributor
Address
City
State Zip
Thank you for purchasing Hobart. Our trained technical support team is dedicated to your
satisfaction. For questions regarding performance, operation, or service, contact us!
(Date which equipment was delivered to original customer.)
Resources Available
Always provide Model Name and Serial/Style Number.
To locate a Service Center:
Call 1-800-332-3281
or visit our website at www.HobartWelders.com/wheretobuy
For Technical Assistance:
Call 1-800-332-3281
8 AM to 5 PM EST – Monday through Friday
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
For Assistance:
Call 1-800-332-3281
ORIGINAL INSTRUCTIONS © Miller Electric Mfg. LLC 2022-01
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