Operator’s Manual
Mobile Max Portable Torch Kit
Model MM-1
WARNING: Do not assemble, install or operate this equipment without reading ALL of
this manual and the safety precautions and warnings illustrated in this manual.
KDAR Company
15009 Manchester Rd. #283
Ballwin, MO 63011
Tel: 866-939-9811
Fax: 636-922-4622
Web Site: www.hotmaxtorches.com
SAFETY PRECAUTIONS AND WARNINGS
PLEASE READ BEFORE USING EQUIPMENT
WARNING
ARC RAYS CAN BURN SKIN AND EYES
• Arc rays when welding produce intense ultraviolet and infrared rays that can burn skin and eyes
• Where face protection, either helmet or shield when operating with ANSI Z49.1 approved shade
• Wear approved safety glasses with side shields under the face protection
• Warn others not to stare at the arc as it can cause damage to the eyes. Provide barriers to protect
• Wear flame resistant gloves, clothing, and shoes when operating
FUMES AND GASES CAN BE HAZARDOUS
• Arc welding produces fumes and gases and breathing these gases is hazardous to your health
• Keep your head out of the fumes and do not breath the fumes while welding
• Work only in a confined area if it has sufficient ventilation, or while wearing an air supplied res-
• Read the MSDS sheets and the instructions from manufacturers for metals to be welded, coat-
• Do not use the welder near hydrocarbon vapors coming from degreasing, cleaning, or spraying
• Do not weld coated metals, such as galvanized, lead, or cadmium plated steel. Before welding,
• Do not weld containers with toxic, flammable, or reactive elements stored in them. They must be
• Keep children away from this equipment
• Protect your self and others from possible injury
• Pacemaker wearers should consult with their doctor before operating
• Read and follow all instructions in this manual before operating
• All installation, operation, and maintenance procedures are to be per-
formed only by qualified individuals
#9 recommended for all cutting currents less than 300 amperes. The lens should conform to
ANSI Z87.1 standards for testing.
other workers in the area from the arc while operating
pirator. Fumes from welding deplete the oxygen supply and can be harmful. Always be sure
there is ample breathing air
ings, and cleaners
operations. The heat and rays can react with solvent vapors to create the gas phosgene, a very
toxic gas and other irritating gases
all plating must be removed. The area must be well ventilated or an air supplied hood must be
used. The coatings and chemicals when burned cause highly irritating and toxic fumes.
emptied and properly prepared before welding.
WELDING SPARKS CAN CAUSE INJURY, FIRE, OR EXPLOSION
• Remove all flammable materials from the welding area.
• Always have a charged fire extinguisher available in the welding area.
• When not welding make sure the welding gas cylinder valves are closed.
• Avoid welding near hydraulic lines, fuel lines, electrical cords, air hoses, or welding gas lines.
• Sparks and hot metal fly out from the work area when welding, wear approved safety glasses with
side shields under approved helmets, wear proper body and hand protection, and wear flame resistant ear plugs to keep sparks from entering the ears
KDAR Company
1
CYLINDERS CAN EXPLODE IF DAMAGED
• Gas cylinders contain gas under very high pressure. If damaged they can result in that cylinder exploding. Gas cylinders are a major part of metalworking and must be treated with care.
• Protect gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs
• Always keep cylinders in an upright position securely fastened to a fixed support
• Valve protection caps should always be in place and hand tight except when the cylinder is in use
• Keep all cylinders away from any welding or electrical circuits
• Never allow the flame or arc from a welder to contact a cylinder
• Never cut any type of pressurized cylinder, an explosion could result
• Always turn your face away from the valve when opening the cylinder
• Read and follow all instructions on compressed gas cylinders, associated equipment, and CGA pub-
lication P-1 listed in the Safety Standards before using
HOT PARTS CAN CAUSE SERIOUS BURNS
• Do not touch hat parts without wearing protection.
• Allow the torch to cool sufficiently before working with parts that could potentially be hot.
NOISE CAN DAMAGE HEARING
• Prolonged noise exposure from welding equipment can cause damage if levels of noise exceed the
OSHA standards
• Wear approved hearing protectors
• Warn other workers nearby of the high noise level and hazard
CALIFORNIA PROPOSITION 65 WARNINGS
• Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause
birth defects, and in some cases, cancer. (California Health and Safety Code Section 25249.5 et seq.)
PRINCIPAL SAFETY STANDARDS
AMERICAN WELDING SOCIETY
• AWS C5.2, Recommended Practices for Plasma Arc Cutting
• AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting
OSHA STANDARDS
• OSHA 29 CFR 1910, Safety and Health Standards
NATIONAL FIRE PROTECTION ASSOCIATION
• NFPA Standard 70, National Electric Code
• NFPA Standard 51B, Cutting and Welding Processes
AMERICAN NATIONAL STANDARDS INSTITUTE
• ANSI Standard Z87.1, Safe practices for Occupation and Educational Eye and Face Protection
• ANSI Standard Z49.1, Safety in Welding and Cutting
KDAR Company 2
Installation & Setup
Features, Benefits & Functions
Features
• Brass & Stainless Construction
• Welds up to 1/4 Inch*
• Cuts up to 4 Inches*
• Welding Tip, #1 Size
• Cutting Tip, 1-3-101 Victor Style
• Twin Welding Hose, 10’ x 3/16”
• Oxygen Regulator
*Larger Tip are Required to do this, Purchase Separately
Functions
• Steel Cutting up to 4”*
• Welding up to 1/4”*
• Acetylene Regulator
• Goggles & Striker
• Torch Handle & Cutting Head
• Heavy Duty Molded Tote Carrier
• Refillable 20 Cubic Foot Oxygen Tank—CGA540
• Refillable 10 Cubic Foot Acetylene Tank—CGA200
• Built in Storage Unit with Clear Door
• Solders up to 3/4” Copper & Brass
• Silver Solders
Benefits
• Everything in one Heavy Duty Molded
Case
• Mobile and Easy to Carry on Job Site
Package Contents
1. Acetylene Regulator
2. Oxygen Regulator
3. Acetylene Tank
4. Oxygen Tank
5. Torch Handle
6. Welding Tip
7. Cutting Head w/Tip
8. Striker
9. Heavy Duty Tote
10. Goggles
11. Acetylene Tank Key
12. Hose
Acetylene
Regulator
Torch Handle
• Attaches to Dual Purpose Cart (100MC), Sold Sepa-
rately
• Cuts, Welds and Solders in One Kit
Oxygen
Regulator
Acetylene
Tank
Oxygen
Tank
Welding Tip
Cutting Head
Striker
Heavy Duty Tote
Goggles
Acetylene Tank
Key
Hose
KDAR Company 3
Installation & Setup
Oxygen & Acetylene Filling
The Mobile Max is shipped with the tanks empty. Therefore, you will have to take the tanks to a local welding
gas supply distributor to have them filled prior to welding. Different welding gas suppliers handle tank filling
differently; some will fill the tanks while you wait while others require a tank exchange. You will need to select the type of supplier you prefer.
Attaching Regulators and Hoses
1. Secure the Mobile Max to an immovable object
such as a pole or a cart specifically designed to
hold the torch kit.
Note: Although the Mobile Max is intended to be
portable; it is important that the unit be secured so
it will not tip over during setup and operation.
2. Briefly open the oxygen tank valve (1) to remove
any debris that may have accumulated.
3. Wipe the oxygen regulator fitting (2) with a clean
dry cloth and tread the fitting onto the tank valve
and tighten with a wrench. Thread in the regulator
valve lever (3).
4. Using the acetylene tank valve key; briefly open
the acetylene tank valve (4) to remove any debris
that may have accumulated.
5. Wipe the acetylene regulator fitting (5) with a
clean dry cloth and thread the fitting onto the tank
valve and tighten with a wrench. Thread in the
regulator valve lever (3).
6. Using compressed air; blow out the hoses prior to
using them for the first time.
7. Attach the hoses to the regulators; green to the
oxygen and red to the acetylene and tighten with a
wrench.
8. Attach the other end of the hose to the appropriate
fittings on the torch handle and tighten with a
wrench.
Note: The acetylene hose has left hand (reverse)
treads and is marked with notches in the fitting (6).
3
4
1
Oxygen Tank
Valve
3
Acetylene
Regulator
Acetylene Tank
Valve Key
2
Oxygen
Regulator
5
Acetylene Tank
Valve
6
Hose Fittings
KDAR Company 4
Installation & Setup
It is important that all fittings have been tightened
with a wrench by this point.
Insure the tank valves, regulators valves and torch
handle valves are turned to the off position.
Opening Valves
1. Attach the welding tip and tighten with a wrench.
2. Slowly open (clockwise) the oxygen cylinder
valve to allow oxygen to flow to the regulator.
Once the regulator begins to register pressure,
open the valve an additional 1 to 1 1/2 turns.
Note: This must be done slowly, as a surge of
pressure could damage the regulator diaphragm.
3. Slowly open the acetylene tank valve with the
tank key. This valve turns left (counter clockwise)
to open. Open slowly and not more then 1 turn.
4. Check for leaks. Leaks can not be seen, therefore,
use soapy water on all connection points to insure
there are no leaks.
Setting Working Pressures—Welding
WA RN I N G
While setting working pressure gases will
be released from the torch. It is important
that no open flame or other heat source is
present during this operation.
1. Attach the welding tip to the end of the torch handle opposite the hose attachment and tighten with
a wrench.
Note: The working pressure for the welding tip supplied with the Mobile Max (#1) is a minimum of 3
and maximum of 5 P.I.S.G. for oxygen and Minimum
of 3 and maximum of 5 P.I.S.G. for acetylene. If
other tips are used consult the tip charts on page 9.
2. Open the acetylene control knob (1) on the torch
handle by turning it clockwise. Turn the control
lever on the acetylene regulator until the desired
working pressure is reached. Once the working
pressure is reached turn off the control knob on
the torch handle. The regulator gauge reading
may increase slightly.
3. Open the oxygen control knob (2) on the torch
handle by turning it clockwise. Turn the control
lever on the oxygen regulator until the desired
working pressure is reached. Once the working
pressure is reached turn off the control knob on
the torch handle. The regulator gauge reading
may increase slightly.
Note: The Mobile Max is equipped with single stage
regulators and as such the working pressure may
need to be adjusted as the gas pressure in the tanks
decreases.
2
1
WA RN I N G
Prior to lighting the torch make sure the
hoses are behind the operator and that
there is no chance of them being hit by a
hot spark or slag.
KDAR Company 5
Operation
WA RN I N G
At this point the operator should be wearing appropriate protective clothing such as
gloves and goggles.
Lighting the Torch
1. Open the acetylene control knob on the torch handle just enough to let some gas flow.
2. Holding the striker close to the welding tip
squeeze it a few times to create the sparks required to light the acetylene.
Note: A oxyacetylene torch should NEVER be lit
with oxygen present in the mixture.
Adjusting the Flame
1. If the acetylene is set too high the flame will be a
few inches away from the tip. Reduce the amount
of acetylene by turning the acetylene control knob
counter clockwise.
2. When the flame is about 8—10 inches long and
only has a small amount of black smoke; begin to
introduce oxygen by turning the oxygen control
knob clockwise.
3. As oxygen is added the flame will turn from a
yellow-orange to a whitish color and flame will
have three distinct cones (Figure 1). This is called
a carburizing flame and is not hot enough for
welding.
4. As oxygen is added to the mix the acetylene
feather will shrink and disappear into the cone
(Figure 2). This a neutral flame and is ideal for
welding.
5. If additional oxygen is added the cone will become shorter and fuzzy (Figure 3). This is a oxidizing flame and will cause breakdowns in the
material being welded and the weld itself.
Once a neutral flame has been achieved the torch
is ready for welding.
Heat Envelope
Acetylene
Feather
Beginning
Figure 1
Figure 2
Short Heat Envelope
Figure 3
of Cone
Heat Envelope
Sharp,
Bright Cone
Short, Fuzzy
Cone
KDAR Company 6
Operation
Shutting Down
1. Using the acetylene control knob turn off the
flow of acetylene to the welding tip. This will
allow oxygen to continue to flow and will insure
any debris that may be in the orifice is blow out.
2. Turn off the oxygen using the oxygen control
knob on the torch handle.
3. If shutting down for only a short period of time,
close the tank valve on both the acetylene and
oxygen and leave the hoses filled with gas.
4. If shutting down for a longer per of time, close
the tank valve on both the acetylene and oxygen.
5. Bleed the acetylene line by opening the acetylene control knob on the torch handle. Watch the
regulator gauge, it should move to reading zero.
6. Close the acetylene control knob on the torch
handle.
7. Bleed the oxygen line by opening the oxygen
control knob on the torch handle. Watch the
regulator gauge, it should move to reading zero.
8. Finally release the pressure on the regulator diaphragm by opening the regulator valve until little
or no pressure is felt. This will significantly improve the life of the regulator.
Setting Working Pressures—Cutting
WA RN I N G
While setting working pressure gases will
be released from the torch. It is important
that no open flame or other heat source is
present during this operation.
Note: At this point the tanks should be turned off
and both the acetylene and oxygen lines cleared of
gas.
1. Remove the welding tip from the torch handle
and attach the cutting head. Tighten with a
wrench.
2. Insure that the both the acetylene and oxygen
control knobs on the torch handle are closed
(clockwise).
3. Insure the oxygen control knob (1) on the cutting
head is closed (clockwise).
1
4. Select the appropriate cutting tip for the material
being cut and attach it to the cutting head (the
Mobile Max is shipped with a #1 tip assembled
to the cutting head). Tighten with a wrench.
Note: The chart on page can be used as a guide
for selecting the correct tip for the job.
5. Close (counter clockwise) both the acetylene and
oxygen regulator valves.
6. Slowly open (counter clockwise) the oxygen cylinder valve to allow oxygen to flow to the regulator. Once the regulator begins to register pressure, open the valve an additional 1 to 1 1/2
turns.
Note: This must be done slowly, as a surge of
pressure could damage the regulator diaphragm.
7. Open the oxygen regulator until the regulator
reaches the desired working pressure.
Note: Working pressure charts are found on
page 9.
KDAR Company 7
Operation
8. Check all connections for leaks. Leaks can not
be seen, therefore, use soapy water on all connection points to insure there are no leaks.
9. Open the oxygen control knob on the torch handle two full turns. No oxygen should flow at this
time because the oxygen flow is controlled by
the valve on the cutting head.
10. Insure oxygen flows by turning the control knob
on the cutting head a quarter of turn. Quickly
close the valve after confirming oxygen flow.
11. Press the oxygen cutting lever (1) briefly to confirm a steam of oxygen flows from the center
hole in the cutting tip.
1
12. Slowly open the acetylene tank valve with the
tank key. This valve turns left (counter clockwise) to open. Open slowly and not more then 1
turn.
13. Open the acetylene regulator until the regulator
reaches the desired working pressure.
Note: Working pressure charts are found on
page 9.
14. Briefly open the acetylene control knob on the
torch handle to confirm acetylene is flowing.
15. Check all connections for leaks using soapy water..
Lighting the Torch
WA RN I N G
Prior to lighting the torch make sure the
hoses are behind the operator and that
there is no chance of them being hit by a
hot spark or slag.
At this point the operator should be wearing appropriate protective clothing such as
gloves and goggles.
1. Open the acetylene control knob on the torch
handle just enough to let some gas flow about a
quarter turn.
2. Holding the striker close to the cutting tip
squeeze it a few times to create the sparks required to light the acetylene.
Note: A oxyacetylene torch should NEVER be lit
with oxygen present in the mixture.
Adjusting the Flame
1. Open the oxygen valve on the cutting head.
2. Develop a neutral flame at the preheat holes
(Figure 4) by that results in a cone about 1/8th
inch long. This is accomplished by alternately
increasing the flow of acetylene and then oxygen.
Cutting Hole
Figure 4
Preheat Holes
KDAR Company 8
Operation
3. Press the oxygen cutting lever briefly to insure
oxygen is flowing through the cutting hole.
4. Further adjustment may now be needed to insure
a neutral flame in the preheat holes. Generally a
reduction in oxygen.
5. The torch is ready for cutting.
Shutting Down
1. Using the acetylene control knob on the torch
handle turn off the flow of acetylene to the welding tip. This will allow oxygen to continue to
flow and will insure any debris that may be in
the preheat holes is blow out.
2. Press the oxygen cutting lever to insure debris is
cleared from the cutting hole.
3. Turn off the oxygen using the oxygen control
knob on cutting head.
3. If shutting down for only a short period of time,
close the tank valve on both the acetylene and
oxygen tank and leave the hoses filled with gas.
4. If shutting down for a longer per of time, close
the tank valve on both the acetylene and oxygen
tanks.
5. Bleed the acetylene line by opening the acetylene control knob on the torch handle. Watch the
regulator gauge, it should move to reading zero.
6. Close the acetylene control knob on the torch
handle.
7. Bleed the oxygen line by opening the oxygen
control knob on the cutting head. Watch the
regulator gauge, it should move to reading zero.
8. Finally release the pressure on the regulator diaphragm by opening the regulator valve until little
or no pressure is felt. This will significantly improve the life of the regulator.
Welding Nozzle Chart
Oxygen Pressure
Metal
Thickness
Up to 1/32" 000 3 5 3 5
1/16"-3/64" 00 3 5 3 5
1/32"-5/64" 0 3 5 3 5
3/64"-3/32" 1 3 5 3 5
1/16"-1/8" 2 3 5 3 5
1/8"-3/16" 3 4 7 3 6
3/16"-1/4" 4 5 10 4 7
Tip
Size
P.S.I.G.
Min. Max. Min. Max.
Acetylene Pressure
P.S.I.G.
Cutting Tip Chart
Oxygen Pressure
Metal
Thickness
1/8" 000 20 25 3 5
1/4" 00 20 25 3 5
3/8" 0 25 30 3 5
1/2" 0 30 35 3 5
3/4" 1 30 35 3 5
1" 2 35 40 3 6
2" 3 40 45 4 8
3" 4 40 50 5 11
4" 5 45 55 6 13
Tip
Size Min. Max. Min. Max.
P.S.I.G.
Acetylene Pressure
P.S.I.G.
Heating Nozzle Chart
Acetylene
Pressure
Range
Tip
P.S.I.G. P.S.I.G.
Size
4 6-10 8-12 6 20 7 22
6 8-12 10-15 14 40 15 44
8 10-15 20-30 30 80 33 88
10 12-15 30-40 40 100 44 110
Oxygen
Pressure
Range
Acetylene Cubic
Feet/Hour
Min. Max. Min. Max.
Oxygen Cubic
Feet/Hour
KDAR Company 9
Maintenance and Additional Products
General Maintenance
1. Prior to EVERY use, inspect hoses for damage.
Note: Never try to repair damaged gas hoses.
Damaged hoses should be replaced.
2. Prior to EVERY use, check all connections for
leaks.
3. Clean splatter and slag off of the outside of
welding and cutting tips as required.
4. Regularly clean tip holes with a welding tip
cleaner (Hot Max P/N TC-1).
Note: Never use oil, grease, pipe dope or Teflon
tape on any part of the Mobile Max equipment.
Additional Hot Max Products
25 Amp Plasma Cutter
(PL-25)
Big Max
Propane
Torch
(500G)
Little Max
Propane
Torch
(50G)
Hot Max Stick Welders
300 Amp AC (AC300)
300/200 AC/DC (ACDC300/200)
Hot Max
Cutting Torch
Kits
(AC-1)
Hot Max MIG Welders
100 Amp (100WFG)
135 Amp (135WFG
175 Amp (175WFG)
KDAR Company 10
Phone: 866-939-9013 Fax: 636-922-4622
KDAR Company
15009 Manchester Rd. #283
Ballwin, MO 63011-4626
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