Hot Max Torches MM-1 User Manual

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
1 Mulch Lane
St. Louis, MO 63044

Tel: [phone]
Fax: [phone]
Web Site: www.hotmaxtorches.com

SAFETY PRECAUTIONS AND WARNINGS

PLEASE READ BEFORE USING EQUIPMENT

WARNING

ARC RAYS CAN BURN SKIN AND EYES

 Gas welding and cutting produce intense ultraviolet and infrared rays that can burn skin and eyes
 Wear 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 light 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

 Gas cutting 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 cutting/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/cut coated metals, such as galvanized, lead, or cadmium plated steel. Before weld-

 Do not weld/cut containers with toxic, flammable, or reactive elements stored in them. They

 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 activities. The lens should conform to ANSI Z87.1 standards for testing.

other workers in the area from the light 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

ing, 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.

must be 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 ex-

ploding. 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 from a torch 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

KDAR Company 3

Goggles

Acetylene Tank

Key

Hose

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 ox-

ygen 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 (r ever se)

treads and is marked with notches in the fitting (6).

1

Oxygen Tank

Valve

3

Acetylene

Regulator

Acetylene Tank

Valve Key

6

2

Oxygen

Regulator

5

Acetylene Tank

Valve

Hose Fittings

3

4

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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 sur ge 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

WARNING

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 wor king pr essur e for the welding tip
supplied with the Mobile Max (#1) is a minimum of 3
and maximum of 5 PISG for oxygen and minimum of
3 and maximum of 5 PSIG 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

WARNING

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

WARNING

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

WARNING

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 tur ned 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 char t 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 sur ge of

pressure could damage the regulator diaphragm.

7. Open the oxygen regulator until the regulator
reaches the desired working pressure.

Note: Wor king pr essur e char ts ar e 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: Wor king pr essur e char ts ar e 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

WARNING

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 Min. Max. Min. Max.

P.S.I.G.

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 tr y to r epair 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 # 22034).

Note: Never use oil, grease, pipe dope, or Teflon
tape on any part of the Mobile Max equipment.

Hot Max Victor ® Style

3 Piece Torch Kits

Model VH-1 - Medium Duty

Model VHD-1 - Heavy Duty

Additional Hot Max Products

Model 100MC

Red Cart for MM-1 Mobile Max

Model VTK-MD

Medium Duty Victor ® Style

Torch Kit

Model VTK-HD-A

Heavy Duty Victor ® Style

Deluxe Gas Torch Kit

KDAR Company 10

Warranty

KDAR Company, and its affiliates, warrants that
all MM-1 Mobile Max torch kits covered under
this warranty is free from defects in material and
workmanship for one year from the date of pur­chase. KDAR also warrants that the hoses are free
from defects in material and workmanship for 90
days from the date of purchase. This warranty is
extended to the original purchaser who uses the
product in a consumer application (personal, resi­dential or household usage). All torch kits cov­ered under this limited warranty which are used in
commercial applications (i.e. income producing)

are warranted to be free from defects in material

and workmanship for 90 days from the date of
original purchase. The product covered under this
warranty is the MM-1 Mobile Max torch kit.

KDAR Company, and its affiliates, will repair or
replace, at KDAR’s sole discretion, parts found to
be defective in material or workmanship within
the warranty period. Warranty service will be
scheduled according to the normal work flow and
business hours of the service center doing the
work as well as the availability of replacement

parts. All decisions from KDAR Company re-

garding this limited warranty shall be final.

Original Purchaser’s Responsibility:

1. Retain the original cash register receipt as
proof of purchase.

2. Follow manual instructions regarding the care
and operation of your torch kit.

3. If warranty work is required, DO NOT RE-

TURN THIS TORCH KIT TO THE RE­TAILER. Contact KDAR Company for in-

structions. Visit www.hotmaxtorches.com or

call KDAR Company M-F 8AM-5PM CST to

locate the nearest Authorized Service Center.

Not Covered:

1. Transportation charges for sending or deliver­ing the torch kit to the Authorized Service
Center or returning the repaired or replacement
torch kit back to the customer. These charges
are the responsibility of the customer.

2. Damages caused by ordinary wear, abuse, rain,
freeze damage, negligence, accident or failure
to operate or maintain the torch kit in accord­ance with the instructions in the operator’s
manual supplied with the equipment.

3. Damage caused by unauthorized repair or al-

terations.

Exclusions and Limitations:

KDAR Company makes no other warranty of
any kind, express or implied. Implied warran­ties, including warranties of merchantability
and of fitness for a particular purpose, are
hereby disclaimed. The warranty service de­scribed above is the exclusive remedy under
this warranty; liability for incidental and conse-

quential damages is excluded to the extent per-

mitted by law.

This warranty gives you specific legal rights, and
you may have other rights which vary from state to
state. Some states do not allow a disclaimer of im­plied warranties, or the exclusion of incidental and
consequential damages, so the above disclaimers
and exclusions may not apply to you.

For warranty service or to obtain service parts
or accessories:

Call: [phone] M-F 8-5 PM, CST

Visit: www.hotmaxtorches.com
Write: KDAR Company

1 Mulch Lane
St. Louis, MO 63044

KDAR Company

1 Mulch Lane

St. Louis, MO 63044

Phone: [phone] Fax: [phone]