G150, GF150, G250,
GF250 & G350
PARTS, SERVICE
& REPAIR BULLETIN
G-SERIES REGULATORS
Manual No: 0056-3764
Issue Date: October 29, 2015
Revision: AB
VictorTechnologies.com
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Victor product. We are proud to have you as our customer and will strive to
provide you with the best service and reliability in the industry. This product is backed by our extensive
warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on
the web at www.VictorTechnologies.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB
product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential
hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Victor, an ESAB brand, is a Global Brand of manual and automation Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable products that have stood
the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working
environment within the welding industry.
WARNING
!
G-Series Regulators - G150, GF150, G250, GF250, G350
Parts, Service & Repair Bulletin
Service Manual Number 0056-3764
Published by:
Victor Technologies
2800 Airport Rd.
Denton, TX 76208
www.VictorTechnologies.com
Copyright 2015 by ESAB
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgment,
the Manufacturer assumes no liability for its use.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for
any loss or damage caused by any error or omission in this Manual, whether such
error results from negligence, accident, or any other cause.
For Printing Material Specification refer to Document 47x1909
Original Publication Date: November 21, 2013
Revision Date: October 29, 2015
Record the following information for Warranty purposes:
Where Purchased:_______________________________ __________
Purchase Date:__________________________________ __________
Power Supply Serial #:___________________________ __________
Torch Serial #:___________________________________ __________
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar
with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc
Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to
install, operate, or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be
sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used.
Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or
replacement become necessary, the manufacturer recommends that a telephone or written request for service advice
be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper use,
faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AND OTHERS!
TABLE OF CONTENTS
SECTION 1: SAFETY ............................................................................................. 1-1
1.0 Safety Precautions ...................................................................................................... 1-1
SECTION 2:
INTRODUCTION ............................................................................................. 2-1
2.01 How To Use This Manual ............................................................................................2-1
2.02 Equipment Identification ............................................................................................. 2-1
2.03 Receipt Of Equipment .................................................................................................2-1
2.04 Commonly Use Terms .................................................................................................2-1
SECTION 3: G150, GF150
SPECIFICATIONS ............................................................................................ 3-3
3.01 Light Duty Basic Dimensions ...................................................................................... 3-3
3.02 Exploded View ............................................................................................................3-4
3.03 Parts List ....................................................................................................................3-5
3.04 Repair Parts List .........................................................................................................3-7
SECTION 4: G150, GF150
SERVICE & REPAIR PROCEDURES ....................................................................... 4-1
4.01 Recommended Tools and Supplies for Repair Procedures .........................................4-1
4.02 Cleaning Procedures ................................................................................................... 4-1
4.03 Disassembly Procedures ............................................................................................4-1
4.04 Assembly Procedures ................................................................................................. 4-2
SECTION 5: G150, GF150
TEST PROCEDURES......................................................................................... 5-1
5.01 Recommended Tools and Supplies for Test Procedures .............................................5-1
5.02 Test & Set Procedures ................................................................................................5-1
SECTION 6: G150, GF150
TROUBLESHOOTING ........................................................................................ 6-1
SECTION 7: G250, GF250 & G350
SPECIFICATIONS ............................................................................................ 7-1
7.01 G250, GF250 MEDIUM DUTY BASIC DIMENSIONS .................................................... 7-1
7.02 G350 HEAVY DUTY BASIC DIMENSIONS ...................................................................7-2
7.03 G250, G350 EXPLODED VIEW .................................................................................... 7-3
7.04 PARTS LIST ................................................................................................................7-4
SECTION 8: G250, GF250 & G350
SERVICE & REPAIR PROCEDURES ....................................................................... 8-1
8.01 Recommended Tools and Supplies for Repair Procedures .........................................8-1
8.02 Cleaning Procedures ................................................................................................... 8-1
8.03 Disassembly Procedures ............................................................................................8-1
8.04 Assembly Procedures ................................................................................................. 8-2
SECTION 9: G250, GF250 & G350
TEST PROCEDURES......................................................................................... 9-1
9.01 Recommended Tools and Supplies for Test Procedures .............................................9-1
9.02 Test & Set Procedures ................................................................................................9-1
TABLE OF CONTENTS
SECTION 10: G250, GF250 & G350
TROUBLESHOOTING ....................................................................................... 10-1
INTERNATIONAL CONTACT INFORMATION ....................................................... REAR COVER
VICTOR G-SERIES REGULATOR
SECTION 1: SAFETY
1.0 Safety Precautions
Users of Victor, an ESAB brand, welding and plasma cutting equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet
the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations should be
observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator
and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- Its operation
- Location of emergency stops
- Its function
- Relevant safety precautions
- Welding and / or plasma cutting
2. The operator must ensure that:
- No unauthorized person stationed within the working area of the equipment when it is started up.
- No one is unprotected when the arc is struck.
3. The workplace must:
- Be suitable for the purpose
- Be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, flame proof
clothing, safety gloves.
- Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualified electrician.
- Appropriate fire extinguishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its
implementation in accordance with national law, electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
Victor can provide you with all necessary cutting protection and accessories.
Manual 0056-3764 1-1 SAFETY INSTRUCTIONS AND WARNINGS
VICTOR G-SERIES REGULATOR
WARNING
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your
breathing zone and the general area.
ARC R AYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and filter
lens and wear protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
Arc welding and cutting can be injurious to yourself and others.
Take precautions when welding and cutting. Ask for your employer's
safety practices which should be based on manufacturers' hazard
data.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmuffs or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERAT-
ING.
PROTECT YOURSELF AND OTHERS!
Do not use the power source for thawing frozen pipes.
WARNING
CAUTION
CAUTION
Class A equipment is not intended for use in residential locations
where the electrical power is provided by the public low-voltage
supply system. There may be potential difficulties in ensuring
electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.
This product is solely intended for metal removal. Any other use
may result in personal injury and / or equipment damage.
CAUTION
SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0056-3764
Read and understand the instruction manual before
installing or operating.
!
SECTION 2:
!
INTRODUCTION
VICTOR G-SERIES REGULATOR
2.01 How To Use This Manual
This Service Manual applies to just specification or part numbers
listed on page i.
To ensure safe operation, read the entire manual, including the
chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION, DANGER,
and NOTE may appear. Pay particular attention to the information
provided under these headings. These special annotations are
easily recognized as follows:
NOTE!
An operation, procedure, or background
information which requires additional
emphasis or is helpful in efficient operation
of the system.
CAUTION
!
A procedure which, if not properly followed,
may cause damage to the equipment.
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others
in the operating area.
2.02 Equipment Identification
The unit’s identification number (specification or part number),
model, and serial number usually appear on a data tag attached to
the rear panel. Equipment which does not have a data tag such as
torch and cable assemblies are identified only by the specification
or part number printed on loosely attached card or the shipping
container. Record these numbers on the bottom of page i for future
reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the invoice to
make sure it is complete and inspect the equipment for possible
damage due to shipping. If there is any damage, notify the carrier
immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area
listed in the inside back cover of this manual.
Include all equipment identification numbers as described above
along with a full description of the parts in error.
Move the equipment to the installation site before un-crating the
unit. Use care to avoid damaging the equipment when using bars,
hammers, etc., to un-crate the unit.
2.04 Commonly Use Terms
WARNING
Gives information regarding possible
electrical shock injury. Warnings will be
enclosed in a box such as this.
DANGER
Means immediate hazards which, if not
!
Additional copies of this manual may be purchased by contacting
Victor at the address and phone number in your area listed on
back cover of this manual. Include the Owner’s Manual number
and equipment identification numbers.
Electronic copies of this manual can also be downloaded at no
charge in Acrobat PDF format by going to the Victor web site
listed below
http://www.VictorTechnologies.com
avoided, will result in immediate, serious
personal injury or loss of life.
OUTLET PRESSURE: The pressure measured at the Regulator’s
outlet port.
INLET PRESSURE: The pressure measured immediately at the
Regulatory’s entry.
DROP: A change in outlet pressure from a no-flow to flowing condition while the inlet pressure remains constant.
RISE: An increase in outlet pressure as the inlet pressure decreases.
CREEP: A gradual increase in outlet pressure.
Manual 0056-3764 2-1 INTRODUCTION
VICTOR G-SERIES REGULATOR
This Page Intentionally Blank
INTRODUCTION 2-2 Manual 0056-3764
SIDE ENTRY
REAR ENTRY
A-12973
1.69 in.
45°
65°
65°
4.77 in.
2.65 in.
3.04 in.
3.45 in.
3.97 in.
2.64 in.
3.04 in.
4.70 in.
2.56 in.
3.73 in.
2.47 in.
1.5”
GAUGES
1.69 in.
65°
95°
SECTION 3: G150, GF150
SPECIFICATIONS
3.01 Light Duty Basic Dimensions
VICTOR G-SERIES REGULATOR
Figure 3-1: G150/GF150 Light Duty Basic Dimensions
Manual 0056-3764 3-3 G150, GF150 SPECIFICATIONS
VICTOR G-SERIES REGULATOR
A-12974
BODY
1
INLET SWIVEL
15
INLET NUT
16
OUTLET
18
H.P. GAUGE
19
20
FILTER
5
FRICTION DAMPER
6
VALVE SPRING
7
SEAT ASSEMBLY
8
GASKET
9
NOZZLE
10
BONNET
2
DIAPHRAGM
ASSEMBLY
3
SLIP RING
4
ADJUSTING
SPRING
11
SPRING BUTTON
12
ADJUSTING SCREW
13
ADJUSTING KNOB,
SCREW & DECAL
14
RETAINING RING
17
3.02 Exploded View
Figure 3-2: G150/GF150 Exploded View
G150, G250 SPECIFICATIONS 3-4 Manual0056-3764
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