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2

These Safety Precautions are for your protection. They sum-marize precautionary information from the references listedin Additional Safety Information section. Before performing anyinstallation or operating procedures, be sure to read and fol-low the safety precautions listed below as well as all othermanuals, material safety data sheets, labels, etc. Failure to ob-serve Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS - Somewelding, cutting and gouging processes arenoisy and require ear protection. Hot metal cancause skin burns and heat rays may injureeyes. Training in the proper use of the pro-cesses and equipment is essential to preventaccidents. Also:

1. Always wear safety glasses with side shields in any work area,even if welding helmets, face shields, or goggles are also re-quired.

2. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt,cuffless trousers, high-topped shoes, and a welding helmet orcap for hair protection, to protect against hot sparks and hotmetal. A flameproof apron may also be desirable as protectionagainst radiated heat and sparks.

3. Hot sparks or metal can lodge in rolled up sleeves, trouserscuffs, or pockets. Sleeves and collars should be kept buttoned,and open pockets eliminated from the front of clothing.

4. Protect other personnel from hot sparks with a suitable non-flammable partition or curtains.

5. Use goggles over safety glasses when chipping slag or grind-ing. Chipped slag may be hot and can travel considerable dis-tances. Bystanders should also wear goggles over safetyglasses.

FIRES AND EXPLOSIONS - Heat from a flamecan act as an ignition source. Hot slag or sparkscan also cause fires or explosions. Therefore:

1. Remove all combustible materials well away from the workarea or completely cover the materials with a protective non-flammable covering. Combustible materials include wood,cloth, sawdust, liquid and gas fuels, solvents, paints and coat-ings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices infloors or wall openings and cause a hidden smoldering fire onthe floor below. Make certain that such openings are protectedfrom hot sparks and metal.

3. Do not weld, cut, or perform any other hot work on materials,containers, or piping until it has been completely cleaned sothat no substances on the material can produce flammable ortoxic vapors. Do not do hot work on closed containers. Theymay explode.

4. Have fire extinguishing equipment handy for instant use, suchas a garden hose, a pail of water or sand, or portable fireextinguisher. Be sure you are trained in its use.

5. After completing operations, inspect the work area to be surethat there are no hot sparks or hot metal which could cause alater fire. Use fire watchers when necessary.

6. For additional information, refer to NFPA Standard 51B, “FirePrevention in Use of Cutting and Welding Processes”, whichis available from the National Fire Protection Association,Batterymarch Park, Quincy, MA 02269.

FUMES AND GASES - Fumes and gases, par-ticularly in confined spaces, can cause dis-comfort or injury. Do not breathe fumes orgases from welding or cutting, Therefore:

1. Always provide adequate ventilation in the work area by natu-ral or mechanical ventilation means. Do not weld, cut, or gougeon materials such as galvanized steel, stainless steel, copper,zinc, lead, beryllium, or cadmium unless positive mechanicalventilation is provided. Do not breathe fumes and gases fromthese materials.

2. If you develop momentary eye, nose, or throat irritation whileoperating, this is an indication that ventilation is not adequate.Stop work at once and take necessary steps to improve venti-lation in the work area. Do not continue to operate if physicaldiscomfort persists.

3. Refer to ANSI/ASC Standard Z49.1 listed below for specificventilation recommendations.

4. WARNING: This product, when used for welding orcutting, produces fumes or gases whichcontain chemicals known to the State ofCalifornia to cause birth defects and, insome cases, cancer. (California Health &Safety Code §25249.5 et seq.)

EQUIPMENT MAINTENANCE - Faulty or improperlymaintained equipment, such as torches, hoses andregulators, can result in poor work, but even moreimportant, it can cause injury or death through fires.Therefore:

1. Always have qualified personnel perform the installation,troubleshooting, and maintenance work. Do not operate orrepair any equipment unless you are qualified to do so.

2. Keep all oxy-fuel equipment free of grease or oil. Grease, oil,and other similar combustible materials, when ignited, can burnviolently in the presence of oxygen.

3. Do not abuse any equipment or accessories. Keep equipmentaway from heat and wet conditions, oil or grease, corrosiveatmospheres and inclement weather.

4. Keep all safety devices in position and in good repair.5. Use equipment for its intended purpose. Do not modify it in

any manner.

GAS CYLINDER HANDLING - Gas cylinders, if mis-handled, can rupture or explode violently. Suddenrupture of a cylinder, valve or relief device can in-jure or kill you. Therefore:

1. Use the proper gas for the process and use the proper pres-sure reducing regulator designed to operate from the com-pressed gas cylinder. Do not use adaptors to mount the regu-lator on the cylinder. Maintain hoses and fittings in good con-dition. Follow manufacturer’s operating instructions for mount-ing the regulator to the gas cylinder.

2. Always secure cylinders in an upright position by chain or strapto suitable hand trucks, benches, walls, post, or racks. Neversecure cylinders to work tables or fixtures where they maybecome part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have the valveprotection cap in place on top of the cylinder if no regulators isinstalled. Secure and move cylinders by using suitable handtrucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, or flame of a weld-ing, cutting, or gouging operation. Never strike an arc on acylinder.

5. For additional information, refer to CGA Standard P-1, “Pre-cautions for Safe Handling of Compressed Gases in Cylin-ders:, which is available from the Compressed Gas Associa-tion, 1235 Jefferson Davis Highway, Arlington, VA 22202.

ADDITIONAL SAFETY INFORMATION - For moreinformation on safe practices for oxy-fuel weldingand cutting equipment, ask your distributor for acopy of “Precautions and Safe Practices for GasWelding, Cutting, and Heating”, Form 2035. Gasapparatus safety guidelines are also available onvideo cassettes from your distributor.

The following publications, which are available from the AmericanWelding Society, 550 N.W. LeJuene Road, Miami, FL 33126, arerecommended to you:1. ANSI/AWS Z49.1 - “Safety in Welding and Cutting”.2. AWS F4.1 - “Recommended Safe Practices for the Prepara-

tion for Welding and Cutting of Containers and Piping ThatHave Held Hazardous Substances”/

3. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

Means immediate hazards which, if not avoided,will result in immediate, serious personal in-jury or loss of life.Means potential hazards which could result inpersonal injury or loss of life.Means hazards which could result in minorpersonal injury.

MEANING OF SYMBOLS - As used throughoutthis manual: Means Attention! Be Alert! Yoursafety is involved.

SP-GA 10/98

SAFETY PRECAUTIONS

3

any doubt about the adequacy of gas flows, use anoxygen test gauge adaptor (P/N 07X17) and eitherthe acetylene (P/N 262510) or fuel gas (P/N 639422)test gauge adaptor while the torch is operating tomake sure that the recommended operating pres-sures are available at the torch inlet.

7. Manifold two or more fuel gas cylinders to assureadequate supply of fuel gas. The tables show thenumber of commonly used cylinders recommendedfor manifolding when using larger heads. If usingother cylinders or gases, check with your fuel gassupplier for recommended withdrawal rate informa-tion.

8. In the event of a flashback, immediately close bothoxygen and fuel gas valves on the torch (preferablyoxygen valve first). For greater protection, install1/4-turn quick shut off valve (P/N 999306) on thetorch oxygen hose connection.

AcetyleneHead Flowrate, Min. No. of Cylinders Required*Size cfh WK Cyl (300 cf) WTL Cyl. (390 cf)55 55 2 170 70 2 2100 100 3 2150 150 4 3200 200 5 4250 250 6 5

* Based on that max. hourly flowrate should not exceed 1/7 of cylinder capacityat 70° F. Example: 1/7 (300 cf WK cyl.) = 43 cfh max.

FG-2 (104 Ib. cyl.) Propane (100 Ib. cyl.)Head Min. No. of Min. No. ofSize Flowrate Cyl Req'd* Flowrate Cyl. Req'd** 70 43 1 40 1100 62 1 58 1150 93 1 86 2200 124 2 116 2250 - - 144 3

* Based on max. continuous withdrawal rate of 110 cfh for 104 Ib. cylinder,1/2 full @ 70° F.

** Based on max. continuous withdrawal rate of 65 cfh for 100 lb. cylinder,1/2 full @ 70° F.Withdrawal rate will increase with wind velocity and intermittent usage;reduce with lower temperature.

9. If the inner cone of the flame appears too short(less than 1/4-in.), you are lacking fuel gas and thehead will tend to overheat. Recheck the aboveprecaution with your set up.

10. Do not bring the head too close to the work. Maintaina distance of at least 1/4-in. between tip and work.

RECOMMENDED HOSE SIZES

Oxygen, Acetylene (medium-pressure) and NaturalGas (at pipeline pressure over 5 psig): With headsizes 4-30, 1/4-in. or 3/8-in. I.D. With head sizes 55 andlarger, 3/8-in I.D.

Acetylene (low-pressure) and Natural Gas (at pipe-line pressure below 5 psi): With head sizes 4-70, 3/8-in. I.D. hose. Head sizes 100-250, 1/2-in. hose. Donot use over 25 feet of hose.

SHUTTING OFFClose the fuel gas valve first, then the oxygen valve.

If operations are to be stopped for a half-hour or more,all pressure should be released from the torch hoses,and regulators by doing the following:

1. Close each cylinder or station valve.2. Open torch valves.3. After relieving the gases, back out the pressure-

adjusting screw of each regulator and close thetorch valves.

IMPORTANT OPERATING NOTES

1. Do not attempt to operate heads size 100 or largerfrom a low-pressure acetylene supply (less than 5psig).

2. Head size number of each welding and heatinghead indicates the rated acetylene capacity incubic feet/hour (cfh). For example, No. 55A re-quires about 55 cfh of acetylene at normal operat-ing pressure. However, on heating heads designedfor other fuel gases, the size indicates the approxi-mate equivalent heating capacity in terms of acety-lene flow. For example, No. 100A and No. 100FGprovide the same average heating output (147,000Btu/hr) but No. 100FG head really requires about62 cfh of FG-2, 57 cfh of propane, or 147 cfh ofnatural gas.

For consumption purposes, the following are the oxy-gen/fuel gas ratios normally required for welding andheating:1.1 to 1.5 cfh oxygen/1.0 cfh acetylene3.2 to 3.6 cfh oxygen/1.0 cfh FG-23.5 to 4.5 cfh oxygen/1.0 cfh propane1.7 to 2.0 cfh oxygen/1.0 cfh natural gas.

PRECAUTIONS - NO. 55 and LARGER HEADSLarge welding and heating heads (No. 55 and above)require high flow of oxygen and fuel gas for properoperation. Failure to follow the following precau-tions can result in serious overheating, flashback,and possible operator injury.

1. Read and understand the operating instructionspacked with your torch as well as these precautionsbefore lighting up the welding or heating head.

2. Always operate with oxygen and fuel gas pressuresgiven in the tables.

3. Do NOT use hose line reverse flow check valveswhen using No. 100 or larger welding or heatinghead.

4. Use 3/8-in. I.D. hoses when using No. 55 or largerwelding or heating head.

5. Do NOT use whip hose, hose splices, nor hosenipples smaller than 1/4-in. I.D. (“B”-size).

6. If using hose lengths greater than 25-ft., or if there is

4

Heating Head Operating Replacement Parts Tip Injector Tip ExtensionsAssembly Pressure Cleaning Cleaning (Accessory)

Fuel Tip Tip Mixer No. of Drill DrillSize� Part No. Oxygen Gas Ass’y Stem Nut Tube Injector Holes Size Size Length Part No.For Acetylene Use55 O-A 998819 35-40 1/2-5 998797 998792 639969 639971 01Z14 9 61 59 12-in. 19X4270 O-A 998820 45-50 1/2-5 998798 998792 639969 639972 01Z15 9 57 57 12-in. 19X42100 O-A 998821 55-60 1/2-5 998799 998793 33A59 16Z54 01Z21 13 57 56 15-in. 19X43200 O-A 998822 15-20 9-12� 998800 998794 998830 998832� 16 54 47 18-in. 998790250 O-A 998823 20-25 12-14� 998827 998826 998831 998832� 16 53 47 21-in. 998825For Fuel Gases Other Than Acetylene (FG-2, propane, natural gas, etc.)70 O-FG 999232 40-45 1/2-5 999224 998792 639969 639972 01Z23 8 51 54 12-in. 19X42100 O-FG 999233 50-70 1/2-5 999227 998793 33A59 16Z54 01Z99 8 52 56 15-in. 19X43200 O-FG 999234 30-55 6-11� 999230 998794 998830 998832� 21 52 47 18-in. 998790

Welding and Heating Head PartsTable 1 - Single-Flame Acetylene Welding Heads

Welding Replacement Parts Cleaning Drill TipHead Oxygen (Size No.) ExtensionAssembly Metal Thickness Pressure Tip Mixer for for (Accessory)Size� Part No. In. mm. psi� Tip Nut Tube Injector Tip Injector Length Part No.4A 639865 1/32-1/16 0.8-1.6 7-18 639684 16Z26 01Z06 64 796A 639866 1/16-3/32 1.6-2.4 8-20 639685 16Z27 01Z07 58 779A 639867 3/32-1/8 2.4-3.2 10-24 639686 639870 16Z28 01Z08 55 7512A 17270 1/8-3/16 3.2-4.8 10-25 17266 16Z29 01Z09 53 7315A 639868 3/16-1/4 4.8-6 11-26 639687 16Z30 01Z10 53 7130A 639869 1/4-1/2 6-13 18-29 17261 998847 16Z32 01Z12 45 6555A 998101 1/2-3/4 13-19 25-39 998060 639969 639971 01Z14 33 59 12-in. 19X4270A 998102 3/4-1 19-25 22-30 998061 639969 639972 01Z15 30 57100A 10X03 45-55 998062 33A59 16Z54 01Z21 25 56 15-in. 19X43150A 10X05 Heating 50-60 64Z22 33A58 16Z56 01Z23 17 54 18-in. 19X44250A 10X07 70-80 12Z80 33A63 16Z58 01Z25 1/4-in. 52 21-in. 19X45

Table 2 - Standard Multiflame Heads

Heating Head Replacement Parts Tip Cleaning Injector Tip ExtensionsAssembly Oxygen Cleaning (Accessory)

Pressure Tip Mixer No. of Drill DrilllSize� Part No. psi� Tip Nut Tube Injector Holes Size Size Length Part No.For Acetylene Use70A 998047 40-45 998071 639969 639972 01Z15 7 56 57 12-in. 19X42100A 11X22 55-60 998072 33A59 16Z54 01Z21 8 55 56 15-in. 19X43150A 11X24 60-65 998073 33A58 16Z56 01Z23 12 55 54 18-in. 19X44250A 11X26 75-80 12Y44 33A63 16Z58 01Z25 12 55 52 21-in. 19X45For FG-2 Use70 FG 998038 33-70 998078 639969 639972 01Z25 7 54 52 12-in. 19X42100 FG-2 998281 34-88 998079 33A59 16Z54 01Z25 8 48 52 15-in. 19X43150 FG-2 998265 32-70 998036 33A58 16Z56 998286 12 48 46 18-in. 19X44For Fuel Gases Other Than Acetylene & FG-270 FG 998038 33-70 998078 639969 639972 01Z25 7 54 52 12-in. 19X42100 FG 11X32 45-55 998079 33A59 16Z54 01Z21 8 48 56 15-in. 19X43150 FG 11X34 50-60 998036 33A58 16Z56 01Z23 12 48 54 18-in. 19X44250 FG 11X36 70-80 12Y60 33A63 16Z58 01Z99 20 48 50 21-in. 19X45

Table 3 -Rosebud-Style Multiflame Heating Heads

� Size indicates approximate acetylene flow rate in cu. ft./hr (cfh) at normal operating pressure. See Important Operating Notes on pg. 3.� Acetylene pressure is 1/2 to 5 psi.

� See Important Operating Notes on pg. 3.� Fuel Gas pressure is 1/2 to 5 psi.

� See Important Operating Notes on pg. 3. This stainless steel extension requires coupling 998838 for 200 size; 998839 for 250 size.� IMPORTANT: P/N 998832 is a mixer; not an injector for low fuel gas pressure. Be sure to use operating pressures as given.

††

††

5

TESTING FOR LEAKS

Every welding and cutting outfit should be thoroughlytested for leaks after it is first hooked up, and at regularintervals thereafter. After all connections have beenmade, make sure both valves on the torch handle areclosed. Then turn in the regulator pressure-adjustingscrew until the oxygen delivery-pressure gauge regis-ters 50 psi, the acetylene delivery-pressure gaugeregisters 10 psi. Using Leak Test Solution suitable foroxygen service, such as P/N 998771 (8 oz. container),check for leaks at the cylinder valves, the cylinder-to-regulator connections, the regulator-to-hose connec-tions, and the hose-to-torch connections. If bubbling atany point indicates leakage, tighten the connection. Ifthis does not stop the leakage, close the appropriatecylinder valve, open the torch valve to remove allpressure from the line, and finally release the regulatorpressure-adjusting screw by turning it counterclock-wise. Then break the leaky connection, wipe metalseating surfaces with a clean, dry cloth, and examinethem for nicks and scratches. Remake the connection(s)and retest. Do not try to light the torch until you aresatisfied that all connections are gas-tight.

After lighting the torch, and adjusting the flames, useleak test solution to check for leakage at all torch valves,and at the connection between the torch handle and thewelding head or cutting attachment.

OPERATING PRECAUTIONS

Flow: There must be proper flow of gases for safeoperation and full performance. This requires the fol-lowing three conditions: (1) the regulators that deter-mine the inlet pressure to the hoses must be set to thecorrect pressure: (2) the hoses and their connectorsmust have adequate capacity for the job (hoses that

are too long, too small or have connectors with smallpassageways can cause problems); and (3) the throttlevalves on the torch must be adjusted with the proce-dure shown in these instructions.

Note: Items (1) and (2) can be checked by measuringthe gas pressures at the torch. Gauge adaptorsare available for this purpose.

Backfire: Improper operation of the torch may causethe flame to go out with a loud ‘pop’. Such a backfiremay be caused by contact of the tip with the work,spatter from the tip, or by attempting to operate with toosmall a flame. After a backfire, you can normally relightthe flame immediately. If backfires occur repeatedly,shut off the torch. Then reopen the oxygen valve,check for correct oxygen pressure, and test for leak-age at the welding head connection nut and tip connec-tion nut. If there is leakage at either point, correct it (bytightening the tip, or cleaning the seating surfaces onthe injector and in the torch body) before resumingwork.

Flashback: Under certain circumstances, the flamemay not ‘pop’ out (backfire) but instead burn back insidethe torch with a shrill hissing or squeal. This is called a‘flashback’. A flashback should never occur if (1) theequipment is in good condition; (2) preheat ports oncutting nozzles or welding tips are cleaned frequently;(3) operating pressures are correct; and (4) throttlevalves are adjusted properly. Should a flashback occur,IMMEDIATELY shut off the torch. Allow it to cool off forat least a minute. Then check your nozzle or tip, gaspressure, readjust regulators if necessary, and relightthe torch. If flashback recurs, send the torch handle andwelding head or cutting attachment to ESABRemanufacturing Center or to your distributor for re-pair.

6

MAINTENANCE INSTRUCTIONS

For all repairs other than those covered below,send the apparatus to your welding equipmentdistributor or to ESAB Remanufacturing Center,Ebenezer Road, Florence, SC 29501. Improperlyrepaired apparatus is hazardous.

Torch Valves: Leakage around either throttle valvecan usually be corrected by tightening the packing nutslightly. If it cannot be corrected, replace throttle valveassembly.

If either valve fails to shut off completely, remove thethrottle valve assembly from torch and wipe the ballseat on the end of the stem with a clean cloth. Thenreinstall the valve and tighten it heavily several times. Ifthis does not eliminate leakage, try a new throttle valveassembly. If then the valve does not shut off completely,send the torch handle to a repair station for reseating ofthe body.

Tip Cleaning: If a welding tip produces a distorted,irregular flame, clean the tip with an OXWELD tipcleaner, or the correct size twist drill (see table on page4). Do not attempt to clean with any other type of tool.When using cleaning drills, push the drill straight in andout; do not twist.

Injector Cleaning: The relative small central oxygenorifice in an injector may become partially clogged withsmall particles conveyed in the oxygen stream orcarbon particles produced by backfires. To clean orreplace an injector, remove it from the mixer tube (afterremoving the connection nut retaining ring and slidingthe nut forward) by grasping it with a pair of pliersbetween the seating surfaces and pulling it straight outwith steady force. Take great care not to mar theinjector seats or O-rings with the pliers. Clean thecentral (oxygen) orifice with the correct size twist drill(see table on page 4). Use no other tools. Replace O-rings if damaged or worn. Replace the injector if its rearseats are marred. When reinstalling injector, be sure topush it in until its retaining O-ring is firmly seated in themixer tube.

7

PARTS INFORMATION

All parts which can be replaced without breaking soldered or brazed joints are illustrated and listed below. Whenordering parts, please give both part number and description (including size where appropriate). Parts may be or-dered from your welding equipment distributor or from ESAB Welding & Cutting Products, Customer Service Depart-ment, Florence, SC.

W-17 Welding Torch Handle ...................... P/N 4250

*O-rings included with Injector. **Except rosebud head assemblies 998822, 998823, 998234 use head nut 998787 and retaining ring 998553.NOTE: If you are having problems inserting the above heads (injector with 3 O-rings) into an old torch handle

made prior to 1978, have the torch handle reseated by an authorized distributor repair service.

THROTTLE VALVE ASSEMBLY (OXY.) - 54A82

THROTTLE VALVE ASSEMBLY (F.G.) - 54A91

SeeNote

STEM (ROSEBUD HEAD)(See Table 3)

TIP (ROSEBUDHEAD) (See Table 3)

TIP (STD.MF HEAD)

(See Table 2)

TIP(WELD HEAD)(See Table 1)

TIP NUT(See Tables)

RING37A41(For All

Heads**)

HEAD NUT36Z39(For All

Heads**)

MIXER TUBE(See Tables)

INJECTOR(See Tables)

*O-RING14K10

206410486W51

NOTE: Apply X-pando Compound (7358-5950) on stem threads before assembly.

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IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com

Hours: 7:30 AM to 5:00 PM EST

A. CUSTOMER SERVICE QUESTIONS:Order Entry Product Availability Pricing DeliveryOrder Changes Saleable Goods Returns Shipping Information

Eastern Distribution Center Telephone: (800)362-7080 / Fax: (800) 634-7548

Central Distribution Center Telephone: (800)783-5360 / Fax: (800) 783-5362

Western Distribution Center Telephone: (800) 235-4012/ Fax: (888) 586-4670

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM ESTWarranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM ESTPerformance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:Telephone: (843)664-4428 / Fax: (843) 679-5864Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:Telephone: (800) ESAB-123 / Fax: (843) 664-4454 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

ESAB Welding & Cutting Products, Florence, SC Welding EquipmentCOMMUNICATION GUIDE - CUSTOMER SERVICES