M O D U L E 4 : T O D E M O N S T R A T E E F F I C I E N C Y I N P R O P E R S E T U P O F R E G U L A T O R S , G A S H O S E S , T O R C H H A N D L E S ,

A N D W E L D I N G N O Z Z L E S

EQUIPMENT SETUP

REGULATORS

REGULATOR SETUP

• Carefully inspect cylinder valve, regulator threads, and mating surfaces for traces of oil, grease, or dirt. • DO NOT wipe the mating

surface with your finger.

• Make sure the regulator has the correct pressure for the cylinder being used.

REGULATOR SETUP

• Momentarily open and close the cylinder valve (called “cracking”) which dislodges any loose contaminants that may be present.• Only open the valve slightly. If the value is opened too much the

cylinder could tip over.

• Do not stand directly in front of the valve. Stand behind or off to the side.

• “Crack” the cylinder in a well-ventilated area. If a mist(when using acetylene) is produced when the cylinder is cracked, let it rest for 30 minutes then try again. If this happens again, contact a gas agent.

REGULATOR SETUP

• Securely attach regulator to cylinder valve with a wrench.• Before attaching the regulator to the cylinder valve, carefully inspect

for damaged threads, dirt, dust, grease, oil, or other flammable substances.

• If any contaminants are present, remove them with a clean cloth.

• Connect gas hose to regulator outlet fitting.

• Release tension on the regulator adjusting screws. Turn them counterclockwise until all pressure is released.

TURNING ON CYLINDERS

• Recheck the regulator adjusting screws to ensure there is no tension.

• Stand so that the cylinder valve is between you and the regulator. Remember not in front of or behind the regulator, when opening a cylinder valve.

• Slowly and carefully

open the cylinder valve

until max pressure

registers on the gauge. Open the valve

completely to seal the

internal valve packing.

NOTE

- Open acetylene valves

¾ of a turn and no

more than 1 ½ a turn.

- All other gas valves

open completely.

GAS HOSES

GAS HOSE SETUP

• Examine the hose for cuts, burns, or cracking.

• Connect the hose to the regulator and tighten the connection firmly with a wrench.

• Adjust regulator to allow 3-5 PSIG to pass through the hose. Allow the flow of gas for 5-10 seconds to clear the hose of contaminants, then shut off flow.

GAS HOSE SAFETY

• Be certain valves and regulator connections are free of contaminants.• If oil, grease, or damage is found DO NOT use the cylinder. (same for

the regulator)

• Never stand directly in front of or behind a regulator when opening the cylinder valve.• Stand so that the cylinder valve is between you and the regulator.

• Always open the cylinder valve slowly and carefully.

• Always check for leaks on the regulator and cylinder valve connections.

TORCH & WELDING NOZZLE

TORCH HANDLE

• Since the cutting attachments and nozzles are all connected to this tool, it is integral to ensure the proper operational condition of the torch handle.

• Inspect torch handle head, valves, and hose connections for damage or contaminants.

• Examine check valves or flashback arrestors.

• Attach hose to torch handle with wrench.

WELDING NOZZLE

• Inspect cone end, coupling nut, O-rings, and welding nozzle for damage or contaminants.

• Connect the welding nozzle to the torch handle by HAND-TIGHTENING the coupling nut, do NOT use a wrench. A wrench could damage the O-rings creating a faulty seal.

• Clean torch tips with tip cleaners, wires, etc.

• Do not re-light torch tip with hot metal.

Tip Cleaner in UseWelding Tip Orifice Cleaner

LEAK TESTING THE SYSTEM

• You must test the system BEFORE lighting the torch.• Close the fuel control valves on the torch handle

• For oxygen, adjust the regulator to 20 PSIG and open.

• For other fuels, adjust the regulator to 10 PSIG and open.

• Close cylinder valves.

• Turn regulator adjusting screws counterclockwise ½ turn.

• Observe the gauges on the regulator for five minutes, if the gauges are inconsistent then there is a leak.

• Follow the appropriate leak detection solution procedure.

IMPORTANT

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