Operator S Manual Mobile Max Portable Torch Kit Model

Operator’s ManualMobile Max Portable Torch KitModel MM-1WARNING: Do not assemble, install or operate this equipment without reading ALL ofthis manual and the safety precautions and warnings illustrated in this manual.KDAR Company3671 New Town BlvdSt. Charles, MO 63301Tel: (636) 493-9920Fax: (636) 493-9921Web Site: www.hotmaxtorches.com

SAFETY PRECAUTIONS AND WARNINGSPLEASE READ BEFORE USING EQUIPMENTWARNING Keep children away from this equipmentProtect your self and others from possible injuryPacemaker wearers should consult with their doctor before operatingRead and follow all instructions in this manual before operatingAll installation, operation, and maintenance procedures are to be performed only by qualified individualsLIGHT RAYS CAN BURN SKIN AND EYES Gas welding and cutting produce intense ultraviolet and infrared rays that can burn skin and eyesWear face protection, either helmet or shield when operating with ANSI Z49.1 approved shade#9 recommended for all activities. The lens should conform to ANSI Z87.1 standards for testing.Wear approved safety glasses with side shields under the face protectionWarn others not to stare at the light as it can cause damage to the eyes. Provide barriers to protectother workers in the area from the light while operatingWear flame resistant gloves, clothing, and shoes when operatingFUMES AND GASES CAN BE HAZARDOUS Gas cutting produces fumes and gases and breathing these gases is hazardous to your healthKeep your head out of the fumes and do not breath the fumes while cutting/weldingWork only in a confined area if it has sufficient ventilation, or while wearing an air supplied respirator. Fumes from welding deplete the oxygen supply and can be harmful. Always be surethere is ample breathing airRead the MSDS sheets and the instructions from manufacturers for metals to be welded, coatings, and cleanersDo not use the welder near hydrocarbon vapors coming from degreasing, cleaning, or sprayingoperations. The heat and rays can react with solvent vapors to create the gas phosgene, a verytoxic gas and other irritating gasesDo not weld/cut coated metals, such as galvanized, lead, or cadmium plated steel. Before welding, all plating must be removed. The area must be well ventilated or an air supplied hood mustbe used. The coatings and chemicals when burned cause highly irritating and toxic fumes.Do not weld/cut containers with toxic, flammable, or reactive elements stored in them. Theymust 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 withside shields under approved helmets, wear proper body and hand protection, and wear flame resistant ear plugs to keep sparks from entering the earsKDAR Company1

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 arcsAlways keep cylinders in an upright position securely fastened to a fixed supportValve protection caps should always be in place and hand tight except when the cylinder is in useKeep all cylinders away from any welding or electrical circuitsNever allow the flame from a torch to contact a cylinderNever cut any type of pressurized cylinder, an explosion could resultAlways turn your face away from the valve when opening the cylinderRead and follow all instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in the Safety Standards before usingHOT 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 theOSHA standardsWear approved hearing protectorsWarn other workers nearby of the high noise level and hazardCALIFORNIA PROPOSITION 65 WARNINGSWarning! This product may expose you to chemicals including lead, which is known in the State ofCalifornia to cause cancer. For more information, go to www.P65Warnings.ca.gov.PRINCIPAL SAFETY STANDARDSAMERICAN WELDING SOCIETY AWS C5.2, Recommended Practices for Plasma Arc Cutting AWS F4.1, Recommended Safe Practices for the Preparation for Welding and CuttingOSHA STANDARDS OSHA 29 CFR 1910, Safety and Health StandardsNATIONAL FIRE PROTECTION ASSOCIATION NFPA Standard 70, National Electric Code NFPA Standard 51B, Cutting and Welding ProcessesAMERICAN 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 CuttingKDAR Company2

Installation & SetupFeatures, Benefits & FunctionsFeatures Brass & Stainless ConstructionWelds up to 1/4 Inch*Cuts up to 4 Inches*Welding Tip, #1 SizeCutting Tip, 1-3-101 Victor StyleTwin Welding Hose, 10’ x 3/16”Oxygen Regulator Acetylene RegulatorGoggles & StrikerTorch Handle & Cutting HeadHeavy Duty Molded Tote CarrierRefillable 20 Cubic Foot Oxygen Tank—CGA540Refillable 10 Cubic Foot Acetylene Tank—CGA200Built in Storage Unit with Clear Door*Larger Tip are Required to do this, Purchase SeparatelyFunctions Steel Cutting up to 4”*Welding up to 1/4”* Solders up to 3/4” Copper & BrassSilver Solders Attaches to Dual Purpose Cart (100MC), SoldSeparatelyCuts, Welds and Solders in One KitBenefits Everything in one Heavy Duty MoldedCaseMobile and Easy to Carry on Job Site Package Contents1. Acetylene Regulator2. Oxygen Regulator3. Acetylene Tank4. Oxygen Tank5. Torch Handle6. Welding Tip7. Cutting Head w/Tip8. Striker9. Heavy Duty Tote10. Goggles11. Acetylene Tank Key12. HoseAcetyleneRegulatorTorch g HeadStrikerWelding TipGogglesHeavy Duty ToteKDAR CompanyAcetylene TankKeyHose3

Installation & SetupOxygen & Acetylene FillingThe Mobile Max is shipped with the tanks empty. Therefore, you will have to take the tanks to a local weldinggas supply distributor to have them filled prior to welding. Different welding gas suppliers handle tank fillingdifferently; 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 Hoses1. Secure the Mobile Max to an immovable objectsuch as a pole or a cart specifically designed tohold the torch kit.1Note: Although the Mobile Max is intended tobe portable; it is important that the unit be securedso it will not tip over during setup and operation.2. Briefly open the oxygen tank valve (1) to removeany debris that may have accumulated.Oxygen TankValve3. Wipe the oxygen regulator fitting (2) with a cleandry cloth and tread the fitting onto the tank valveand tighten with a wrench. Thread in the regulatorvalve lever (3).34AcetyleneRegulator6. Using compressed air; blow out the hoses prior tousing them for the first time.7. Attach the hoses to the regulators; green to the oxygen and red to the acetylene and tighten with awrench.8. Attach the other end of the hose to the appropriatefittings on the torch handle and tighten with awrench.Note: The acetylene hose has left hand (r ever se)treads and is marked with notches in the fitting (6).KDAR CompanyOxygenRegulator54. Using the acetylene tank valve key; briefly openthe acetylene tank valve (4) to remove any debristhat may have accumulated.5. Wipe the acetylene regulator fitting (5) with aclean dry cloth and thread the fitting onto the tankvalve and tighten with a wrench. Thread in the regulator valve lever (3).32Acetylene TankValveAcetylene TankValve Key6Hose Fittings4

Installation & SetupIt is important that all fittings have been tightenedwith a wrench by this point.Insure the tank valves, regulators valves and torchhandle valves are turned to the off position.Opening Valves1. Attach the welding tip and tighten with a wrench.2. Slowly open (clockwise) the oxygen cylindervalve 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 ofpressure could damage the regulator diaphragm.3. Slowly open the acetylene tank valve with thetank key. This valve turns left (counter clockwise)to open. Open slowly and not more then 1 turn.2. Open the acetylene control knob (1) on the torchhandle by turning it clockwise. Turn the controllever on the acetylene regulator until the desiredworking pressure is reached. Once the workingpressure is reached turn off the control knob onthe torch handle. The regulator gauge readingmay increase slightly.3. Open the oxygen control knob (2) on the torchhandle by turning it clockwise. Turn the controllever on the oxygen regulator until the desiredworking pressure is reached. Once the workingpressure is reached turn off the control knob onthe torch handle. The regulator gauge readingmay increase slightly.Note: The Mobile Max is equipped with singlestage regulators and as such the working pressuremay need to be adjusted as the gas pressure in thetanks decreases.4. Check for leaks. Leaks can not be seen, therefore,use soapy water on all connection points to insurethere are no leaks.2Setting Working Pressures—WeldingWARNING While setting workingpressure gases will be released from the torch. It is important thatno 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 witha wrench.Note: The wor king pr essur e for the welding tipsupplied with the Mobile Max (#1) is a minimum of 3and maximum of 5 PISG for oxygen and minimum of3 and maximum of 5 PSIG for acetylene. If other tipsare used consult the tip charts on page 9.1WARNINGPrior to lighting the torch make sure thehoses are behind the operator and thatthere is no chance of them being hit by ahot spark or slag.KDAR Company5

OperationWARNINGAt this point the operator should be wearing appropriate protective clothing such asgloves and goggles.Once a neutral flame has been achieved the torchis ready for welding.Lighting the Torch1. Open the acetylene control knob on the torch handle just enough to let some gas flow.2. Holding the striker close to the welding tipsqueeze it a few times to create the sparks required to light the acetylene.Note: A oxyacetylene torch should NEVER be litwith oxygen present in the mixture.Heat EnvelopeAcetyleneFeatherFigure 1Beginningof ConeAdjusting the Flame1. If the acetylene is set too high the flame will be afew inches away from the tip. Reduce the amountof acetylene by turning the acetylene control knobcounter clockwise.2. When the flame is about 8—10 inches long andonly has a small amount of black smoke; begin tointroduce oxygen by turning the oxygen controlknob clockwise.Heat EnvelopeFigure 23. As oxygen is added the flame will turn from ayellow-orange to a whitish color and flame willhave three distinct cones (Figure 1). This is calleda carburizing flame and is not hot enough forwelding.Sharp,Bright ConeShort Heat Envelope4. As oxygen is added to the mix the acetylenefeather will shrink and disappear into the cone(Figure 2). This a neutral flame and is ideal forwelding.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 thematerial being welded and the weld itself.KDAR CompanyFigure 3Short, FuzzyCone6