ESAB PM-GST Post-Mix Hand Cutting Torch Troubleshooting instruction

Brand: ESAB

Model: PM-GST Post-Mix Hand Cutting Torch

Type: Troubleshooting instruction

This manual is also suitable for

OXWELD® PM-GST Post-Mix Hand Cutting Torch

ESAB PM-GST Post-Mix Hand Cutting Torch is a versatile tool for manual cutting operations that require the torch to be ready for immediate use, such as emergency hot cast billet cutting. It provides substantial gas savings in pilot mode and features highly efficient mixing of gases due to the distribution of preheat and shielding gases around the cutting oxygen stream. This results in an exceptionally long high-heat zone, allowing for increased torch-to-workpiece standoff, which extends the life of the torch and nozzle.

INSTRUCTIONS for

F-15-365-C

July, 2000

Be sure this information reaches the operator.

You can get extra copies through your supplier.

DO NOT use torch with any fuel gas except natural

gas or propane. Using other fuel gases can over-

heat and damage the torch which can cause per-

sonal injury.

The PM-GST Cutting Torch is a post mixed design per-

mitting the oxygen and fuel gas to be mixed externally

near the exit end of the torch. No internal mixing of the

combustibles occurs in the torch. Highly efficient mixing

occurs due to the distribution of preheat gases and

shielding gases around the cutting oxygen stream. This

produces an extraordinarily long high-heat zone permit-

ting high standoff of torch to workpiece, thus increasing

the life of the torch and nozzle.

The PM-GST was designed for manual cutting opera-

tions that require torch to be in the stand-by pilot flame

mode ready for immediate use, such as emergency hot

cast billet cutting. The PM-GST (Post-Mix-Gas Saving

Torch) provides substantial gas savings in pilot mode

but remains ready for cutting without the operator hav-

ing to light the torch.

The PM-GST Cutting Torch can be used on hot or cold

material and because of intense preheat capability pro-

vides extremely fast starts and cutting speeds.

DO NOT position the torch with the pilot flame ig-

nited close to any combustible materials. When pi-

lot flame is ignited torch must be held firmly by the

operator or in a stand-by holding fixture.

OPERATING INSTRUCTIONS

EQUIPMENT REQUIRED (See Fig. 1)

1. Hoses - To obtain the best performance from the

PM-GST Torch, use 1/2 -in. (12.7 mm) I.D. hose for

oxygen and 3/8-in. (9.5 mm) I.D. hose for fuel gas.

Attach 1/2-in. oxygen hose, such as P/N 2120399

(50-ft.) with proper size fittings (7/8"-14 right hand

threads) to the oxygen supply regulator. Attach

3/8-in. fuel gas hose (9/16-18 left hand threads) to

fuel gas supply regulator. Heat protection of hoses

is recommended when working over hot cutting ar-

eas. (Note: 3/8-in. I.D. oxygen hose may be used

but torch performance will be reduced. To use 3/8-

in. I. D. oxygen hose order P/N 18X19, “C” to “B”

adaptor.)

2. Regulation - High-Flow Two Outlet Regulation

Panel, P/N 2119101. Panel is complete with R-52

Oxygen regulator, oxygen filter, R-6702 Fuel Gas

Regulator, and H-16 Fuel Gas Safety Valve. It is

OSHA approved, preassembled, and ready for per-

manent or portable wall or column mounting.

3. Cutting Nozzles - Select desired nozzle from Cut-

ting Data table.

OPTIONAL ACCESSORIES

1. Riding Skid, P/N 22073.

CONNECTING

1. Before connecting, make sure all metal seating sur-

faces of hoses, torch, and regulators are not dam-

aged and cleaned free of grease and oil.

2. Connect hoses (1 oxygen; 1 fuel gas) to the proper

fitting on the torch and to the manual valves down-

PM-GST

POST-MIX HAND CUTTING TORCH

(See Fig. 2 for listing of available torch assemblies.)

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for oxy-fuel

gas equipment, we urge you to read our booklet “Precautions and Safe Practices for Gas Welding, Cutting and Heating,” Form 2035. 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.

The cutting torches covered by these instructions are listed by Underwriter’s Laboratories only when using parts manufactured by ESAB Welding

& Cutting Products to the specifications on file with Underwriter’s Laboratories, Inc., and when they are used in the gas service for which they are

designed and listed. The use of other parts voids the manufacturer’s warranty.

These Safety Precautions are for your protection. They sum-

marize precautionary information from the references listed

in Additional Safety Information section. Before performing any

installation or operating procedures, be sure to read and fol-

low the safety precautions listed below as well as all other

manuals, material safety data sheets, labels, etc. Failure to ob-

serve Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS - Some

welding, cutting and gouging processes are

noisy and require ear protection. Hot metal can

cause skin burns and heat rays may injure

eyes. Training in the proper use of the pro-

cesses and equipment is essential to prevent

accidents. 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 or

cap for hair protection, to protect against hot sparks and hot

metal. A flameproof apron may also be desirable as protection

against radiated heat and sparks.

3. Hot sparks or metal can lodge in rolled up sleeves, trousers

cuffs, 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 safety

glasses.

FIRES AND EXPLOSIONS - Heat from a flame

can act as an ignition source. Hot slag or sparks

can also cause fires or explosions. Therefore:

1. Remove all combustible materials well away from the work

area 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 in

floors or wall openings and cause a hidden smoldering fire on

the floor below. Make certain that such openings are protected

from 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 so

that no substances on the material can produce flammable or

toxic vapors. Do not do hot work on closed containers. They

may explode.

4. Have fire extinguishing equipment handy for instant use, such

as a garden hose, a pail of water or sand, or portable fire

extinguisher. Be sure you are trained in its use.

5. After completing operations, inspect the work area to be sure

that there are no hot sparks or hot metal which could cause a

later fire. Use fire watchers when necessary.

6. For additional information, refer to NFPA Standard 51B, “Fire

Prevention in Use of Cutting and Welding Processes”, which

is 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 or

gases 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 gouge

on materials such as galvanized steel, stainless steel, copper,

zinc, lead, beryllium, or cadmium unless positive mechanical

ventilation is provided. Do not breathe fumes and gases from

these materials.

2. If you develop momentary eye, nose, or throat irritation while

operating, 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 physical

discomfort persists.

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

ventilation recommendations.

4. WARNING: This product, when used for welding or

cutting, produces fumes or gases which

contain chemicals known to the State of

California to cause birth defects and, in

some cases, cancer. (California Health &

Safety Code §25249.5 et seq.)

EQUIPMENT MAINTENANCE - Faulty or improp-

erly maintained equipment, such as torches, hoses

and regulators, can result in poor work, but even

more important, it can cause injury or death

through fires. Therefore:

1. Always have qualified personnel perform the installation,

troubleshooting, and maintenance work. Do not operate or

repair 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 burn

violently in the presence of oxygen.

3. Do not abuse any equipment or accessories. Keep equipment

away from heat and wet conditions, oil or grease, corrosive

atmospheres 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. Sudden

rupture 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 strap

to suitable hand trucks, benches, walls, post, or racks. Never

secure cylinders to work tables or fixtures where they may

become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have the valve

protection cap in place on top of the cylinder if no regulators is

installed. Secure and move cylinders by using suitable hand

trucks. 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 a

cylinder.

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 more

information on safe practices for oxy-fuel welding

and cutting equipment, ask your distributor for a

copy of “Precautions and Safe Practices for Gas

Welding, Cutting, and Heating”, Form 2035. Gas

apparatus safety guidelines are also available on

video cassettes from your distributor.

The following publications, which are available from the American

Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are

recommended 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 That

Have 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 in

personal injury or loss of life.

Means hazards which could result in minor

personal injury.

MEANING OF SYMBOLS - As used throughout

this manual: Means Attention! Be Alert! Your

safety is involved.

SP-GA 10/98

SAFETY PRECAUTIONS

NOTE: The optimal amount of preheat oxygen is auto-

matically regulated by the torch. The pilot oxy-

gen valve is used only to adjust the pilot flame.

Cutting: Preheating is done while cutting lever is fully

depressed. Position torch on the far side of steel to be

cut. While maintaining at least 4 in. nozzle-to-work stand-

off, position the flame on the edge of the steel. Pull torch

towards you to begin cutting.

NOTE: The flame is hottest at the edge of the cutting

oxygen stream. Placing the edge of the cutting

oxygen stream on the edge of the steel will give

the fastest starts.

Torch head, nozzle, and nozzle nut become VERY

hot while pilot flame is on and remain hot for sev-

eral minutes after torch is turned off. Do NOT allow

hot torch to contact anything flammable.

SHUTTING OFF

1. Release cutting oxygen lever.

2. Close the pilot oxygen and fuel gas valves.

If operations are to be stopped for a half-hour or more,

pressure should be released from all regulators in the

following order:

1. Close station valve of each gas supply.

2. Open all torch shutoff valves.

3. When pressure on each regulator gauge drops down

to zero, back out regulator pressure-adjusting screw.

4. Close torch shutoff valves.

OPERATING PRECAUTIONS

Flow: There must be proper flow of gases for safe op-

eration and full performance. This requires the following

three conditions: (1) the regulators that determine the

inlet pressure to the hoses must be set to the correct

pressure: (2) the hoses and their connectors must have

adequate capacity for the job (hoses that are too long,

too small or have connectors with small passageways

can cause problems); and (3) the throttle valves on the

torch must be adjusted with the procedure shown in these

instructions.

NOTE: Items (1) and (2) can be checked by measuring

the gas pressures at the torch. Gauge adaptors

are available for this purpose.

Backfire: Improper operation of the torch may cause

the flames to go out with a loud “pop”. Such a backfire

may be caused by contact of nozzle with the work, by

the use of incorrect gas pressures or by leakage at the

cutting nozzle seats due to dirt or nicks on the seats or

to a loose nozzle nut.

ADJUSTING GAS PRESSURES

1. Depress the cutting lever fully. Adjust cutting oxy-

gen regulator to the desired pressure (see Figure 1)

compensating for any line loss to the torch through

the hose and valve. Then immediately release the

lever.

2. Adjust fuel gas regulator to provide 20 psig at the

torch with flow.

TESTING FOR LEAKS

The system should be thoroughly tested for leaks after

it is first hooked up, and at regular intervals thereafter.

With the system pressurized down to the shutoff valves,

apply Leak Test Solution suitable for oxygen service,

such as P/N 998771 (8 oz. container), on all joints and

connections. Bubbling of the solution indicates leakage.

If leakage is detected, tighten the connection. If this does

not stop leakage, then shut off the appropriate gas sup-

ply and open the torch valve to remove pressure from

the system. Break the leaky connection, wipe metal seat-

ing surface with a clean dry cloth, and examine them for

nicks and scratches. Remake the connection(s) and re-

test. Do not try to light the torch until you are satisfied

that all connections are gas tight.

After lighting the torch and adjusting the flames, use leak

test solution to check for leakage around hose connec-

tions at each valve and torch fitting.

LIGHTING AND FLAME ADJUSTMENT

Lighting Pilot Flame: Open fuel gas valve fully and light

the gas about 2 inches from the nozzle with a friction

lighter. DO NOT use a match. Use of a match can seri-

ously burn your hand. Slowly open the pilot oxygen valve

until the pilot flame is adjusted as desired. For best per-

formance, a flame extending just beyond the nozzle skirt

is recommended.

Cutting Flame Adjustment: While torch is lit in pilot

mode, point torch in a safe direction, hold torch firmly

and depress cutting lever fully. CAUTION: The torch will

tend to kick back from the force of the cutting oxygen.

Adjust fuel gas valve to give desired flame. Release cut-

ting lever to return to pilot mode. Depress cutting lever

several times, both slowly and quickly to ensure pilot

flame is set properly. If torch extinguishes itself when

lever is released, open pilot oxygen valve slightly to in-

crease pilot oxygen flow, relight torch and readjust pilot

oxygen valve.

stream of the regulator. Tighten the connecting nuts

firmly using two wrenches to prevent damage to the

torch.

3. Assemble desired nozzle (see Table) to the torch

and tighten nozzle retaining nut firmly.

Never touch the nozzle to the work piece.

NON-METRIC DATA

NOZZLE STEEL GAS PRESSURE, PSIG NOZZLE GAS CONSUMPTION, CFH

PART THICKNESS NAT. GAS STAND-OFF NATURAL

NO. (IN.) OXYGEN* OR PROP.* (IN.) OXYGEN GAS

2118700 10-16 80 - 110 10 - 30 4 TO 6 2080 225-500

2118701 6-10 80 - 110 10 - 30 4 TO 6 1640 225-500

2118702 3-6 80 - 110 10 - 30 4 TO 6 1260 225-500

METRIC DATA

NOZZLE STEEL GAS PRESSURE, BARS NOZZLE GAS CONSUMPTION, M

/HR

PART THICKNESS NAT. GAS STAND-OFF NATURAL

NO. (MM) OXYGEN* OR PROP.* (MM) OXYGEN GAS

2118700 254-406 5.5 - 7.6 0.6 - 1.9 95 58 6.4-14.2

2118701 152-254 5.5 - 7.6 0.6 - 1.9 95 46 6.4-14.2

2118702 76-152 5.5 - 7.6 0.6 - 1.9 95 36 6.4-14.2

*NOTE:Oxygen pressure: Set while cutting lever is depressed; pressure measured at the torch.

Natural gas or propane pressure: Set while cutting lever is depressed and fuel gas valve is wide

open; pressure measured at the torch.

OPERATING DATA

GENERAL NOTE:

1. 1/2" (12.7 mm) hose is recommended for oxygen, 3/8" (9.5 mm) hose is recommended for fuel gas.

2. Oxygen pressure is measured at the torch inlet connection.

3. The conditions listed in the table are based on typical conditions for cutting mild steel at ambient temperatures.

They should only be used as a starting point. Cut quality can vary depending on the temperature and metallurgical

content of the steel, steel quality, surface condition, oxygen purity, etc., in addition to the pressures and cutting

speed.

4. The post mix nozzles have divergent bore cutting orifices that are intended for applications where it is necessary

to cut quickly. For other specific applications, contact your ESAB representative or distributor.

Figure 1

maximum force. If this does not eliminate leakage, try a

new valve assembly. If then the valve does not shut off

completely, send the torch to a repair station for reseating

of the body.

Cutting Oxygen Valve

If leakage develops around the oxygen valve stem, re-

place the valve packing bushing. If leakage develops

through the oxygen valve, replace the valve seat. Re-

placement procedure as follows:

1. Unscrew the lever attaching screw and lift the lever

off.

2. Unscrew the valve stem guide and remove the valve

assembly from the guide.

3. Use Leak Test Solution to moisten the stem head,

then remove the packing bushing and ferrule. Re-

move the sealing ring from the bushing. Lift off the

spring and spring support.

4. Replace the valve seat (stem) if necessary and any

other parts which are worn or damaged.

5. Reassemble the valve following the above instruc-

tions in reverse order.

Cleaning Cutting Nozzle: If the cutting nozzle does not

produce straight, uniform flames, or if any of the pre-

heat nozzle holes become clogged, clean them by us-

ing the serrated tip cleaners in the cleaning kit supplied

with the torch, part number 751F00. Maintaining clean

preheat holes is essential for quality performance of this

equipment.

If the cutting orifice becomes clogged or fouled, gently

insert and twist the appropriate tapered cleaning tool

found in the cleaning kit. Nozzle P/N 2118703 should

only be cleaned with Oxweld nozzle cleaning compound

P/N 761F00. The use of twist drills for cleaning holes is

not recommended. Nozzles should be cleaned periodi-

cally in a solution of OXWELD Nozzle Cleaning Com-

pound (P/N 761F00), made up and used as directed on

the container in which it is packed.

MAINTENANCE

For all repairs other than those covered below, send the

torch to ESAB Welding & Cutting Products

Remanfacturing Center, 411 South Ebenezer Road, Flo-

rence, SC 29501.

Testing Seats: Under normal use the internal seating

surfaces in the nozzle socket should last the life of the

torch. Should reseating be necessary, reseating should

be done only by the factory or a qualified repair person.

To test the seat, thinly coat the seating surfaces of a

new nozzle with nondrying Prussian blueing. Insert the

nozzle into the nozzle socket without the nozzle nut and

rotate the nozzle by hand one half turn. Remove the

nozzle and observe the seating surfaces in the socket.

Blueing should be evenly distributed on both seating

surfaces. Depressions or the absence of uniform blue-

ing indicates the nozzle socket requires reseating.

Reseating: By hand, screw in reseating tool P/N

5230207 into nozzle head. Do not overtighten or dam-

age to head could result. While gently tightening and

holding threaded nut of reseating tool, slowly rotate

reamer allowing tapered seat to be reseated. Make sure

reamer is rotated at least two revolutions so that reseated

surfaces are true. Retest seats and repeat if necessary

until seating surfaces have been restored. Clean out

metal shavings before putting torch back into service.

PM nozzles cannot and should not be reseated.

Preheat Valves: Leakage around either throttle valve

can usually be corrected by tightening the packing nut

slightly. If this does not stop the leakage, replace the

throttle valve.

If either preheat valve fails to shut off completely, re-

move the throttle valve assembly from the torch. With a

clean cloth, wipe the ball in the end of the stem. Then

reinsert valve assembly and tighten it several times with

PARTS INFORMATION

Replaceable parts are illustrated below. When ordering parts, please give both part number and description. DO NOT order by part number alone.

Fig. 2 - Replacement Parts, PM-GST Torch Assembly (75° Head illustrated)

PM-GST Torch Assembly

Part Numbers

Length 75° Head 90° Head 180° Head

4-ft 22086 22094 22098

5-ft 22087 22095 22099

6-ft 22088 22096 22100

8-ft 22089 22097 22101

10-ft 22090 - 22102

12-ft 22091 22106** 22103

16-ft 22092 22107** 22104

18-ft 22093 - 22105

GUIDE - 52Z88

FERRULE - 73A93

WASHER - 37A39

O-RING - 86W70

BUSHING - 57A18

SPRING - 29Z37

SPRING SUPPORT -

73Z90

VALVE SEAT/STEM -

33Y43

DETAIL “A”

VALVE ASS’Y- 22110

(ENLAGED VIEW)

NUT EXTENDED - 22075 (1.06"-18)

THROTTLE VALVE ASS’Y - 54A87

O-RING - 96W97

PLUG - 35Z64

FG VALVE ASS’Y - 22084

VALVE ASS’Y - 22110

(See Detail “A”)

SCREW - 34Z50

BUSHING - 39Z58

LOCKWASHER #12

LEVER ASS’Y - 25Y16

DETAIL “A”

FG VALVE ASS’Y- 22084

(ENLARGED VIEW)

VALVE STEM -

22080

BUSHING -

92Z18

GUIDE -

22083

SPRING -

28Z43

BUSHING -

92Z18

SLIP RING -

38Z64

DIAPHRAGM -

30Z54

** NEW

HEADS

75° - 22076

90° - 22077

180° - 22078

SUPPORT -

22072

ADAPTOR -

22070

REAR BODY -

22066

RIDING SKID (NOT SHOWN) - 22073

F-15-365-C 07/2000 1C Printed in U.S.A.

ESAB PM-GST Post-Mix Hand Cutting Torch Troubleshooting instruction

Brand: ESAB

Model: PM-GST Post-Mix Hand Cutting Torch

Type: Troubleshooting instruction

This manual is also suitable for

OXWELD® PM-GST Post-Mix Hand Cutting Torch

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ESAB PM-GST Post-Mix Hand Cutting Torch Troubleshooting instruction

This manual is also suitable for

ESAB PM-GST Post-Mix Hand Cutting Torch Troubleshooting instruction

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