ESAB Parts Troubleshooting instruction

Brand: ESAB

Model: Parts

Type: Troubleshooting instruction

This manual is also suitable for

G-SERIES REGULATORS

PARTS, SERVICE

& REPAIR BULLETIN

G150, GF150, G250,

GF250 & G350

VictorTechnologies.com

Issue Date: October 29, 2015

Manual No: 0056-3764

Revision: AB

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

Read and understand this entire Manual and your employer’s safety practices before install-

ing, 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.

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

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 equip-

ment, 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 accompany-

ing labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provid-

ed. 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

INTERNATIONAL CONTACT INFORMATION ....................................................... REAR COVER

SECTION 10: G250, GF250 & G350

TROUBLESHOOTING .......................................................................................10-1

VICTOR G-SERIES REGULATOR

Manual 0056-3764 1-1 SAFETY INSTRUCTIONS AND WARNINGS

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.

SECTION 1: SAFETY

VICTOR G-SERIES REGULATOR

SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0056-3764

WARNING

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.

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with applica-

ble 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 RAYS - 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 mate-

rials nearby.

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!

WARNING

Do not use the power source for thawing frozen pipes.

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 loca-

tions, due to conducted as well as radiated disturbances.

CAUTION

This product is solely intended for metal removal. Any other use

may result in personal injury and / or equipment damage.

CAUTION

Read and understand the instruction manual before

installing or operating.

VICTOR G-SERIES REGULATOR

Manual 0056-3764 2-1 INTRODUCTION

SECTION 2:

INTRODUCTION

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.

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

avoided, will result in immediate, serious

personal injury or loss of life.

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

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 concern-

ing 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

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 condi-

tion while the inlet pressure remains constant.

RISE: An increase in outlet pressure as the inlet pressure decreases.

CREEP: A gradual increase in outlet pressure.

VICTOR G-SERIES REGULATOR

INTRODUCTION 2-2 Manual 0056-3764

This Page Intentionally Blank

VICTOR G-SERIES REGULATOR

Manual 0056-3764 3-3 G150, GF150 SPECIFICATIONS

Figure 3-1: G150/GF150 Light Duty Basic Dimensions

SIDE ENTRY

REAR ENTRY

A-12973

1.69 in.

45°

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

G150, G250 SPECIFICATIONS 3-4 Manual0056-3764

3.02 Exploded View

A-12974

BODY

INLET SWIVEL

INLET NUT

OUTLET

H.P. GAUGE

L.P. GAUGE

FILTER

FRICTION DAMPER

VALVE SPRING

SEAT ASSEMBLY

GASKET

NOZZLE

BONNET

DIAPHRAGM

ASSEMBLY

SLIP RING

ADJUSTING

SPRING

SPRING BUTTON

ADJUSTING SCREW

ADJUSTING KNOB,

SCREW & DECAL

RETAINING RING

Figure 3-2: G150/GF150 Exploded View

VICTOR G-SERIES REGULATOR

Manual 0056-3764 3-5 G150, GF150 SPECIFICATIONS

3.03 Parts List

Ref. No. Description Part No. Qty

1 Body See Table 3-1A/B/C 1

2 Bonnet 0720-0289 1

Diaphragm Assembly 0730-0082 1

Slip Ring 0705-0016 1

Filter 0717-0038 1

Friction Damper 0738-0015 1

7 Valve Spring 0762-0060 1

Seat Assembly See Table 3-1A/B/C 1

Gasket. Nozzle 1408-0107 1

10 Nozzle 0702-0073 1

11 Adjusting Spring See Table 3-1A/B/C 1

12 Spring Button 0706-0022 1

13 Adjusting Screw 0751-0086 1

14 Adjusting Knob, Screw & Decal See Table 3-1A/B/C 1

15 Inlet Swivel See Table 3-1A/B/C 1

16 Inlet Nut See Table 3-1A/B/C 1

17 Retaining Ring See Table 3-1A/B/C 1

18 Outlet Connection See Table 3-1A/B/C 1

19 Gauge, High Pressure See Table 3-1A/B/C 1

20 Gauge, Low Pressure See Table 3-1A/B/C 1

* Items most commonly required for regulator repair and recommended for stock.

Items 3, 4, 5, 6, 8 and 9 are availabe together in convenient Repair Kits:

0790-0179RP G150 Repair Kit for Oxygen, Inert, CO

0790-0180RP G150 Repair Kit for Acetylene, LP Gas

VICTOR G-SERIES REGULATOR

G150, G250 SPECIFICATIONS 3-6 Manual0056-3764

G150, GF150 MODEL-SPECIFIC PART NUMBERS

Ref

Description G150-60-540 G150-60-540R G150-60-540R

020 (“A” Hose)

G150-15-200 G150-15-200R G150-15-200R

021 (“A” Hose)

1 Body 0701-0261 0701-0267 0701-0267 0701-0261 0701-0267 0701-0267

8 Seat Assembly 0739-0025 0739-0025 0739-0025 0739-0026 0739-0026 0739-0026

11 Adjusting Spring 0761-0000 0761-0000 0761-0000 0761-0001 0761-0001 0761-0001

14 Adj. Knob, Screw &

Decal

0790-0226RP 0790-0226RP 0790-0226RP 0790-0227RP 0790-0227RP 0790-0227RP

15 Inlet Swivel 0967-0033 0967-0119 0967-0119 0964-0005 (a) 0964-0020 0964-0020

16 Inlet Nut 0967-0044 0967-0044 0967-0044 (a) 0964-0004 0964-0004

17 Retaining Ring 1406-0130 - - - - -

18 Outlet Connection 0950-0068 0950-0027 0950-0029 0960-0029 0960-0018 0960-0023

19 Gauge, High Pressure 1435-0096RP 1435-0096RP 1435-0096RP 1435-0094RP 1435-0094RP 1435-0094RP

20 Gauge, Low Pressure 1435-0091RP 1435-0091RP 1435-0091RP 1435-0090RP 1435-0090RP 1435-0090RP

Table 3-1A: Model - Speciﬁc Part Numbers

(a) Inlet is a complete assembly which includes Swivel, Adapter and Nut.

G150, GF150 MODEL-SPECIFIC PART NUMBERS

Ref

Description G150-15-300 G150-15-510 G150-15-520 G150-60-510LP G150-60-580 G150-60-320

1 Body 0701-0261 0701-0261 0701-0261 0701-0261 0701-0261 0701-0261

8 Seat Assembly 0739-0026 0739-0026 0739-0026 0739-0026 0739-0025 0739-0025

11 Adjusting Spring 0761-0001 0761-0001 0761-0001 0761-0000 0761-0000 0761-0000

14 Adj, Knob, Screw &

Decal

0790-0227RP 0790-0227RP 0790-0227RP 0790-0228RP 0790-0229RP 0790-0230RP

15 Inlet Swivel 0968-0014 0970-0005 0969-0005 0970-0005 0970-0005 0985-0004 (b)

16 Inlet Nut 0968-0003 0970-003 0969-0003 0970-0003 0973-0003 0985-0030

17 Retaining Ring - - - - - -

18 Outlet Connection 0960-0029 0960-0029 0960-0029 0960-0029 0950-0017 0950-0017

19 Gauge, High Pressure 1435-0094RP 1435-0094RP 1435-0094RP 1435-0095RP 1435-0097RP 1435-0097RP

20 Gauge, Low Pressure 1435-0090RP 1435-0090RP 1435-0090RP 1435-0092RP 1435-0092RP 1435-0092RP

Table 3-1B: Model - Speciﬁc Part Numbers

(b) Requires Inlet Washer Part No. 1408-0065.

G150, GF150 MODEL-SPECIFIC PART NUMBERS

Ref # Description GF150-50-580

(Flowgauge)

GF150-50-320

(Flowgauge)

1 Body 0701-0261 0701-0261

8 Seat Assembly 0739-0025 0739-0025

11 Adjusting Spring 0761-0000 0761-0000

14 Adj. Knob, Screw & Decal 0790-0229RP 0790-0230RP

15 Inlet Swivel 0970-0005 0985-0004 (b)

16 Inlet Nut 0973-0003 0985-0030

17 Retaining Ring - -

18 Outlet Connection 0950-0138 (c) 0950-0138 (c)

19 Gauge, High Pressure 1435-0097RP 1435-0097RP

20 Gauge, Low Pressure 1435-0093RP 1435-0093RP

Table 3-1C: Model - Speciﬁc Part Numbers

(b) Requires Inlet WASHER Part No. 1408-0065.

VICTOR G-SERIES REGULATOR

Manual 0056-3764 3-7 G150, GF150 SPECIFICATIONS

3.04 Repair Parts List

Part No. Description Components

0790-0226RP Green Adjusting Knob w/ Screw &

Decal

0750-0026

1400-0205

0707-1437

Knob Green G150

Screw

Decal (Victor)

0790-0227RP Red Adjusting Knob w/ Screw & Decal 0750-0227

1400-0205

0707-1437

Knob Red G150

Screw

Decal (Victor)

0790-0228RP Orange Adjusting Knob w/ Screw &

Decal

0750-0228

1400-0205

0707-1437

Knob Orange G150

Screw

Decal (Victor)

0790-0229RP Black Adjusting Knob w/ Screw & Decal 0750-0229

1400-0205

0707-1437

Knob Black G150

Screw

Decal (Victor)

0790-0230RP Gray Adjusting Knob w/ Screw & Decal 0750-0230

1400-0205

0707-1437

Knob Gray G150

Screw

Decal (Victor)

0790-0179RP G150 Repair Kit for Oxygen, Inert, CO

0717-0038

0738-0015

1408-0107

0739-0025

0705-0016

0730-0082

Filter

Friction

Gasket

Seat Assembly

Slip Ring

Diaphragm Assembly

0790-0180RP G150 Repair Kit for Acetylene, LP Gas 0717-0038

0738-0015

1408-0107

0739-0026

0705-0016

0730-0082

Filter

Friction Damper

Gasket

Seat Assembly

Slip Ring

Diaphragm Assembly

1435-0090RP Gauge 1.5” 2.0bar/15psi ACET 1435-0090 Gauge 1.5” 2.0bar/15psi ACET

1435-0091RP Gauge 1.5” x 6bar/87psi OXY 1435-0091 Gauge 1.5” x 6bar/87psi OXY

1435-0092RP Gauge 1.5” x 6bar/87psi GENERIC 1435-0092 Gauge 1.5” x 6bar/87psi GENERIC

1435-0093RP Gauge 1.5” 25L/m(50CFH) Ar/CO

1435-0093 Gauge 1.5” 25L/m(50CFH) Ar/CO

1435-0094RP Gauge 1.5” 40bar/580psi ACET 1435-0094 Gauge 1.5” 40bar/580psi ACET

1435-0095RP Gauge 1.5” 40bar/580psi GENERIC 1435-0095 Gauge 1.5” x 40bar/580psi GENERIC

1435-0096RP Gauge 1.5” 315bar/4568psi OXY 1435-0096 Gauge 1.5” 315bar/4568psi OXY

1435-0097RP Gauge 1.5” 315bar/4568psi GEN 1435-0097 Gauge 1.5” 315bar/4568psi GEN

Table 3-2: G150/GF150 Service & Repair (See exploded view for reference numbers)

VICTOR G-SERIES REGULATOR

G150, G250 SPECIFICATIONS 3-8 Manual0056-3764

This Page Intentionally Blank

VICTOR G-SERIES REGULATOR

Manual 0056-3764 4-1 G150, GF150 SERVICE & REPAIR PROCEDURES

SECTION 4: G150, GF150

SERVICE & REPAIR PROCEDURES

4.01 Recommended Tools and Supplies for Repair Procedures

• Inlet Swivel Assembly Plug

• Sockets:

”,

”, and

”

• Socket Wrench

• Torque Wrench

• Open End Wrenches:

”,

” and 1-

”

• Bench Vise

• Repair Tool RT-180 (8” Leverage bar with

-18 NPT [M] End)

• Oxygen-compatible Teﬂon® tape

• Loctite® #222 Threadlocker

• CHRISTO-LUBE® #129 Lubricant

• Phillips Screwdriver

4.02 Cleaning Procedures

It is recommended to clean all metal parts for oxygen service, regardless of Regulator Model being repaired. There are several ways to

clean components for oxygen service. The following standards are recommended reading for more detailed information on methods and

processes:1

• CGA G-4.1 “Cleaning Equipment for Oxygen Service”

• ASTM G-93 “Standard Practice for Cleaning Methods and Cleanliness Levels for Material and Equipment Used in Oxygen-Enriched

Environments”

• ASTM G-127 “Standard Guide for the Selection of Cleaning Agents for Oxygen Systems”

For metal parts, Victor, an ESAB brand, suggests using CCI Envirospray Liquid, used per the manufacturer’s instructions, followed by a

hot water rinse and thorough drying. Additional information can be found at http:://www.ccichemical.com.

DO NOT allow non-metal parts to come in contact with cleaning solvents. Cleaning solvents can cause non-metal parts to swell and/or

crack. To clean these parts, use a non-petroleum based mild soap solution, followed by a thorough rinsing in water. Dry parts completely

prior to reassembling.

4.03 Disassembly Procedures

Refer to

Section 3-Figure 3-2

for the reference numbers [shown in brackets].

1. Mount the Inlet Swivel Assembly Plug in the Bench Vise and ﬁrmly attach the Regulator.

2. Remove the Knob Decal, then remove the #10-32 Screw located inside the knob [14]. Remove the Knob from the Adjusting

Screw [13], the remove the Adjusting Screw from the Bonnet.

3. Unscrew the Bonnet [2] from the Body [1].

4. Remove the Adjusting Spring [11], Spring Button [12], Diaphragm Assembly [3] and Slip Ring [4].

5. Unscrew the Knozzle [11] from the Body.

6. Remove the Seat Assembly [8], Valve Spring [7], Friction Damper [6], Filter [5] and Gasket [9] from the Body.

7. Unscrew the Outlet Connection [18] from the Body.

8. Unscrew the High and Low Pressure Gauges [19, 23] from the Body.

9. Screw the Leverage Bar Tool RT-180 into the outlet port of the Body (lightly hand tight), and use the bar to unscrew the Body off

the Inlet Swivel [15].

VICTOR G-SERIES REGULATOR

G150, GF150 SERVICE & REPAIR PROCEDURES 4-2 Manual 0056-3764

NOTE!

Watch the Inlet Swivel while trying to turn the Body. If the Swivel is turning with the Body, then you need

to tighten the Inlet Nut tighter on the Inlet Swivel Assembly Plug.

CAUTION

Discard the used Gasket, Filter, Diaphragm Assembly, Seat Assembly and Friction Damper. Replace them

with new parts each time you assemble a regulator.

All of the recommended components in

Table 4-1

are available together in convenient repair kits for your G150 or GF150 model

Regulator:

Part No. Description

0790-0179RP G150 Repair Kit for Oxygen, Inert Gases, CO

0790-0180RP G150 Repair Kit for Acetylene, LP Gas

Table 4-1

4.04 Assembly Procedures

Refer to

Section 3-Figure 3-2

for the reference numbers [shown in brackets].

NOTE!

When using Teﬂon

tape where noted: Apply two to three layers around the threads, leaving the ﬁrst

thread clean. Ensure your Teﬂon

tape is oxygen-compatible.

When using Loctite

#222 Threadlocker where noted: Apply two to three drops to the second and third

thread, leaving the ﬁrst thread clean.

1. Apply either Teﬂon

tape or Loctite

#222 to the Inlet Swivel threads.

2. If not already in place, mount the Inlet Swivel Assembly Plug back in the Bench Vise. Firmly attach the Inlet Swivel and Inlet

Nut [16] onto the Inlet Swivel Assembly Plug.

3. Screw the body onto the Inlet Swivel. Screw the Leverage Bar Tool RT-180 into the outlet port of the Body (light hand tight),

and then use the Leverage Bar to tighten the body onto the Inlet Connection. Tighten to approximately 15 ft-lbs torque. At

this point, you should not be able to turn the body by hand without the assistance of the Leverage Bar.

4. Wrap the High and Low Pressure Gauges [19, 20] with Teﬂon

tape and screw the Gauges into the Body with a minimum of 6

ft-lbs torque.

5. Apply only Loctite

#222 threadlocker to the Outlet Connection [18] threads. Screw the Outlet Connection into the body and

torque to 15ft-lbs.

6. At the point, thoroughly blow out the Body assembly with pressurized oil-free air or dry nitrogen to ensure it is completely

free of chips and debris

7. Assemble the Seat Assembly and Friction Damper “ears” should fold upward, around the Seat Assembly and between the

ribs, to be pushed up into the nozzle as shown:

Friction Damper

Seat Assembly

Nozzle

Ears folded up

Ribs

A-12975

VICTOR G-SERIES REGULATOR

Manual 0056-3764 4-3 G150, GF150 SERVICE & REPAIR PROCEDURES

8. Install the Filter [5], Valve Spring [7] and Gasket [9] into the Body, then carefully install the Nozzle/Seat Assembly/Friction

Damper and tighten to a torque of 8 to 10 ft-lbs.

9. Install the Diaphragm Assembly [3], Slip Ring [4], Adjusting Spring [11], and Spring Button [12] onto the Regulator Body.

10. Thread the Bonnet [2] onto the Body and torque to 14-17 ft-lbs.

11. Apply a small amount of CHRISTO-LUBE

#129 to the nose and threads of Adjusting Screw, then thread the Adjusting Screw

into the Bonnet until the nose makes contact with the Spring Button and begins to compress the Spring - then back out one

turn.

12. Reinstall the Knob, #10-32 Screw and new Knob Decal (included with [14]).

VICTOR G-SERIES REGULATOR

G150, GF150 SERVICE & REPAIR PROCEDURES 4-4 Manual 0056-3764

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ESAB Parts Troubleshooting instruction

Brand: ESAB

Model: Parts

Type: Troubleshooting instruction

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