PARTS, SERVICE & REPAIR BULLETIN

Transcription

1 WH4C PARTS, SERVICE & REPAIR BULLETIN 400 SERIES HEAVY DUTY WELDING HANDLE Manual No: Issue Date: October 07, 03 Revision: AA VictorTechnologies.com

2 Table of Contents SECTION : GENERAL SAFETY INFORMATION....0 Commonly Used Terms... SECTION : SPECIFICATIONS WH4C Victor Welding Handle Repair Parts List...3 SECTION 3: SERVICE & REPAIR INSTRUCTIONS Recommended Tools & Supplies for Repair Procedures Cleaning Procedures Handle for 400 Series Welding Handle Control Valve Repair Kit Check Valve Repair Kit Fuel and Oxygen Inlet Connections Gas Feed Tubes...6 SECTION 4: TEST PROCEDURES Recommended Tools & Supplies for Test Procedures Leak Testing the Welding Handle Testing the Check Valves...8 SECTION : GENERAL SAFETY INFORMATION Read and understand all safety and operating instructions provided before using this apparatus. RETAIN THESE INSTRUCTIONS IN A READILY AVAILABLE LOCATION FOR FUTURE REFERENCE.! WARNING DO NOT attempt to use this apparatus unless you are trained in its proper use or are under competent supervision. For your safety, practice the safety and operating procedures described in this booklet every time you use the apparatus. Deviating from these procedures may result in fire, explosion, property damage, and/or operator injury. If at any time the apparatus you are using does not perform in its usual manner, or you have any difficulty in the use of the apparatus, STOP using it immediately. DO NOT use the apparatus until the problem has been corrected!! WARNING Apparatus improperly operated, maintained or repaired can be dangerous. Some parts and accessories manufactured by others may fit VICTOR apparatus but not conform to VICTOR s exacting standards. For your own protection, specify and use ONLY VICTOR-made parts and accessories with your VICTOR apparatus.! WARNING Service or repair of apparatus should be performed only by a qualified repair technician capable of servicing gas apparatus in strict accordance to applicable Part and Service bulletins for VICTOR manufactured products. Improper service repair, or modification of the product could result in damage to the product or injury to the operator.! WARNING WARNING: This product contains chemicals, including lead, known to the State of California to cause birth defects and other reproductive harm. Wash hands after handling..0 COMMONLY USED TERMS BACKFIRE - The return of the flame into the torch, producing a popping sound. The flame will either extinguish or reignite at the tip. SUSTAINED BACKFIRE - The return of the flame into the torch with continued burning within the torch. This condition may be accompanied by a popping sound followed by a continuous hissing or whistling sound. FLASHBACK - The return of the flame through the torch into the hose and even into the regulator. It may also reach the cylinder. This condition could possibly cause an explosion in the system.

3 SECTION : SPECIFICATIONS.0 WH4C VICTOR WELDING HANDLE Intuitive knobs: color coded, clearly marked lettering with increase/decrease label; understandable in any language Built-in check valves High strength alloy handle Textured, precision contoured handle -/ 8-/8 3-/8-5/8.0 REPAIR PARTS LIST Right Handle All dimensions are approximate. Left Handle Control Valve Head Gas Feed Tubes Inlet Connection Oxygen Check Valves WH4C Inlet Connection Fuel 3

4 SECTION 3: SERVICE & REPAIR INSTRUCTIONS 3.0 RECOMMENDED TOOLS & SUPPLIES FOR REPAIR PROCEDURES 5/8, 9/6, and /6 Open-End Wrenches Vise /4-0 Bolt 45% Silver Solder Pliers Silver Solder Flux Hand Reamer RT-58 Loctite # (Part Number ) Brazing Torch Christo-Lube 9 (Part Number ) Disconnect the torch from any gas lines or other hardware before beginning any service or repair. 3.0 CLEANING PROCEDURES Contact your local chemical supplier for recommended cleaning solvents applicable to the metals used in this product. Always use cleaning solvents in accordance with the manufacturer s instructions HANDLE FOR 400 SERIES WELDING HANDLE 3 WARNING DO NOT allow nonmetal components (seat, O-rings, dust seal, gaskets) to contact cleaning solvents! Cleaning solvents cause elastomeric and plastic parts to swell and stress crack. If these parts require cleaning, use a mild soap solution, followed by a thorough rinsing in water. Dry these parts completely before installing. REPLACE NONMETAL PARTS THAT HAVE COME IN CONTACT WITH OIL, GREASE OR ANY OTHER PETROLEUM-BASED SUBSTANCE! Petroleum-based substances become dangerously flammable in the presence of oxygen. 4 Figure 3- Handle for 400 Series Welding Handle Left Handle * Right Handle * 3 Self-Threading Screw * 4 Decal for WH4C *. Peel the decal off of the right handle. *Sold as part of kit only.. Use a phillips head screwdriver to remove both screws from the handle. 3. Separate the left handle from the right handle and remove them from the gas feed tubes.. Position the right and left handles in place over the gas feed tubes. Ensure that the handles fit over the tubes correctly.. Hold the right and left handles together and fasten both self-threading screws through the right handle into the left handle. 3. Place the decal on the right handle as shown in Figure 3-. 4

5 3.04 CONTROL VALVE REPAIR KIT 3.05 CHECK VALVE REPAIR KIT 3 Figure 3- Control Valve Repair Kit Valve Stem * Knob Decal (Red F ) * 3 Knob Decal (Green O ) * *Sold as part of kit only. This welding handle uses two control valves. Follow these steps to service, disassemble, and assemble either control valve. The control valve repair kit includes only one valve stem assembly. Service Wipe with a dry cloth. Do not use any cleaning solvents. Check for leaks.. Use a wrench to unscrew the control valve nut.. Apply Christo-Lube to the assembly threads.. Screw the control valve assembly into the welding handle body. 3. Use a wrench to tighten the control valve nut. 4. Place the correct decal on the knob (See Figure 3-). Figure 3-3 Check Valve Repair Kit Check Valve Follow these steps to disassemble and assemble either check valve.. Screw the /4-0 bolt into the check valve until it is finger tight.. Place the shank of the bolt in the vise. The head of the bolt must catch on the vise jaws, and the bolt must be able to move freely. 3. Grab the welding handle firmly and pull it up. The head of the bolt will catch on the vise jaws, and the check valve will pull out of the welding handle. 4. Repeat steps through 3 for the other check valve. This assembly requires a class B dual hose for oxygen and fuel. The red hose connects to the fuel inlet connection. The green hose connects to the oxygen inlet connection.. Press the check valve into the inlet connection.. Place the hose connection over the check valve and thread it onto the inlet connection. Use a wrench to tighten the hose onto the inlet connection until the check valve is properly seated. 3. Remove the hose. 4. Repeat steps through 3 for the other check valve. 5

6 3.06 FUEL AND OXYGEN INLET CONNECTIONS Figure 3-4 Oxygen Inlet Connection Fuel Inlet Connection Follow these steps to disassemble and assemble either inlet connection GAS FEED TUBES Remove the handle before beginning this task (see Section 3.03).. Place the welding handle in a vise.. Use a wrench to loosen and unscrew either inlet connection from the welding handle. 3. Clean all debris from the inlet connection threads. 4. Repeat steps and 3 for the other inlet connection.. Apply a small amount of Loctite to the beginning of the inlet connection threads. Loctite must completely cover the beginning two threads of the inlet connection.. Screw the inlet connection onto the welding handle body and wrench tighten. 3. Repeat steps and for the other inlet connection. 4. Remove the welding handle from the vise. 5. Install the check valves (see Section 3.05, ). 6. Reattach the handle. Head Seat CAUTION Always wear gloves when handling heated parts. 6 Figure 3-5 Gas Feed Tubes /6 Tube * 3/8 Tube * *Sold as part of kit only. Service. Check the gas feed tubes for leaks and wear. a. If you find a leak around the head, use hand reamer RT-58 to ream the head seat.. Remove all chips and debris from around the head seat area. Remove the handle, control valves, and inlet connections before beginning this task (see Sections 3.03, 3.04, and 3.06).. Place the large diameter of the head in a vise, positioned so that the tube bores face up. Avoid placing the threads in the vise as this may damage them.. Heat the gas feed tubes near the welding handle body until the solder liquefies. Use pliers to remove the welding handle body from the tubes. 3. Heat the gas feed tubes near the head until the solder liquefies. Use pliers to remove the tubes from the head. 4. Allow all parts to cool before beginning assembly.

7 . Clean all solder and debris from the welding handle body and head.. Place the large diameter of the head in a vise, positioned so that the tube bores face up. Avoid placing the threads in the vise as this may damage them. 3. Insert the gas feed tubes into the head, followed by the welding handle body. 4. Solder the fitting around the head and repeat for the welding handle body side. Allow all parts to cool before beginning the next step. 5. Reattach the inlet connections, control valves, and handle. 6. Check for leaks and remove the welding handle from the vise. SECTION 4: TEST PROCEDURES 4.0 RECOMMENDED TOOLS & SUPPLIES FOR TEST PROCEDURES Oil-free air or dry nitrogen supplies Plugged welding nozzle RT-58 and RT-33 Reamers 5/8, 9/6, and /6 Open-end wrenches Small water tank Christo-Lube 9 (Part Number ) 4.0 LEAK TESTING THE WELDING HANDLE. Attach the fuel and oxygen hoses to the welding handle.. Install the plugged welding nozzle in the head by hand. Do not tighten with a wrench. Plugged Hole Figure 4- Welding Nozzle 3. Close the oxygen control valve. Pressurize the oxygen side of the welding handle to 80 PSIG with oil-free air or dry nitrogen. 4. Completely submerse the welding handle in water. a. Check the oxygen inlet body port. If there is a leak, bubbles will pass through the /4-NPT threaded port. 5. Open the oxygen and fuel control valves. a. Check both control valve nuts, the gas feed tubes, and all external connections. There should be no leakage (no bubbles) for five seconds. b. If there is a leak from one of the control valve nuts, tighten it until -/4 to in-lbs of torque is required to adjust the valve stem. 6. Close the oxygen control valve and remove the welding handle from the water. 7. Depressurize both hoses and open the oxygen control valve. 8. Tighten each valve stem assembly knob to 7 to 8 in-lbs of torque. 9. Remove the welding nozzle. 0. Pressurize the oxygen side of the welding handle to 80 PSIG and submerse the welding handle in water. a. Check the head. If bubbles appear at the head, the oxygen control valve seat is leaking. b. If there is a leak, you may have to reseat the valve seat. Use valve seat reamer RT-33 to repair the valve seat. c. Remove all chips and debris from the valve seat area. d. Retest for leaks.. Repeat step 0 for the fuel side of the welding handle. 7

8 4.03 TESTING THE CHECK VALVES WARNING The 400 Series Welding Handle is equipped with internal check valves to prevent gases from mixing in the hoses or regulators. Mixed gases may result in a fire or explosion that can cause serious injury. Test the check valves at least every six months. Test them more often if the hoses are frequently disconnected from the welding handle.. Remove the small O-ring from the plugged welding nozzle and install the nozzle in the head of the welding handle. Removing the O-ring ensures that, for testing purposes only, back pressure will reach the check valves.. Connect the fuel and oxygen hoses to the welding handle. 3. Disconnect either the fuel hose from the fuel regulator or the oxygen hose from the oxygen regulator. 4. Open both the fuel and oxygen valve stem assemblies. 5. Open the cylinder or manifold valve. Adjust the regulator that is still connected to deliver -5 PSIG. 6. Place the loose end of the disconnected hose under water for at least ten seconds. 7. Check the hose end for bubbles. If there is more than one bubble in five seconds, replace the check valve. 8. Repeat steps 3 through 7 to test the other check valve. Plugged Hole Welding Nozzle Small O-Ring THE AMERICAS Denton, TX USA U.S. Customer Care Ph: (tollfree) Fax: (tollfree) International Customer Care Ph: Fax: Miami, FL USA Sales Office, Latin America Ph: Fax: Oakville, Ontario, Canada Canada Customer Care Ph: Fax: (tollfree) EUROPE Chorley, United Kingdom Customer Care Ph: Fax: Milan, Italy Customer Care Ph: Fax: ASIA/PACIFIC Cikarang, Indonesia Customer Care Ph: Fax: Rawang, Malaysia Customer Care Ph: Fax: Melbourne, Australia Australia Customer Care Ph: (tollfree) Ph: Fax: International Ph: Fax: Shanghai, China Sales Office Ph: Fax: Singapore Sales Office Ph: Fax: Figure 4- T ECHNOLOGIES INNOVATION TO SHAPE THE WORLD U.S. Customer Care: Canada Customer Care: International Customer Care: Victor Technologies International, Inc. Printed in Mexico