Broco Prime-Cut User manual

OPERATING INSTRUCTIONS
AND
TECHNICAL MANUAL
FOR
PRIME-CUT
ULTRATHERMICCUTTINGSYSTEM
READ THIS MANUAL
BEFORE OPERATING
ARMY EXOTHERMIC CUTTER
PC/MIL-60 (RECOVERY) REV. June 2015

WARNING: Read this Manual Before
Operating
WARNING! You must read and understand these operating instructions thoroughly
and follow the procedures contained herein for the operation and servicing of the
Prime-Cut equipment to avoid serious injury or death to operator or bystanders or
damage to property.
Employers must be familiar with the correct operation of this torch and provide
operator training before allowing their personnel to begin using the Prime-Cut
equipment.
Prime-Cut cutting systems operate at a temperature of approximately 10,000°F,
enabling them to cut or melt virtually any known material. Sparks, splatter and
molten material generated by this process can cause fire, severe property damage,
bodily injury or death.
If you have any questions regarding the safe operation of Prime-Cut systems please
call: Broco, Inc.
400 S. Rockefeller Ave.
Ontario, CA 91761
Tel: [phone]
TO AVOID SERIOUS INJURY OR DEATH:
•Never use the Prime-Cut cutting system or rods underwater with a
welding power source.
•Always use a DC ignition system.
•Always wear flame or spark resistant clothing, shoes and eye and face
protection.
•Always know the composition of the target material.
•Always know what is behind the target material.
•Always clear the work area of bystanders and flammable materials.
•Never point the torch at anybody.
•Always use caution when cutting overhead to avoid falling sparks,
molten material and falling objects.
•Always ensure that all parts of the Prime-Cut system are in good working
order prior to use to avoid potential malfunction.

TABLE OF CONTENTS
1.0 PURPOSE AND SCOPE
2.0 WARNINGS AND SAFETY PRECAUTIONS
2.1 Warnings
2.2 Safety Precautions
3.0 COMPONENTS
3.1 Required Equipment
3.2 Accessory Equipment
4.0 SETUP PROCEDURES
4.1 Preparing the Work Area
4.2 Pre-Assembly Inspection
5.0 ASSEMBLY PROCEDURES
5.1 Oxygen System
5.2 Battery
5.2.1 Slave Plug (600143)
5.3 Leather Shield (PC/LS)
5.4 Cutting Rod Insertion
5.5 16" Rod Extender (PC/TACXT16)
5.6 Hose/Cable Extension Kit (PC/EXMIL60)
6.0 OPERATING PROCEDURES
6.1 Cutting Rod Ignition
6.2 Techniques
6.2.1 Piercing
6.2.2 Cutting
6.2.3 Gouging
6.3 Shutdown
7.0 PRIME-CUT TORCH MAINTENANCE
7.1 Flash Arrestor & Flash Arrestor Screen
7.2 Coupler Assembly Removal/Replacement
7.3 Oxygen Control Valve Disassembly/Reassembly
7.4 Oxygen Control Valve Assembly Leak Testing Procedure
8.0 STRIKER PLATE ASSEMBLY
8.1 Inspection
8.2 Striker Plate Disassembly
8.3 Striker Plate Reassembly
9.0 TROUBLESHOOTING
9.1 Oxygen Leaks
9.2 Uneven Oxygen Flow
9.3 Cutting Rod Doesn't Fit Collet
9.4 Valve Stem Won't Move Freely
10.0 REPLACEMENT PARTS, SERVICE & REPAIR

1.0 PURPOSE AND SCOPE
The purpose of this document is to describe the recommended operating
procedures, maintenance requirements and repair procedures necessary to ensure
proper operation of the Broco® Prime-Cut cutting torch system.
Components for which procedures are described are the cutting torch, the striker
plate assembly, and accessory equipment.
Oxygen regulator repairs should be conducted only by qualified personnel trained
and authorized to perform work on high pressure oxygen regulators.
Inspection/repairs of oxygen cylinders and oxygen cylinder valves should be
conducted only by qualified personnel trained and authorized to perform work on
high pressure oxygen cylinders and oxygen cylinder valves.
2.0 WARNINGS AND SAFETY PRECAUTIONS
2.1 Warnings
All users and their supervisory personnel must read and be thoroughly familiar with
the contents of this manual prior to using this equipment or disassembling any part
of the Prime-Cut cutting torch system.
Never modify this equipment in any manner or use it in any way not specified in this
manual.
Oxygen mixed with oil or grease reacts explosively. Never use compressed air, oil,
solvents or other material to clean the oxygen system. Always keep oil and grease
away from the cutting torch, oxygen cylinders, valves, regulators, hoses and fittings.
Never use this equipment in conjunction with any power source other than a 12 volt
DC or 24 volt DC battery.
Never use the Prime-Cut exothermic cutting system or rods underwater with a
welding power source. Prime-Cut products are not intended for diving operations
and are not insulated to protect from the risk of electrical shock.
Never use this equipment unless you are familiar with acceptable industrial welding
and cutting procedures and practices.
Always use this equipment following generally accepted industrial safety
procedures and practices.
Always apply and adhere to ANSI/ASC Z49.1-88 “Safety in Welding and Cutting”
standards, or similar locally prevailing standards when using this equipment.

Never remove, cover or alter the warning labels attached to this equipment.
Never modify this equipment in any manner or use it in any way not specified in this
manual.
2.2 Safety Precautions
WARNING!
Failure to heed these safety precautions may result in severe property
damage, bodily injury or death.
Protect yourself and others. Fumes and gases developed may be dangerous to your
health. Arc rays and splatter can injure eyes and exposed skin. Electric shock can
kill.
Oxygen mixed with oil or grease reacts explosively.
The operator and all bystanders must always wear adequate protective clothing,
shoes and welder’s gloves when Prime-Cut systems are being used.
Never operate this equipment without proper eye protection. Always use a number
5 or 6 shade filter.
Always use the Leather Shield to protect yourself from sparks and splatter.
Always keep your head away from the fume plume.
Always use adequate ventilation and exhaust at the arc point to keep fumes and
gases from your breathing zone and the general area. Special breathing apparatus
must be used when welding or cutting galvanized, cadmium plated (or other heavy
metal plated) or painted parts to avoid inhalation of toxic fumes.
Always keep the ignited tip of the rod away from the oxygen cylinder, battery and
hoses.
Always use extreme caution when operating the torch in windy or adverse
conditions.
Never allow falling sparks or molten metal to contact any part of the Prime-Cut
system. Damage may result which could render the equipment unsafe to operate.
Always keep oil and grease away from oxygen cylinders, valves, regulators, hoses
and fittings.

Never clean any internal part of the oxygen system. Never use compressed air, oil,
solvents or any other material to clean the oxygen system. The oxygen system could
become contaminated and cause internal burning in the torch or hose. All service
on oxygen delivery parts must be performed by a qualified and knowledgeable
technician.
Never leave the torch unattended while the oxygen cylinder valve is open and/or
there is pressure in the hose.
Never touch live electrical parts. Always wear welder’s gloves when inserting the
rod into the torch and/or extender. Never let the rod touch any unprotected part of
your body.
SEE: American National Standard Z49.1 “Safety in Welding and Cutting”
Published by the American Welding Society, 8669 NW 36 Street, # 130,
Miami, Florida 33166-6672.
OSHA Safety and Health Standards “29 CFR 1910” available from the
U.S. Department of Labor, Washington, D.C. 20210.
IN CASE OF EMERGENCY – CALL IMMEDIATELY FOR MEDICAL AID

3.0 COMPONENTS
3.1 Required Equipment
•Torch Assembly (PC/T-30)
•Striker Plate Assembly (PC/SP-30)
•3/16”, 1/4”, 3/8” or 1/2” Collet with Collet Washer
•Broco® Prime-Cut Cutting Rods
•Leather Shield (PC/LS)
•Oxygen Regulator (HR-3500-1)
•Oxygen Supply
•12 Volt DC or 24 Volt DC Battery
•Protective Clothing: welding leathers, gloves and tinted eye
shield (See Safety Precautions).
3.2 Accessory Equipment
•16" Cutting Rod Extender (PC/TAC-XT)
•Slave Plug with Cam-Lok Quick Connects (600143)

4.0 SETUP PROCEDURES
4.1 Preparing the Work Area
WARNING!
Never operate the torch in an explosive or flammable environment.
Never cut into unknown material.
Never operate the torch with other personnel or bystanders in front of the torch or in
the immediate work area.
Caution:
Some plastics, paints and plated parts give off toxic fumes. Organic
materials may by combustible. Exotic metals may ignite. Glass and thin porcelain
may shatter. Rock and minerals may spall.
1. Clear the work area of bystanders.
2. Place the oxygen supply and battery in a location away from the immediate
work area.
3. Know the composition of the target material.
4. Know what is beyond the target material. Never cut near power cables, pipes,
flammable objects or bystanders.
5. When the target material is a container or pipe, know the material previously
contained therein. Always thoroughly purge pipelines and containers with an
inert gas (such as nitrogen or argon) prior to cutting.
6. Check to see that falling material (molten metal, sparks or severed pieces of
target material) will not cause injury to operator or bystanders or damage to
property.

4.2 Pre-Assembly Inspection
WARNING!
Never use any equipment which is unsafe or appears to be unsafe.
Always replace damaged or worn components to reduce the risk of injury.
Never operate the torch without the flash arrestor and flash arrestor screen in
place.
1. Always inspect the oxygen hose for damage or wear prior to and immediately
following each use of the Prime-Cut system.
2. Always inspect the ignition power cables and connectors for damage or wear
prior to and immediately following each use of the Prime-Cut system.
3. Always inspect the torch for damage or wear prior to and immediately
following each use.
4. Always inspect the collet, collet washer, flash arrestor and flash arrestor
screen prior to and immediately following each use of the Prime-Cut torch.
5. Check the battery for leaks. Never use a leaking battery.

5.0 ASSEMBLY PROCEDURES
5.1 Oxygen System
WARNING!
Never stand directly in front of or directly behind the oxygen regulator
while opening the oxygen cylinder valve to reduce the risk of injury in the unlikely
event of regulator failure.
Oxygen mixed with oil or grease reacts explosively. Never use compressed air, oil,
solvents or other material to clean the oxygen system. Always keep oil and grease
away from the cutting torch, oxygen cylinders, valves, regulators, hoses and fittings.
Always make sure the oxygen cylinder is a safe distance form the immediate work
area. Never let sparks or molten material come into contact with the oxygen
cylinder.
1. Connect the oxygen regulator to the oxygen source.
2. Purge the regulator to remove debris by slightly opening the oxygen cylinder
valve and turning the regulator knob clockwise until a small stream of gas
escapes. Close the oxygen cylinder valve. (For preset regulators that have no
adjustment knob, slightly open, then immediately close the oxygen cylinder
valve to purge the regulator.)
3. Connect the oxygen hose to the regulator.
4. Slowly open the oxygen cylinder valve, pausing to let the pressure in the
cylinder, regulator and hose equalize before continuing.
5. Adjust the oxygen regulator to between 10 and 80 psig, depending on the
target material and the type of work being performed. (Typical setting is 60-70
psig for cutting steel approximately 1” thick.)
6. Check all connections for oxygen leaks.

5.2 Battery
•
CHARGE A NEW BATTERY BEFORE USING.
•
CHARGE AFTER EACH SUBSEQUENT USE.
•
DO NOT STORE A RECHARGEABLE BATTERY IN A FULLY OR PARTIALLY
DISCHARGED STATE.
•
NOTE- BATTERIES MAY LOSE UP TO 3% OF THEIR CHARGE PER MONTH
DURING STORAGE.
WARNING!
Always use a 12 volt DC or 24 volt DC battery . Never use any other
power source.
Always make sure the battery is a safe distance from the immediate work area.
Never let sparks or molten material come into contact with the battery.
Never use a battery for ignition that is connected to a battery charger. Always
unplug the battery charger before attaching the ignition power cables to the
battery.
Never let the striker plate accidentally contact the torch, rods, or work area.
Electrical shock and sparks may result.
Caution:
The battery can discharge if the striker plate continuously contacts the
work area. Exercise caution to prevent complete discharge of the battery.
NOTE:
Polarity does not matter for ignition since a direct short is required to ignite
the rod.
1. Connect the power cable from the torch to the black battery clamp by
connecting the black Cam-Lok plug on the torch cable to the Cam-Lok
receptacle inside of the black handle grips.
2. Connect the power cable from the striker plate to the red battery clamp by
connecting the red Cam-Lok plug on the torch cable to the Cam-Lok
receptacle inside of the handle grips.
3. Connect the battery clamps to the terminals of a 12v or 24v battery.

5.2.1 Slave Plug (600143)
1. Connect the power cable from the torch to the slave plug by connecting the
black Cam-Lok plug on the torch cable to the black Cam-Lok receptacle on the
slave plug.
2. Connect the striker plate to the slave plug by connecting the red Cam-Lok plug
on the torch cable to the red Cam-Lok receptacle on the slave plug.
3. Plug the slave plug into the vehicle slave receptacle.
5.3 Leather Shield (PC/LS)
WARNING!
Always use the
leather shield (PC/LS) designed
for the torch to protect yourself
from spark and splatter burns.
NOTE:
Make sure the leather
shield is not between the oxygen
control lever and the torch
handle where it would interfere
with the operation of the torch.
1. Remove the collet nut from
the torch.
2. With the smooth finished
side of the shield facing away
from the torch, slide the leather
shield onto the collet nut.
3. Screw the collet nut back onto the torch.
4. Position the leather shield so the long end covers the oxygen control lever.
5.4 Cutting Rod Insertion
WARNING!
Always wear welding gloves when inserting rods into or removing rods
from the Prime-Cut
torch.
Always insert the correct end of the cutting rod into the torch.
Never use a damaged cutting rod.

Always ensure the neoprene collet washer is in good condition and in place to
prevent oxygen leaks.
Caution:
Always use Broco® Prime-Cut cutting rods with the Prime-Cut torch.
Never use any other rods as hazardous backflashes or internal burning may result.
Note:
To determine the correct rod size for the target material and type of work
being performed refer to the table below. Use the appropriate collet washer for the
rod being used. Red washer is for 3/16” rod. All other rods use black washer.
1. Check to see that the collet in the torch is the appropriate size to properly fit
the rod being used.
To replace collet:
Remove the collet nut and collet from the torch. Make sure the neoprene
collet washer is in place. Insert the desired collet and replace the collet nut.
2. Loosen the collet nut 1/2 turn.
3. Insert the end of the rod that has the recessed internal rods into the collet until
it is securely bottomed out on the collet washer. Tighten the collet nut to lock
the rod in place.
4. Check for oxygen leaks at the
collet nut. If a leak exists:
a. Make sure the rod is
firmly seated on the collet washer.
b. Inspect the rod for
damage.
c. Inspect the collet
washer for damage and replace if
necessary.
Note: Place the end of the rod with the
recessed internal wires into the torch.

Cutting Rod Size Selection Chart
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
CUTTING
Lock hasps and shanks
Reinforcement bar in concrete (re-bar)
All steel plate (mild and high strength) to 1/2” thick
All steel plate (mild and high strength) over 1/2” thick to 2” thick
All steel plate (mild and high strength) over 2” thick
Aluminum, titanium, magnesium alloys and other volatile alloys*
PIERCING
Broken bolts to 3/4” diameter
Pins and broken bolts 3/4” diameter to 1 1/4” diameter
Steel plate less than 6” thick
Steel plate greater than 6” deep*
Concrete to 4” thick*
Concrete over 4” thick*
GOUGING
Gouge cutting steel composite barriers to 2” thick
Gouge cutting steel composite barriers over 2” thick
* Use the accessory cutting rod extender
5.5 16" Rod Extender (PC/TACXT16)
Note:
The rod extender is used to enable the operator to reach otherwise
inaccessible places and provide a safety standoff when cutting materials that may
spall or be under tension.
1. Check to see that the collet in the rod extender is the appropriate size to
properly fit the cutting rod being used.
To replace the collet:
Remove the collet nut and remove the collet from the PC/TACXT16. Make
sure the neoprene collet washer is in place. Insert the desired collet and
replace the collet nut.
2. Make sure the 3/8” collet is in the torch.
3. Loosen the torch collet nut 1/2 turn.
3/16”
1/4” 3/8” 36”L 1/2”

4. Insert the end of the rod extender into the torch collet until it is firmly seated
on the collet washer.
5. Tighten the torch collet nut to lock the rod extender in place.
6. Check for oxygen leaks at the collet nut. If a leak exists:
a. Make sure the rod extender is firmly seated on the collet washer.
b. Inspect the rod extender for damage.
c. Inspect the collet washer for damage and replace if necessary.
7. Insert the cutting rod into the rod extender as instructed in the section
“Cutting Rod Insertion.”
5.6 Hose/Cable Extension Kit (PC/EXMIL60)
Note:
The hose/cable extension kit is used to enable the operator to work farther
from the oxygen source and battery than is possible with the standard 30’ long
hose.
Disconnect the oxygen hose from the regulator utilizing the quick connect fitting.
Disconnect the torch power cable and striker plate power cable from the slave plug
or battery clamps.
Connect the male plug on the torch hose into the quick connect coupler on the
extension hose.
Connect the male plug on the extension hose into the quick connect coupler on the
oxygen regulator.
Connect the torch power cable to the extension cable by connecting the black Cam-
Lok plug on the torch cable to the black Cam-Lok receptacle on the extension
cable.
Connect the striker plate power cable to the extension cable by connecting the red
Cam-Lok plug on the torch cable to the red Cam-Lok receptacle on the extension
cable.
Connect the extension cables to the slave plug/battery clamps by connecting the
Cam-Lok plugs on the extension cables to the Cam-Lok receptacles on the slave
plug/battery clamps.

6.0 OPERATING PROCEDURES
WARNING!
Always protect yourself from spark and splatter burns. Never operate
the torch without the leather shield in place.
6.1 Cutting Rod Ignition
WARNING!
Always hold the striker plate
by the plastic handle to avoid electric
shock. Never touch the copper plate.
Never touch or hold an ignited cutting rod.
Caution:
Prolonged contact between the
cutting rod and the striker plate can
overheat the battery causing damage.
1. Point the cutting rod away from your body. Never point the rod at bystanders.
2. Start the flow of oxygen by lightly squeezing the oxygen control lever on the
torch.
3. Bring the striker plate into contact with the end of the rod.
4. While holding the rod at a 45°- 90°angle to the striker plate, slowly pull the
rod across the striker plate surface.
5. Rod sparkling indicates ignition. Approximately 2-5 seconds of contact is
required for ignition.
6. Maintain slight pressure on the oxygen lever to ensure complete ignition.
7. Lift the rod from the striker plate and bring it to the target material.
8. Place the striker plate in a safe location away from the work area.
9. Commence cutting, piercing or gouging according to the following directions.

6.2 Techniques
WARNING!
Never let the cutting rod burn down into the torch. Always release the
oxygen lever to extinguish the torch while there are at least 2 inches of rod
remaining.
6.2.1 Piercing
WARNING!
Always wear adequate protective clothing and a full face shield, and
use the leather shield (PC/LS) during piercing operations. Blowback is greater
when piercing. Exercise extreme caution.
1. With the oxygen lever slightly depressed (low oxygen flow), press the burning
tip of the rod against the target material at a 90°angle, allowing it to melt a
1/4” deep hole.
2. Insert the rod tip into the depression.
3. Keeping the tip of the rod in the hole, increase the oxygen flow to increase
penetration by slowly depressing the oxygen lever.
4. As the target material melts and flows back out of the hole, move the rod in
and out and around to enlarge the hole and allow the oxygen pressure to wash
away molten material.
5. Remove the rod from the hole before releasing the oxygen lever.
6. When piercing is
completed, release the
oxygen control lever to
extinguish the torch. The rod
will continue to burn only as
long as oxygen is supplied.
7. Never touch a used rod,
the target material or the
work surface with a bare
hand until it has cooled.
Always wear welding gloves.

Suggestions:
Set the oxygen regulator to 35 psig when starting piercing operations
to avoid excessive blowback. When the penetration is approximately 2” deep,
increase the oxygen pressure to 50-60 psig.
To pierce a pin ¾” in diameter or smaller, weld a small piece of angle iron on to the
head of the pin at the 3 o’clock and 9 o’clock positions to establish a trough guide.
This helps to assure the production of a straighter hole. After penetrating 3-4”,
remove the angle guide and complete the hole.
When piercing a pin longer than 5”, it is best to use a 3/8” diameter rod.
6.2.2 Cutting
Note:
Keep the burning tip of the cutting rod in direct contact with the target
material.
1. Place the burning tip
of the rod against the
target material at a
45°- 90°angle.
2. Increase the oxygen
flow by slowly
depressing the
oxygen lever.
3. Keep the rod tip in
the cut.
4. Pull the rod in the direction of the cut. Be sure that the molten material is
blown forward through the cut and does not splash backwards towards the
operator.
5. Complete the cut by making sure all the hangers are removed.
6. After completing the cut, release the oxygen control lever to extinguish the
torch. The rod will continue to burn only as long as oxygen is supplied.
7. Never touch a used rod, the target material or the work surface with a bare
hand until it has cooled. Always wear welding gloves.

6.2.3 Gouging
1. With the oxygen control lever slightly depressed (low oxygen flow), lay the rod
flat on the work piece (5°- 10°angle) with the burning tip of the rod against
the target material.
2. Increase the oxygen flow by slowly depressing the oxygen lever.
3. The target material will puddle in approximately 1-2 seconds. Keep the rod at
a very slight angle to the work piece and the tip of the rod in the puddle.
4. With the oxygen lever fully depressed, push the rod in the direction of the
desired gouge.
5. When the gouge is complete, lift the rod tip from the target material.
6. Release the oxygen control lever to extinguish the torch. The rod will continue
to burn only as long as oxygen is supplied.
7. Never touch a used rod, the target material or the work surface with a bare
hand until it has cooled. Always wear welding gloves.
6.3
Shutdown
WARNING!
Always disconnect the ignition power cables prior to charging the
battery.
Note:
Always place a protective cap or piece of tape over the open end of the
oxygen hose to prevent dirt or foreign objects from entering during storage.
1. Close the oxygen cylinder valve.
2. Depress the oxygen control lever to relieve any pressure from the oxygen hose.
3. Turn the oxygen regulator adjustment knob counter-clockwise to take pressure
off the diaphragm.

4. Disconnect the oxygen hose from the regulator and cap the open end of the
hose.
5. Disconnect the torch and striker plate power cables from the battery.
6. Wipe down the torch assembly and striker plate assembly with a clean oil-free
cloth.
7. Remove the collet nut, collet, collet washer, flash arrestor and flash arrestor
screen and inspect for damage or wear. Clean and reassemble. Always replace
any damaged or worn parts with factory replacement parts.
8. Always inspect the cables and hose for cuts, burns or any other signs of
damage or wear.
9. Store the Prime-Cut torch in a clean, dry place.
10. Charge the battery according to the manufacturer’s instructions for the battery
and battery charger being used.