ESAB CIGWELD COMET User manual

COMETPlatecutterOPERATING MANUALManual Part No: 338198-01-O18

2
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new CIGWELD 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 accredited service network. To locate your nearest distributor or
service provider call 1300-654-674, or visit us on the web at
www.cigweld.com.au.
This Operating Manual has been designed to instruct you on the correct
use and operation of your CIGWELD 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. CIGWELD is a Market
Leading Brand of Arc and Gas Cutting & Welding Products for ESAB.
We are a mainline supplier to major gas cutting & welding industry sectors
in the Asia Pacific and emerging global markets including; Manufacturing,
Construction, Mining, Automotive, Engineering, Rural and DIY.
We distinguish ourselves from our competition through market leading
dependable brands that have stood the test of time, technical innovation,
competitive prices, excellent delivery, superior customer service and
technical support, together with excellence in sales and marketing
expertise.
We are committed to develop technologically advanced products to
achieve a safer working environment for industry operators.

WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing
this product.
While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer
assumes no liability for its use.
Instruction Manual Number 338198-01-418 for:
Comet Platecutter
Published by:
CIGWELD Pty Ltd
CIGWELD An ESAB Brand
71 Gower Street
Preston, Victoria, Australia, 3072
www.cigweld.com.au
Copyright 2018 by
CIGWELD An ESAB Brand
All rights reserved.
A 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.
Publication Date: Oct 15, 2018
Record the following information for Warranty purposes:
Where Purchased: ___________________________________________
Purchase Date: ___________________________________________

This page intentionally left blank.

TABLE OF CONTENTS
SECTION 1:
GAS EQUIPMENT SAFETY INSTRUCTIONS AND WARNINGS ..............................Page 6
1.01 Personal Safety.............................................................................................Page 6
1.02 Cylinders –General.......................................................................................Page 6
1.03 Oxygen Cylinders..........................................................................................Page 7
1.04 Acetylene Cylinders.......................................................................................Page 7
1.05 LPG Cylinders...............................................................................................Page 8
1.06 Regulators ....................................................................................................Page 8
1.07 Flashback Arrestors ......................................................................................Page 9
1.08 Gas Welding Hose ........................................................................................Page 9
1.09 Electrical System ..........................................................................................Page 10
SECTION 2:
INTRODUCTION..............................................................................................................Page 11
2.01 Box Contents ................................................................................................Page 11
2.02 Gas Requirements ........................................................................................Page 11
SECTION 3:
INSTALLATION AND USE.......................................................................Page 12
3.01 Pre-Operation Handling Precautions.............................................................Page 12
3.02 Testing For Leaks Before Use .......................................................................Page 13
3.03 After Completion of Use (Shut-down)...........................................................Page 14
SECTION 4:
CUTTING OPERATION.....................................................................................................Page 15
4.01 One Torch Set...............................................................................................Page 15
4.02 Two Torch Set ..............................................................................................Page 15
4.03 Preparation for Operation ............................................................................Page 16
4.04 Operation .....................................................................................................Page 16
4.05 Circle Cutting Attachment ............................................................................Page 17
SECTION 5:
MAINTENANCE AND INSPECTION..................................................................................Page 18
SECTION 6:
TROUBLE-SHOOTING .....................................................................................................Page 18
SECTION 7:
WIRING DIAGRAM..........................................................................................................Page 20
SECTION 8:
ASSEMBLY DIMENSIONS...............................................................................................Page 20
SECTION 9:
CUTTING DATA...............................................................................................................Page 21
SECTION 10:
ACCESSORIES & SPARE PARTS ....................................................................................Page 21
SECTION 10:
WARRANTY ....................................................................................................................Page 22

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SECTION 1: GAS EQUIPMENT SAFETY INSTRUCTIONS AND WARNINGS
The information shown under this note must be followed carefully to avoid injuring the operator or anyone in the
operating area.
When an accident does occur with gas equipment, it’s usually due to the operator having become careless through
over-familiarity. Remember, the safest of equipment, if wrongly handled, can cease to be safe. For safe welding
and cutting check and re-check the points in this article. Each point is there for a purpose.
1.01 Personal Safety
Be neat and clean about your work. Maintain your equipment in good condition. Wear goggles with the correct shade
filter when using gas equipment. Goggles protect your eyes against sparks and injurious rays. It is essential that the
goggles and filters are of a type intended for cutting work. Quite apart from safety, they help you see your work better.
Wear suitable gloves, aprons, shoes and protective clothing. Watch for sparks in sleeves, cuffs and open pockets. Never
use oxygen to dust clothes or work. Use a flint lighter or pilot light to light blowpipe. Never use matches. Keep flame,
sparks or metal away from cylinders and tubing. When working with lead, lead bearing materials, steel coated with lead
paints, cadmium-coated materials or any objects containing metals giving off toxic fumes, always use a suitable
respirator.
1.02 Cylinders –General
Industrial gas cylinders are made to rigid specifications and are inspected each time they are refilled by your supplier.
They are safe –if properly handled. All Government and insurance regulations relating to the storage of oxygen,
acetylene and LPG cylinders should be closely observed. Keep all cylinders, empty or full, away from radiators, furnaces
and other sources of heat. Also avoid contact with electrical circuits. Keep oil and grease away from cylinders.
Cylinders standing in the open should be screened against direct rays of the sun. Protect cylinders valves from bumps
and falling objects. Keep the valves clean, free from oil, grease and all foreign materials. Close cylinder valves when not
in use, when empty, or when moving cylinders. Always remove regulators when moving cylinders. Be sure the cylinder
valve is tightly closed before removing regulators. Never allow anyone to strike an arc or tap an electrode against any
cylinder. Never try to fill a cylinder or mix gases in a cylinder. Never tamper with or alter cylinder numbers or markings.
Never use cylinders as supports or rollers. When transporting cylinders using a crane, do not use slings- use a cylinder
cradle. Never draw gas from cylinders except through properly attached pressure regulators or equipment designed for
the purpose. If damaged, send the regulator to the supplier or appointed agent for repairs. If unable to make a gas-tight
seal between the cylinder valve and a regulator spigot, first check whether the spigot nut is tight. If so check the
regulator spigot. If the cylinder valve is damaged notify the gas supplier. Never insert washers of lead or other material
between the regulator and the cylinder valve. Never use oil or grease on these connections. Use only standard cylinder
keys to open cylinder valves, never extend the length of these keys under any circumstances. If valves cannot be opened
by hand, do not use a hammer or wrench; notify the supplier. Open all cylinder valves slowly. Leave cylinder key in
position when fuel gas cylinder valves are open.

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1.03 Oxygen Cylinders
Oxygen cylinders are steel shells of ample strength for their purpose. Besides routine inspections, they periodically
undergo a searching examination, which includes a hydraulic pressure test. Always call oxygen “Oxygen” not “Air”.
Never use oxygen in pneumatic tools, in oil pre-heating burners, to start engines, to blow out pipelines or to freshen the
atmosphere in confined spaces.
In short, under no circumstances use oxygen as a substitute for compressed air or other gases.
1.04 Acetylene Cylinders
Acetylene cylinders contain porous material, which is impregnated with acetone. The acetylene is dissolved under
pressure in this acetone. All acetylene cylinders are fitted with fusible plugs. These are designed to vent the cylinder
contents in the event of an unsafe condition arising in the cylinder due to any cause such as overheating or
decomposition arising from either incorrect operating technique, faulty equipment alone, or in conjunction with
excessive temperature. In the event of a safety devise functioning, always notify the supplier. The reason for the devise
operating always warrants special investigation. Always call acetylene “acetylene” not Gas. Always keep acetylene
cylinders upright, whether in use or in store, full or empty. Always keep acetylene cool, store them upright in a well
protected, well ventilated dry location, away from highly combustible materials and oxygen cylinders. Should an
acetylene valve leak around the spindle, close the valve and tighten the gland. If this fails, or if the fusible plug is leaking,
remove cylinder to open air. Keep the cylinder well away from anything which could possibly set the escaping acetylene
on fire. Tag the cylinder to explain the trouble. Notify suppliers at once. If acetylene, escaping from a leaking cylinder
valve gland or from an improperly seated regulator spigot ignites, immediately close the cylinder valve. If this is
impossible, treat from point two below. If an acetylene cylinder is heated accidentally or becomes hot through severe
flashback, or other cause, action should be taken promptly in the following manner:
- Shut the cylinder valve
- Clear all personal from the area
- Cool the cylinder with a copious supply of water and notify the fire brigade
NOTE: The person directing the fire hose should be protected behind some suitable shelter. If the safety device
functions and the issuing gas ignites, cool the cylinder as above, but avoid extinguishing the flames. If the
escaping gas does not ignite, care must be taken to avoid an air/acetylene explosion. No source of ignition must
be permitted to enter the area. Existing sources of ignition should be rendered safe.
- Continue cooling the cylinder with copious quantities of water until it is quite cool. This maybe determined by
removing the cooling water at intervals and watching whether the water on the cylinder fries off, or whether the
cylinder remains wet.
- Notify the supplier
- In cases where the supplier’s representative is unavailable or cannot reach the scene of the incident within half
an hour, the cylinder may after this period be removed carefully to an open space away from buildings and any
source of ignition provided it remains cool and wet.
- The cylinder valve should then be opened until the cylinder is empty. During this period a copious quantity of
water should be poured on the cylinder.
- When the cylinder is empty check whether the cylinder is cool, if so, close the valve.

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1.05 LPG Cylinders
LPG cylinders are provided with relief valves or fusible plugs to discharge their contents and keep the cylinder pressure
within safe limits should the cylinder be overheated by a fire. LPG cylinders should be used and stored upright in the
open, away from combustible material. Do not store LPG cylinders with oxygen cylinders. Do not store LPG cylinders
closer than 1.5 m horizontally from any opening into a building. If LPG cylinder valve leaks around the spindle, or if the
relieve valve or fusible plug is leaking, remove the cylinder to open air away from buildings and sources of ignition; tag
the cylinder to explain the trouble; notify the supplier as soon as possible. If LPG escapes from a leaking cylinder valve
gland or from a regulator spigot ignites, immediately close the cylinder valve. If LPG escaping from a fusible plug ignites,
direct a fine water spray at the cylinder and surrounding equipment. On no account should the flame be extinguished,
since escaping unburned gas in a confined space may re-ignite and cause an explosion. LPG is not toxic and is
odourless, but an odorant is added to give a distinctive smell. If the distinctive odour is detected an immediate check
should be made for leaks. Soapy water is recommended for this purpose. As soon as the leak is located, turn off the LPG
cylinder valve and tighten or repair the equipment. If LPG is leaking do not strike matches or operate any electrical
appliance in the vicinity. Remove all sources of ignition and open all doors and windows. Do not attempt to relight LPG
until all traces of LPG odour have disappeared. Remember, LPG is heavier than air and will remain in open containers,
cellars and confined spaces for a considerable time.
1.06 Regulators
Do not work with damaged equipment. Have leaking or damaged equipment repaired by an authorized repair agent. Give
your gas equipment the care you would give any other dependable tool. Do not use oil or grease on any regulator. Do not
handle equipment with an oil rag, oily gloves or hands. Keep your equipment clean. Never use regulators for purposes
other than that for which they were intended. Inspect connections and all seating surfaces on regulators before use.
Damaged connections can cause leaking or flashbacks. Never hang a blowpipe or tubing on a regulator or cylinder valve.
Crack cylinder valves before attaching regulators. Cracking means to open the valve a little, then immediately close, to
blow out dust or foreign matter. Cracking should always be done gently. Never crack a fuel gas valve near other welding
works, sparks or open flame. Never crack a Hydrogen cylinder as this can cause the gas to self-ignite. Never force
connections. Be sure all connections are tight. Never test for leaks with a flame. Never try to connect a regulator to a
cylinder containing gas other than that for which the regulator is meant. Never subject the regulator to inlet pressures
greater than its rated inlet pressure, as shown on regulator body and associated literature. If a regulator shows excessive
creep (pressure build-up when blowpipe valves are closed), close cylinder valve and have regulator repaired at once.
Quite apart from risks, creeping regulators lead to poor work. Pressure build-up in excess of 35 kPa is to be regarded as
excessive and call for immediate attention. Periodically, have pressure gauges on regulators tested for accuracy. Ensure
before using that regulators have both a cylinder pressure and a delivery pressure gauge in working order. Before
opening cylinder valves always fully release regulator adjusting knob (turn fully anticlockwise). A sudden pressure rise in
a regulator whose adjusting knob is screwed in puts a heavy strain on the mechanism and may cause damage. Never
release the regulator adjusting knob while there is pressure in the tubing. If the pressure gauge indicator fails to return to
the stop when pressure is released, have the gauge checked.
Always take care to keep the regulators free of oil and grease. Oil and grease should be removed chemically by a
qualified repair technician. Never use oil or grease on the regulator, cylinder or manifold connections. Do not
change the inlet connection on a regulator in an attempt to use the regulator for a different gas service.
GasguardTM safety device (where fitted to selected regulators)
GasguardTM is a non-return valve that completely seals off the gas should the regulator break from the cylinder. In order
for this to operate correctly it must be used in conjunction with the extended nut provided with the regulator. Failure to
do so could result in the Gasguard feature not operating in line with its intended design function.

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1.07 Flashback Arrestors
A flashback occurs when mixed gases within a cutting and welding blowpipe system ignite and, due to several possible
reasons burn back through the system against the flow of gas. The consequences of a flashback range from sooting of
the hose, to serious equipment fires and possible explosion. Low operating pressures, inadequate gas supply, damaged
equipment or poorly maintained equipment substantially increase the likelihood of flashbacks occurring. Flashback
arrestors correctly used virtually eliminate the possibility of a flashback causing harmful damage.
CIGWELD’s market leading range of COMET flashback arrestors conform to national and international standards
(AS4603, EN 730, ISO 5175 - Connection fittings to AS4267) and are manufactured under an ISO9001 accredited quality
management system. This comprehensive range includes products suitable for all applications.
CIGWELD’s COMET flashback arrestors have been designed with state of the art technology to provide the ultimate
protection and virtually eliminate flashbacks because it is impossible to either predict or completely eliminate the
potential hazard of a flashback.
Standards
Australian Standard AS 4267 - 1995 Pressure Regulators for use with Industrial Compressed Gas Cylinders recommends
flashback arrestors be used in Oxy-fuel gas applications. Australian Standard AS 4289 - 1995 Oxygen and Acetylene Gas
Reticulation Systems, specifies the use of flashback arrestors in Oxy-fuel applications. AS4603 is a new standard for
flashback arrestors only. Make sure the flashback arrestors you use now have this labelled on them.
Testing
AS 4289-1995 states flashback arrestors shall be tested annually, this can be done by one of CIGWELD’s extensive
network of accredited service agents. Flashback arrestors should also be tested if they have been subjected to backfiring
and flashbacks. Contact your nearest distributor for advice on the correct type of flashback arrestors that should be fitted
to cater for your application(s)
NOTE: In Western Australia the Occupational Safety and Health Regulations 1996 (Reference 3.98) requires flashback
arrestors to be fitted at the outlet side of each regulator or gas discharge of a manifolded cylinder pack; and at the
blowpipe. This is also supported by Australian Standard AS 4839 that recommends the use of flashback arrestors and
list 3 options in order of preference for their fitment. CIGWELD recommends fitting flashback arrestors to both the
regulator outlet and blowpipe inlet connections, providing the ultimate protection for the operator.
1.08 Gas Welding Hose
Gas welding hose is an essential yet vulnerable link in the system that provides flexibility and freedom of movement for
the operator. Quality hoses, such as CIGWELD’s COMET hoses, which comply to Australian Standards, are designed and
manufactured to safely withstand high pressures, crushing, contact with certain chemical compounds, contaminants,
ignition as well as burning, and environmental abuse. Hoses however are the weakest point of the Oxy-fuel system and
provide potentially the greatest source of gas leaks. As a result, only quality hose which complies to AS 1335 - 1995
should be used (in conjunction with compatible hose fittings), so as to maximise the safety and durability of this part of
the system. Welding hoses which comply to Australian Standards are colour coded to the gas for which they are to be
used (Red-Acetylene, Blue-Oxygen, Orange-LPG, and Black-Inert).
Hose assemblies should be checked regularly for gas leaks, signs of external damage, perishing and for fit up to the hose
fittings. If required the necessary repairs or replacement should be made immediately. For large flow applications and
long lengths of hose 10mm or 13mm bore hose should be used.

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Pressure Drop
Pressure drop simply means that for gas to flow through the hose, for a given pressure at the beginning of the hose (eg.
at the regulator), the pressure at the other end of the hose (eg. at the blowpipe) will be less. For a given flow and length
of hose, the pressure drop in a small bore hose, will be greater than in a larger bore hose. This means, that wherever
possible, hose lengths should be kept to a minimum and hose bore diameters kept to a maximum. Doing so will reduce
the amount of pressure drop, therefore minimising the chance of affecting the performance or stability of the process
flame. Minimising hose lengths also provides greater protection to the hose against damage. Excessive pressure drops
can starve a tip or nozzle of an adequate gas supply, which in turn can lead to reduced flame intensity, backfiring or
flashbacks.
Hose Fittings
The design of the hose connection must provide high mechanical strength and resistance to leakage under a wide range
of conditions. Further, non-interchangeability of hose fittings is maintained by using a right hand (RH) thread for Oxygen
and a left hand (LH) thread for fuel. CIGWELD’s COMET hose fittings fulfil all of these important requirements.
Dimensions for hose fitting connector nuts and nipples are given in AS 4267.
1.09 Electrical System
Ensure that the supply voltage does not vary more than ±10% of the rated voltage, as this may cause a breakdown.
Ensure the power cable machine connection is fully screw on and tight.
Stop operation and turn off the power in the following cases, and have a qualified electrician to repair the machine.
- Broken or abraded cable.
- When the machine has been in contact with water, or in case of liquid damage to machine.
- Abnormal machine operation despite operating the machine according to this operating manual.
- Poor performance or machine breakdown.

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SECTION 2: INTRODUCTION
2.01 BOX CONTENTS
The Comet Platecutter Box comes complete with the components listed below. Ensure when unpacking the box that all
components are present.
1 x Comet Platecutter
1 x Operating Manual
1 x Torch Holder with Rack
1 x Torch
1 x Gas Distributor
1 x Twin Hose 600 mm
1 x Power Cord
1 x Nozzle Type 41 Size 8
2 x Rail 1.8 m
2 x Hose End Fittings
2 x Spanner
1 x Tip Cleaner
1 x Hex Key
2.02 GAS REQUIREMENTS
This Comet Platecutter is suitable for use with oxygen/acetylene gases only. Cylinders of these gases are available in
various sizes dependent upon your usage requirements. Your local gas distributor will be able to assist in obtaining the
suitable grades of gases and cylinder sizes required for this Platecutter.

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SECTION 3: INSTALLATION AND USE
3.01 PRE-OPERATION HANDLING PRECAUTIONS
1
Power input socket
10
Torch up/down handle
2
Speed adjustment knob
11
Heat shield
3
Switch stop/forward/reverse
12
Holder fixing handle
4
Fuel hose (red/orange)
13
Drive wheel
5
Oxygen hose (blue)
14
Rack bar
6
Handle
15
Cross feed handle
7
Preheat oxygen valve
16
Gas distributor
8
Cutting oxygen valve
17
Clutch
9
Idle wheel
Specifications
Machine Size
370 x 140 x 165
Wheel distance
160 mm
Cutting thickness
Up to 100 mm
Cutting shape
Square and bevel (up to 45°)
Power source
240 VAC ± 10%
Reduction gear
Single cone system
Motor speed
1500 rpm
Nozzle
Type 41

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The machine case is made mainly from aluminium alloy for lightness, so can be damaged by shocks and
impacts. Therefore, take care not to let heavy objects fall on the machine and do not drop the machine when
moving it.
Have the motor turning when adjusting the speed.
Always keep the rail surface clean to prevent knocking. Pay special attention to places along which the wheels
pass. Also, be careful not to damage the drive wheel or idle wheel.
Take care that the path of the machine is not hindered by the hoses running from the regulator to the distributor
connection.
Always make sure the cutting tip is fastened tightly to the torch. Be careful when handling the cutting tip not to
damage the tapered section.
WARNING –Never use the machine outdoors in wet weather. This may cause electric shock and damage the
machine.
Never move the machine when the pre-heat flame is on
When moving the rail, be sure to take down the machine body off the rail.
3.02 TESTING FOR LEAKS BEFORE USE
After assembly and before use, it is recommended that the following procedure be adopted to check for leaks.
Before opening the cylinder valve, turn the Regulator adjusting knob fully anti-clockwise until there is no
pressure on the internal adjusting spring and the knob turns freely.
Ensure all valves on downstream connected equipment are closed.
Stand to the side of the cylinder opposite the Regulator adjusting knob before opening the cylinder valve. Keep
the cylinder valve between you and the Regulator.
Open the cylinder valve slowly - if opened quickly, a sudden pressure surge may damage internal Regulator
parts. Set the Regulator to show approximately 100 kPa on the delivery gauge, by turning the adjusting control
knob clockwise.
Close the cylinder valve.
Turn the adjusting knob anti-clockwise one turn:
a) If the high pressure (cylinder contents) gauge reading drops, there is a leak in the cylinder valve, inlet fitting,
or high pressure gauge.
b) If the low pressure (delivery) gauge drops, there is a leak in the downstream equipment, hose, hose fitting,
outlet fitting, or low pressure gauge. Check for leaks using a suitable leak detection solution.
c) If the high pressure gauge drops and the low pressure gauge increases at the same time, there is a leak in the
internal Regulator seat.
d) If the Regulator requires service or repair, refer to Section 5.
If there are no leaks found, then the system is ready for use.
Repeat test for the second gas system (where applicable)

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IMPORTANT:
This test should be done quickly, and it is important that there are no sources of ignition present during this process, as
a certain amount gas will be released to the atmosphere. If no leaks are detected, the system is ready for use. In an
Oxy/Fuel system, particular care needs to be taken to ensure that gasses are not mixed, as this may lead to flashback
upon lighting up. If leaks are detected in the system, then the joint should be re-tightened and re-tested, or the leaking
item replaced. If any leaks are detected from a torch, it should be returned to the distributor from which it was
purchased.
3.03 AFTER COMPLETION OF USE (SHUT-DOWN)
Close the cylinder valve whenever the Regulator is not in use. To shut down for extended periods (more than 30
minutes):
a) Close the cylinder or upstream valve tightly.
b) Open the downstream equipment valves to release all gas pressure from the system. Bleed gas into a well
ventilated area and away from any ignition source.
c) After gas is drained completely, turn the Regulator adjusting knob anti-clockwise until there is no pressure
on the internal adjusting spring and the knob turns freely.
d) Close the downstream equipment valve.

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SECTION 4: CUTTING OPERATION
4.01 ONE TORCH SET
Follow the instructions below to prepare your machine for operation:
1. Gently remove the machine from its case and set it on the rail.
2. Assemble the torch set parts in the following order;
a. Insert the rack bar into the main unit in the direction of the arrow.
b. Fit the torch holder onto the rack bar as shown.
c. Fit the torch into the torch holder and adjust the torch up/down setting.
d. Fit the hoses between the torch and gas distributor connection. (The blue hose has a right-hand thread,
and the fuel hose has a left-hand thread).
e. When the torch stroke in insufficient to cut the plate beneath the rail when carrying out lower-edge
preparation, change the torch holder to the position indicated by the arrow.
3. Refer to the Cutting Data (see page 19) to select the right cutting nozzle for the thickness of steel plate to be cut.
4. Always use two spanners to tighten the nozzle on the torch. This is to avoid damaging the torch.
4.02 TWO TORCH SET
1. Insert the rack bar into the main unit in the direction of the arrow.
2. Fit the two cross-feed torch holders onto the rack bar.
3. Position and fix the torch holders into the cross-feed holders, then fit the torches.

16
4. Fit the gas Y-pieces onto the main unit and connect the 600 mm (24”) and 900 mm (36”) hoses from the
distributor to the two torches.
5. Fix the weight bar and weight.
6. When the torch stroke in insufficient to cut the plate beneath the rail when carrying out lower-edge preparation,
change the torch holders to the position indicated by the arrow.
4.03 PREPARATION FOR OPERATION
1. After fixing the nozzle to the torch, adjust the gas pressure to the standard settings shown in the Cutting Data
(see page 19). (Confirm first that all torch valves are closed.)
2. Ensure the switch on the machine is OFF and connect the power cord to the body and power supply.
3. Refer to the Cutting Data to find the correct cutting speed.
4.04 OPERATION
1. Align the nozzle with the scribed cutting line.
2. Open the fuel gas valve, slightly open the preheat oxygen valve and ignite the torch with the lighter. Next, fully
open the gas valve and adjust the preheat oxygen valve to obtain a neutral flame.
3. Adjust the distance between the nozzle and plate. (This distance should be ~2-3 mm from the white tip of the
flame.)
4. Engage the clutch, and after sufficiently preheating the plate, open the cutting oxygen valve and put the direction
switch forward or reverse to start cutting.
5. After cutting has started, observe the condition of the cut carefully and adjust the cutting speed to the optimum
level.
6. When cutting has finished, close the cutting oxygen valve, turn off the direction switch, close the fuel gas valve,
then the preheat oxygen valve and return the clutch to the “stop” position.
Note: Check that the flow of cutting oxygen is at right-angles to the plate. For a proper cut, base gas pressures in
accordance with the settings given in the Cutting Data (see page 19). However, carry out pressure corrections in
accordance with the cutting conditions.

17
4.04 CIRCLE CUTTING ATTACHMENT
1. Attach radius bar and pivot for cutting large or small circles as shown.
2. Adjust the height of centre pivot pin so that the drive wheel at the centre side is 1.0mm above the work
piece.
3. Align the pivot pin with the centre of the circle.
4. Loosen the butterfly screw and fix the idle wheel to an angle suitable to the cutting radius.

18
SECTION 5: MAINTENANCE AND INSPECTION
5.1 Daily Inspection
1. Wipe the exterior of the machine with a clean cloth.
2. Lubricate the shaft of the idle wheel with machine oil.
3. Clean the outer surface of the drive wheel with an oily cloth.
5.2 Monthly Inspection
1. Lubricate the cross-feed handle shaft and the clutch lever.
2. Measure the insulation resistance between the machine body and the power plug by tilting the switch toward either
“Forward” or “Reverse. It must read over 5KΩ.
3. Remove the operation panel and clean the electrical parts inside.
5.3 3-Month (2000-hour) Inspection
1. Remove the motor and speed change cone and replace the old grease inside the gear box with new grease.
2. Completely remove oil, if any, from the motor disc and speed change cone with thinners, etc.
SECTION 6: TROUBLE-SHOOTING
Backfire and Flashback
The most basic problems involve backfire and flashback. While the two terms are often confused, strictly speaking
backfire is when the flame ignites momentarily inside the torch and then goes out, or goes out and re-lights (punching
backfire), whereas flashback refers to the flame burning continuously inside the torch (sustained flashback).
1. Backfire –causes
a) Incorrectly adjusted gas pressures.
b) Overheated nozzle.
c) Slag sticking to nozzle.
d) Tapered seat of nozzle or torch are damaged.
Should backfire occur, find the cause and take appropriate action before using the machine again.
2. Sustained Flashback
If the flame disappears back into the torch and burns there (making a soft, hissing sound), shut the valves off in the
following order immediately.
Preheat Oxygen Fuel Gas Cutting Oxygen
As with backfire, find the cause and take appropriate action before using the machine again.
1. Carriage does not move. (Motor does not run).
Possible cause
Procedure
Remedy
1
No electrical power
Check power source and connections.
2
Broken power cord
Use a circuit tester to check the cord. If the
tester shows ∞, the power cord is broken.
Repair or replace the broken cord.
3
Faulty plug
Check the wire soldering.
Resolder the wire.
4
Faulty switch
Remove the mode terminal and test the
switch.
Replace faulty switch.
5
Faulty condenser
Check the condenser with a tester. If the
tester handle slightly vibrates and shows ∞
immediately, the condenser is normal.
Replace faulty condenser.
6
Faulty connection
Check soldering.
Resolder faulty connection.
7
Broken lead wire
Test each lead wire.

19
8
Faulty motor windings
A faulty motor is indicated if all the above
tests results are normal.
Repair or replace the motor.
2. Carriage does not move. (Motor runs).
Possible cause
Procedure
Remedy
1
Faulty clutch
Remove the clutch and check the inside
mechanism.
2
Cone friction slips
Check the spring or greasy friction face.
Replace the spring or clean surface
with thinners, etc.
3. Abnormal Carriage.
Possible cause
Procedure
Remedy
1
Severe vibration and noise
a.) Foreign matter caught in gear.
b.) Gear worn.
c.) Motor faulty.
d.) Cone worn or damaged.
Repair or replace.
Replace.
Repair or replace.
Replace.
2
Clutch not disengaging
Snap ring of the clutch pin is off.
Replace.
3
Knocks
a.) Gear worn.
b.) Faulty clutch pin.
c.) Clutch key worn.
d.) Loose shaft or drive wheel.
e.) Worn or damaged cone.
f.) Heat shield touches the work surface or
rail.
g.) Damaged rail or foreign objects on rail.
h.) Hoses or power cord interferes with
carriage movement.
i.) Faulty idle wheel.
j.) Foreign matter is attached to drive wheel,
or wheel is damaged.
Replace worn gear.
Replace faulty pin.
Repair or replace worn key.
Repair or replace.
Replace.
Exercise caution.
Repair or clean.
Exercise caution during operation.
Repair or replace.
Repair or replace.

20
SECTION 7: WIRING DIAGRAM
SECTION 8: ASSEMBLY DIMENSIONS