Hobart 770 500 User manual

Portable Tote Oxy-Acetylene
Cutting and Welding Outfit
770 500
www.HobartWelders.com
Description
OM-254 957B 2013−12
File: Accessory
Accessory
Processes
Oxy-Fuel Welding and Cutting

Hobart is registered to
the ISO 9001 Quality
System Standard.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................
1-1. Symbol Usage 1.......................................................................
1-2. Welding, Cutting, Brazing, And Heating Hazards 1...........................................
1-3. California Proposition 65 Warnings 3......................................................
1-4. Principal Safety Standards 3.............................................................
SECTION 2 − INTRODUCTION 4...............................................................
SECTION 3 − HAZARDOUS EVENTS 4.........................................................
SECTION 4 − ASSOCIATED HAZARDS OF RECOMPRESSING PURE OXYGEN 4...................
SECTION 5 − SPECIFICATIONS 5..............................................................
5-1. Equipment Included With The Kit 5........................................................
5-2. Specifications 5........................................................................
5-3. Welding (Brazing) Tip And Gas Pressure Guide 6...........................................
5-4. Cutting Tip And Gas Pressure Guide 6....................................................
5-5. Victor-Compatible Components 6.........................................................
SECTION 6 − INSTALLATION 7................................................................
6-1. Installing Cylinders 7...................................................................
6-2. Installing Regulators On Cylinders 8......................................................
6-3. Installing Hoses On Regulators 9.........................................................
6-4. Attaching Hoses To Torch Flashback Arrestors/Check Valves 10................................
6-5. Attaching Cutting Attachment To Torch Handle 10............................................
6-6. Installing Cutting Tip On Cutting Attachment 11..............................................
6-7. Attaching Welding/Brazing Tip To Torch Handle 11............................................
6-8. Testing The System For Leaks 12.........................................................
SECTION 7 − OPERATION 13...................................................................
7-1. Purging Oxygen From The System And Adjusting Oxygen Pressure 13..........................
7-2. Purging Fuel From The System And Adjusting Fuel Pressure 14................................
7-3. Lighting And Using The Cutting Torch 15....................................................
7-4. Lighting And Using The Brazing Tip 16.....................................................

OM-254 957 Page 1
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
OXY FUEL 2013−0
9
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plainedin the text.
NOTICE − Indicates statements not related to personal injury.
.Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym
-
bols and related instructions below for necessary actions to avoid the
hazards.
1-2. Welding, Cutting, Brazing, And Heating Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-4. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment.
During operation, keep everybody, especially children, away.
Do not use this equipment unless you are trained in its proper
use or are under competent supervision. Follow the proced-
ures described in this booklet every time you use the equip-
ment. Failure to follow these instructions may cause fire, ex-
plosion,asphyxiation, property damage, or personal injury.
This equipment must be used in accordance with all Federal,
State, and local regulations as well as DOT (Department of
Transportation) and CGA (Compressed Gas Association)
regulations.Contact your gas supplier for more information
on the proper use of compressed gases.
.In this document, the phrase “welding and cutting” also refers to oth-
er oxy-fuel operations like brazing and heating.
READ INSTRUCTIONS.
DRead and follow all labels and the Owner’s
Manualcarefully before installing, operating, or
servicing equipment. Read the safety informa-
tionat the beginning of the manual and in each
section.
DUse only genuine replacement parts from the manufacturer.
DPerform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
HOT PARTS can burn.
DDo not touch hot parts bare handed.
DAllow cooling period before working on equip
-
ment.
DTo handle hot parts, use proper tools and/o
r
wear heavy, insulated welding gloves and cloth
-
ing to prevent burns.
Welding and cutting produces fumes and gases
.
Breathingthese fumes and gases can be hazardou
s
to your health.
FUMES AND GASES can be hazardou
s.
DKeep your head out of the fumes. Do not breathe the fumes.
DIf inside, ventilate the area and/or use local forced ventilation at the
flame to remove welding and cutting fumes and gases. Some
gases (natural gas and acetylene) are lighter than air and will col-
lect in high areas. Other gases (propane and butane) are heavier
than air and will collect in low areas. Heavier-than-air gases are
moredifficult to diffuse and are more likely to accumulate. The rec-
ommended way to determine adequate ventilation is to sample for
the composition and quantity of fumes and gases to which person-
nel are exposed.
DIf ventilation is poor, wear an approved air-supplied respirator.
DRead and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables,coolants, degreasers, fluxes, and metals.
DWork in a confined space only if it is well ventilated, or while
wearingan air-supplied respirator. Always have a trained watch-
personnearby.Welding and cutting fumes and gases can displace
air and lower the oxygen level, causing injury or death. Be sure the
breathingair is safe.Test atmospheres in confined spaces for ex-
plosive and toxic gases before using oxy-fuel equipment.
DDo not weld or cut in locations near degreasing, cleaning, or spray-
ing operations. The heat from welding or cutting flame can react
with vapors to form highly toxic and irritating gases.
DDo not weld or cut on coated metals, such as galvanized, lead, or
cadmium-plated steel unless the coating is removed from the af-
fected area, the area is well ventilated, and while wearing an air-
suppliedrespirator. The coatings and any metals containing these
elementscan give off toxic fumes if welded or cut.
DDo not weld or cut on sealed air conditioning or refrigeration sys-
tems unless all refrigerants have been removed from the system.
Light rays from the welding and cutting process
produceintense visible and invisible (ultraviolet and
infrared)rays that can burn eyes and skin. Sparks fly
off from the weld.
LIGHT RAYS can burn eyes and skin
.
DWear approved face protection fitted with a proper shade of filter
lenses to protect your face and eyes from light rays and sparks
when welding, cutting, or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
DWear welding goggles, or wear welding helmet /welding faceshield
over approved goggles/safety glasses with side shields.
DUse protective screens or barriers to protect others from flash,
glareand sparks; warn others not to watch the welding or cutting.
DWear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothingsuch as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.

OM-254 957 Page 2
Weldingand cutting on closed containers, such a
s
tanks, drums, or pipes, can cause them to blow u
p.
Sparks can fly off from the welding or cuttin
g
operations.The flying sparks, hot workpiece, and h
ot
equipmentcan cause fires and burns. Check and be sure the area
is
safe before doing any welding or cutting.
WELDING AND CUTTING can cause
fire or explosion.
DDo not use this welding and cutting equipment with gases and
pressures other than those for which it is intended. Oxygen is not
flammable; however, the presence of pure oxygen will drastically
increasethe speed and force with which burning takes place. Oxy-
gen must never be allowed to contact grease, oil, or other petro-
leum-based substances; therefore, be sure there is no oil or
grease on the regulator, cylinder, valves, or equipment. Do not use
petroleum-based pipe sealants. Do not use or store near excess-
ive heat (above 125°F/51.5°C) or open flame. Do not refer to oxy-
gen as air and do not use oxygen as a substitute for compressed
air. Do not use oxygen to clean clothes or work area, for ventilation,
or to operate pneumatic tools. Open oxygen cylinder valves slow-
ly. Be sure regulator adjusting handle is in the full out (off) position
beforeopening oxygen cylinder valve.
DInspectall equipment before use. Do not use damaged, defective,
or improperly adjusted welding and cutting equipment. Make sure
levers and valves work properly, threads on equipment are clean
(no grease or oil) and not deformed, gauges are intact and easy to
read,regulator is clean and free of oil or dirt, and fittings are prop-
erly sized for the cylinder. Make sure hoses are clean (no grease or
oil) and ferrules are properly installed so the fitting does not slip in-
side the hose. Be sure all connections are tight.
DIt is recommended that a reverse-flow check valve or a flashback
arrestor be installed between the torch handle and the regulator.
Check valves do not prevent the propagation of a flame upstream
(flashback)but are designed to prevent the unintentional backflow
of gases into the cutting attachment, torch, hoses, or regulator
which could cause an explosion or fire. A flashback arrestor can
be installed on the torch handle instead of a check valve. Miller
flashback arrestor have a reverse flow check valve and prevent
the propagation of a flame upstream. If a flashback arrestor is in-
stalled,a check valve is not necessary. Using a flashback arrestor
and a check valve may reduce gas flow and affect torch operation.
To help prevent the reverse flow of gases, be sure the cylinders
containenough gas to complete the work.
DPerform work only in an area with a fireproof floor (concrete). Do
not heat concrete because it may expand and explode violently.
DPerformwork on a fireproof surface. Use heat resistant shields to
protectnearby walls and flooring.
DDo not use if grease or oil is present on equipment or if equipment is
damaged.Have equipment cleaned/repaired by a qualified per-
son.
DDo not open a cylinder valve quickly or the regulator may be dam-
aged and cause a fire.
DDo not open acetylene cylinder valve more than 3/4 turn. (For all
gases except acetylene, open cylinder valve fully to backseal the
cylinder valve.) Keep cylinder wrench on the cylinder for quick
shut-off.
DDo not slightly open or “crack” fuel cylinder valve to blow debris
from the valve outlet. Remove the debris using nitrogen, air, or a
clean, oil-free rag.
DAlways purge gas from the system before lighting torch. Purge gas
in a well-ventilated area and away from flame or sparks.
DKeeptorch flame or sparks away from cylinder, regulator, and gas
hose.
DUse only the gases recommended by the manufacturer of the
oxy-fuel equipment being used.
DNever light a torch with matches or a lighter. Always use a striker.
DDo not use acetylene above 15 psi (103 kPa) flowing. It is accept-
able to use acetylene regulators that indicate a static pressure up
to 22 psi (151 kPa).
DCheck oxy-fuel system for leaks with an approved leak detection
solution or leak detector. Never test for gas leaks with a flame.
DRemove all flammables within 35 ft (10.7 m) of the welding or cut-
ting operation. If this is not possible, tightly cover them with ap-
proved covers.
DDo not weld or cut where flying sparks can strike flammable
material.
DProtect yourself and others from flying sparks and hot metal.
DBe alert that welding and cutting sparks and hot materials from
weldingand cutting can easily go through small cracks and open-
ings to adjacent areas.
DWatch for fire, and keep a fire extinguisher nearby.
DBe aware that welding or cutting on a ceiling, floor, bulkhead, or
partitioncan cause fire on the hidden side.
DDo not weld or cut on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
DDo not weld or cut where the atmosphere may contain flammable
dust, gas, or liquid vapors (such as gasoline).
DWear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothingsuch as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
DDo not use fuel gases to clean clothes or work area.
DRemove any combustibles, such as a butane lighter or matches,
from your person before doing any welding or cutting.
DAftercompletion of work, inspect area to ensure it is free of sparks,
glowingembers, and flames.
DFollowrequirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
BUILDUP OF GAS can injure or kill.
DShut off compressed gas supply when not in
use.
DAlways ventilate confined spaces or use
approvedair-supplied respirator.
Compressed gas cylinders contain gas under high
pressure.If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding o
r
cuttingprocess, be sure to treat them carefully.
CYLINDERS can explode if damaged
.
DProtect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, and sparks.
DInstall cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping. Do not lay
acetylenecylinders on their sides or acetone will flow out of the cyl-
inderand damage the equipment.
DKeepcylinders away from any arc welding, cutting, or other electri-
cal circuits.
DNever drape a welding or cutting torch over a gas cylinder.
DNever weld or cut on a pressurized cylinder − explosion will result.
DUse only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition. Do not use compressed
gas cylinder unless an approved gas regulator is attached to the
gas valve.
DTurn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
DKeepprotective cap in place over valve except when cylinder is in
use or connected for use.
DUse the right equipment, correct procedures, and sufficientnum-
ber of persons to lift and move cylinders.
DStore compressed gas and oxygen cylinders in separate loca-
tions.
DStore empty cylinders with valves closed and caps in place.
DDo not modify or repair cylinders or valves. Store leaking acet-
ylene cylinders outdoors in a safe area. Identify leaking cylinders
and return them to the supplier.
DDispose of used disposable cylinders according to the manufac-
turer’s recommendations. Do not throw cylinders in fire.
DFollow instructions provided by the gas supplier and on com-
pressedgas cylinders, associated equipment, and in Compressed
Gas Association (CGA) publication P-1 listed in Safety Standards.

OM-254 957 Page 3
FLYING METAL or DIRT can injure eyes.
DWelding,cutting, chipping, wire brushing, and
grindingcause sparks and flying metal.
DWear welding goggles, or wear welding helmet
/welding faceshield over approved goggles/
safety glasses with side shields.
1-3. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductiveharm. Wash hands after use.
1-4. Principal Safety Standards
SafetyinWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.orgor purchased from Global Engineering Documents
(phone:[phone], website: www.global.ihs.com).
SafePractices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: [phone],
website: www.global.ihs.com).
SafePractices for Weldingand Cutting Containers that have Held Com-
bustibles,American Welding Society Standard AWS A6.0, from Global
EngineeringDocuments (phone: [phone],
website: www.global.ihs.com).
SafeHandling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone],
website:www.cganet.com).
Acetylene, CGA Pamphlet G-1, from Compressed Gas Association,
14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone:
703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2,from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
SafePractice For Occupational And Educational Eye And Face Protec-
tion,ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone],
website: www.ansi.org).
Standardfor Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
ApplicationsManual for the Revised NIOSH Lifting Equation, The Na-
tional Institute for Occupational Safety and Health (NIOSH), 1600
CliftonRd, Atlanta, GA 30333 (phone: [phone],
website: www.cdc.gov/NIOSH).
Recommended Practices for Safe Oxyfuel Gas Cutting Torch Opera-
tion C4.2/C4.2M, and Recommended Practices for Safe Oxyfuel Gas
Heating Torch Operation C4.3/C4.3M from Global Engineering Docu-
ments (phone: [phone], website: www.global.ihs.com).

OM-254 957 Page 4
SECTION 2 − INTRODUCTION
!Inspectall equipment before use. Do not use damaged, defective, or improperly adjusted welding and cutting equipment. Make sure
leversand valves work properly, threads on equipment are clean (no grease or oil) and not deformed, gauges are intact and easy
to read, regulator is clean and free of oil or dirt, and fittings are properly sized for the cylinder. Make sure hoses are clean (no grease
or oil) and ferrules are properly installed so the fitting does not slip inside the hose. Be sure all connections are tight and there are
no leaks in the system.
This booklet offers basic information regarding the Medium Duty Oxy-Acetylene Cutting and Welding Outfit. Given reasonable care, this equipment
will provide trouble-free use for many years.
SECTION 3 − HAZARDOUS EVENTS
The following events are very hazardous and can occur in any oxy-fuel system. It is important to understand these hazards and know how to
prevent them.
Backfire:The return of the flame into the torch, usually accompanied by a popping sound. The flame may be extinguished or it may re-appear at the
tip end.
Sustained Backfire: The return of the flame into the torch that continues to burn inside the torch with a hissing or squealing sound.
Flashback:The return of a flame into and through the torch or into the hose. In some instances it can reach the regulator and even enter the cylinder. This
is generally caused by the mixing of the oxygen and fuel gas in the system. This is a very dangerous situation that can cause an explosion anywhere in the
system. This is why purging is so important (see Sections 7-1 and 7-2 ).
SECTION 4 − ASSOCIATED HAZARDS OF
RECOMPRESSING PURE OXYGEN
!Open oxygen cylinder valves slowly. Opening an oxygen cylinder valve quickly can cause a fire or explosion. Be sure regulato
r
adjusting handle is in the full out (off) position before opening an oxygen cylinder valve.
Recompressinghigh pressure oxygen in a low pressure cavity may create heat, resulting in combustion. For combustion to occur, oxygen, fuel, and
kindlingtemperatures must be present. All of these components may be present when oxygen is recompressed by opening the tank valve too
quickly.
Oxygen:High purity oxygen accelerates the rate of combustion, increases heat output, and lowers the combustible point at which various materi
-
als will burn.
Fuel: The fuel for combustion may be the regulator itself if enough heat is produced to reach the kindling temperature of the regulator’s components
.
Kindling Temperatures: Enough heat may be generated to ignite the regulator components by the friction created when recompressing
high-pressure oxygen. This heat is known as the heat of recompression.
!If an internal fire or flashback occurs (indicated by a whistling sound or inverted flame), do the following:
DTurn off the torch oxygen valve immediately.
DTurn off the torch fuel valve.
DTurn off the oxygen cylinder valve.
DTurn off the fuel gas cylinder valve.
Do not relight the torch until the equipment has cooled to the touch and the flashback cause has been determined and corrected.

OM-254 957 Page 5
SECTION 5 − SPECIFICATIONS
5-1. Equipment Included With The Kit
!Use only acetylene or propane gas
and oxygen with this equipment.
!Flashback arrestors/check valves
are factory installed on the torch
handle.Do not remove these com-
ponents.
!The empty (unlabeled) cylinders
supplied with this kit must be ex-
changedfor full cylinders through
your local welding gas distributor.
Filled cylinders will be properly
labeled.DOT regulations prohibit
the transportation of unlabeled cyl-
inders that contain hazardous sub-
stances.Follow the cylinder trans-
portation instructions supplied by
the gas distributor.
1 Grade T Oxy-Fuel Hose
2 MC Acetylene Cylinder (Empty)
3 Carrier
4 R Oxygen Cylinder (Empty)
5 Regulator − Oxygen (Green)
6 Cutting Tip
7 Cutting Attachment
8 Torch Handle
9 Flashback Arrestors/Check Valves
10 Welding (Brazing) Tip
11 T-Handle (Two)
12 Tip Cleaner
13 Spark Lighter
14 Cylinder Key Wrench
15 Welding Goggles
16 Regulator − Fuel (Red)
1
2
3
4
5
7
891011121314
15
16
6
161-042
5-2. Specifications
Description Fuel Gas Cutting Capacity Welding
Capacity Eye Protection Hoses Cylinders Warranty
Medium Duty
Oxy-Fuel
Cutting and
Welding
Equipment
Acetylene
Propane
(with Optional
Propane Tips)
Cuts Materials to
1/2 in. (12 mm)
Thickness with
Supplied Tips
Cuts Materials to
1-1/2 in. (38 cm)
Thickness with
Optional Tips
Welds Materials to
3/32 in. (2.4 mm)
Thickness with
Supplied Tips
Welds Materials to
3/16 in. (5 mm)
Thickness with
Optional Tips
Oxy-Fuel
Goggle
Flip Front
No. 5 Shade
2 x 4-1/4 in.
(51 x 108 mm)
Type T
3/16 in. ID x
12.5 ft
(4.8 mm x
3.8 m)
20 ft3(566 L)
Type R
Oxygen
Cylinder
10 ft3(283 L)
Type MC
Acetylene
Cylinder
Two-Year
Limited

OM-254 957 Page 6
5-3. Welding (Brazing) Tip And Gas Pressure Guide
Welding (Brazing) Tip Selection Guide
Hobart No. Victor No. Tip Size Material Thickness Fuel Gas Pressure Oxygen Pressure
−− Type 13 000 28 − 22 Gauge 3 − 5 psi (21 − 34 kPa) 3 − 5 psi (21 − 34 kPa)
−− Type 13 00 22 − 16 Gauge 3 − 5 psi (21 − 34 kPa) 3 − 5 psi (21 − 34 kPa)
−− Type 13 016 − 14 Gauge 3 − 5 psi (21 − 34 kPa) 3 − 5 psi (21 − 34 kPa)
5-4. Cutting Tip And Gas Pressure Guide
Cutting Tip Selection Guide
Hobart No. Victor No. Tip Size Material Thickness Fuel Gas Pressure Oxygen Pressure
−− 00-3-101 00 1/8 in. (3 mm) 2 psi (13 kPa) 25 psi (172 kPa)
770 153 0-3-101 01/4 in. (6 mm) 2 psi (13 kPa) 25 psi (172 kPa)
770 154 1-3-101 13/8 in. (10mm) 3 psi (21 kPa) 25 psi (172 kPa)
5-5. Victor-Compatible Components
Acetylene Regulators And Gauges
.All Gauges Feature Dual Scales (psi/kPa)
Hobart No. Description
770 127 LP Acetylene Low Pressure Gauge
770 125 LP/Acetylene High Pressure Gauge
770 622 Acetylene Regulator w/CGA-200 Connection
Oxygen Regulators And Gauges
.All Gauges Feature Dual Scales (psi/kPa)
Hobart No. Description
770 503 Oxygen Regulator CGA-540
770 128 Air/Oxygen Low Pressure Gauge
770 126 Air/Oxygen High Pressure Gauge
Oxy-Acetylene Gas Welding Hose
.R-grade hose is for acetylene gas. T-grade hose is for all gases, including propane.
Hobart No. Description Grade Length Diameter
770 130
Twin Welding Hose
R25 ft (7.6 m) 3/16 in. (5 mm)
770 132 R25 ft (7.6 m) 1/4 in. (6 mm)
770 133 R50 ft (15.2 m) 1/4 in. (6 mm)
770 131 T25 ft (7.6 m) 1/4 in. (6 mm)
770 515 R100 ft (30.5 m) 1/4 in. (6 mm)
Acetylene Cutting Tips − 3-101
Hobart No. Size
770 153 No. 0 − 3/8 in. (10 mm)
770 154 No. 1 − 3/4 in. (19 mm)
Victor-Compatible Cutting Attachment
Hobart No. Description
770 201 Medium Duty
Victor-Compatible Torch Handle
Hobart No. Description
770 200 Medium Duty

OM-254 957 Page 7
SECTION 6 − INSTALLATION
6-1. Installing Cylinders
!Install cylinders in an upright
position by securing to a
stationarysupport or cylinder
rack to prevent falling or tip-
ping. Maintain a clear path
from the cylinders to the work
area.
!Inspect equipment before
use. Do not use if grease or oil
is present on equipment or if
equipment is damaged. Have
equipment cleaned/repaired
by a qualified person.
!Do not slightly open or
“crack” fuel cylinder valve to
blow debris from the valve
outlet. Remove the debris us-
ing nitrogen, air, or a clean,
oil-free rag.
Remove the protective cap from the
cylinder valve.
Use nitrogen, air, or a clean oil-free
rag to remove dust or debris from
valve outlet. These particles can
damageregulators or cause a fire or
explosion. 161-019
Secure cylinders
to prevent falling
or tipping.
Notes

OM-254 957 Page 8
6-2. Installing Regulators On Cylinders
!Use only acetylene or propane
gas and oxygen with this
equipment.
!Do not slightly open or
“crack” fuel cylinder valve to
blow debris from the valve
outlet. Remove the debris us-
ing nitrogen, air, or a clean
oil-free rag.
!Do not use petroleum-based
pipe sealants.
!Do not handle oxygen regulat-
ors with oily hands and never
applyoil to any part of an oxy-
gen regulator.
NOTICE − Do not use cylinder ad-
aptors to connect regulators to cylin-
ders. Regulators have CGA con-
nections (manufactured to stan-
dards of the Compressed Gas As-
sociation) which allow the regula-
tortoonlybeinstalledontheappro-
priate cylinder valve for the inten-
ded gas.
.Brass to brass connections gen-
erally do not require pipe seal-
ant.
1 Oxygen Regulator
(Green Label)
2 Fuel Regulator
(Red Label)
Install the two-piece fitting of the
oxygen regulator (green) on the cor-
responding fitting on the oxygen
cylinder. The oxygen cylinder has
right-hand (clockwise) threads. Use
wrench to tighten hex nut.
Installthe two-piece fitting of the fuel
regulator (red) on the fuel cylinder
(acetyleneor propane only). The fuel
cylinder has right-hand (clockwise)
threads.Use wrench to tighten hex
nut.
.Contact the gas supplier if the
regulator fittings do not match
the cylinder fittings.
3 Working Pressure Gauge
4 Cylinder Pressure Gauge
Each regulator has two gauges. The
gaugeclosest to the cylinder shows
the pressure in the cylinder. The
other gauge shows the outlet pres-
sure going to the torch handle.
Tools Needed:
Pipe Sealant
1
2
3
4
1 in.
161-028 / 044

OM-254 957 Page 9
!Use only industrial grade
hose. Grade T hose (supplied
with kit) is acceptable for all
fuel gases. Grade R hose is for
acetyleneonly.
!Replacehoses at the first sign
of any defects, flaws, or dam-
age. The hoses should other-
wise be replaced every four
years.Inspect hoses for dam-
age or leaks before each oper-
ation. Do not allow hoses to
come in contact with hot met-
al, molten solder, or corrosive
chemicals. Do not expose
hoses to fluxing agents as
these agents will deteriorate
the hose materials and cause
them to leak.
!Do not splice or use damaged
hoses.
1 Regulator
2 Hose
3 Flow Adjustment Handle
Connectgreen hose to the regulator
on the oxygen cylinder. Connect red
hose to the regulator on the fuel gas
cylinder.
.The fuel fittings have left-handed
threads.
Use wrench to tighten fittings.
NOTICE − Before opening the cylin-
der valves, turn regulator adjusting
screws all the way out to release
pressure on the regulator dia-
phragm.Pressure may damage the
regulators.
Standwith the oxygen cylinder valve
between you and the regulator.
Slowly open the oxygen cylinder
valve 1/4 turn until the tank pressure
stabilizes,then fully open the oxygen
valve to seat it in the open position.
Tighten the adjustment handle (on
the regulator adjustment screw) to
bring the pressure up to 5 psi (34
kPa). Allow oxygen to flow through
hose for about 10 seconds. Stop
oxygen flow by turning adjustment
handlecounterclockwise.
Stand with the fuel cylinder valve
betweenyou and the regulator. Us-
ing the supplied key wrench, slowly
open the fuel cylinder valve 1/4 turn
until the tank pressure stabilizes,
thenopen the fuel valve to a maxim-
um of one full turn (acetylene) or fully
open (all other fuel gases). Leave
wrench on cylinder so cylinder can
be shut off quickly.
Tighten the adjustment handle (on
the regulator adjustment screw) to
bring the pressure up to 5 psi (34
kPa). Allow fuel gas to flow through
hose for about 10 seconds. Stop fuel
gas flow by turning adjustment
handlecounterclockwise.
Tools Needed:
Pipe Sealant
6-3. Installing Hoses On Regulators
11/16 in.
1
2
3
161-030

OM-254 957 Page 10
6-4. Attaching Hoses To Torch Flashback Arrestors/Check Valves
!Do not use petroleum-based
pipe sealants.
!Flashback arrestors/check
valves are factory installed on
the torch handle. Do not re-
move these components.
.The hex nut on the fuel hose has
notches on the corners. The hex
nut corners are smooth on the
oxygen hose.
1 Torch Handle
2 Fuel Hose (Red)
3 Oxygen Hose (Green)
4 Flashback Arrestors/Check
Valves
Flashback arrestors/check valves
are designed to prevent the reverse
flow of gases and stop a flashback
from going beyond the point where
they are installed.
Attach fuel hose (red) to fuel inlet
fittingon torch flashback arrestor. The
nut on the fuel hose has left-hand
threads.
Attach oxygen hose (green) to oxy-
gen inlet fitting on torch flashback
arrestor. The nut on the oxygen hose
has right hand threads.
Use supplied wrench to tighten
connections.
Tools Needed:
Pipe Sealant
11/16 in.
1
2
3
4
161-031
6-5. Attaching Cutting Attachment To Torch Handle
!Do not use cutting attach-
ment if the o-rings are miss-
ing or damaged.
!Do not use petroleum-based
pipe sealants.
.See Section 6-7 for attaching
brazingtip to torch handle.
1 Cutting Attachment
2 Torch Handle
The cutting attachment uses two
o-rings to seal the connection to the
torch handle. If replacing the cutting
attachment,be sure the o-rings are
properlyinstalled.
Attach cutting attachment to torch
handle.
Use wrench to tighten connections.
Tools Needed:
Pipe Sealant
3/4 in.
12
161-032

OM-254 957 Page 11
6-6. Installing Cutting Tip On Cutting Attachment
!Do not use petroleum-based
pipe sealants.
NOTICE − Do not drop or mis-
handlethe cutting tip or the seating
surface may be damaged.
Cutting tips are available in differ-
ent sizes to accommodate various
metalthicknesses. Use the table in
Section 5-4 to select the correct tip,
and to determine the correct fuel
and oxygen pressures.
Inspect cutting tips for damage and
to ensure that the cutting orifice and
preheatholes are not blocked with
dirt or slag.
.A No. 0 cutting tip is already in-
stalled in the cutting attach-
ment.
1 CuttingTip
2 Cutting Attachment
Install correct cutting tip in cutting
attachment.
Use wrench to tighten connections.
Tools Needed:
Pipe Sealant
1 2
1 in.
161-033
6-7. Attaching Welding/Brazing Tip To Torch Handle
!Do not use petroleum-based
pipe sealants.
Welding/brazing tips are available
in different sizes to accommodate
various metal thicknesses. Use the
table in Section 5-4 to select the
correct tip, and to determine the
correct fuel and oxygen pressures.
.A No. 0 welding/brazing tip with
mixer is supplied with the kit.
1 Welding/Brazing Tip With
Mixer
2 Torch Handle
Attach welding/brazing tip to torch
handle.
Use wrench to tighten connections.
Tools Needed:
Pipe Sealant
1
2
3/4 in.
161-034

OM-254 957 Page 12
6-8. Testing The System For Leaks
!Leak test the system before
lighting the torch. Repeat
this procedure every time
the equipment is set up or a
cylinderis changed.
!Use an approved oil-free leak
detectionfluid or leak detec-
tor to locate possible leaks.
!Do not stand in front of or be-
hind the regulator when
opening the cylinder valve.
Never open a cylinder valve
suddenlyas this can damage
a regulator or cause an oxy-
gen regulator fire.
1 Fuel Regulator Adjustment
Handle
2 Oxygen Regulator Adjustment
Handle
3 Torch Handle Fuel Valve
4 Torch Handle Oxygen Valve
5 Oxygen Cylinder Valve
6 Acetylene Cylinder Valve
Turn the fuel and oxygen regulator
adjustmenthandles to the Off posi-
tion (counterclockwise).
Close the fuel and oxygen valves
on the torch handle.
Slowly open the oxygen cylinder
valve one turn and adjust pressure
to 20 psi (138 kPa) by turning
oxygen regulator adjustment
handleclockwise.
Using the supplied key wrench,
slowly open the fuel cylinder valve.
Adjust pressure to 10 psi (69 kPa)
by turning fuel regulator adjustment
handleclockwise.
Check every connection and joint
from the cylinder valve to the torch
tip with an approved leak detection
solutionor leak detector. If leaks are
detected, eliminate them before
proceeding.If leaks cannot be elim-
inated, do not put the equipment
into service until it has been re-
pairedor replaced.
Close cylinder valves.
Tools Needed:
Pipe Sealant
61
2
5
11/16, 3/4, 1 in.
43
.Check all fittings
and connections
for leaks.
161-013 / 031 / 036

OM-254 957 Page 13
SECTION 7 − OPERATION
7-1. Purging Oxygen From The System And Adjusting Oxygen Pressure
!Inspectall equipment before
use. Do not use damaged,
defective, or improperly ad-
justed welding and cutting
equipment.Make sure levers
and valves work properly,
threads on equipment are
clean (no grease or oil) and
not deformed, gauges are in-
tact and easy to read, regu-
lator is clean and free of oil or
dirt, and fittings are properly
sized for the cylinder. Make
sure hoses are clean (no
grease or oil). Be sure all
connections are tight and
there are no leaks in the sys-
tem.
!Always purge gas from the
systembefore lighting torch
to prevent a possible
mixed-gas explosion. Purge
gas in a well ventilated area
and away from flame or
sparks.
.See Sections 5-4 and 5-3 for
oxygen and fuel pressure re-
commendations.
.Purgefuel from the system ac-
cordingto Section 7-2.
Purging Oxygen And Setting
Pressure
1 Oxygen Cylinder Valve
2 Torch Handle Oxygen Valve
3 Preheat Oxygen Valve
4 Oxygen Regulator Adjustment
Handle
Slowly open the oxygen cylinder
valve until valve is fully open.
Open oxygen valve on torch 1/4
turnfor five to ten seconds. (If using
welding attachment, also open pre-
heat oxygen valve.) While the oxy-
gen is flowing, turn the adjustment
handle on the oxygen regulator to
achieve the desired working pres-
sure.
Close the oxygen valve and the
preheatoxygen valve on the torch
handle.
Purge fuel from the system and
adjust fuel pressure according to
Section7-2.
Tools Needed:
1
4
2
3
161−032 / 036

OM-254 957 Page 14
7-2. Purging Fuel From The System And Adjusting Fuel Pressure
!Inspectall equipment before
use. Do not use damaged,
defective, or improperly ad-
justed welding and cutting
equipment.Make sure levers
and valves work properly,
threads on equipment are
clean (no grease or oil) and
not deformed, gauges are in-
tact and easy to read, regu-
lator is clean and free of oil or
dirt, and fittings are properly
sized for the cylinder. Make
sure hoses are clean (no
grease or oil). Be sure all
connections are tight and
there are no leaks in the sys-
tem.
!Always purge gas from the
systembefore lighting torch
to prevent a possible
mixed-gas explosion. Purge
gas in a well ventilated area
and away from flame or
sparks.
.See Sections 5-3 and 5-4 for
oxygen and fuel pressure re-
commendations.
.Purgeoxygen from the system
accordingto Section 7-1.
Purging Fuel Gas And Setting
Fuel Pressure
1 Fuel Cylinder Valve
2 Torch Handle Fuel Valve
3 Preheat Oxygen Valve
4 Fuel Regulator Adjustment
Handle
Using the supplied key wrench,
slowly open the fuel cylinder valve
one turn maximum (for acetylene).
Fully open fuel cylinder valve for all
other fuel gases.
Openfuel valve on torch 1/4 turn for
five to ten seconds. (If using weld-
ing attachment, also open preheat
oxygen valve.) While the fuel is
flowing,turn the adjustment handle
on the fuel regulator to achieve the
desired working pressure.
Closethe fuel valve and the preheat
oxygen valve on the torch handle.
Tools Needed:
4
1
2
3
161-032 / 043

OM-254 957 Page 15
7-3. Lighting And Using The Cutting Torch
Tools Needed:
1
!Always purge gas from the system
before lighting torch to prevent a
possible mixed-gas explosion.
Purge gas in a well ventilated area
and away from flame or sparks. See
Sections 7-1 and 7-2.
!Do not use matches or a cigarette
lighter to ignite the gas.
.See Sections 5-4 and 5-3 for oxygen
and fuel pressure recommendations.
.See Sections 7-1 and 7-2 for informa-
tionon adjusting oxygen and fuel pres-
sure.
1 Spark Lighter
2 Oxygen Valve
3 Preheat Oxygen Valve
4 Fuel Valve
5 Cutting Lever
Lighting The Torch
Hold the spark lighter near the torch tip.
Slowly open the fuel valve on the torch
handle 1/4 turn and quickly squeeze the
spark lighter to light the flame.
Slowly open the oxygen valve on the torch
to the desired pressure.
Continue to open the fuel valve until the
black sooty smoke disappears and the
flamebegins to move away from the tip.
!Failure to force a sufficient amount
of fuel gas through the tip will cause
the tip to overheat and may cause a
flashback or backfire.
Slowly open the preheat oxygen valve on
the cutting attachment; a white-hot feather
(flame)appears.
Slowly add oxygen until the feather begins
to disappear into the bright cone at the end
of the tip. This produces a neutral flame
(ratio of fuel to oxygen is 1:1).
Using The Cutting Torch
Hold the torch tip about 1/4 in. (6 mm) from
the metal to be cut.
Heat the metal until it is bright red (about
1550°F or 843°C).
Slowly depress the cutting lever on the
cuttingattachment. Let the oxygen stream
burn through the metal, then completely
depress the lever to begin the cutting
process.
When Finished Cutting
NOTICE − Shut down the torch in the cor-
rect sequence or the torch may be dam-
aged. Oxygen must be released from the
system first or residual fuel in the handle or
fuel hose may burn. Fuel cannot burn
withoutoxygen.
When finished cutting, release the cutting
lever. Close the oxygen preheat valve on
the torch handle first and then close the fuel
valve on the torch handle.
Turn valves at fuel and oxygen cylinders
clockwise to the closed position.
Open the fuel valve on the torch handle to
relieve pressure; both gauges on the fuel
regulatorshould indicate zero (0) pressure.
Close the fuel valve on the torch handle.
Turn fuel regulator adjustment handle coun-
terclockwise until there is no pressure on
the regulator diaphragm.
Openthe preheat oxygen valve on the torch
handleto relieve pressure; both gauges on
the oxygen regulator should indicate zero
(0) pressure. Close the preheat oxygen
valve and oxygen valve on the torch
handle.
Turn oxygen regulator adjustment handle
counterclockwiseuntil there is no pressure
on the regulator diaphragm.
Neutral Flame
Even mixture of fuel and oxygen
2
3 45
161-037 / 038

OM-254 957 Page 16
7-4. Lighting And Using The Brazing Tip
!Always purge gas from the system
before lighting torch to prevent a
possible mixed-gas explosion.
Purge gas in a well ventilated area
and away from flame or sparks. See
Sections7-1 and 7-2.
!Do not use matches or a cigarette
lighter to ignite the gas.
!Do not allow the flame to touch the
brazing tip or allow the brazing tip to
overheat.
.See Sections 5-3 and 5-4 for oxygen
and fuel pressure recommendations.
.See Sections 7-1 and 7-2 for informa-
tion on adjusting oxygen and fuel pres-
sure.
1 Spark Lighter
2 Oxygen Valve
3 Fuel Valve
Lighting The Torch
Hold the spark lighter near the torch tip.
Slowly open the fuel valve on the torch
handleabout 1/8 turn and quickly squeeze
the spark lighter to light the flame.
Slowly open the oxygen valve on the torch
to neutralize the flame.
Open the fuel valve on the torch handle
another 1/8 turn and then increase the
oxygen to neutralize the flame.
Continuethis procedure until the maximum
amountof fuel gas is used and the desired
flame is present.
When Finished Welding/Brazing
NOTICE − Shut down torch in correct se-
quence or the torch may be damaged.
Oxygen must be released from the system
first or residual fuel in the handle or fuel
hose may burn. Fuel cannot burn without
oxygen.
When finished welding/brazing, close the
oxygen valve on the torch handle first and
then close the fuel valve on the torch
handle.
Turn valves at fuel and oxygen cylinders
clockwise to the closed position.
Open the fuel valve on the torch handle to
relieve pressure; both gauges on the fuel
regulatorshould indicate zero (0) pressure.
Close the fuel valve on the torch handle.
Turn fuel regulator adjustment handle
counterclockwiseuntil there is no pressure
on the regulator diaphragm.
Openthe oxygen valve on the torch handle
to relieve pressure; both gauges on the
oxygen regulator should indicate zero (0)
pressure. Close the oxygen valve on the
torch handle.
Turn oxygen regulator adjustment handle
counterclockwiseuntil there is no pressure
on the regulator diaphragm.
Tools Needed:
1
23
161-039 / 040

Resources Available
Always provide Model Name and Serial/Style Number.
To locate a Service Center:
Call 1-800-332-3281
or visit our website at www.HobartWelders.com/wheretobuy
For Technical Assistance:
Call 1-800-332-3281
7 AM to 5 PM EST − Monday through Friday
ORIGINAL INSTRUCTIONS − PRINTED IN USA ©2013 Hobart Brothers Co.. 2013-01
Hobart Brothers Co.
An Illinois Tool Works Company
2200 Corporate Drive
Troy, OH 45373 USA
For Assistance:
Call1-800-332-3281
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Please complete and retain with your personal records.
Owner’s Record
Thank you for purchasing Hobart. Our trained technical support team is
dedicated to your satisfaction. For questions regarding performance, op-
eration, or service, contact us!