Volume 1.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E UNPACKING THE ITEM Caution: This machine is packed together with items that may be sharp, oily and overly heavy objects. Remove the machine from the packaging in a safe manner. Check to ensure all accessories are included with the item while unpacking. If any parts are found to be missing, contact the retailer as soon as possible. Do not throw away the packaging until the item is out of the guarantee period.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E Table of Contents SAFETY 1 PRE-OPERATIONAL SAFETY CHECKS OPERATIONAL SAFETY CHECKS 1 1 SPECIFICATIONS 3 INCLUDED ACCESSORIES 3 ADDITIONAL ACCESSORIES FOR THIS MACHINE CAN BE FOUND IN BLUEROCK ® TOOLS ONLINE SHOP AT WWW.BLUEROCKTOOLS.COM OR FROM YOUR LOCAL RETAILER.
C G - 2 1 1 Y T O R C H B U R N E R 1 Chapter M A C H I N E Safety DO NOT USE THIS MACHINE UNLESS YOU HAVE READ THE OPERATING INSTRUCTIONS! Welding safety glasses must be worn at all times in work areas. Long and loose hair must be contained. Appropriate steel toe footwear must be worn. Close fitting/protective leather clothing must be worn. Leather safety gloves should be worn at all times and jewelry must not be worn. Hearing protection should be worn when using this machine.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E Ø DO shut off gas while changing cutting tips so as not to accidentally cause gas related injuries. Ø DO ensure all tightening points, brackets, wing-nuts, and lever-bolts are tight and stable prior to turning the machine on and/or starting the gas flame. Ø DO use a dust/fumes extraction system for cutting all materials. The operator should also wear a protective respiratory device in accordance with welding safety standards.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E 2 Chapter Specifications MECHANICAL DATA Forward or Reverse Movement Type Wormwheel Electricity Used Cutting Tip Types Minimum Pipe Cutting Diameter Cutting Depth Cutting Speed Cutting Movement Precision Bevel Angle Machine Main Structure Material Yes Manual Hand Power Yes No G02, G03 (similar to Airco Brand) 4” (100mm) to 24” (600mm) with Chain Provided With additional chain there is no maximum pipe size.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E Cutting Tip Specifications Type GO2 Acetylene Cutting tip G03 Propane Cutting tip Model Cutting Diameter (mm) Cutting Thickness (mm) Cutting Speed (mm) Oxygen Pressure (Mpa) Acetylene Pressure (Mpa) #00 #0 #1 #2 #3 #4 #5 #6 #7 #8 #9 #10 0.8 1 1.2 1.4 1.6 1.8 2 2.4 2.8 3.2 3.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E 3 Chapter Operations WARNING DO NOT attempt to use this machine unless you are trained in its proper use as well as trained in the proper use of gas cutting equipment. THOROUGHLY READ THROUGH THE ENTIRE MANUAL BEFORE OPERATING THIS MACHINE! PURPOSE Ø The purpose of the CG-211Y is to cut steel pipe using oxy-acetylene or propane gas flame cutting. The machine is designed to cut straight and bevel cuts.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E SETTING UP THE MACHINE Ø Install the main spreader bar and the torch holder assembly. o Ø Tighten the appropriate wing-nuts. Install the torch holder into the torch holder assembly. o Make certain the inside if the torch holder is clean and does not have any burrs. Also make certain any tips you use are free or burrs or defect. It is important the seats are tight.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E Ø Tighten the valve assembly side onto the top of the flat steel bar left of the main chain tightener wing nut (see figure above). Ensure it is secured tightly. Ø Install the large wheels if you are going to be cutting smaller pipe (see figure below). o Note: You do not want the middle of the machine to high center on smaller pipe, hence the need for the large wheels.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E RUNNING THE MACHINE Ø Do all pre-operational and operational safety checks from Chapter 1. Ø Consider your security and stability as well as the orientation of the machine in the work area. Ø o Consider the work surface material, condition, strength, density and rigidity. These factors directly affect the tools use. o WARNING: Ensure the piece being cut will be stable after the cut has been made.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E • 12= Constant • Example: d=299mm=29.9cm=30 sections of chain. o Ø Ø D=30+12=42 Sections of Chain Total, So you would use 42 sections of chain for a pipe 299mm in diameter. Tighten up the main chain tightening wing-nut until the machine is adequately tight. o Do not over-tighten wing-nut. o Ensure the chain is at a straight 90 degree to the pipe. Engage the clutch handle on the clutch carriage assembly.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E PROPER LIGHTING OF GAS TORCH Ø Ø Before attempting to light the torch tip follow this check list: o Verify the regulator pressure adjustment screws are backed out. o Verify the torch valves are in the closed position. o Position yourself away from the front side of the regulator. o Slowly open the oxygen valve and acetylene valve at the cylinder. o Adjust regulator pressure adjustment screws to the tip pressure.
C G - 2 1 1 Y Ø T O R C H B U R N E R M A C H I N E If done using the machine, close oxygen and gas valves on the main cylinder regulators. o Purge oxygen and gas lines.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E 4 Chapter Troubleshooting Note SERVICING SHOULD ONLY BE DONE BY A QUALIFIED TECHNICIAN. No 1 Problem Leak gas and/or flame in the joint of torch and torch cutting tip. The flame goes out as soon as the oxygen valve is opened Cause 1. The torch holder inlet is damaged. 2. There is copper burr or materials on the surface of the torch tip. Solution 1. Softly grind the torch cone with small sand paper to clean out the burr. 2.
C G - 2 1 1 Y T O R C H B U R N E R M A C H I N E 5 Chapter General Maintenance Ø Inspect valve assembly connections. Ø Lubricate all moving parts in the clutch assembly. Ø Keep machine clean and free of debris. o Make sure to frequently clean metal scraps from the roll wheels. Ø Check for misalignment, binding and breakage of all moving parts. If damaged, repair tool before use. Ø Check to ensure the torch holder is clean and free of debris. o Inspect the inside of the holder as well.