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Broco Prime-Cut Operating Instructions Manual

Ultrathermic cutting system
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OPERATING INSTRUCTIONS
AND
TECHNICAL MANUAL
FOR
PRIME-CUT
ULTRATHERMIC CUTTING SYSTEM
READ THIS MANUAL
BEFORE OPERATING
ARMY EXOTHERMIC CUTTER
PC/MIL-60 (RECOVERY)
June 2015
REV.

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Summary of Contents for Broco Prime-Cut

  • Page 1 OPERATING INSTRUCTIONS TECHNICAL MANUAL PRIME-CUT ULTRATHERMIC CUTTING SYSTEM READ THIS MANUAL BEFORE OPERATING ARMY EXOTHERMIC CUTTER PC/MIL-60 (RECOVERY) June 2015 REV.
  • Page 2 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.

  • Page 3: Table Of Contents

    Techniques 6.2.1 Piercing 6.2.2 Cutting 6.2.3 Gouging Shutdown PRIME-CUT TORCH MAINTENANCE Flash Arrestor & Flash Arrestor Screen Coupler Assembly Removal/Replacement Oxygen Control Valve Disassembly/Reassembly Oxygen Control Valve Assembly Leak Testing Procedure STRIKER PLATE ASSEMBLY Inspection Striker Plate Disassembly Striker Plate Reassembly...

  • Page 4: Purpose And Scope

    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.

  • Page 5: Safety Precautions

    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...
  • Page 6 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.

  • Page 7: 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 •...

  • Page 8: Setup Procedures

    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.

  • Page 9: Pre-Assembly Inspection

    Always inspect the torch for damage or wear prior to and immediately following each use. Always inspect the collet, collet washer, flash arrestor and flash arrestor screen prior to and immediately following each use of the Prime-Cut torch. Check the battery for leaks. Never use a leaking battery.

  • Page 10: Assembly Procedures

    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.

  • Page 11: Battery

    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.

  • Page 12: Slave Plug

    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.
  • Page 13 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.

  • Page 14: 16" Rod Extender (Pc/Tacxt16)

    Cutting Rod Size Selection Chart 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”...

  • Page 15: Hose/Cable Extension Kit (Pc/Exmil60)

    Insert the end of the rod extender into the torch collet until it is firmly seated on the collet washer. Tighten the torch collet nut to lock the rod extender in place. Check for oxygen leaks at the collet nut. If a leak exists: Make sure the rod extender is firmly seated on the collet washer.

  • Page 16: Operating Procedures

    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.

  • Page 17: Techniques

    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.

  • Page 18: Cutting

    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.

  • Page 19: Gouging

    6.2.3 Gouging 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. Increase the oxygen flow by slowly depressing the oxygen lever. The target material will puddle in approximately 1-2 seconds.
  • Page 20 Always inspect the cables and hose for cuts, burns or any other signs of damage or wear. 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.

  • Page 21: Prime-Cut Torch Maintenance

    7.0 PRIME-CUT TORCH MAINTENANCE 7.1 Flash Arrestor and Flash Arrestor Screen Inspection/Replacement WARNING! Never operate the torch without a flash arrestor and screen in place. The flash arrestor and screen perform an important safety function by suppressing flashbacks which could otherwise cause injury to the operator or damage the equipment.

  • Page 22: Coupler Assembly Removal/Replacement

    7.2 Coupler Assembly Removal/Replacement Note: The coupler assembly is replaced as part of a major overhaul of the torch or when damaged by a catastrophic flashback. During the normal course of operations it should not be necessary to remove or replace the coupler assembly. The repair procedure calls for securing brass components in a vise.

  • Page 23: Oxygen Control Valve Disassembly/Reassembly

    7.3 Oxygen Control Valve Disassembly/Reassembly WARNING! Oxygen mixed with oil or grease reacts explosively. Always keep oil and grease away from oxygen cylinders, valves, regulators, hoses and fittings. Use only certified oxygen compatible silicon lubricants on the valve stem and valve stem o-ring.
  • Page 24 Reassembly: Place a new rubber gasket in the recess of the control valve nut. If the valve stem o-ring is to be replaced, secure the valve stem with rounded end exposed. Apply a light coating of silicon lubricant to the rounded end of valve stem. Slide the new o-ring on the valve stem until it seats in the groove.

  • Page 25: Oxygen Control Valve Assembly Leak Testing Procedure

    7.4 Oxygen Control Valve Assembly Leak Testing Procedure Connect the oxygen hose to the oxygen hose adapter on the oxygen control valve assembly. Connect the oxygen hose to a regulated oxygen source. Fill a tank or tub with enough fresh water to completely submerge the control valve assembly.

  • Page 26: Striker Plate Assembly

    8.0 STRIKER PLATE ASSEMBLY General: Repeated ignitions will cause a buildup of slag deposits on the surface of the striker plate. This buildup is easily removed by scraping the striker plate across a rough surface or hard edge. Disconnect the striker plate power cable from the battery prior to cleaning the striker plate surface.

  • Page 27: Striker Plate Reassembly

    8.3 Striker Plate Reassembly Push the striker plate power cable up through the base of the insulator until the wire terminal lug slides into the relief in the insulator. Insert the copper striker plate into the groove in the wooden insulator taking care to overlap the wire terminal lug with the copper striker plate.

  • Page 28: Troubleshooting

    9.0 TROUBLESHOOTING This guide is intended to assist in determining the probable causes of torch malfunction and their associated repairs. For each potential problem identified, a probable cause and recommended repair procedure is listed. 9.1 Oxygen Leaks Oxygen leaks at hose adapter: Oxygen hose fittings are not tight enough. Tighten fittings and test with soapy water.

  • Page 29: Uneven Oxygen Flow

    9.2 Uneven Oxygen Flow The flash arrestor is dirty or worn. Follow flash arrestor inspection/replacement procedures to remove the flash arrestor. Clean or replace as needed. The screen is dirty or worn. Remove the screen as described in the repair procedure.

  • Page 30: Service And Repair

    (800) 845-7259; (909) 483-3222 Sales@Brocoinc.com Broco, Inc. shall not otherwise be held liable in contract or in tort for any damages including but not limited to incidental damages, consequent damages, or special damages in any way related to this merchandise. Broco, Inc. neither expresses nor implies warranties which extend beyond the warranties contained herein.
  • Page 31 NSN 3433-01-560-8668, PC/MIL-60, TORCH SET, CUTTING NSN 3439-01-553-0279, 12478096, WELDING ACCESSORY KIT BROCO CAGE 59491 BROCO PC/MIL-60 EXOTHERMIC TORCH SET ITEM ITEM IDENTIFICATION U/I QTY PART NO NSN’s STORAGE CASE W/ CUSTOM FOAM PC/C-1600M 8145015549719 SHIELD, LEATHER PC/LS 3433014633286 ROD HOLDER, BLACK, 36"...

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