W-24R Welding Torch: Instructions For

INSTRUCTIONS for F-3119-S
June 2009
W-24R WELDING TORCH

P/N 10A48
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of opera-
tion and safe practices for oxy-fuel gas equipment, we urge you to read ESAB booklet “Precautions and Safe
Practices for Gas Welding, Cutting and Heating,” Form 2035. Do NOT permit untrained persons to operate this
equipment. DO NOT attempt to operate this equipment until you have read and fully understand these instruc-
tions. If you do not fully understand these instructions, contact your supplier for further information.
The welding torches covered by these instructions are listed by Third Party Listed only when used in combina-
tion with tips and parts manufactured to ESAB Welding & Cutting Products to the specifications on file with
Third Party Listed, and when they are used in the gas service for which they are designed and listed. The use
of other parts that cause damage or failure to the equipment will voids the manufacturer’s warranty.
SPECIFICATIONS
Welding Range............................. Thin gauge to over 1-in.

Heating Range.............................1 to 250 cfh acetylene
Length................................................................... 8-1/4-in.
Weight..........................................................................1 lb. Flashbacks can cause serious burns.
Torch-Hose Connections......... ORS Oxy - 41/64—18 fem. Be sure gas flow is sufficient for head or nozzle
ORS F.G. - 41/64—18 LH fem. size. Adjust regulators for proper psig pressures.
Adjust throttle valves properly. Keep torch in good
 Equivalent to approximately 1400 to 37,000 Btu/hr. repair. DO NOT throttle back gases to use large
Acetylene and other fuel gases may be used. head or nozzle on thin material.
ADJUSTING GAS PRESSURES
Medium-Pressure Fuel Gas: Open the torch fuel gas

OPERATING INSTRUCTIONS valve one-half turn. Turn in the pressure-adjusting
screw on the fuel gas regulator until delivery-pressure
CONNECTING gauge indicates a pressure of 5 psi. IMMEDIATELY
1. Attach regulators to the oxygen and acetylene close the acetylene valve.
cylinders. Follow all instructions supplied with your
regulators. Low-Pressure Acetylene: Open the shut-off valve
2. Attach oxygen and acetylene hoses to the regu- at the station.
lators and to the torch handle, after making sure
all metal seating surfaces are clean. Tighten all Oxygen: Open the torch oxygen valve at least one
connection nuts with a wrench. full turn. Turn in the pressure-adjusting screw on the
3. Attach welding or heating head to the torch handle. oxygen regulator until its delivery-pressure gauge
Tighten the connection nut with a wrench, but use indicates the desired pressure. (See table on pg. 4.)
only slight force, since the threads have a low pitch Close the oxygen valve.
and excessive force may distort them.
4. Check throttle valve packing nuts for tightness.
Be sure this information reaches the operator.

You can get extra copies through your supplier.
reaD anD unDerstanD instruction manual Before installing
or operating. protect Yourself anD others!
caution
these instructions are for experienced operators. if you are not fully familiar with the prin-
ciples of operation and safe practices for gas welding and cutting equipment, we urge you to read
our booklet, “precautions and safe practices for gas Welding, cutting, and heating,” form f-2035.
Do not permit untrained persons to install, operate, or maintain this equipment. Do not attempt
to install or operate this equipment until you have read and fully understand these instructions. if
you do not fully understand these instructions, contact your supplier for further information. Be
sure to read the safety precautions before installing or operating this equipment.
user responsiBilitY
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-
vice facility designated by the manufacturer.
important safeguarDs
When using Oxy-Fuel Gas Torches, basic safety precautions should always be followed:
a. Never use Acetylene gas at a pressure over 15 psig.
b. Never use damaged equipment.
c. Never use oil or grease on or around Oxygen equipment.
d. Never use Oxygen or fuel gas to blow dirt or dust off clothing or equipment.
e. Never light a torch with matches or a lighter. Always use a striker.
f. Always wear the proper welding goggles, gloves and clothing when operating Oxy-Acetylene equipment.
Pants should not have cuffs.
g. Do not carry lighters, matches or other flammable objects in pockets when welding or cutting.
h. Always be aware of others around you when using a torch.
i. Be careful not to let welding hoses come into contact with torch flame or sparks from cutting.
j. SAVE THESE INSTRUCTIONS.
Be sure this information reaches the operator.
You can get extra copies through Your supplier.
saVe these instructions!
2
SAFETY PRECAUTIONS
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�� 4. WARNING: This product, when used for welding or
�� cutting, produces fumes or gases which
�� contain chemicals known to the State of
�� California to cause birth defects and, in
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�� some cases, cancer. (California Health &
�� Safety Code �25249.5 et seq.)
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�� MEANING OF SYMBOLS - As used throughout
�� this manual: Means Attention! Be Alert! Your
�� safety is involved.
�� Means immediate hazards which, if not avoided,
�� will result in immediate, serious personal in-
�� jury or loss of life.
�� Means potential hazards which could result in
�� personal injury or loss of life.
�� Means hazards which could result in minor
�� personal injury.
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LIGHTING AND FLAME ADJUSTMENT
1. Open the torch oxygen valve one-quarter of a turn. 1. Read and understand the operating instructions packed
2. Open the torch fuel gas valve one-half turn (two full turns with your torch as well as these precautions before light-
if low-pressure acetylene is being used) and light the gas ing up the welding or heating head.
at the tip with a friction lighter. DO NOT USE A MATCH. 2. Always operate with oxygen and fuel gas pressures
Use of a match can seriously burn your hand. given in the tables.
3. Open the oxygen valve wide and adjust the fuel gas 3. Do NOT use hose line reverse flow check valves when
valve to secure the desired flame. If a softer flame is using No. 100 or larger welding or heating head.
desired, reduce the oxygen flow by throttling the oxygen 4. Use 3/8-in. I.D. hoses when using No. 5 or larger welding
valve and then readjust the fuel gas valve. or heating head.
5. Do NOT use whip hose, hose splices, nor hose nipples
NOTE: When operating with a very soft flame, the welding smaller than 1/4-in. I.D. (“B”-size).
head will tend to heat up and transfer some of this 6. If using hose lengths greater than 25-ft., or if there is
heat to the torch handle. This may create some any doubt about the adequacy of gas flows, use an
discomfort to the operator. oxygen test gauge adaptor (P/N 07X17) and either the
acetylene (P/N 262510) or fuel gas (P/N 639422) test
SHUTTING OFF gauge adaptor while the torch is operating to make sure
that the recommended operating pressures are available
Close the fuel gas valve first, then the oxygen valve. at the torch inlet.
7. Manifold two or more fuel gas cylinders to assure ad-
If operations are to be stopped for a half-hour or more, all equate supply of fuel gas. The tables show the number
pressure should be released from the torch, hoses, and of commonly used cylinders recommended for manifold-
regulators by doing the following: ing when using larger heads. If using other cylinders
or gases, check with your fuel gas supplier for recom-
1. Close each cylinder or station valve. mended withdrawal rate information.
2. Open torch valves. 8. In the event of a flashback, immediately close both oxy-
3. After relieving the gases, back out the pressure-adjusting gen and fuel gas valves on the torch (preferably oxygen
screw of each regulator and close the torch valves. valve first). For greater protection, install 1/4-turn quick
shutoff valve (P/N 999306) on the torch oxygen hose
IMPORTANT OPERATING NOTES connection.
1. Do not attempt to operate head size 100 or larger from

a low-pressure acetylene supply. Acetylene
2. Head size number on each welding and heating head Head Flowrate, Min. No. of Cylinders Requires*
indicates the rated acetylene flow capacity in cubic feet/ Size cfh WK Cyl (300 cf) WTL Cyl. (390 cf)
hour (cfh). For example, No. 55A requires about 55 cfh
of acetylene at normal operating pressure. However, on 55 55 2 1
heating heads designed for other fuel gases, the size 70 70 2 2
indicates the approximate equivalent heating capacity 100 100 3 2
in terms of acetylene flow. For example, No. 100A and 150 150 4 3
No. 100FG provide the same average heating output 200 200 5 4
(147,000 Btu/hr) but No. 100FG head really requires 250 250 6 5
about 62 cfh of FG-2, 57 cfh of propane, or 147 cfh of
natural gas. * Based on that max. hourly flowrate should not exceed
1/7 of cylinder capacity at 70° F. Example: 1/7 (300 cf
For consumption purposes, the following are the oxygen/ WK cyl.) = 43 cfh max.
fuel gas ratios normally required for welding and heat-
ing:
1.1 to 1.5 cfh oxygen/1.0 cfh acetylene FG-2 (104 lb. cyl.) Propane (100 lb. cyl.)
3.2 to 3.6 cfh oxygen/1.0 cfh FG-2 Head Min. No. of Min. No. Of
3.5 to 4.5 cfh oxygen/1.0 cfh propane Size Flowrate Cyl. Req’d* Flowrate Cyl. Req’d**
1.7 to 2.0 cfh oxygen/1.0 cfh natural gas
70 43 1 40 1
100 62 1 58 1
PRECAUTIONS - NO. 55 and LARGER HEADS 150 93 1 86 2
200 124 2 116 2
Large welding and heating heads (No. 55 and above) require 250 - - 144 3
high flow of oxygen and fuel gas for proper operation. Failure
* Based on max. continuous withdrawal rate of 110 cfh for 104 lb. cylin-
to follow the following precautions can result in serious der, 1/2 full @ 70° F.
overheating, flashback, and possible operator injury. ** Based on max. continuous withdrawal rate of 65 cfh for 100 lb. cylinder,
1/2 full @ 70° F.
Withdrawal rate will increase with wind velocity and intermittent usage;
reduce with lower temperature.
4
9. If the inner cone of the flame appears too short (less OPERATING PRECAUTIONS
than 1/4-in.), you are lacking fuel gas and the head will
tend to overheat. Recheck the above precaution with Flow: There must be proper flow of gases for safe operation
your set up. and full performance. This requires the following three condi-
10. Do not bring the head too close to the work. Maintain a tions: (1) the regulators that determine the inlet pressure to
distance of at least 1/4-in. between tip and work. the hoses must be set to the correct pressure; (2) the hoses
and their connectors must have adequate capacity for the
RECOMMENDED HOSE SIZES job (hoses that are too long, too small or have connectors
with small passageways can cause problems); and (3) the
Oxygen, Acetylene (medium-pressure) and Natural Gas throttle valves on the torch must be adjusted with the pro-
(at pipeline pressures over 5 psig): With head sizes 4-30, cedure shown in these instructions.
1/4-in. or 3/8-in. I.D. With head sizes 55 and larger, 3/8-in
I.D. Acetylene (low-pressure) and Natural Gas (at pipeline Note: Items (1) and (2) can be checked by measuring the
pressure below 5 psi): With head sizes 4-70, 3/8-in. I.D. gas pressures at the torch. Gauge adaptors are
hose. Head sizes 100-250, 1/2-in. I.D. hose. Do not use available for this purpose.
over 25 feet of hose.
Backfire: Improper operation of the torch may cause the
TESTING FOR LEAKS flame to go out with a loud “pop”. Such a backfire may be
caused by contact of the tip with the work, spatter from the
Every welding and cutting outfit should be thoroughly tested tip, or by attempting to operate with too small a flame. After
for leads after it is first hooked up, and at regular intervals a backfire, you can normally relight the flame immediately. If
thereafter. After all connections have been made, make backfires occur repeatedly, shut off the torch. Then reopen
sure both valves on the torch handle are closed. Then turn the oxygen valve, check for correct oxygen pressure, and
in the regulator pressure-adjusting screw until the oxygen test for leakage at the welding head connection nut and tip
deliver-pressure gauge registers 50 psi, the acetylene connection nut. If there is leakage at either point, correct it
delivery-pressure gauge registers 10 psi. Using Leak Test (by tightening the tip, or cleaning the seating surfaces on the
Solution suitable for oxygen service, such as P/N 998771 injector and in the torch body) before resuming work.
(8 oz. container), check for leaks at the cylinder valves. The
cylinder-to-regulator connections, the regulator-to-hose con- Flashback: Under certain circumstances, the flame may not
nections, and the hose-to-torch connections. If bubbling at “pop” out (backfire) but instead burn back inside the torch
any point indicates leakage, tighten the connection. If this with a shrill hissing or squeal. This is called a “flashback”. A
does not stop the leakage, close appropriate cylinder valve, flashback should never occur if (1) the equipment is in good
open the torch valve to remove all pressure from the line, condition; (2) preheat ports on cutting nozzles or welding
and finally release the regulator pressure-adjusting screw tips are cleaned frequently; (3) operating pressures are cor-
by turning it counterclockwise. Then break the leaky con- rect; and (4) throttle valves are adjusted properly. Should a
nection, wipe metal seating surfaces with a clean, dry cloth, flashback occur, IMMEDIATELY shut off the torch. Allow it to
and examine them for nicks and scratches. Remake the cool off for at least a minute. Then check your nozzle or tip,
connection(s) and retest. Do not try to light the torch until gas pressure, readjust regulators if necessary, and relight the
you are satisfied that all connections are gas-tight. torch. If flashback recurs, send the torch handle and welding
head or cutting attachment to your distributor for repair.
After lighting the torch, and adjusting the flames, use leak
test solution to check for leakage at all torch valves, and at
the connection between the torch handle and the welding
head or cutting attachment.
Table 1 - Single-Flame Acetylene Welding Heads
Replacement Parts Cleaning Drill

Welding Head Metal Oxy. (Size No.) TipExtension
Assembly Thickness Press Tip Mixer for for (Accessory)
Size† Part No. in. psi Tip Nut Tube Injector Tip Injector Length Part No.
4A 639974 1/32-1/16 7-8 639684 16Z26 01Z06 64 79  
6A 639975 1/16-3/32 8-20 639685 16Z27 01Z07 58 77  
9A 639976 3/32-1/8 10-24 639686 639870 16Z28 01Z08 55 75  
12A 17271 1/8-3/16 11-25 17266 16Z29 01Z09 54 73  
15A 639977 3/16-1/4 11-26 639687 16Z30 01Z10 53 71  
30A 639978 1/4-1/2 18-29 17261 998847 16Z32 01Z12 44 65
50A 639979 1/2-3/4 25-39 998060 639969 639971 01Z14 33 59 12-in. 19X42
70A 639981 3/4-1 22-30 998061 639969 639972 01Z15 30 67
100A 11X71 45-55 998062 33A59 16Z54 01Z21 25 56 15-in. 19X43
150A 11X73 Heating 50-60 64Z22 33A58 16Z56 01Z23 17 54 18-in. 19X44
250A 11X75 70-80 12Z80 33A63 16Z58 01Z25 1/4-in. 52 21-in. 19X45
† See Important Operating Notes on page 3.

 Acetylene pressure is 1/2 to 5 psi.
5
Table 2 - Rosebud Style Multiflame Heating Heads
Complete Pressure, Avg. Replacement Parts

Head Assembly psig Heat Tip Extension Tip
Fuel No. of Output Tip Tip Mixer Injector Head Retain. (Accessory) Cleaning
Size† Part No. Oxy. Gas Flames Btu/hr. Assy. Stem Nut Tube or Mixer Nut Ring Length P/N Drill Size
For Oxy-Acetylene Use
100 O-A 999842 55-60 1/2-5 12 147,000 998799 998793 33A59 16Z54 01Z21 998596 37A41 15-in. 19X43 57
200 O-A 999844 15-20 9-12 16 294,000 998800 998794  998830 998832 999910 998553 18-in. 998790 54
For Oxy-Fuel Gas FG-2, propane, natural gas etc.
100 O-FG 999843 50-70 1/2-5 8 148,000 999227 998793 33A59 16Z54 01Z99 998596 37A41 15-in. 19X43 49
200 O-FG 999845 30-55 6-11 21 297,000 999230 998794  998830 998832 999910 998553 18-in. 998790 52
† See Important Operating Notes on page 3.

 Requires extension coupling 998838.
 IMPORTANT: P/N 998832 is a mixer; not an injector for low fuel gas pressure. Be sure to use operating pressures as given, using lower pressure can overheat
the tip and cause torch to flashback.
MAINTENANCE INSTRUCTIONS
For all repairs other than those covered below, send

the apparatus to your welding equipment distributor
or to ESAB’s Remanufacturing Center, Ebenezer Road,
Florence, SC 29501. Improperly repaired apparatus is
hazardous.
Torch Valves: Leakage around either throttle valve can

usually be corrected by tightening the packing nut slightly. If
it cannot be corrected, replace throttle valve assembly.
If either valve fails to shut off completely, remove the throttle

valve assembly from torch and wipe the ball seat on the end
of the stem with a clean cloth. Then reinstall the valve and
tighten it heavily several times. If this does not eliminate
leakage, try a new throttle valve assembly. If then the valve
does not shut off completely, send the torch handle to a repair
station for reseating of the body.
Tip Cleaning: If a welding tip produces a distorted, irregular

flame, clean the tip with an OXWELD tip cleaner, or the cor-
rect size twist drill (see table on page 4). Do not attempt to
clean with any other type of tool. When using cleaning drills,
push the drill straight in and out; do not twist.
Injector Cleaning: The relatively small central oxygen ori-

fice in an injector may become partially clogged with small
particles conveyed in the oxygen stream or carbon particles
produced by backfires. To clean or replace an injector, re-
move it from the mixer tube (after removing the connection
nut retaining ring and sliding the nut forward) by grasping it
with a pair of pliers between the seating surfaces and pulling
it straight out with steady force. Take great care not to mar
the injector seats or O-rings with the pliers. Clean the central
(oxygen) orifice with the correct size twist drill (see table on
page 4). Use no other tools. Replace O-rings if damaged or
worn. Replace the injector if its rear seats are marred. When
reinstalling injector, be sure to push it in until its retaining
O-ring is firmly seated in the mixer tube.
6
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ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:

Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
B. ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specifications Equipment Recommendations
D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING

Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123

Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site offers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
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INSTRUCTIONS for F-3119-S

W-24R WELDING TORCH

Welding Range............................. Thin gauge to over 1-in.

ADJUSTING GAS PRESSURES

Medium-Pressure Fuel Gas: Open the torch fuel gas

Be sure this information reaches the operator.

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1. Do not attempt to operate head size 100 or larger from

Table 1 - Single-Flame Acetylene Welding Heads

Replacement Parts Cleaning Drill

† See Important Operating Notes on page 3.

Complete Pressure, Avg. Replacement Parts

† See Important Operating Notes on page 3.

For all repairs other than those covered below, send

Torch Valves: Leakage around either throttle valve can

If either valve fails to shut off completely, remove the throttle

Tip Cleaning: If a welding tip produces a distorted, irregular

Injector Cleaning: The relatively small central oxygen ori-

A. CUSTOMER SERVICE QUESTIONS:

E. WELDING EQUIPMENT REPAIRS:

F. WELDING EQUIPMENT TRAINING

G. WELDING PROCESS ASSISTANCE:

H. TECHNICAL ASST. CONSUMABLES:

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

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