FG-03: Hand Burn Prfile Page 1 f 9 SAFETY FIRST Fllw all Caterpillar facility safety standards when perfrming this task. An explsive hazard exists if acetylene leaks when wrking in a cnfined space r if wrking arund explsive material. A fire hazard exists when wrking with xygen acetylene, have a fire extinguisher r surce f water available near yu. EQUIPMENT basic Maintenance Mechanic hand tls xygen and acetylene tanks and trch with cutting head assrtment f cutting tips shaded glasses r a welding mask lng sleeves r a welding jacket hammer/slag remval tl straight edge/hle guide hle cutting guide RESOURCES jb ticket Jurneyman requesting the wrk
Page 2 f 9 Hand Burn Prfile 1. Set up the xygen and acetylene tanks. Open the supply valve fr the acetylene tank, n mre than 1/2 turn, and verify that there is an adequate supply f gas fr the jb. Adjust the acetylene regulatr until the gage reads between 5 and 15 psig. Never ver 15 psi! Nrmally between 5-7 psi. Open the supply valve fr the xygen tank and verify that there is an adequate supply f gas fr the jb. Adjust the xygen regulatr until the gage reads between 25 and 75 psig, depending n metal thickness. Use the fllwing chart as a guide. Metal Thickness Oxygen Pressure 0-3/16 15-30 psig 3/16-3/8 20-30 psig 3/8-5/8 30-40 psig 5/8-1 35-50 psig 1-2 40-55 psig 2-3 45-60 psig 3-6 50-75 psig Pull the hse t the wrk area.
Page 3 f 9 2. Set up the cutting trch. Select a cutting tip apprpriate fr the thickness f the material and type f cut yu are making. Check and clean the tip with an apprpriate size tip cleaner. 3. Mark the material. Set up the material n the wrkbench s the sectin yu are cutting is ver the scrap bin. Measure the part accrding t the written request n the jb rder. Mark the part with sap stne r center punch, if necessary, s that yu can see where t cut when the trch is ignited.
Page 4 f 9 Use a straight edge r circle guide t mark the material and guide the trch.
Page 5 f 9 Warning: Wear tinted safety glasses, lng sleeves, and glves when wrking with xygen acetylene. 4. Ignite the cutting trch. Open the red acetylene valve n the cutting trch, apprximately ne half turn. Light the trch. Open acetylene valve until flame stps excessive smking. Open the green xygen valve n the cutting trch. Adjust the flame s there is a slid blue cutting flame (neutral flame). Cutting Trch Ignitin 5. Preheat the material. Hld the trch apprximately 3/8 t 1/2" frm the material where yu plan t begin yur cut n a line r trch ver the material at the center f the circle, if applicable. Allw the flame t heat up the surface.
Page 6 f 9 6. Cut a straight line. T cut a straight line, hld the cutting trch at the edge yu plan t start cutting and press the xygen dispensing arm n the cutting trch. Rest the side f the trch tip against the guide fr additinal supprt. Mve the trch alng the mark, slwly and steadily. Make sure the piece that is cut ff lands in the bin.
Page 7 f 9 Warning: Turn ff the acetylene first t avid a ventilatin prblem. Turn ff the trch after the cut is finished. 7. Cut a circle. T cut a hle, hld the cutting trch in the center f the circle and press the xygen dispensing arm. Rest the side f the trch tip against the guide fr additinal supprt. T cut a circle, after burning a hle thrugh the center f the circle, cut a line t the edge f the circle. Nte: If a guide is nt available, cut frm the circle center t the inside edge f the line. Make the hle bigger if necessary. Mve the trch alng the mark, slwly and steadily.
Page 8 f 9 Make sure the piece that is cut ff lands in the bin. Warning: Turn ff the acetylene first t avid a ventilatin prblem. Turn ff the trch after the cut is finished. 8. Verify the cut. Make sure yur measurements are accurate.
Page 9 f 9 9. Remve the slag. Remve slag with a hammer r slag remval tl. Fr a smther surface, grind the material. 10. Turn ff the xygen and acetylene tanks. Open the trch valves and bleed pressure frm the lines befre backing ut the regulatrs. 11. Clean up the wrk area. Put away the cutting trch and hand tls.