CG 1-

1-30
Item # 0000CG130Y

OPERATOR’S MANUAL

Read carefully and understand RULES FOR SAFE OPERATION and instructions
before operating. Failure to follow the safety rules and other basic safety precautions
may result in serious personal injury.
 Operator’s Manual

The Respectable User:

The detailed information provided below, which contains about the

installation, trial run, operation and maintenance of “CG1-30 Type

Oxy-acetylene Cutting Machine ”, is intended for your kind perusal to

help you minimize the operational problems so that the product can work

as smoothly as it is expected.

INDEX

1. Product Description --------------------------------------------2

2. Outline Sketch---------------------------------------------------2

3. Technical Property----------------------------------------------2

4. Main Structure---------------------------------------------------3

5. Operation---------------------------------------------------------4

6. Safety Operation------------------------------------------------7

7. Maintenance and Service--------------------------------------7

8. Trouble Shooting-----------------------------------------------7

9. Main Circuit Chart---------------------------------------------8

10. Spare Parts List--------------------------------------------------9

11. Guarantee--------------------------------------------------------9

1
1. Product Description
This machine , employing medium-pressure acetylene and high-pressure oxygen, is a
multi-purpose cutting machine, not only suitably used in the main for straight-line cutting of steel
plates with thickness over 5mm, but also used for circular cutting(more thanΦ200mm circular
cutting ) , bevel cutting as well as V-groove cutting. If equipped with special attachments, the
machine may be used for flame quenching and plastic welding by taking use of its drive.

The surface finish of the edges out by this machine may be up to , which needs no further
cutting processes under general circumstances.
This machine features compact construction, easy and safe operation, short non-working time,
thus yielding better economic results. It is recommended for use in ship, bridge and heavy
machine building industries as well as in metal cutting works of various sizes.

2. Outline Sketch

3. Technical Property

3.1 Technical Characteristic:

3.1.1 Dimension and Weight
Machine Body Dimension (LXWXH): 470X230X240mm
Total Weight: 25.6kg
Machine Body Weight: 11kg
Cutting Nozzle Weight: 0.45kg (3pcs)
Cutting Torch Weight: 2.35kg (1 group)
Convex Track Weight: 10kg (2 pcs)
Concave Track Weight: 7kg (1 pc)
Power Cord: 0.8kg (1pc)
Radius Rod Weight: 1kg
3.1.2 Cutting Range
Cutting Thickness on Steel Plate: 8-100mm

2
 Speed Adjustment Range: 50-1000mm/min(stepless adjsutment)
Diameter of Circular Cutting: Φ200-2000mm
3.1.3 Track
There are two kinds of track which are selected by users: convex track and concave track .
3.1.4 Input Power: AC220V 50HZ
3.1.5 Motor: DC Motor
Working voltage: DC110V ; Current 0.5A ; Power: 30w; Rotate Speed: 3600-4600r/min
3.1.6 The machine is equipped with GO2-1#-3# nozzles. Other nozzles could be purchased
separately.
3.2 Cutting Nozzle Specification

Nozzle NO. Cutting Thickness Oxygen Pressure Acetylene Pressure Cutting Speed
mm MPa Mpa mm/min
00 5--10 600--450
0.20-0.30
0 10--20 480--380
>0.03
1 20--30 400--320
0.25-0.35
2 30--50 350--280
3 50--70 300--240
0.3-0.4
4 70--90 >0.04 260--200
5 90--120 0.4-0.5 210--170

4. Main Structure

4.1 Machine Body

It is made of aluminum alloy, featuring light weight, high strength and corrosion resistance.
4.2 Motor and Reduction Mechanism
A DC servomotor with an output of 30W is adopted for the machine, which is of small size
and good durability and is able to rotate in both forward and reverse direction. It is direct coupled
with the reduction mechanism to actuate the drive wheels.
The two-stage worm wheel drive with a total speed ratio of 1:1035 is shown in the following
figure.
4.3 Speed Regulator
The stepless speed variation of the motor is abtained through the opening angle of a Rc
out-phase controlled SCR. During operation, merely turn the potentiometer of 47kΩ and the
cutting speed may be steplessly varied within a range of 50-750mm/min.
4.4 Cutting Torch Assembly
It is consists of gas distributor, cantilever and cutting nozzle delvating device. The cutting
nozzle can be adjusted right and left or up and down through the rack and pinion mechanism and
the torch can be swiveled in an angle of ±45°if the clamping screw is loosened.
4.5 Track
There are two types (convex track and concave track) of the track which can be selected by the
users. There are connectors on the track end for track lengthening for cutting long work piece.

3
5. Operation

5.1 For straight cutting, place the guide rails on the steel plate to be cut and then the machine on
the guide rails with the cutting torch side facing the operator. The cutting nozzle is selected
and the cutting angle and speed are preset according to thickness of the steel plate to be cut.
5.2 Connect the oxygen cylinder and acetylene generator with the gas distributor by means of
hoses, turn on the main switch and adjust the gas control valve. After firing up the gas at the
cutting nozzle and adjusting will the flame, the cutting process may be carried out.(Attention:
ignition at the moment of turning on the acetylene valve to prevent the acetylene from
entering the machine)
5.3 For bevel cutting, first loosen the clamping screw on the torch seat and swivel the torch to an
angle required, then retighten the clamping screw.(see picture 2)
For V-groove cutting, the double torches are required. Another torch including distributor
should purchased separately.
5.4 Machine Driving
The front drive, back drive and stop of the machine are controlled by the 3-step switch. Set
the knob on the different graduation to control the different speed.
5.5 Torch and Nozzle
There are three control valves. Namely acetylene valve, preheating oxygen valve, cutting
valve (see picture 3) . The acetylene valve and the preheating oxygen valve are used to control
the preheating flame of mixed gas. After preheating to a certain temperature, turn open the
cutting oxygen valve to have the oxygen jetting out. At this time the cutting machine will be
driven along the rails for straight cutting. After cutting, close the cutting oxygen valve and
turn off the single-blade switch thus the machine stops moving.
During the mounting of the selected cutting nozzle, the nut must be turned gently. Examine
the tightness of the connecting parts as well as screws and nuts, before cutting is carried out,

4
 in order to obtain normal operation.
Only select the nozzle manufacturing by our factory, the torch sealed capability can be
assured to prevent gas leakage and backfire.
5.6 Circular Cutting
5.6.1 Drill a 60°centre hole on the steel plate before hand
5.6.2 Loosen the screw at the steering wheel, and demount one of the wheels which is near to the
center of the circle.
5.6.3 Mount the radius bar on the machine, plate the positioning pin in the center hole on the steel
plate and tighten the positioning screw according to the radius of the cycle to be cut. Raise
the machine by the side of the positioning pin to have the wheel at that side apart from the
steel plate and use the other two wheels run around the center for circular cutting.
5.6.4 For cutting cycle of small diameter, the positing pin is placed at the same side of the torch,
while for big diameter placed at the opposite side.

5
6
6. Safety Operation

6.1 Please always comply with the safety rules .

6.2 The self-protection apparatus should be equipped at the gas cutting job site.
6.3 Before cutting, check earnestly the machinery、wiring、gas path perfect or not.
6.4 Flammable or explosive material are prohibited to access the job site.
6.5 Flame cutting is prohibited in the indoor circumstance of air mixed with gas (acetylene or
propane ) in case of explosion.
6.6 Never allow the unqualified personnel to operate the machine.

7. Maintenance and Service

7.1 The machine must be stored in a dry place free from corrosive gases
7.2 Apply best quality lubricant to the reduction gearbox once half a year
7.3 It is prohibited to operate the machine outdoors when it is raining to avoid moisture to the
electric elements
7.4 Inspection must be made before operation. The clearances of the moving parts must be well
adjusted and the connecting parts tightened
7.5 If the operator rests or leaves the machine for a long time, the main switch must be turned off
to prevent the motor from burning due to excessive heat.
7.6 The machine should be operated and maintained by fixed personnel and regular inspection
and maintenance to the machine must be carried out.
7.7 The screws must be loosening and the cove must be relaxed on left-hand, when wiring the
electrical plug.

8. Trouble Shooting

Trouble Analysis Solution Remarks

1. Check to see if there is short circuit Check the switch is short connection
connection in the output terminals or not
2. Check to see if the connection-peg Reinsert the connection-peg
is tight or not
3. Check to see the potentiometer on Measure the resistance of the
the front panel is open or not potentiometer
4. The input of the measuring PCB is Check the power cord and the plug
The motor
220v or not and fuse on the front panel
does not run
5. the motor brush is locked or not Take out the brush, grind the
forepart. Mount on until it is
available
6. The small PCB is broken Repair or replace the small PCB
7. The clutch is not closed. Close the clutch
8.The connections of the gear box fall Check the pin in the gear box fall off
off or not
The fuse is 1. The 220v input is short connection The power switch is short connection

7
 or not
2. The power cord is broken or the Replace the fuse
input 380v by mistake
3.The rectifier is short connection repair
melt down
4.The PCB is short connection caused repair
by capacitor leakage
5. The quality of the fuse is poor Replace the fuse(Note: adopts 2A(T)
relay fuse)
The indicator 1.The small plug on the PCB falls off Fasten the small plug on the PCB
is off 2. The -4.5v wingding of the Repair or replace the transformer
transformer is broken
3. The quality of the indicator is poor Replace the indicator
There is a big 1. There is sundries on the track. Clear out
noise in the 2. The worm wheel is broken Check the worm wheel or replace
machine 3. The motor is broken Replace the motor
There is gas 1. Unmerited operation causes the Repair the 30°cone-shaped surface
or fire bad contact of the 30°cone-shaped with studded emery cloth
leakage surface
2. The nuts on the crater are not Fasten the crater nuts
fasten,
1. There is barrage on the cutting Use pin to removing the barrage
nozzle

The cutting 2. Low supply gas pressure and low Check the gas pressure and the
flame is oxygen purity oxygen purity
unstable

9. Main Circuit Chart

8
10. Spare Parts List

NO. Items Type & Code Qty.

1 DC Motor ZYT261.A5
2 Thyristor Rectifier ZYT261/H1.A3
3 Silicon Rectifying 3CT5A.5A.300V
Diode
4 Silicon Rectifying 2CZ83E.300V.0.3A
Diode
5 Resistance 2CZ83D.200V.0.1A
6 Capacitance RT.0.5W.10Ω
7 capacitance CD11-33uf.250V
8 capacitance CJ30.T2.2-LUF.250V
9 Mini Transformer E193 Type Input
Transformer
10 Resistance RT.0.5W
11 Potentiometer WX-030.3W.4.7Ω
12 Resistance RT.0.5W.4.7KΩ
13 Indicator XDX1-H-6.3V
14 Switch KN3-203
15 Power Transformer DB68-80.110V.6.3V
16 Fuse BLX-1
17 Power Cord & Socket YQ-3×0.5 ,CX16Z3FGM
18 Rectangular Socket CB2-6J/K
19 Knob K18-1

11. Quality Guarantee

Users are advised to operate in compliance with the instruction given in the
guideline. On condition that the cutter is installed, stored, used, maintained properly
in compliance with the guidelines, we guarantee to get the cutter repaired at our
expense within 6 months upon the purchase of the cutter if and when the cutter is
found either damaged partially or working improperly.
Note: No guarantee to keep the cutters in good repair if the damage caused by the
wrong operation

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 Packing List: Certificate
Article： CG1-30 Serial NO.: Article: CG1-30 Serial NO:
Packing NO.: Date:
Weight
NO. Description Qty.
(kg)
Remarks Inspection Items
1 Machine 1pc √
Torch Single 1 pc distributor for Cutting Speed 50—1000mm/min
2 single torch
Airtight Test:
Double 1pc distributor for
Torch No leakage when tested under double working
double torch
pressure
CG2-1-3# Nozzle 1 pc
1 3 Stable running, no noise and abnormal sound
1 pc Driving Run
4 Power Cord Socket 1 pc each √
Orientation 1 pc √ Match the radius
5
Bracket rod
6 Operator’s 1 pc √ This machine has been tested according to the above test items and it is
Manual, Certificate acceptable for ex-works
1 Radius Rod 1 pc √
2 Concave Track 1 pc Convex wheel
2 Checker: Date:
Convex Track 2 pcs Concave wheel
Note: the dimension(cm) : 47[L]X 23[B]X24[H]
Inspector: Date:

Inspector: Date:
Shanghai Gas Welding Equipment CO.; LTD
Shanghai Gas Welding Equipment CO.; LTD

10
 Complete Spare Parts List for CG1-30

Date: Mar. 19th, 2007

No. in Part Item Description Qty.

Diagram numbers in Chinese in English /model
1 H011010113 移动座 moving pedestal 1
2 H020632704 开槽平端紧定螺钉M4*6 bolt 1
3 H011000114 龆轮轴 gear shaft 1
4 H011000115 龆轮轴承 gear bearing 1
5 H011000116 手轮 wheel 1
6 H020630718 弹性圆柱销2.5*18 bolt 3
7 H011010130 销键 bolt key 1
8 H011000107 齿条 rack 1
9 H011000112 夹紧螺钉组件 clip bolt assembly 1
10 H011000105 螺钉 bolt 4
11 H020612711 开槽圆柱头螺钉 bolt 4
12 H011010101 机体 main body 1
13 H011000126 支柱 support 4
14 H011000127 隔热板 adiabatic board 2
15 H020610004 开槽沉头螺钉M3*20 bolt 4
16 H000110002 变速箱总成 complete gear box 1
16.1 H011010227 拉簧B型 spring(B) 1
16.2 H011010218 六角螺钉 bolt 1
16.3 H011010217 连杆 rod 1
16.4 H020630720 弹性圆柱销3*20 bolt 1
16.5 H011010116 拨叉 shift fork 1
16.6 H011010219 扳手轴 shaft 1
16.7 H011010220 轴衬 bushing 1
16.8 H011010221 拉簧螺钉 spring bolt 1
16.9 H020605004 六角螺母M6 nut 1
16.10 H011010222 轴衬 bushing 1
16.11 H020632715 开槽圆柱端紧定螺钉M4*8 bolt 1
16.12 H110002021 滚轮 roller 1
16.13 H110002016 蜗杆 worm 1
16.14 H011010223 拨叉 shift fork 1
16.15 H110002022 滚轮轴 short shaft 1
16.16 H020612703 开槽圆柱头螺钉4*8 bolt 8
16.17 H020631710 半园键4*￠13 key 2
16.18 H011000206 垫圈 washer 2
16.19 H020610708 开槽沉头螺钉M4*10 bolt 2
16.20 H011010226 主轴衬套 1
 No. in Part Item Description Qty.
Diagram numbers in Chinese in English /model
16.21 H020610704 开槽沉头螺钉3*6 bolt 6
16.22 H011010102 轴承盖 bearing cover 2
16.23 H020628728 轴承1000096 bearing 2
16.24 H011010201 30型变速箱体 gear box 1
16.25 H020612701 开槽圆柱头螺钉M3*6 bolt 8
16.26 H011010214 盖板 cover 1
16.27 H011010215 主轴 main shaft 1
16.28 H011000212 离合器 clutch 1
16.29 H020619704 轴用弹性档圈 ring 2
16.30 H011010210 斜齿轮 gear 1
16.31 H011010208 轴承座 bearing seat 2
16.32 H020630709 弹性圆柱销2*12 bolt 1
16.33 H011010203 短轴 short shaft 1
16.34 H110002012 蜗轮 worm wheel assembly 1
16.35 H020630711 弹性圆柱销2*16 bolt 2
16.36 H011010211 蜗杆 worm 1
16.37 H020617002 弹簧垫圈4 washer 4
16.38 H020612707 开槽圆柱头螺钉4*16 bolt 4
16.39 H020723705 电机 motor 1
16.40 H110002161 驱动轮（凸） drive roller 2
17 H011010123 底盖 cover 1
18 H020617001 垫圈3 washer 6
19 H020610704 开槽盘头螺钉M3*6 bolt 6
20 H110001221 手柄球 knob 1
21 H011000122 手柄 handle 1
22 H011000121 支承 shaft support 2
23 H011010118 轴 shaft 1
24 H011000120 板臂 arm 1
25 H011010119 螺钉 bolt 1
26 H020609718 开槽盘头螺钉M10*22 bolt 2
27 H020624704 铆钉8*20 rivet 2
28 H110101023 衬套 bushing 2
29 H1101010222 转向轮（凸） wheel 2
30 H110101021 滚轮架焊件 roller assembly 2
31 H110001081 手柄组件 handle 1
33 H011000125 标牌 name plate 1
34 H020610704 开槽盘头螺钉M3*6 bolt 4
35 H020710702 电源变压器 transformer 1
36 H000110007 电器箱组合 complete wiring assembly 1
36.1 H011010702 电器箱壳 box 1
 No. in Part Item Description Qty.
Diagram numbers in Chinese in English /model
36.2 H011010709 线路板（包括以下元器件） P.C board(including following) 1
H020703713 可控硅整流器 3CT5A 5A 300V Silicon-control Rectifier 1
H020703701 硅整流二级管2CZ83E 300V 0.3A Silicon-commute Diode 1
H020703708 硅整流二级管2CZ83D 200V 0.1A Silicon-commute Diode 1
H020701702 碳膜电阻RT 0.5W 10Ω Resistance 1
H020702703 金属壳电解电容 CD11-33uf 16v Electrolytic Capacitance 1
H020702701 Paper Capacitance
密封纸质电容 CJ30 T2.2-1uf 250v 1
H020710701 小型变压器 E193型输入变压器 Mini Transformer 1
H020701705 碳膜电阻 RT 0.5W Resistance 1
H020701701 碳膜电阻 RT 0.5W 4.7KΩ Resistance 1
H020720702 PCB PCB
36.3 H020722708 钮子开关(NK3-203) switch 1
36.4 H011010701 电器箱面板 panel 1
36.5 H020609704 十字槽盘头螺钉 bolt 2
36.6 H020712704 线绕电位器(WX-030  4.7K) potentiometer 1
36.7 H020614701 垫圈 washwr 1
36.8 H020719702 旋钮  K18-1 knob 1
36.9 H020301701 电源线 cable 1
36.10 H020703706 指示灯 XDX1-H-6.3V indicasting light 1
36.11 H020716715 三线电源插座 CF11 250V/10A socket 1
36.12 H020718703 保险丝BLX-1 fuse stand 1
37 H020624701 铆钉2*8 rivet 2
38 H011010135 司标 indicator 1
39 H020612712 开槽沉头螺钉M5-12 bolt 4
40 H011010110 支架座 bracket support 1
41 H020605005 六角螺母M8 hexangular nut 1
42 H011000603 定位螺钉 bolt 1
43 H020605006 六角螺母10 nut 1
44 H011000601 定位架 positioning bracket 1
45 H011000604 半径杆 radius bar 1
46 H020630724 弹性圆柱销4*30 bolt 1
47 H011000605 定位销 positioning bolt 1
48.1 H011000116 手轮 wheel 1
48.2 H011000115 龆轮轴承 gear bearing 1
48.3 H020630718 弹性圆柱销2.5*18 bolt 2
48.4 H011000114 龆轮轴 gear shaft 1
48.5 H011000105 螺钉 bolt 1
48.6 H011010130 销键 bolt key 1
same with
48.7 H020632704 开槽平端紧定螺钉M4*6 bolt
Item No. 2
 No. in Part Item Description Qty.
Diagram numbers in Chinese in English /model
48.8 H011010328 翼形螺钉 bolt 1
48.9 H011000109 翼形螺钉 bolt 3
48.10 H011010329 垫圈 washer 1
48.11 H011010322 夹持器 connector 1
48.12 H011010315 横柱 bar 1
48.13 H011000321 火口螺母 nut 1
48.14 H011010304 氧气二通阀 valve 2
48.15 H110103011 气体分配器(单头) gas distributor 1
48.16 H011000319 氧气乙炔皮管接头 hose connector 2
48.17 H011000320 接头螺母 nut 1
48.18 H011000317 接头螺母 nut 1
48.19 H011010303 乙炔二通阀 valve 1
48.20 H011000305 乙炔橡胶管组件 acetylene hose 1
48.21 H011000306 氧气橡胶管组件 oxygen hose 2
48.22 H011000316 割炬 torch 1
48.23 H020609710 开槽盘头螺钉4*18 bolt 2
48.24 H011000314 轴承 bearing 1
48.25 H011010311 割炬座架 torch pedestal 1
48.26 H011000307 斜齿轮 gear 1
48.27 H011000308 手轮 wheel 1
48.28 H011000313 齿条 rack 1
48.29 H011000312 升降柱 moving bar 1
48.30 H020609704 十字槽盘头螺钉3*6 bolt 3
48.31 H020630723 弹性圆柱销4*22 bolt 1
48.32 H011010325 连接器 Connector 1
48.33 H000008021 割嘴 Cutting Nozzle 3
48.34 H011000326 垫圈 washer 1
49 H000110005 导轨 Track (Concave) 1