DHC 2000

OPERATING INSTRUCTIONS

Page 1
PLEASE NOTE: Important safety instructions are located
on the following page. Please read them carefully before
using this product and associated attachments.
MAINTENANCE INSTRUCTIONS ARE LOCATED ON PAGE 16.
INDEX.......................................................................... Page No.
INTRODUCTION .......................................................................1
SAFETY INSTRUCTIONS.........................................................2
PURGING.................................................................................. 3
PRESSURE SETTING, METHOD 1......................................... 3
PRESSURE SETTING, METHOD 2 .........................................3
FLAME CHARACTERISTICS................................................... 4
FLAME SETTING...................................................................... 4
EXTINGUISHING FLAME......................................................... 4
TIP CLEANING......................................................................... 4
TIP SELECTION....................................................................... 5
WELDING.................................................................................. 6
GAS PRESSURES.................................................................... 6
WELDING POSITION............................................................... 7
WELDING TECHNIQUE........................................................... 8
BACKHAND WELDING............................................................. 9
TEMPERATURE..................................................................... 10
FLUXES.................................................................................. 10
PREPARATION, CLEANING.................................................. 10
TRIGGER................................................................................ 10
CUTTING................................................................................ 11
CUTTING THICK STEEL........................................................ 12
ASSEMBLY................................................................... 12
FLAME SETTING.......................................................... 12
PROCEDURE................................................................ 12
TIP POSITION............................................................... 13
CUTTING THIN SHEET STEEL............................................. 14
ASSEMBLY................................................................... 14
FLAME SETTING.......................................................... 15
TIP POSITION............................................................... 15
PROCEDURE................................................................ 15
ROSEBUD HEATING TIP....................................................... 16
AIR ACETYLENE HEATING ATTACHMENT......................... 16
ASSEMBLY................................................................... 17
PROCEDURE................................................................ 17
MAINTENANCE INSTRUCTIONS......................................... 17
FAULT FINDING..................................................................... 18
FLOW RATE TABLE................................................................19
APPENDIX A - WELDING ROD & FLUX SELECTION........ A-1
APPENDIX B - GLOSSARY OF TERMS.............................. B-1
APPENDIX C - PARTS LIST................................................. C-1
APPENDIX D - WARRANTY REGISTRATION..................... D-1
 Introducing the
DHC 2000
Torch
Manufactured by Cobra Torches, Inc.
INTRODUCTION
The DHC 2000 Torch has been developed over a period of thirty
years. It is manufactured to exacting specifications to achieve the
required characteristics.

To obtain optimum performance of the unit these instructions

should be read and thoroughly understood. For those already
experienced with similar type equipment, some minor and simple
changes to operator technique are required and this will be
emphasized throughout these instructions.

These instructions are intended for experienced operators and /

or those working under the close supervision of skilled welders.
Operation and maintenance of welding and cutting equipment
should conform to the provisions of American National Standard
Z49.1, “Safety in Welding and Cutting”. American Welding
Society Manual C4.2-78, “Operator’s Manual For Oxy-Fuel Gas
Cutting”, also deserves careful study.

REFERENCE PUBLICATIONS
AWS C4.2-78 - “Operator Manual for Oxy-Fuel Gas Cutting” -
American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
ANSI Z49.1 - “Safety in Welding and Cutting” - American National
Standards Institute, 1430 Broadway, New York, NY 10018
Compressed Gas Association (CGA)
1235 Jefferson Davis Highway, Arlington, VA 22202
• Safety Bulletin SB.8 - “Use of Oxy-Fuel Gas Welding and
Cutting Apparatus”
• Pamphlet E-1 - “Standard Connections for Regulator Outlets”
• CGA Standard V-1 - “Compressed Cylinder Valve Inlet and
Outlet Connections”
Page 1
SAFETY INSTRUCTIONS
Warning: When using welding and cutting torches, basic safety precautions
must always be followed to reduce the risk of fire and personal injury.
Some general precautions are as follows:

1. Wear protective attire. Always wear welding goggles to protect eyes from sparks and light rays.
Use appropriate gloves and wear protective clothing. Watch for sparks in cuffs. Do not wear oily
gloves.
2. Handle gas cylinders with care. Chain or otherwise secure cylinders to a permanent fixture. Take
care when moving. To transport cylinders, remove regulators and replace with valve cap. Never
use any cylinder in other than an upright position.
3. Use “good housekeeping” in the work area. Keep sparks and flame away from combustibles.
Prepare your work area before welding or cutting.
4. Do not oil or grease equipment. The equipment does not require lubrication. Oil or grease is
easily ignited and burns violently in the presence of oxygen.
5. “Crack” oxygen cylinder valve before installing regulator. Open valve slightly and then close.
This will clear valve of dust or dirt, which may be carried into the regulator and cause damage or
accident. Do not discharge flow of gas at any person or flammable material.
6. Use check valves. Check valves must be fitted to the torch hand piece to prevent back flow of
gasses. Test check valves for correct function frequently, at least every six months or in the event
of a flashback or backfire. The use of flashback arrestors is also strongly recommended.
7. Be sure all connections are tight. Do not force connections. Never test for leaks with a flame.
Use a soapy water solution and check for bubbles.
8. Purge oxygen and fuel gas passages separately before lighting torch. This will aid in
preventing improper mixes of gases.
9. Use recommended pressure settings. Improper pressures are wasteful. Extreme pressure build
up in regulators is a warning they need repair.
10. Never use oxygen to blow off work or clothing. Oxygen supports combustion, spark can ignite
oxygen-saturated clothing.
11. Purge system after use. When shutting down; close cylinder valves then bleed system by
emptying both hoses independently. First, open torch oxygen “OX” needle valve, drain line until
pressure is zero, then close oxygen needle valve. Repeat process with torch fuel “GAS” needle
valve.
12. Do not work with damaged or leaking equipment. Use soapy water when checking for leaks.
Do not use frayed or damaged hose. Never use torch as a hammer or to knock slag from work.
13. Handle equipment with care. Continued good service and your safety depend on it.
14. Keep work area well ventilated. Flammable materials burn violently in an oxygen atmosphere.
Flames and glowing materials (smoking) must be avoided when using oxygen. See American
National Standard Z49.1, paragraph 8.1.2.
15. When working with acetylene, never use at pressures over 15 PSIG (Pounds per Square Inch
Gage).
16. Do not force connectors and threads. The differences are intentional for the various gases.
17. Should you experience a backfire or flashback immediately close the oxygen valves on your
torch and tank, followed by the acetylene valves. Refer to page 19 of this manual for further
instruction.

DANGER!!! DO NOT ALLOW FUEL TANK OR OXYGEN CYLINDER TO BECOME COMPLETELY

EMPTY WHILE IN USE. Doing so could lead to unbalanced pressures and/or reverse flow of gasses
which in turn can lead to backfire and/or flashback.

WARNING!!! Each Oxy-fuel process will require a certain amount of gas flow (measured in
SCFH) – see Flow Rate table on page 19. The Withdrawal rate of an individual acetylene cylinder
must not exceed 1/7 of the tank contents per hour. To calculate the withdrawal rate identify the SCFH
requirement of the tip used and multiple that number by 7. For example, If you are using the number 2
tip your equation would be 7 x 7 = 49. In order to safely use that tip your cylinder must have a capacity
that meets or exceeds 49 cubic feet.
Page 2
PURGING
Always purge system before using. Read all steps and fully understand this procedure
prior to doing it.
Warning: Purge only in a well ventilated area. Do not direct flow of gas towards any
person or any flammable materials. Do not purge near open flames or any source of
ignition.
1. With both valves on the torch body closed and the trigger button locked in the off
position, slowly open supply valve on the Oxygen cylinder, then adjust regulator to 4
psi or until the oxygen gauge shows a reading.
2. Open the Oxygen (blue) torch valve and allow gas to flow about one second for
each ten feet of hose length. Close torch valve.
3. Slowly open supply valve on the Acetylene cylinder not more than one full turn, then
adjust regulator to 4 psi .5 Bar pressure.
4. Open the Acetylene (red) torch valve and allow gas to flow for about one second for
each ten feet of hose length. Close torch valve.
5. The torch is now purged.

PRESSURE SETTING
Note: All pressure settings assume (should be set in) a “flow” condition. Please
see glossary for further detail.
Method 1: Pressures are set at 4psi .5 Bar using gauges on regulators.
This first method requires that you have pressure gauges fitted to your oxygen and
acetylene cylinders that can reliably indicate as low as 4 psi .5 Bar. If your gauges are
not capable of establishing 4 P.S.I. .5 Bar use Method 2 to set up correct pressures.
Method 2: Setting Pressures using flame characteristics.
This method is used if you do not have a pressure gauge fitted to your oxygen or
acetylene cylinder that can reliably indicate as low as 4 psi.
Read all steps and fully understand this procedure prior to doing it.
1. Fit the No. 3 tip (3 grooves) to the shank. Ensure that the shank is firmly
tightened within the barrel.
2. With both valves on the torch body closed, slowly open supply valve on the
Oxygen cylinder. Be sure valve is completely open to prevent leakage.
3. Slowly open supply valve on the Acetylene cylinder not more than one full turn,
then adjust regulator to 4 psi .5 Bar pressure.
4. Open the Acetylene (red) torch valve 1/2 turn and light the flame.
5. Now fully open (at least two turns) the Acetylene (red) valve. A bright full flame
will result.
6. Slowly open the oxygen (blue) torch valve until fully open, at least two turns.
7. Slowly open the Oxygen regulator until you get a neutral flame. (Usually there
will be no pressure reading on the Oxygen gauge).
8. The unit is now set at approximately 4 psi .5 Bar. (28 Kpa) for both Oxygen and
Acetylene. Once this pressure setting is achieved any size tip can be used with
the gas flow now being controlled at the valves on the torch.
9. Flame Cone should be 1/2” long, if not adjust until this dimension is obtained.
(See Fig. 6 below)

Page 3
FLAME CHARACTERISTICS

______________________________
FLAME DETAIL FIG. 1
FLAME SETTING
JUST
RIGHT
OFF FEATHER (J.O.F.)
Equal Oxygen and Acetylene
FIG. 2


CARBURIZING
Excess Acetylene RIGHT (Stainless)
FIG. 3
Use carburizing flame with inner
cone
to weld stainless steel or
stainless to other metal.

WRONG
OXIDIZING
Excess Oxygen
FIG. 4
The performance of the DHC 2000 is TOTALLY dependent on the correct
flame setting. Regardless of tip size, the flame MUST be set in the “JUST OFF
FEATHER” (J.O.F.) condition. The only exception to this is when welding stainless
steel, where a carburizing flame is used. To obtain a J.O.F. flame, start with a
carburizing flame and gradually increase the Oxygen or decrease the Acetylene
until the feather has JUST disappeared.
When J.O.F. has been obtained a dark neutral streak or shadow will appear to run
from the tip of the cone. If the cone is taken beyond this point, by increasing the
oxygen, the neutral streak will disappear. This is now an oxidizing flame.
USE CARBURIZING FLAME WITH INNER CONE TO WELD
STAINLESS STEEL OR STAINLESS TO OTHER METAL.

EXTINGUISH FLAME
To extinguish the flame, the normal method is to turn off the oxygen control
valve before turning off the acetylene control valve.

TIP CLEANING
Always use the wire tip cleaners provided as part of your torch kit..

Page 4
TIP SELECTION
A range of eight (8) tips are used to cover normal welding. An additional
ninth tip is used for cutting only.

APPROXIMATE GUIDE TO USE OF TIPS - FIG. 5

No. 00 Tip. (Identified by diamond knurl on No. 0 Tip. (Identified by smooth
barrel) (optional tip) barrel)*

Used for very fine work requiring the smallest For use in welding materials up to
possible flame. Jewelry & 24-28 gage steel. 1.5mm (1/16”). 20-22 gage steel.

No. 0.5 Tip (Identified by single V groove on No. 1 Tip (Identified by single
barrel)* (optional tip) groove on barrel)

*This tip is ideal for use in extensive welding For use in welding materials of
of 20 ga.- 1/16 material. 1.5mm to 3.0mm (1/16” to 1/8”).

No. 1.5 Tip (Identified by one full groove & 1 partial groove (optional tip)

For use in welding materials at 1/8” to 3/16”

No. 2 Tip (identified by two square grooves No. 2.5 Tip (Identified by straight
on barrel) lines on barrel)* (optional tip)

For use in welding materials of 3mm to 6mm *This tip is useful for heavy steel, cast
and (3/16” to 1/4”) iron, & aluminum welding over 1/4”.

No. 3 Tip (Identified by three square Copper Cutting Tip (Identified by

grooves on barrel) color and diamond knurl on barrel)

*For use as a heating tip and set up purposes. For use only when cutting.

Page 5
WELDING
STRIVE FOR EXCELLENCE THROUGH PRACTICE,
PRACTICE, AND MORE PRACTICE.

The DHC 2000

TORCH shown
assembled for
Welding.

SAFETY CHECK VALVES MUST BE INSTALLED

BEFORE USE!

GAS PRESSURES
For all welding the DHC 2000 Torch functions on equal pressures and
equal volumes of oxygen and acetylene.

OXYGEN 4 psi (28 Kpa) .5 Bar

ACETYLENE 4 psi (28 Kpa) .5 Bar

Page 6
WELDING POSITION
For all welding, the unit should be approximately 10∞ to 20∞ off the
perpendicular (or 70∞ to 80∞ from the material being welded.)

CORRECT WELDING POSITION INCORRECT

WELDING POSITION
FIG. 6 FIG. 7

THIS IS AN IMPORTANT TECHNIQUE CHANGE. QUALITY

WELDING WILL NOT BE OBTAINED UNLESS FOLLOWED.
The greatest heat source is between 3mm to 5mm (1/8”-3/16”) from the tip of
the cone.

Page 7
WELDING TECHNIQUE
Due to the unique characteristics of the DHC 2000 flame, the cleaning of
material to be welded and the use of flux is in many cases unnecessary.

A DIP IN - DIP OUT ACTION should be adopted.

DIP IN - DIP OUT

FIG 8

FEED THE WELDING ROD UNDER AND BEHIND THE TIP OF THE
FLAME CONE.

ROD POSITION
FIG. 9

IT IS IMPORTANT FOR THE FLAME TO BE IN FRONT OF THE WELDING

PROCESS as the molten metal will follow the flame (frequently referred to as
a capillary action).

Page 8
METAL FLOW
FIG. 10

DO NOT push the molten metal forward with the flame (face feeding). Keep
the flame moving forward as fast as the welding process will allow, if the
flame is stationary the molten deposit will build up behind the flame.

BACKHAND WELDING
Backhand welding is a normal process which can be simply achieved using
the DHC 2000 Torch. It is usually recommended for steel plate exceeding
5mm (3/16”) thickness.

BACKHAND WELD
FIG. 11

Page 9
TEMPERATURE
It should be noted an increase in gas pressure will NOT increase the
temperature rating of the flame, as the unit is designed to operate at
maximum efficiency at 4 psi .5 Bar (28 Kpa) If a greater volume of heat is
required, increase the size of the flame or change to a larger tip.

FLUXES
In all instances where fluxes are used, minimal quantities are required. There
are frequent occasions where no flux is required.

DO NOT use heavy coatings of flux.

SUGGESTED METHOD OF FLUXING

A method of fluxing a welding or brazing rod, to minimize the amount of flux

used, is to put the flux into a fluxing stand, then wipe of the excess with a
piece of scrap wood or similar, back into the flux container, leaving a residue
in the flux stand. Heat the rod for about 8” (200 mm) of its length and place in
the vee area. Do not twist the rod as enough flux will adhere to facilitate the
weld or braze. For mixing ratios refer to manufacturers label.

PREPARATION -CLEANING
The cleaning of the area to be welded is, in most cases, unnecessary.
Salt, sand and carbon deposits should be removed.

TRIGGER
The trigger button is located on the body of
the torch and Is in the ‘ON’ (unlocked) position
when the arrow is pointing upwards as in FIG.
13. To lock ‘OFF’, pull out and turn to left or
right as in FIG. 13. It is recommended to have
the trigger in the ‘OFF’ position when welding,
but it must be in the ‘ON’ position when cutting.

CAUTION: Prolong use or over heating of

brass tips during cutting will damage brass tip.
Use copper cutting tip when ever possible.

Page 10
CUTTING

Cutting with the DHC 2000 Torch requires a different technique to that of
conventional equipment – in part due to separate delivery points for the oxygen
and acetylene. Attention should be given to all details set out in this section.

CHECK THE DISTANCE BETWEEN TIPS

After attaching the cutting attachment to the torch (see Assembly) double
check the distance between the tips. Use the wrench from kit to gage
distance between tips (see diagram below) If distance is not correct please
contact Cobra Torches, INC. This is important in that if the distance is too
narrow the cutting tip may become melted by the heating tip.

Note: In this manual, the term “cutting tip” refers to the tip through which
only oxygen passes and will be affixed to one of two possible cutting
attachments. The term “heating tip” refers to the tip through which a
mixture of fuel and oxygen pass, this will be the tip secured directly upon
the shank of the torch.

Distance between
these two lines should
be approximately 5/32”
(4mm) or the thickness
of the wrench provided
in kit.
Page 11
CUTTING - THICK STEEL
Fig 13. The DHC 2000 Torch shown assembled for cutting thick steel using
the over cutter, complete with guide wheels and optional heat shield.
The following table describes the recommended pressure settings
and tips to use when cutting mild steel of various thicknesses. Please
note that, regardless of material thickness, the acetylene is always
maintained at 4 psi (28Kpa)

Thick Steel Table

Material Oxygen Heating Cutting
Thickness Pressure Setting Tip Tip
3/16” 6-8 PSI #1 Copper Tip
1/4” 8-12 PSI #2 Copper Tip
1/2” 14-16 PSI #2 Copper Tip
3/4” 18-20 PSI #2 Copper Tip
1” 22-25 PSI #2 Copper Tip
ASSEMBLY
Fit the overcutter to the DHC2000 Torch as shown in Fig. 13. This is
accomplished by:
1. remove the ‘body plug’ from the cutting port,
2. then (without a heating tip fitted) slide the overcutter onto the shank while
engaging the threaded fitting into the open cutting port.
3. Tighten the threaded fitting sufficiently to secure the overcutter in place and
prevent oxygen leakage. Be careful not to over tighten.
4. Tighten the ‘copper cutting tip’ to the end of the overcutter, again, do not
over tighten
5. Tighten the #2 (or #1, see table above) to the shank for heating.
Note: The use of the guide wheel assembly is optional.

SETTING THE FLAME FOR CUTTING

When using your torch for cutting steel it is important to note that the oxygen
supply to the torch is shared between the heating flame and the cutting flame.
Thus when the cutting trigger is squeezed the heating flame may become
acetylene rich (carburizing). The heating flame must be adjusted to be correct
while oxygen is flowing to the cutting tip as described below.
1. Light the torch and establish a flame as described in FLAME DETAIL Fig.1.
2. Squeeze the trigger to allow oxygen to flow through the cutting tip.
3. With the trigger still depressed, adjust the flame to the desired size in Just
Off Feather condition
4. Release the trigger

PROCEDURE
Heat the edge of the steel to a bright cherry red, depress the trigger and move
the oxygen delivery point over the heated edge - cutting will commence.
Beveling can be carried out by angling the handpiece in the direction the
beveled angle is required.
IMPORTANT - AT ALL TIMES WATCH THE OXYGEN DELIVERY POINT,
NOT THE FLAME to ensure the correct distance from the material is maintained.
Page 12
 TIP POSITION - CUTTING STEEL PLATE.
FIG. 14

IMPORTANT

(1) Use a No. 2 tip for most
applications. The No.3 tip

should not be used in the
cutting process. (See table
on page 10)
From 1/16” (1.5MM)
to
touching surface

PULL CUT

IMPORTANT:
The oxygen delivery point (cutting tip) must be just out of the flame area.
The flame size can vary for thickness of material being cut and operator
technique

For any oxygen and acetylene cutting, whether the unit is used manually
or a wheel guide is used, the unit is held with the oxygen delivery point
perpendicular (90 degrees) to the surface of the material being cut..

The oxygen delivery point should be maintained approximately 1/16”

(1.5mm) from the surface to be cut.

Piercing holes is achieved using the normal method i.e. after bringing the
surface to a very bright red, raise the oxygen delivery point to approximately
12mm (1/2”) before introducing the oxygen. Once the plate is penetrated,
return to the normal height 1.5mm (1/16”) above work and proceed to cut
the hole.
For optimum cutting, the oxygen delivery point should follow immediately
behind the heating point.

Page 13
CUTTING - SHEET STEEL

FIG. 15 The DHC 2000 Torch shown assembled for cutting sheet steel using
the under cutter.

The following table describes the recommended pressure settings and

tips to use when cutting sheet steel of various thicknesses. Please
note that, regardless of material thickness, the acetylene is always
maintained at 4 psi (28Kpa)

Sheet Steel Table

Material Oxygen Heating Cutting
Thickness Pressure Setting Tip Tip
.010 - .025 4-5 PSI #0 #00
.030 - .065 4-5 PSI .5 #0
.075 - 1/8” 4-5 PSI .5 #0

ASSEMBLY
Fit the undercutter to the DHC2000 Torch as shown in Fig. 13. This is
accomplished by:
1. remove the ‘body plug’ from the cutting port,
2. then (without a heating tip fitted) slide the undercutter onto the shank while
engaging the threaded fitting into the open cutting port.
3. Tighten the threaded fitting sufficiently to secure the undercutter in place
and prevent oxygen leakage.
4. Tighten the desired “cutting tip” (see table above) to the end of the
undercutter,
5. Tighten the desired “heating tip” (see table above) to the shank for heating.
Note: The use of the guide wheel assembly is optional.

CAUTION: Prolong use or over heating of brass tips during cutting will
damage brass tip. Use copper cutting tip when ever possible.

Page 14
SETTING THE FLAME FOR CUTTING SHEET STEEL
When using your torch for cutting steel it is important to note that the oxygen
supply to the torch is shared between the heating flame and the cutting flame.
Thus when the cutting trigger is squeezed the heating flame may become
acetylene rich (carburizing). The heating flame must be adjusted to be correct
while oxygen is flowing to the cutting tip as described below.

1. Light the torch and establish a flame as described in Section 16.

2. Squeeze the trigger to allow oxygen to flow through the cutting tip.
3. With the trigger still depressed, adjust the flame to the desired size in
Just Off Feather condition (Approx. 3 to 4mm - 1/8” to 3/16”)
4. Release the trigger

TIP POSITION - CUTTING SHEET STEEL

FIG. 16

0.5 tip
0 tip

Push Cut
From 1/16” (1.5MM)
to
touching surface

PROCEDURE
Heat the edge of the steel to a bright red, depress the trigger and move the
oxygen delivery point over the heated edge - cutting will commence.
The flame size can vary for thickness of plate and operator technique.
Position the oxygen delivery point (cutting tip) should be at approximately 45°
from the surface of the material being cut. The operator may wish to slightly
vary this angle to suit individual style.

IMPORTANT - AT ALL TIMES, WATCH THE OXYGEN DELIVERY POINT

(NOT THE FLAME) and maintain the cutting tip no more than 1.5mm (1/16”)
from the surface being cut. The cutting tip can be allowed to touch the
surface although this will slightly reduce tip life.

Page 15
ROSEBUD HEATING TIP (OPTIONAL FEATURE)
Our rosebud heating tip is designed to run efficiently on 4lb of acetylene and
4lb of oxygen.

Rosebuds require a good amount of fuel. So, be sure that your fuel tank
capacity is large enough to support consumption requirements (see Fuel
Consumption chart on p19). If your tank is too small or the fuel level in it is
too low then you will risk starving the heating tip or drawing acetone out of
your tank.

ASSEMBLY
Remove shank form the barrel and insert Rosebud heating tip. Tighten with
wrench – DO NOT over tighten.

LIGHTING PROCEDURE
Set regulator pressures at 5 and 5 (psi). Note: Setting at 5 and 5 will account
for line drop of a 12’ hose so that when the fuel mixture is in a “flow” condition
the gauges should read 4psi.

Open acetylene valve and light at tip.

Slowly open oxygen valve until a neutral flame condition is obtained.

Note: If you are having difficulty lighting verify that the fuel and oxygen
gauges still read 4psi when the valves are open. If not, incrementally adjust
the regulator knobs until the proper pressure settings are established for the
“flow condition.

SHUTDOWN PROCEDURE
Close the Oxygen valve on the torch, followed by the acetylene valve.

AIR ACETYLENE HEATING ATTACHMENT (OPTIONAL

FEATURE)
For soft soldering, leading, tinning, silver soldering and general light heating
without the oxidizing of materials. The acetylene and air tip can be used in
many instances. A soldering bit can be fitted for continued heating in soft
soldering. BARREL

AIR-ACETYLENE HEATING
ATTACHMENT FIG. 17

Page 16
ASSEMBLY
Remove tip and shank from barrel and insert air acetylene tip to barrel as shown
in Fig. 17. Tighten with wrench provided. Do not over tighten. The acetylene
setting is 4 psi (21-28 Kpa)
IMPORTANT OXYGEN MUST NEVER BE USED WITH THE AIR-
ACETYLENE HEATING ATTACHMENT.

PROCEDURE
With the acetylene cylinder supply valve open a maximum of one turn and
regulator set at 4 psi, open the acetylene valve on the torch body and light the
flame at the end of the Air-Acetylene attachment. A cone condition will form in all
instances regardless of low settings at the torch body valve. Too high a flow or
pressure will extinguish the flame when the handpiece control valve is fully open.
Should a burning occur at the holes of the air-acetylene attachment (this can
occur if the acetylene pressure is very low), an increase of acetylene will
immediately allow the cone to ‘fix’ at the tip.

MAINTENANCE INSTRUCTIONS
Check Valves
Leak test Check Valves at least every six months, as follows:
1. Shut off fuel gas supply and disconnect hose from check valve.
2. Set oxygen regulator to 5 P.S.I., open all gas valves on torch or cutting
attachment.
3. Plug tip and check for reverse flow to fuel gas check valve. Use soapy water
or immerse in water to check for leaks. Set pressure to zero after test.
4. Reconnect fuel gas hose and disconnect oxygen hose.
5. Repeat steps 2 and 3 using fuel gas regulator as pressure source.
6. Reconnect hoses and purge system before use.

Regulator Test
A leak test of the regulators may be made as follows: (also see your regulator
instruction manual)
1. Shut off acetylene gas regulator by turning counter-clockwise until loose.
2. Close fuel acetylene cylinder valve.
3. Close acetylene (red) torch valve.

NOTE:
• Watch acetylene cylinder pressure gage for several minutes. A pressure drop
indicates a leak in the inlet side. Tighten connection and recheck.
• Also watch the delivery pressure gauge. A rise in pressure indicates a leak in
the regulator valve.
• If leak cannot be stopped, DO NOT USE THE REGULATOR!
• All gauges should read zero when the pressure is removed. If they do
not, the gauges may be damaged. If damaged, check system for cause of
damaged gauges. Have the damage repaired by a qualified repairman or
replace the damaged gauges.
• Repeat procedure shown above for the oxygen regulator.

Page 17
CLEANING GAUGES
The gauge crystals are typically made of Lexan. Use only soapy water to clean,
then wipe dry using soft cloths. Do not use solvents. ® General Electric Company

CHANGING CYLINDERS

A cylinder is depleted and is considered empty when it is unable to deliver

fuel gas or oxygen to the torch tip at the set pressure.
1. Close supply valve of depleted cylinder and bleed off all gas in depleted
line at torch. Close torch valve.
2. Disconnect hose and regulator from depleted cylinder.
3. Screw Valve Protection Cap onto cylinder, mark “EMPTY”, and remove.
4. Follow the procedure under set-up instructions provided with the new
cylinder.
5. Purge system (see below)
TORCHES AND CUTTING ATTACHMENTS
1. Periodically check for leaks using a leak test solution or by immersing in
water and checking for bubbles.
2. Tighten connections and packing nuts to stop leaks. Do not use
excessive force.
STORAGE
When not in use, store equipment in a clean and safe, clean, and dry place.

FAULT FINDING
WELDING
PROBLEM POSSIBLE CAUSE REMEDY

Handpiece getting hot

1. Incorrect pressure Pressure setting, page 3
2. Incorrect flame setting Flame setting, page 4
3. Reflected heat from job Use heat shield

Tip backfiring
1. Tip too large for job Tip selection, page 5
2. Flame setting too low for tip size Tip selection, page 4
3. Flame cone forced into Welding technique, page 8
molten metal
Unsatisfactory weld
1. Incorrect flame setting Flame setting, page 4
2. Torch held at wrong angle Welding position, page 7
3. Rod not being used correctly Welding technique, page 8

Fluctuating flame
1. Oxygen or acetylene regulator Have regulators serviced.
diaphragm faulty
CUTTING

Page 18
PROBLEM POSSIBLE CAUSE REMEDY
Wide cut, excessive Slag
1. Oxygen delivery point Position (Cutting), page 13
too far from surface being cut
2. Insufficient pressure Pressures (Cutting), page 12
Melting end of cutting tip
1. Tip inside flame area Flame setting (Cutting), page 12
Oxygen delivery tip
1. Tip allowed into molten metal Position (Cutting), page 13

ADDITIONAL NOTES ON SAFETY BACKFIRE AND

FLASHBACK
CAUTION!!! A Backfire is where the flame goes out followed by a loud pop. A backfire is
more of a nuisance than a danger but if the conditions that lead to it remain uncorrected
a more serious condition (i.e. flashback) may arise. Backfires may derive from any one
of the following: overheating the tip, pressure setting too low, touching tip against work or
otherwise blocking the tip orifice.

DANGER!!! A Flashback is a condition where the mixed gases are burning inside the
torch tip - it is accompanied by a shrill hissing/squealing sound and lack a visible flame.
[Note: a partially blocked tip may also result in a hissing or whistle type sound but the
flame will still be visible]
If allowed to persist, a flashback may continue to burn back through the system (torch,
hose, etc.) resulting in damage to equipment and possible explosion. For this reason it is
recommended that flashback arrestors be installed in your system.

If you encounter this immediately shut off the oxygen valve on your torch followed by
the oxygen valve on your tank, then the fuel both valves. Before further use, Identify the
cause of the flashback, remediate as necessary, and inspect all equipment. A flashback
derives from starvation which in turn may be caused by any of the following:
• Some of the same conditions that can lead to a backfire, restrictions in
gas line or extreme length of small diameter hose,
• Insufficient gas supply, improper pressure settings
• Damaged or mishandled needle valve on fuel tank or oxygen cylinder
• Low gas levels in tank/cylinder.

FLOW RATES

Oxygen Acetylene Acetylene Flow Rate

Tip Size Dia (in)
(psig) (psig) (SCFH)
{00} 0.0145 4 4 0.5
0 0.021 4 4 1
0.5 0.026 4 4 2
1 0.035 4 4 3
1.5 0.044 4 4 5
2 0.052 4 4 7
2.5 0.074 4 4 14
3 0.095 4 4 23
Copper Cutting 0.052 4 4 7

Rose-bud BTU/cf
Heating Tip - 4 4 6 1470

Page 19
WELDING ROD and FLUX SELECTION
DESCRIPTION OF SUGGESTED ROD SUGGESTED FLUX
APPLICATION
Aluminum - Soft 1100 Cobra High-temp
(For Car Bodies) Alum welding flux
Aluminum - Hard 4043 or 5356
Series & T-6
Brass Bare Brass Rod
Cast Iron Cast Iron Rod – Cobra High-temp
Cobra brand 100% Cast Iron welding flux
cast iron rod
Chromoly Steel or Copper
coated Mild Steel Rod
Copper Copper Wire or #14
(Romex) house wire
Galvanize Everdue or Silicone Not required
Bronze or Steel
Magnesium Magnesium Rod Magnesium Flux
Stainless 316 or 308 Not required
Stainless 309 Not required
(joining to Steel)
Stainless (For Aircraft) 347 or 321 Not required
Steel Copper coated Mild Not required
Steel or Steel Rod –
E70S-2 or 6

ADDITIONAL NOTES REGARDING ROD AND FLUX

• Use ø1/16” rod for light gauge metal
• Use ø .023 - .045 rod for very thin metal (less than .045 thick; Mig wire is
fine)
• Use ø3/32” to ø1/8” rod for 5/32” metal & above
• For welding over 1/8” metal (steel) – Bevel Edges – Get metal red before
welding.
• You can also knock the flux off of stick electrodes and use on heavier
(steel) plate.
• Pre-heat all thick aluminum (including sheets) before welding.

A-1
GLOSSARY OF TERMS
Bead – The fused metal deposited over the seam where two metals are
welded together. It will look like a series of tight, overlapping ovals.
Delivery Point – the point where a gas exits the cutting or heating tip.
Ferrous Metals – Metals, such as wrought and cast iron, steel and cast steel,
that combine iron and other elements in their makeup. Magnets attach to these
types of metals easily.
Filler Metal – The additional metal most weld-seams require, filler metal is
added by melting filler rod or wire in to the weld-joint.
Flow Condition – refers to the condition or state of a pressurized gas.
For example, when a gas moves uninterrupted (from the tank, through the
hose, and out of the tip) it is said to be in a “flow” condition. (see also Static
Condition)
Flux – A chemical coating applied to metal to prevent oxidation during the
joining operations; to promote the flow of the alloy and to facilitate the bonding
action between the metal and the deposited (filler) metal.
Heat Affected Zone – The area, running along either side of a weld affected
by heat. A visible discoloration will occur on welded ferrous metals.
Malleability – The formability, or responsiveness, of heated metal when being
shaped
Mild Steel – Same as low-carbon steel. Common throughout the world, it is
highly malleable.
Non-Ferrous Metals – Metals that contain no iron: such as aluminum, brass,
bronze, copper, magnesium and nickel.
Out of Position Welding – Any welding operation, such as vertical or
overhead welding, in which the parts are not laid out flat in front of the operator.
Penetration – Describes the extent of the depth into each piece of metal the
welding fusion penetrates: The deeper the penetration, the stronger the joint.
Puddle – The active welding bead melting the heated parent metal and the
filler rod together. The finished weld is a hardened row of overlapping puddles.
Rod – The consumable filler steel used to weld metals. In stick welding the
rod is coated with shielding flux and often called an electrode. In gas and TIG
welding it is usually uncoated.
Sheet Metal – Thin metals, generally between 12 and 24 gauge, used in auto
bodies, household appliances and HVAC applications.
Static Condition – refers to the condition or state of a pressurized gas. For
example, when a gas is under pressure but interrupted (e.g. by a closed valve)
it is said to be in a “static” or non-moving condition. (see also Static Condition)
Tack Weld – Small, preliminary welds located at both ends and the middle of a
seam meant simply to align and secure metal work-pieces before the final weld
is begun. This is a precautionary measure. Tack welds are easily broken when
design alterations become apparent.

B-1
 Optional
Tip Cleaner

Optional

PARTS LIST
W3006-106 Shank W3103-378 Tip Cleaner Set
W3031-142 Body Plug W3105-369 Trigger Button Assembly
W3039-160 #0 Tip W3107-365 Oxygen Valve
W3040-122 #1 Tip W3107-366 Acetylene Valve
W3041-123 #2 Tip W3108-272 Cutting Attachment
W3041-159 Copper Cutting Tip W3111-273 Sheet Metal Cutter
W3042-124 #3 Tip W3110-143 Brackets
W3045-132 Handle - Right W3102-148 Nut / Bolt
W3044-133 Handle - Left W3101-363 Guide Rails
W3052-155 Wrench W3100-368 Torch Body

OPTIONAL ACCESSORIES
W3038-176 #00 W3047-361 Shield
W3039-161 #0.5 Tip W3005-000 Curved Extension
W3040-132 #1.5 Tip W3004-000 Straight Extension
W3043-177 #2.5 Tip W3104-364 Air / Acetylene Tip
W3104-500 Rose Bud

For additional products and information call us or visit our

website. Contact information on the back of this manual.

C-1
 We believe the two main ingredients
for successful welding are
observation on the part of the
welder and the use of the
DHC 2000 Torch.

TO BE RETAINED BY CUSTOMER
Serial No. C
Fill in the number stamped on valve body opposite control valves.

COBRA: LIfetime Limited Warranty

The DHC 2000 Welding & Cutting handpiece is guaranteed
for the lifetime of the original purchaser against any defect
due to faulty material or workmanship, excluding tips. Upon
the discretion of the manufacturer you will receive free of
charge, a replacement unit or the free repair and replacement
of faulty parts. Please note that, unless otherwise stated by
a representative of Cobra, the customer is responsible for all
shipping costs. Cobra Torch, Inc. accepts no responsibility for
defects, damage or faulty performances caused by misuse,
careless handling or where repairs have been made or
attempted by unauthorized persons. No other guarantees,
written or verbal, are authorized to be made on the behalf of
Cobra Torch, Inc. All other conditions and warranties whether
expressed or implied are, to the extent permitted by law,
hereby excluded. Complete Warranty Registration online at
www.detroittorch.com.

Date of Purchase________________________

Purchased From_________________________

D-1
 D
The Power of Detroit in your Hand.

CM

MY

CY

MY

K Need Help?

Check us out online at

www.detroittorch.com
or Give us a Call
1-866-875-7066

180 Engelwood Drive Suite J

Orion, Michigan 48359

A Division of Cobra Torches, Inc.

Manufacturer of the DHC2000