INSTRUCTIONS FOR
F-6440-Y
May, 2009
C-59 SCARFING TORCH
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and
safe practices for oxy-fuel gas equipment, we urge you to read our booklet “Precautions and Safe Practices For Gas
Welding, Cutting, and Heating”, Form 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.
1. GAS SUPPLY AND REGULATION
REQUIREMENTS
A. Pressures
This C-59 can be used with any fuel gas other than
acetylene such as natural gas, propane, and many
proprietary gases. Fuel gas pressures of 5 to 20 psi
are adequate for scarfing.
With 75 feet of 1/2 inch hose, the approximate pressure drop will be 90 psi. The regulator therefore must
be set to a delivery pressure of approximately 135
psi.
The C-59 operates most efficiently under normal conditions with an oxygen pressure of 45 psi at the torch
inlet. The torch is adjusted at the factory for this condition. Under unusual operating conditions, pipeline
size and/or pressure may be inadequate to provide
oxygen at this level. Under such conditions, a slight
opening of the compensator valve (located in the torch
body) may be necessary. Instructions for adjusting
the compensator valve are given in Section III-A.
B. Hose Sizes
To obtain an oxygen pressure of 45 psi at the torch,
the regulator must be set to a pressure sufficiently
high to allow for the pressure drop through the hose.
To avoid excessive pressure drop 1/2 inch hose and
standard OXWELD “C” size hose fittings, such as
P/N 2120399 (50-ft.), must be used. Hose larger than
1/2 inch may be required where lengths greater than
75 feet are used.
With 50 feet of 1/2 inch hose, the approximate pressure drop will be 60 psi. The regulator must therefore be set to a delivery pressure of approximately
105 psi.
Fuel gas hose should be 3/8 inch with standard “B”
size fittings, such as P/N 2120404(50-ft).
Also available is a fitted 65-ft. Scarfing Hose Assembly, P/N 2119324, which includes 50-ft. of 3/4" hose
with “D” size fitting on one end for connecting to oxygen regulator spliced with 15-ft. of 1/2" hose with “C”
size fitting for torch connection, and 65 ft. of 3/8" fuel
gas hose with “B” size fittings.
C.Station Regulator Panel P/N 21 19101
This regulator panel includes the R-52 Oxygen Regulator (20A16) and the R-76-75-025 Fuel Gas Regulator (19153) conveniently mounted on a frame for wall
mounting. The panel also includes shutoff and check
valves, oxygen line filter, and fuel gas safety valve.
The R-52 Oxygen Regulator has ample capacity to
meet gas flow requirements under normal operation
conditions. However, to obt ain the required delivery
pressure at the regulator, the line pressure ahead of
the regulator must be at least 10 lb. per sq. inch
greater -- that is, at least 145 lb. per sq. in. (135 +
10).
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 principles 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 accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions 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 immediately. 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 service facility designated by the manufacturer.
IMPORTANT SAFEGUARDS
When using Oxy-Fuel Gas Torches, basic safety precautions should always be followed:
Never use Acetylene gas at a pressure over 15 psig.a.
Never use damaged equipment.b.
Never use oil or grease on or around Oxygen equipment.c.
Never use Oxygen or fuel gas to blow dirt or dust o clothing or equipment.d.
Never light a torch with matches or a lighter. Always use a striker.e.
Always wear the proper welding goggles, gloves and clothing when operating Oxy-Acetylene equipment. f.
Pants should not have cus.
Do not carry lighters, matches or other ammable objects in pockets when welding or cutting.g.
Always be aware of others around you when using a torch.h.
Be careful not to let welding hoses come into contact with torch ame or sparks from cutting.i.
SAVE THESE INSTRUCTIONS.j.
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
SAVE THESE INSTRUCTIONS!
SAFETY PRECAUTIONS
These Safety Precautions are for your protection. They summarize precautionary information from the references listed
in Additional Safety Information section. Before performing any
installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other
manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS - Some
welding, cutting and gouging processes are
noisy and require ear protection. Hot metal can
cause skin burns and heat rays may injure
eyes. Training in the proper use of the processes and equipment is essential to prevent
accidents. Also:
1. Always wear safety glasses with side shields in any work area,
even if welding helmets, face shields, or goggles are also required.
2. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt,
cuffless trousers, high-topped shoes, and a welding helmet or
cap for hair protection, to protect against hot sparks and hot
metal. A flameproof apron may also be desirable as protection
against radiated heat and sparks.
3. Hot sparks or metal can lodge in rolled up sleeves, trousers
cuffs, or pockets. Sleeves and collars should be kept buttoned,
and open pockets eliminated from the front of clothing.
4. Protect other personnel from hot sparks with a suitable nonflammable partition or curtains.
5. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can travel considerable distances. Bystanders should also wear goggles over safety
glasses.
FIRES AND EXPLOSIONS - Heat from a flame
can act as an ignition source. Hot slag or sparks
can also cause fires or explosions. Therefore:
1. Remove all combustible materials well away from the work
area or completely cover the materials with a protective nonflammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices in
floors or wall openings and cause a hidden smoldering fire on
the floor below. Make certain that such openings are protected
from hot sparks and metal.
3. Do not weld, cut, or perform any other hot work on materials,
containers, or piping until it has been completely cleaned so
that no substances on the material can produce flammable or
toxic vapors. Do not do hot work on closed containers. They
may explode.
4. Have fire extinguishing equipment handy for instant use, such
as a garden hose, a pail of water or sand, or portable fire
extinguisher. Be sure you are trained in its use.
5. After completing operations, inspect the work area to be sure
that there are no hot sparks or hot metal which could cause a
later fire. Use fire watchers when necessary.
6. For additional information, refer to NFPA Standard 51B, Fire
Prevention in Use of Cutting and Welding Processes, which
is available from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
3. Refer to ANSI/ASC Standard Z49.1 listed below for specific
ventilation recommendations.
EQUIPMENT MAINTENANCE - Faulty or improperly
maintained equipment, such as torches, hoses and
regulators, can result in poor work, but even more
important, it can cause injury or death through fires.
Therefore:
1. Always have qualified personnel perform the installation,
troubleshooting, and maintenance work. Do not operate or
repair any equipment unless you are qualified to do so.
2. Keep all oxy-fuel equipment free of grease or oil. Grease, oil,
and other similar combustible materials, when ignited, can burn
violently in the presence of oxygen.
3. Do not abuse any equipment or accessories. Keep equipment
away from heat and wet conditions, oil or grease, corrosive
atmospheres and inclement weather.
4. Keep all safety devices in position and in good repair.
5. Use equipment for its intended purpose. Do not modify it in
any manner.
GAS CYLINDER HANDLING - Gas cylinders, if
mishandled, can rupture or explode violently.
Sudden rupture of a cylinder, valve or relief device can injure or kill you. Therefore:
1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors to mount the regulator on the cylinder. Maintain hoses and fittings in good condition. Follow manufacturers operating instructions for mounting the regulator to the gas cylinder.
2. Always secure cylinders in an upright position by chain or strap
to suitable hand trucks, benches, walls, post, or racks. Never
secure cylinders to work tables or fixtures where they may
become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have the valve
protection cap in place on top of the cylinder if no regulators is
installed. Secure and move cylinders by using suitable hand
trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, or flame of a welding, cutting, or gouging operation. Never strike an arc on a
cylinder.
5. For additional information, refer to CGA Standard P-1, Precautions for Safe Handling of Compressed Gases in Cylinders:, which is available from the Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.
ADDITIONAL SAFETY INFORMATION - For more information on safe practices for oxy-fuel welding and
cutting equipment, ask your distributor for a copy of
Precautions and Safe Practices for Gas Welding, Cutting, and Heating, Form 2035. Gas apparatus safety
guidelines are also available on video cassettes from
your distributor.
The following publications, which are available from the American
Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are
recommended to you:
1. ANSI/AWS Z49.1 - Safety in Welding and Cutting.
2. AWS F4.1 - Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That
Have Held Hazardous Substances/
3. AWS SP - Safe Practices - Reprint, Welding Handbook.
FUMES AND GASES - Fumes and gases, particularly in confined spaces, can cause discomfort or injury. Do not breathe fumes or
gases from welding or cutting, Therefore:
1. Always provide adequate ventilation in the work area by natural or mechanical ventilation means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel, copper,
zinc, lead, beryllium, or cadmium unless positive mechanical
ventilation is provided. Do not breathe fumes and gases from
these materials.
2. If you develop momentary eye, nose, or throat irritation while
operating, this is an indication that ventilation is not adequate.
Stop work at once and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical
discomfort persists.
This symbol appearing in this manual means
Attention! Be Alert! Your safety is involved.
Used to call attention to immediate hazards
which, if not avoided, will result in immediate,
serious personal injury or loss of life.
Used to call attention to potential hazards
which could result in personal injury or loss of
life.
Used to call attention to hazards which could
result in minor personal injury.
2
SP-GA 7/97
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for your protection. Before performing any
installation or operating procedures, be sure to read and follow the saf ety precautions listed below. Failure to observe these Safety Precautions can result in per sonal
injury or death.
1. PERSONAL PROTECTION — Heat rays (infrared radiation) from an oxy-fuel
flame or hot metal can injure eyes. Therefore:
a. Wear shaded safety goggles made for gas welding and cutting purposes
for protecting your eyes from radiation burns as well as sparks or spatter.
WARN bystanders not to watch the flame and not expose themselves to the
rays of the flame or hot metal.
b. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless
trousers, high topped shoes, and a cap for hair protection, to protect
against hot sparks or hot metal. A flameproof apron may also be desirable
as protection against radiated heat and sparks.
c. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or
pockets. Sleeves and collars should be kept buttoned, and pockets
eliminated from front of clothing.
d. Protect other personnel from rays and hot sparks with a suitable
nonflammable partition.
e. Always wear safety glasses or goggles when in a work area. Use safety
glasses with side shields or goggles when chipping slag or grinding.
Chipped slag may be hot and can travel considerable distances.
Bystanders should also wear safety glasses and goggles.
f. Some gouging and cutting processes produce excessively high noise
levels and require ear protection.
2. FIRE-PREVENTION — Hot slag or sparks can cause serious fires when in contact
with combustible solids, liquids or gases. Oxygen causes fire to burn more rapidly. Fuel gas can explode in air or oxygen. Therefore:
a. Remove all combustible materials well away from the work area or completely
cover the materials with a protective nonflammable covering. Such combustible materials include wood, clothing, sawdust, gasoline, kerosene, paints,
solvents, natural gas, acetylene, propane, and similar combustible articles.
b. Hot sparks or hot metal can fall into cracks in floors or wall openings and
cause a hidden smoldering fire. Make certain that such openings are protected from hot sparks and metal.
c. Do not weld, cut or perform other hot work until the workpiece has been
completely cleaned so that there are no substances on the workpiece which
might produce flammable or toxic vapors.
d. For fire protection, have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or portable fire extinquisher.
e. After completing operations, inspect the w ork area to make certain there are
no hot sparks or hot metal which could cause a later fire.
f. For additional information, refer to NFPA Standard 51B, “Fire Prevention in
Use of Cutting and Welding Processes”, which is available from the National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
3. VENTILATION — Fumes, particularly in confined spaces, can cause discomfort
and physical harm. Do not breathe fumes. Therefore:
a. At all times provide adequate ventilation in the work area by natural or me-
chanical ventilation means. Do not weld, cut, or heat materials such as galvanized steel, zinc, lead, beryllium, cadmium, etc. unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.
b. If you develop momentary eye, nose, or throat irritation while operating, this
is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work are. Do not continue to operate
if physical discomfort persists.
c. Refer to AWS Standard Z49.1 in item 5 for specific ventilation recommenda-
tions.
d. Air samples can be used to find out what respiratory protection is needed.
4. EQUIPMENT MAINTENANCE — Faulty or improperly maintained equipment can
result in poor work, but most importantly it can cause physical injury or death
through fires. Therefore:
a. Always have qualified personnel perform the installation, troubleshooting,
and maintenance work. Do not operate or repair any equipment unless you
are qualified to perform such work.
b. Keep all oxy-fuel equipment free of grease or oil. Grease, oil and other simi-
lar combustible materials once ignited can burn violently in the presence of
oxygen.
c. Maintain torches, hoses, and regulators in safe working order. Do not oper-
ate any equipment in faulty conditions.
d. Do not abuse equipment or accessories. Keep equipment away from exces-
sive heat and wet conditions, oil or grease, corrosive atmospheres and in-
clement weather.
e. Keep all safety devices in position and in good repair.
f. Use equipment for its intended purpose. Do not modify it in any manner.
5. ADDITIONAL SAFETY INFORMATION — For more information on safe practices
for setting up and operating oxy-fuel welding and cutting equipment and on good
working habits, ask your welding equipment supplier for a copy of “Precautions
and Safe Practices for Gas Welding, Cutting, and Heating”, Form 2035. The following publications, which are a v ailable from the American Welding Society, 550
N.W. LeJuene Rd., Miami, FL 33126, are recommended to you:
a. “Safety in Welding and Cutting” -AWSZ49.1 (ANSI)
b. “Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping that have held Hazardous Substances” AWSF4.1
The R-76-75-025 Fuel Gas Regulator is designed for
high flow delivery of fuel gas.
D. Central Regulation
If the oxygen supply is regulated from a central point
in a distribution line piping system, the R-83-40M Oxygen S tation Regulator should be used. A single unit
is usually sufficient, but several units may be required.
Where operations are continuous and extremely
heavy , an OXWELD R-600 Series S t ation Regulator
may be needed.
II. OPERATING INSTRUCTIONS
NOTE: As received from the factory the starting rod
feeder is offset for right-handed operations.
For left-handed operation, see III-B, Page
5.
A. T o Connect
Check that the packing nuts on the torch valves are snug.
Attach the oxygen and fuel gas hoses to the torch. Use
1/2 in. hose for the oxygen supply and 3/8 in. hose for
the fuel gas supply . Where lengths of hose greater than
75 ft. are desired, it may be necessary to use a section
of larger than 1/2 in. hose in the oxygen line to reduce
the pressure drop between the regulator and torch at
the normal operating flows.
Attach an 1806, size 62 nozzle (see Table 1) to torch
head, and tighten the connection nut firmly with a wrench.
Insert the starting rod (steel rod, .178 to .195 in. in diameter) in the rear end of the rod feed body. Remove end
burrs from starting rod prior to inserting. The rod must
move freely. Slide it forward until the end is even with
the tip of the nozzle. A 3/16" diam. X 36" long OXWELD
No. 7 rod, Part No. 1031F15 (50 lb. package), is recommended, mainly because of its freedom from burrs and
uniformity in size.
B. T o Adjust Pressures
Oxygen Pressure
If individual station regulators are used, connect an
OXWELD test gauge adaptor (Part No. 21X48) between
the oxygen hose and the torch. Set the delivery pressure on the oxygen regulator at 105 psi if using 50 ft. of
hose, or at 135 psi if using 75 ft. of hose. Open the torch
cutting oxygen valve and turn the pressure-adjusting
screw on the regulator until the test gauge shows a pressure of 45 lb. per sq. in. Note the exact pressure on the
regulator gauge. Then release the pressure-adjusting
screw of the regulator , release the torch cutting o xygen
valve, and remove the test gauge from the line. Read-
2
just the regulator (with the torch cutting oxygen valve
open) until it shows the pressure noted during the test
and then close the cutting oxygen valve.
Fuel Gas Pressure
Open the torch fuel gas valve and adjust the fuel gas
delivery pressure at the regulator to between 10 and 20
psig.
C.To Light the Torch
Open the preheat oxygen valve just enough to provide a
slight flow of preheat oxygen. Open the fuel gas valve
one turn. Light the gas at the nozzle with a friction lighter .
Adjust the flames with the preheat oxygen valve. Then
open the cutting oxygen valve. If the flames blow away
from the nozzle or blow away as soon as lit, close the
fuel gas valve slightly , or if operations are controlled from
a main line, reduce the fuel gas line pressure.
Tables I and II give operating data as well as other useful information that will be helpful in the normal use of
the C-59 torch. Cleaning drill sizes are specified as T ab le
I, and the oxygen and fuel gas flows for a range in operating pressure are given in Table II so as to give an indication of actual gas usage.
The cutting oxygen pressure should normally be set at
45 psi with the cutting oxygen v alve wide open so as to
obtain a reasonably wide scarfing path width. The fuel
gas pressure should be set at the high end of the range,
although at times the available pressure at the supply
station will be the controlling factor . When the torch pressures and torch valve adjustments (including the adjustment of the preheat oxygen compensator valve) are
properly set, the preheat flames will be stable and should
not blow off the end of the nozzle as the cutting oxygen
lever is fully depressed and then released. The high
velocity flames, pale in color (oxidizing), should be just
below the flow-off point when the cutting oxygen v alve is
closed.
D.T o Feed the Starting Rod
With the rod adjusted until the end almost touches the
preheat flames, press the torch cutting oxygen lever
about halfway down. This movement f eeds the rod, but
does not open the cutting oxygen valve. Hold the lever
at the halfway position until the rod is heated; then push
the lever all the way down to open the cutting oxygen
valve. During the latter half of the stroke, the rod remains stationary.
T o feed the rod independently of the cutting o xygen, limit
the movement of the valve lever to about half a stroke.
To operate the cutting oxygen valve independently of
the rod feed, confine the lever movement to the lower
half of the stroke - as would be desirable for fin burning.
The amount of rod fed at each stroke of the lever may
be regulated between 0 and a maximum of about 5/8
Nozzle
Size Part No.
1806 Series (Fuel Gas)
62 15X44
GAS PRESSURE & CONSUMPTION DA TA - 1806 SERIES, SIZE 62 (P/N 15X44)
T ABLE 1
NOZZLE INFORMA TION - 1806 SERIES
Scarfing
Path
Width in (mm)
thru 3-3/16"
2-1/4"
(57 - 81mm)
Holes
16
Preheat Cutting
1/16" 5/8"
T ABLE II
(Pressure measured at the torch inlet connection)
Cutting Oxygen
Inlet
Pressure
psig (BARS)
20 (1.38)
30 (2.07)
40 (2.76)
50 (3.45)
60 (4.14)
Hose Sizes: For oxygen, use "C" size hose (1/2" I.D.), P/N 2120399 (50-ft.).
For Fuel gas, "B" size hose (3/8" I.D.), P/N 2120404.
Flow
3
cfh (m
/hr)
4300 (121)
5600 (159)
7000 (198)
8300 (235)
9600 (272)
Natural Gas
Inlet
Pressure,
psig (BARS)
5 (0.35)
10 (0.69)
15 (1.04)
20 (1.38)
Flow
cfh (m
40 (1.13)
75 (2.12)
105 (2.97)
130 (3.68)
3
/hr)
Replacement PartsCleaning Drill SizePreheat
Wear Ring
Assembly
60Y92
Nozzle
Nut
37Z23
OIL OR GREASE IS EASILY IGNITED AND BURNS VIOLENTLY IN THE PRESENCE OF OXYGEN UNDER PRESSURE. HANDLE
OXYGEN APP ARATUS ONL Y WITH CLEAN HANDS OR GLO VES. NEVER USE OSYGEN A S A SUBSTITUTE FOR COMPRESSED AIR.
3
inch. To make this adjustment, increase or decrease
the lever movement as the lever arm acts against the
anvil within the rod feed body. Turning the rod-feed anvil locknut (71Z91) further down on anvil (77Z49) will
reduce the contact distance, thus less feed is obtained.
By unscrewing the nut to increase the anvil length, the
lever will work through a greater arc for longer feeds.
IMPORT ANT : Do not increase the an vil length to the
extent that the lever extension will not clear it, before the spring between the rod feed block and the
cap screw set solid.
E. To Shut Off
First close the torch fuel gas valve, then the torch oxygen valve.
F . Operating Precautions
Improper handling of the torch may cause the flame to
backfire — go out with a loud snap. This may be caused
by overheating the nozzle or by dirt on the nozzle seat.
Should the flame flash back — burn back inside the torch
— immediately close the oxygen v al ve . Then close the
fuel gas valve. After checking the apparatus for causes
of flashback indicated above, relight the torch in the usual
manner. If flashbacks occur repeatedly, the torch should
be sent ESAB Remanufacturing Center , 411 S. Ebenezer
Rd., Florence SC 29501 for a complete checkup.
III. MAINTENANCE INSTRUCTIONS
For all repairs other than those covered below , send
the apparatus to ESAB Remanufacturing Center , Florence, SC Improperly repaired apparatus is hazardous.
A. Torch
1. The Preheat-Oxygen Compensator Valve
Replacement of any of these parts will require readjustment of the compensator valve stem, as follows:
a. Turn the adjustable stem in (clockwise) as far as it
will go.
b. Set the oxygen and fuel gas pressures, and light
the torch in the usual manner.
c. Open the fuel gas valve wide, and adjust the pre-
heat oxygen valve until a high velocity pointed flame
is obtained.
d. Open the torch cutting oxygen val ve . The preheat
flames will become longer or blow off , indicating a
lack of preheat oxygen. Hold the cutting oxygen
valve open and adjust the compensator stem outward (counterclockwise), until the preheat flames
show a minimum of change when the cutting oxygen valve is opened and closed.
e. Any change in the cutting oxygen pressure at the
torch will require readjustment of the compensa-
tor stem. An increase in pressure will require an
inward (clockwise) adjustment, a decrease in pressure will require an outward (counter clockwise)
adjustment.
2. Floating Mixer
If the mixer becomes clogged, it may be removed for
cleaning as follows:
Unscrew the body plug between the two hose connections to the rear body. Remove the spring which
holds the mixer in place. Screw a standard No. 1032 machine screw , tw o inches or more in length, into
the rear of the mixer and pull out the mix er. To clean
the mixer , use a No. 35 drill (0.110 in. diameter) or a
soft brass or copper wire; other tools might enlarge
or bellmouth the orifice, hence they should not be
used. If the mixer is bent, or if its tip has been badly
nicked or marred it should be replaced by a new one.
Whenever the mixer is removed from the torch, the
"O" ring should be replaced with a new one. Apply a
light coat of soap film to the surface of the “O” ring
and then insert the mixer carefully (with a twisting motion) into the torch to avoid damage to the “O” ring.
3. To Reseat the Head
For reseating the head, use Tool No. 5230089 with
Leak Test Solution (998771) as lubricant. If the nozzle
nut threads in the head become fouled, they should
be chased with a 1-3/8 x 18 tap.
4. Fuel Gas or Preheat-Oxygen Valves
If leakage dev elops around the valve stems or if the y
turn too easily, tighten the packing nuts. If this does
not help, remove the valve stem assembly and replace the sealing washer. In the original factory assembly the sealing washer is a solid ring. The replacement sealing washer is split so that it can be
placed around the valve stem. Before inserting the
valve stem assemb ly into the v alve body, be sure the
sealing washer is snug about the valve stem so that
the washer will start properly into the packing recess.
To seal properly, the packing material should be
molded in place. To do this, the packing nut should
be tightened until it is difficult to turn the valve. If
possible set the torch aside for 3 or 4 hours (preferably o ver-night), then back off the packing nut slightly
until the proper friction is obtained for satisfactory valve
adjustment. Test valve for leakage around the nut
and stem when the friction has been adjusted to
the desired amount. If either torch valve does not
shut off tightly , remove the v alve stem assemb ly . Wipe
the seating portions of the valve stem and body with
a clean cloth. If the valve stem is damaged, the stem
assembly should be replaced. If the valve still leaks,
4
the valve body should be reseated at the ESAB Remanufacturing Center, Florence, SC or the nearest
ESAB distributor.
side of the center line for normal right or left-hand
operation. Always reverse the shims in pairs to assure proper alignment.
5. Cutting Oxygen Torch
If leakage develops through the cutting valve, replace
the valve seat. If leakage is around the valve stem,
replace the stem "O" ring seal. Proceed as follows to
replace these parts:
a. Remove cutting lever mounting nut (186W58), re-
taining screw (34Z91), and lever bushing (92Z66)
from lever (25Z56). Remove lever from torch.
b. Unscrew valve stem guide (637431) from the valve
body and carefully remove the cutting valve assembly.
c.Using soapy water, moisten the cutting va lv e stem
(48Z67) through the stem guide and slide the stem
out of the guide.
d.Remove the “O” ring seal (85W10). spring washer
(637430), “O” ring (86W70) and valve spring
(29Z37) from the valve stem. Discard the “O” rings.
e.Remove seat retaining screw (6124-4880), w asher
(94Z08), and valve seat (52Z89) from the bottom
of the valve stem. Discard the old valve seat.
f. Carefully clean and examine valve stem, spring,
guide, locknut and adjusting screw for damage and
excessive w ear. Replace parts as necessary.
g.Install new va lve seat(52Z89) (flat face in) and se-
cure in place with washer and screw.
h.Place new brass washer (94Z08) (countersink out)
against seat.
i. Install valve spring on top of upper valve shoulder,
and slide washer on top of the spring.
j. Apply a light coat of DuPont Krytox 240 (73585064)
on the new “O” ring seals (85W10) and (86W70)
slide the “O” rings into place.
k. Carefully slide the stem guide on the valve stem,
over the spring washer and “O” ring (85W10).
l. Insert the valve assembly in the torch valve body
and tighten the valve guide until it seats firmly.
m.Install the cutting valve lever on the torch and se-
cure with the lever bushing, retaining screw and
nut.
B.Starting Rod Feeder
1. Off-Center Adjustment
A pair of offset shims inserted between the mounting
bracket and the rod feed body locate the center line
of the starting rod approximately 1/4 in. off from the
nozzle center line. By offsetting the rod, the full benefit of four to six preheat ports is obtained instead of
two, as would be the case if the rod were fed through
the nozzle center line.
2. Off-the-Nozzle Adjustment
The rod feed body can be adjusted up or down for
varying the distance between the nozzle face and the
starting rod. An eccentric bolt (34Z90), bushing
(78Z96), and holding bolt (6164-1028) are provided
for this adjustment. The eccentric bolt head is turned
(with a wrench) and the eccentric bushing at the same
time. After the proper adjustment is obtained, make
sure that the bolt head and bushing engage the shims
and are against the sides of the mounting bracket
before tightening the eccentric cap nut. Then tighten
the holding bolt.
3. To Adjust the Anvil Locknut
Lift the stop nut (71Z91) clear of the broached hole
in which it is located, and turn it for proper adjustment. (See Section II-D in Operating Instructions.)
4. T o Replace Feed Block, Spring, and Guide Block
(Refer to View “A”)
To make these replacements, first remove the rod
feed bottom cover (31Z76) by unscrewing the guide
screw (35Z80). The remove the guide block (39Z68)
by unscrewing the attaching screw (34Z57) with a
socket wrench. Examine all parts for wear or distortion, and replace where needed. P arts most frequently
requiring replacement will be feed block spring
(29Z23) and the spring (28Z82) and balls (90A13) in
guide block (39Z68). If guide block shows wear, it
should also be replaced.
Replacement of guide block spring and balls can be
accomplished by first prying the spring (28Z82) out
of the confining groove in the guide block. The two
balls should fall free of the guide block. Install two
new balls and new spring. Make sure the hole in the
spring is centered over the countersink recess in the
block groove. Carefully insert the guide block in rod
feed body recess, with center bore approach taper
facing out, and the hole in the spring and countersink
recess in the guide block in line with the screw hole
of the rod feed body. Replace attaching screw
(34Z57), making sure the point of screw enters countersink recess in block for proper engagement.
Tighten attaching screw securely, but do not overtighten.
5. Rod Feed Mechanism Replacements
To replace parts of the rod feed mechanism, the rod
feed body must be removed from the rod feed mounting bracket. Remove the cutting oxygen valve lever
screw (34Z91) and the rod feed clevis pin (93Z42).
The shims may be rev ersed to shift the body to either
5
Slide the cutting oxygen lever from the head of the
cutting valve stem. Attach a length of string to the
rod feed sleeve for guiding purposes and remove the
rod feed eccentric bolt (34Z90) and bushing (78Z96).
Also remove the remaining rod feed body holding bolt
(6164-1028). Remo val of both bolts will free the cov er
plate and shims. Pull the rod feed body toward the
torch head until the lever (78Z93) and pull rod clevis
(68Z64) clears the mounting bracket (50Y59). The
pull rod clevis and lever are joined together by an
expansion pin (85W29). To remove the lever from
the pull rod clevis, drive out the e xpansion pin. Ho wev er, to avoid distortion of cle vis, the section surrounding the pin must be supported from the bottom. Removal of the expansion pin will free the rod f eed body
by snapping out the anvil spring (29Z18) and lifting
out the assembly. To remove the lev er from the lev er
guide block (78Z99), back up the block from the bottom and drive out the rod feed lever pin (85W61).
T o replace the rod f eed clevis (68Z64), pull rod spring
(29Z34), or pull rod (78Z95), move the pull rod toward the torch head until the offset in the pull rod
strikes the mounting bracket (50Y59). Lift the pull
rod up slightly on the clevis end and unscrew the
clevis. To remove the pull rod, push the rod toward
the rear body of the torch guiding the rod with the
string attached to the end feed sleeve.
Remove the pull rod sleeve. When the pull rod clevis
end clears the mounting bracket, the rod can be pulled
free of the torch by bending the offset end past the
mounting bracket. Reassemble the pull rod to the
torch in the rev erse order . Inserting the pull rod may
cause it to bend. Howe ver , the bowed sections of the
rod (between the tube support brackets) can be
straightened out after the rod feed has been assembled to the torch.
The 42 and 48 inch long torches are made up from the
basic 36 inch long torch. This is accomplished by
coupling the correct length extensions to the oxygen
and mixer tubes to make up the extra length. Thus
all parts shown in C-59 (36 inch) parts picture are
common to the 42 and 48 inch torches. The sketch
below shows the coupling and extensions used on
the 42 and 48 inch torches.
C-59 TORCHES
Part No. Description
02X67 36 in. Long Torch with Rod Feed Mechanism
02X68 48 in. Long Torch with Rod Feed Mechanism
02X91 42 in. Long Torch with Rod Feed Mechanism
ACCESSORIES
Part No. Description
21X48 "C"-size 200 lb. Gauge Adaptor Assembly
33Y64 C-59 Compensator Valve for conversion (In
cudes 85W10, 48Z41 and 83Z26)
163Z25 OXWELD 54 Anti-Friction Compound, for
Valve Threads
7358-5064 DuPont Krytox 240 Anti-Friction Compound,
for "O" Rings
HARDWARE
Part No. Description
6124-4880 8-32 x 1/2 in. Long Flat Socket Head Screw,
Steel
6133-2996 6-32 x 5/16 in. Long Oval Hd. Self-Tapping
Screw, Parker Kalon Type “F”
6164-1028 1/4-28 x 1-5/16 in. Long Hex. Head
Capscrew, Stainless Steel
6260-0001 1/32 x 1/2 in. Long Cotter Pin, Stainless
Steel
6430-4075 1/4 in. Standard SAE Plain Washer, Steel
C. Replacement Parts
OXYGEN TUBE EXTENSION -
COUPLING - 150Z56
PULL ROD -
MIXER TUBE EXTENSION -
147Z13 (02X91)
147Z15 (02X68)
Fig. 1 - C-59 Scarfing T orch - 02X68- 48 in. long
35-1/8"
(02X91)
39-1/4" (02X68)
BRACKET - 71Z94
BRACKET - 151ZO6
MIXER TUBE AND EXTENSION MUST BOTTOM IN COUPLING
150Z69 (02X91)
82Z05 (02X68)
147Z14 (02X91)
147Z16 (02X68)
02X91- 42 in. long
6
"C"
SEE VIEW "D"
27 1/4"
"A"
"C"
BRACKET - 71Z94
"A"
SEE VIEW "E"
(4) SCREW - 6133-2996
HANDLE - 24Y28
LEVER - 25Z56
OXYGEN TUBE - 27Z45
BODY - 80Z10
SILVER SOLDER
(Includes)
0-RING - 84W85
MIXER NOZZLE ASS'Y. - 01Y43
TUBE MUST BOTTOM
(Includes)
MIXER THROAT - 17Z75
MIXER TUBE ASS'Y. - 16Y87
SILVER SOLDER
SCREW - 6164-1028
WASHER - 6430-4075
BOLT - 34Z90
(2) nut - 186W59
BRACKET - 50Y59
SILVER SOLDER
ASSEMBLING
PEEN TUBE BEFORE
BOTT OM TUBE AT THIS END
7
SLEEVE
1 3/8-18
HEAD - 83Z97
(Includes Sleeve - 92Z67)
27Z88
STOP - 68Z48
BUSHING
78Z96
NOZZLE NUT- 37Z23
PLATE - 78Z92
(2) SHIM - 78Z94
SEE VIEW "A"
SLEEVE - 92Z67
(Included in Head - 83Z97)
Fig. 2A - C-59 Scarfing Torch - 02X67 (36-in. Long)
Note: Parts for the cutting lever and arm assembly used on the Series 5 torch are not interchangeable with those used on Series 4. The series 4 can easily
be converted to accept these parts by enlarging the hole in the body lug (to which the lever is attached) with a 7/32 in. diameter drill.
#5 - 40
78Z95
PULL ROD
68Z63
RETAINER
LOCK - 78Z90
SPRING -
29Z18
SPRING -
29Z34
LOCKNUT - 71Z91
ANVIL - 77Z49
(2) BALL - 90A13
SPRING -
28Z82
BLOCK - 39Z68
SCREW - 34Z57
COVER - 31Z76
PLUG
35Z91
"O" RING - 96W97
28Z91
SPRING
GAS TIGHT SEAL
5/8 - 25
VIEW "D"
CLEVIS - 68Z64
3/8 - 28
"O" RING - 85W10
PIN - 85W29
PIN - 85W61
LEVER - 78Z93
BLOCK - 78Z99
BODY - 20Y75
BLOCK - 51Z53
SCREW - 35Z80
SPRING -
29Z23
VIEW "E"
BALL - 53A61
#10-32
SPRING - 28Z92
7/16 - 20
SCREW -
VIEW "A"
34Z91
"B"
BUSHING -
92Z66
NUT - 186W58
BUSHING -
2222859
10Z82
OXYGEN
CONNECTION
7/8 - 14
"O" RING - 84W85
(Included In Mixer
Nozzle - 01Y43)
SECTION "C" - "C"
CLEVIS PIN - 93Z42
SNAP-RING - 202-8372
SLEEVE - 77Z46
"B"
FUEL
9/16 -
18 (L.H.)
SILVER SOLDER
999082
CONNECTION
Fig. 2B - C-59 Scarfing Torch - 0X67 (36-in. Long)
STEM - 48Z41
LEVER SCREW - 34Z91
NUT
186W58
BODY - 83Z26
SECTION "A" - "A"
92Z66
BSHING
2222859
F-6640-Y 05 / 2009 Printed in U.S.A.
BUSHING
SPRING - 29Z37
GUIDE - 637431
NUT - 136Z18
ADJUSTING SCREW - 134Z0-6
"O" RING - 86W70
PLATE - 637430
"O" RING - 85W10
"O" RING - 86W70
STEM - 48Z67
3/4 - 20
SCREW - 6124-4880
GAS TIGHT SEAT
SEAT - 52Z89
(2) GAS TIGHT
SEAT
WASHER - 94Z08
(2) STEM ASSEMBLY - 54A87
APPLY ANTI FRICTION COMPOUND
PART NO. 163Z25
SECTION "B" - "B"
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