ESAB C-59 Scarfing Torch Troubleshooting instruction

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 cus. 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 manufacturers 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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