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. The same information appears in the “Oxy-Acetylene Handbook” which may be purchased from any ESAB Distributor. Do NOT permit untrained persons to inst all, 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.
F-805-S
May , 2009
The cutting torches covered by these instructions are listed by third parties only when using parts manufactured
by ESAB Welding & Cutting Products to the specifications on file with third party listed, and when they are used in
the gas service for which they are designed and listed. The use of other parts that cause damage or failure to the
equipment will void the manufacturer’s warranty.
OPERA TING INSTRUCTIONS
3. Attach nozzle to torch head, and tighten connection
nut with a wrench.
4. Check throttle valve packing nuts for tightness.
The C-66 can be used with any fuel gas EXCEPT
acetylene. Use of acetylene can cause a flashback
which can cause serious burns and damage the
torch.
Be sure gas flow is sufficient for nozzle size.
Adjust regulators for proper psig pressures.
Adjust throttle valves properly .
Keep torch in good repair.
DO NOT throttle back gases to use large nozzle on
thin material.
ADJUSTING GAS PRESSURES
Fuel Gas: If fuel gas is supplied from a station outlet
without a regulator , merely open the station valve. If fuel
gas is being supplied through a station or cylinder regulator, open the fuel gas valve on the torch, turn in the
pressure-adjusting screw on the regulator until the regulator deliver-pressure gauge indicates the desired pressure (see chart on page 4). Then immediately close the
fuel gas valve.
Oxygen: Open the cutting oxygen valve by depressing
its valve lever fully . Turn in the pressure-adjusting screw
CONNECTING
1. Attach regulator to the oxygen cylinder or station
valve; attach fuel gas regulator to cylinder or station
valve unless fuel gas is to be supplied through a
hydraulic or check valve from a pipeline at desired
pressure.
2. Attach oxygen hose to the oxygen regulator; attach
fuel gas hose to the fuel gas station valve or regula-
until the regulator delivery-pressure gauge registers the
desired pressure (see cutting chart on page 4). Then
release the cutting oxygen lever .
NOTE: When gaugeless regulators are used, do not
open torch valves. Merely turn in the pressureadjusting screws to the desired pressures as
indicated on the scales of the regulator caps.
tor. Attach both hoses to torch. Tighten all connections nuts with a wrench.
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/
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
TESTING FOR LEAKS
Every cutting outfit should be thoroughly tested for leaks
after it is first hooked up, and at regular intervals thereafter. Af ter all connections have been made, make sure
all valves on the torch handle are closed. Then adjust
regulators, or open station valves, to apply 60 psi oxygen pressure and up to 10 psi fuel gas pressure on the
hoses.
Using Leak Test Solution (P/N 998771), or any other
solution suitable for oxygen service, check for leaks at
the cylinder valves, the cylinder-to-regulator connections,
the regulator-to-hose connections, and the hose-to-torch
connections. If bubbling at any point indicates leakage,
tighten the connection. If this does not stop the leakage,
close the appropriate cylinder valve, open the corresponding torch valve to remove all pressure from the
line, and finally release the regulator pressure-adjusting
screw by turning it counterclockwise; then break the
leaky connection, wipe metal seating surfaces with a
clean dry cloth, and examine them for nicks and
scratches. Remake the connection(s) and retest. Do not
try to light the torch until you are satisfied that all connections are gas-tight.
After lighting the torch and adjusting the flames, use leak
test solution to check for leakage at all torch valves and
at the nozzle nut.
LIGHTING AND FLAME ADJUSTMENT
With Low-Pressure Natural Gas (Torch equipped
with injector 01Y56, 01Y57, or 01Y61)
1. Open the preheat oxygen valve wide (two turns).
2. Open the fuel gas valve about one turn and light the
gas at the nozzle with a friction lighter. DO NOT USE
A MATCH. Use of a match can seriously burn your
hand.
3. Then open the cutting oxygen valve and adjust
flames with the fuel gas valve. Flames are hottest
when inner cones are shortest. Do not throttle the
preheat oxygen valve unless flames blow off, or burn
away from the nozzle.
With Medium-Pressure Natural Gas (T orch equipped
with injector 01Y58):
1. Open the preheat oxygen valve one turn or less.
2. Open the fuel gas valve wide (two turns) and light
the gas at the nozzle with a friction lighter. DO NOT
USE A MATCH. Use of a match can seriously burn
your hand.
3. Then open the cutting oxygen valve and adjust
flames with preheat oxygen valve. Flames are hottest when inner cones are shortest. Do not throttle
the fuel gas valve unless flames blow off or burn
away from end of nozzle.
NOTE: Because of the several factors involved (injec-
tor, nozzle size, gas pressures) the adjustment
procedures given above do not apply in all situations. However, this is a good rule-of-thumb if
you want preheat flames at maximum effectiveness. You should usually be able to keep one
preheat valve wide open if regulator oxygen
pressure has been set correctly for the nozzle
in use.
SHUTTING OFF
Release the cutting oxygen valve lever. Then close the
fuel gas valve, and finally the preheat oxygen valve.
If operations are to be stopped for half-hour or more, all
pressure should be released from the torch, hoses, and
regulators by doing the following:
1. Close each cylinder or station valve.
2. Open torch valves.
3. After relieving the gases, back out the pressure-adjusting screw of each regulator and close the torch
valves.
OPERA TING PRECAUTIONS
Backfire: Improper operation of the torch may cause
the flames to go out with a loud “pop”. Such a backfire
may be caused by contact of nozzle with the work, by
spatter from the work, by the use of incorrect gas pressures, or by leakage at the cutting nozzle seats due to
dirt or nicks on seats or to a loose nozzle nut.
Flashback: Under certain circumstances, the flame may
not “pop” out (backfire) but instead burn back inside the
torch with a shrill hissing or squeal. This is called a “flashback”. A flashback should never occur if (1) the equipment is in good condition; (2) preheat ports on cutting
nozzles or welding tips are cleaned frequently; (3) operating pressures are correct; and (4) throttle valves are
adjusted properly . Should a flashback occur, IMMEDIA TEL Y shut off the torch. Allow it to cool off for at least a
minute. Then check your nozzle or tip, gas pressure,
readjust regulators if necessary , and relight the torch. If
flashback recurs, send the torch to your distributor or to
ESAB Remanufacturing Center, 41 1 S. Ebenezer Road,
Florence, SC 29501 for repair .
3
OPERA TING DA T A, CLEANING DATA, AND P ART NUMBERS
GENERAL NOTES:
1. Pressures given are measured at the torch; therefore, pressure drop through hose should be considered when setting pressure at the regulator. Generally, 1/4-in. hoses up to 25-f t. long are adequate for
cutting steel up to 4-in. thick. If longer hoses are
required and if cutting thicker steel, 3/8-in. hoses
Fuel Gas Two-Piece Cutting Nozzles
should be used. If using low-pressure fuel gas, 3/8in. fuel gas hose should be used for all cutting operations.
2. The table shows average values based on typical
conditions. The type and quality of steel, its surface
condition, the purity of the oxygen, etc. will always
have a bearing on the end results.
Nozzle(Internal)Nat. Gas FG-2FG-2Thicknesspsigft3/hrDrill Size
Use where high preheat intensity is desired.
Consumption of MAPP or propane is approximately the same as FG-2.
* Use soft-bristled brush (750F99) to clean preheat slots of internal nozzles.
Heavy-duty sleeve (14Z96) available for use in place of 14Z77 sleeve.
C-66 INJECTORS FOR NA TURAL GAS*
P/N 01Y56 - Low Pressure, Medium Capacity (LPMC) - For natural
gas at any supply pressure down to 0.5 psi. Max. preheat capacity:
95 cfh oxygen (adequate to cut 12-in. steel).
P/N 01Y57 - Low Pressure, High Capacity (LPHC) - For natural
gas at 2 psi or more. Max. preheat capacity: 180 cfh oxygen.
P/N 01Y58 - Medium Pressure, High Capacity (MPHC) - For natural gas at 3 psi or more. With nozzles smaller than size 12, 01Y56 is
preferred. Max. preheat capacity: 300 cfh oxygen.
P/N 01Y61 - Low Pressure, Medium Capacity (LLPMC) - For natural gas at pressures below 0.5 psi. Max. preheat capacity: 40 cfh
oxygen (adequate to cut 8-in. steel).
*When propane is used as fuel gas, use injector 01Y56 for cutting up to 12-in. steel. 01Y58 for heavier cuts.
4
MAINTENANCE INSTRUCTIONS
For all repairs other than those covered below, send the
apparatus to the nearest ESAB distributor or to ESAB
Remanufacturing Center, 411 S. Ebenezer Road, Florence, SC 29501. Improperly repaired apparatus is hazardous.
Preheat Valves: Leakage around either throttle valve
can usually be corrected by tightening packing nut
slightly. If this does not stop the leakage, replace the
valve assembly .
4. Remove the internal O-ring (85W10) from the guide
and insert a new O-ring. Replace the external Oring (86W70) if it shows distinct signs of wear.
5. Reassemble by placing retaining washer and spring
in guide, then placing stem through spring and Oring in guide.
6. Screw valve assembly into body . Before reassembling cutting lever, connect torch to oxygen source,
apply at least 60 psi pressure, and check for leakage through the valve, around the stem, and around
the guide.
7. Reassemble cutting lever to torch.
If either preheat valve fails to shut off completely, remove the valve assembly from the torch. With clean
cloth, wipe the ball in the end of the stem. Then reinsert
valve assembly and tighten it several times with maximum force. If this does not eliminate leakage, try a new
valve assembly . If then the valve does not shut off completely , send the torch to a repair station for reseating of
the body .
After installing a new throttle valve assembly , tighten the
packing nut until the valve can be turned only with great
difficulty , and set the unit aside, for three or four hours at
least, to set the packing. Then back off the p acking nut
until the valve turns readily .
Cutting Valve: If leakage develops around the cutting
valve stem or between the cutting valve guide and the
torch body, or if the cutting valve fails to shut off completely , proceed as follows:
1. Remove cutting valve lever by merely driving out
the fulcrum spiral-pin, using a drill or piece of rod (7/
32-in. dia. or smaller).
2. Unscrew cutting valve guide and lift out entire valve
assembly: guide (with external and internal O-rings)
valve stem, spring, and O-ring retaining washer .
3. Pull stem out of guide. Replace it with new part unless the molded rubber seat appears to be in excellent condition.
Injector: To remove the injector for inspection or replacement, first unscrew the injector chamber plug and
remove the injector spring. Then run a long No. 10—32
machine screw into the threads in the end of the injector and withdraw the injector by pulling on the screw .
Before reinstalling a previously-used injector, be sure
that the O-rings at each end of the injector assembly
are in good condition. Replace them if necessary . Also
be sure the injector chamber plug is fitted with an Oring in good condition (even in cases where the plug
carried no O-ring originally).
Cleaning Cutting Nozzles: Cutting nozzle orifices
should be cleaned by hand using OXWELD tip cleaners, whenever a flame distortion is noticed. Maintaining clean orifices is highly recommended for reducing
any incidence of flashbacks. If you do not have tip cleaners, twist drills of the correct sizes (see table on pg. 4)
may be used. Insert the drill carefully , and push it back
and forth. DO NOT TWIST THE DRILL.
To clean the preheat slots on internal nozzles, remove
the external sleeve and use a soft bristled brush
(750F99).
5
P ARTS INFORMA TION
All parts which can be replaced without breaking soldered or brazed joints are illustrated below . When ordering parts,
please give both part number and description (including size, where appropriate). Parts may be ordered from your
ESAB welding equipment distributor or from ESAB Welding & Cutting Products, Customer Service Department,
Florence, SC.
ASSEM.
(2) 54A87
THROTTLE V ALVE
PLUG
134Z55
GUIDE - 638243
“O”RING - 86W70
“O”RING - 85W10
PIN
SPRING - 29Z97
WASHER - 638241
62399001
50Z38
THUMBPIECE
#52 (.0635) DRILL
DRILL AT ASSEMBLY
STEM - 638891
51Z31
INSERT
50Z37
LATCH
PIN
6232-0009
638981
LEVER ASSEMBLY
86W85
“O”RING
86W04
“O”RING
40A39
SPRING
01Y58 (MPHC)
01Y56 (LPMC)
01Y57 (LPHC)
*INJECTOR ASSEM.
*See page 4 for detailed description on injectors.