ESAB Gas Tech Prest-O-Weld GT Medium-Duty Welding and Cutting Outfit Troubleshooting instruction
Page 1
INSTRUCTIONS for
WELDING AND CUTTING OUTFIT
F-15-105-A
May, 1996
Gas Tech
PREST-O-WELD
GT
MEDIUM-DUTY
P/N 21320
which includes
W-250 Welding Torch ......................................... P/N 21189
CW-250 Cutting Attachment ..............................P/N 21190
No. 1 1/2" 4202 Series Cutting Nozzle.............P/N 16K10
No. 6 Welding Head ...................................... P/N 2214380
If you desire to extend the range of this outfit, other welding heads (thin gauge to 1" thick steel) and cutting nozzle (1/16-in thick
steel) are available for attachment to the W-250 welding torch and CW-250 cutting attachment (see tables).
Table 1 - Specifications
W-250 Welding Torch
P/N 21189
Welding Range ............................................ Thin Gauge to 1-in.
Heating Range......................................... 2 to 70 cfh acetylene*
Length ............................................................................ 7-3/4-in.
Weight............................................................................. 1-1/4 lb
Torch-Hose Connections ............ Oxy-CGA-022 (9/16" - 18RH)
...........F.G. - CGA-023 (9/16" - 18LH)
* Equivalent to approximately 2,8000 to 102,000 Btu/Hr. Acetylene
** Equipment is available for other gases.
ACCESSORY: Flash Arrestor/Check Valve combination units: Matched Pair, P/N 20357; Oxygen, P/N 20373; Fuel Gas, P/N 20374.
Connects between torch and hose to prevent reverse flow of gases and stop flashbacks.
R-36-15-510 Acetylene Regulator .....................P/N 21184
R-36-75-540 Oxygen Regulator ......................... P/N 21185
CW-250 Cutting Attachment (90 deg. head)
P/N 21190
Cutting Range using acetylene ............................... 1/16 to 4-in.
Cutting Range using other fuel gases.................. 1/16 to 2-in.**
Length ................................................................................ 10 in.
Weight............................................................................ 1-1/2 lb.
Cutting Nozzles .......................................................4200 Series
F-15-105-A
Be sure this information reaches the operator.
Y ou can get extra copies through your supplier.
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.
The welding torch handle, cutting attachment and regulators covered by these instructions are listed by Underwriter’s Laboratories only when used in combination with welding tips, cutting nozzles and parts manufactured by ESAB Welding & Cutting
Products to the specifications on file with Underwriter’s Laboratories, Inc. and when they are used in the gas service for which
they are designed and listed. The use of other welding tips, nozzles and parts voids the manufacturer’s warranty.
For packing purposes, the pressure-adjusting screw of the regulator may be either turned in or packed separately. If installed in
regulator, back out screw (turn counterclockwise) until it turns freely. If packed separately, install the screw in the regulator cap
and turn it in (clockwise) only one or two turns.
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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.
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.
3. Refer to ANSI/ASC Standard Z49.1 listed below for specific
ventilation recommendations.
4. WARNING: This product, when used for welding or
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.
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.
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.
2
cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety Code §25249.5 et seq.)
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:
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:
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.
MEANING OF SYMBOLS - As used throughout
this manual: Means Attention! Be Alert! Your
safety is involved.
Means immediate hazards which, if not avoided,
will result in immediate, serious personal in-
jury or loss of life.
Means potential hazards which could result in
personal injury or loss of life.
Means hazards which could result in minor
personal injury.
SP-GA 10/98
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OPERA TING INSTRUCTIONS
CONNECTING
1. Attach regulators to the oxygen and fuel gas cylinders. Follow all instructions supplied with your regulators.
2. Attach oxygen and fuel gas hoses (see Note 1 in
Operating Data section on pg. 4 for recommended
hose sizes) to the regulators and to the torch handle
after making sure all metal seating surfaces are
clean. Tighten all connection nuts with a wrench.
3. Using Welding or Heating Head: Remove weld-
ing head connection nut from torch handle. Insert
welding head into handle using slight back and forth
twisting motion as you push. Slip connection nut over
the head and hand-tighten to handle.
Using Cutting Attachment: Set the welding head
connection nut aside and insert the cutting attachment to the torch handle in the same manner as the
welding head. Remove nozzle nut and insert cutting
nozzle into the cutting attachment head. Slip nut over
the nozzle and tighten with a wrench.
4. Check valve stem packing nuts for tightness.
ADJUSTING GAS PRESSURES
Fuel Gas: With oxygen valve closed, open the fuel gas
valve on the torch handle about one turn. Turn in the
pressure adjusting screw on the fuel gas regulator until
its delivery-pressure gauge indicates the desired pressure (refer to operating tables starting on page 4). Then
immediately close the torch fuel gas valve.
tainer), 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 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 connections, 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.
LIGHTING & FLAME ADJUSTMENT
CAUTION: Use friction lighter for lighting torch. Do NOT
use a match. Use of a match can seriously
burn your hand.
Welding or Heating Head (Acetylene)
1. Open fuel gas valve about 1/2 turn and light the gas
at the tip.
2. Slowly close the fuel gas valve until the yellow flame
just starts to throw off smoke.
3. Open oxygen valve slowly until you have a neutral
flame.
4. If harsher or softer flame is desired, readjust the
two valves.
NOTE: When operating with a very soft flame, the weld-
ing head will tend to heat up and transfer some
of this heat back to the torch handle. This may
create some discomfort to the operator.
Oxygen, Using Welding or Heating Head: Open the
torch oxygen valve at least 1-1/2 turns. Adjust oxygen
pressure at the regulator to the desired pressures (refer
to T able 2, 3, or 4) and then close the torch oxygen valve.
Oxygen, Using Cutting Attachment: Open the torch
oxygen valve WIDE and leave the preheat oxygen valve
on the cutting attachment closed. Depress the cutting
oxygen valve lever on the cutting attachment. Adjust the
oxygen pressure at the regulator to the desired pressure (refer to Table 4 or 5). Shut off the oxygen flow by
releasing the cutting oxygen valve lever only .
TESTING FOR LEAKS
Every welding and cutting outfit should be thoroughly
tested for leaks after it is first hooked up, and at regular
intervals thereafter. After all connections have been
made, make sure both valves on the torch handle are
closed. Then turn in the regulator pressure-adjusting
screws clockwise until the oxygen delivery-pressure
gauge registers 50 psi, the fuel gas delivery-pressure
gauge registers 10 psi. Using Leak Test Solution suitable for oxygen service, such as P/N 998771 (8 oz. con-
Cutting Attachment (Acetylene)
1. Open the acetylene valve on the torch handle about
1/2 turn, and light the gas at the nozzle.
2. Slowly close the acetylene throttle valve until the
yellow flame just starts to throw off black smoke.
3. Slowly open preheat oxygen valve on cutting attachment until neutral flames are obtained.
4. Finally, open the cutting oxygen valve by depressing lever and readjust the neutral flames by turning
preheat oxygen valve.
The flame now has the proper strength for any cutting
job. With this flame, acetylene is being consumed economically and the cutting attachment will be operating
at best resistance to flashback. If greater preheat flame
temperature is desired for faster starts or piercing, open
the cutting oxygen valve and adjust the preheat oxygen
valve until the flame inner cones shorten about 10 percent and become sharply pointed.
Cutting Att achment (Fuel Gases except Acetylene)
1. Crack the fuel gas valve and light the gas at the
nozzle.
2. Open the fuel gas valve until flame starts to leave
3
the end of the nozzle.
Page 4
3. Slowly open preheat oxygen valve on cutting attachment until flame stabilizes.
4. Depress lever to open cutting oxygen valve and then
adjust preheat oxygen valve until preheat flames are
at their shortest length.
5. If larger or smaller preheat flames are desired, depress cutting oxygen valve lever and alternately readjust fuel gas and preheat oxygen valve to obtain
the final flame setting.
SHUTTING OFF
Close the fuel gas valve first, then the oxygen valve
whether you are using a welding head or cutting attachment. However, if the cutting att achment is to be relighted
within a half-hour, you may close the preheat oxygen
valve on the attachment instead of the oxygen valve on
the torch handle.
If operations are to be stopped for a half-hour or more,
you should release all pressure from regulators. To do
this, first close both cylinder valves. Then open the torch
valves. Finally, back out the regulator pressure-adjusting screws until they turn freely .
1. Pressures given in T ables 2 through 8 are measured
at the regulator using 25-ft. long hoses (1/4-in. I.D.
up through size No. 30 welding/heating head or for
cutting up to 3-in. thick steel; 3/8-in. I.D. for larger
heads or cutting nozzles). If longer hoses re required,
only 3/8-in. I.D. hoses should be used and pressure
drop between regulator and torch should be considered. Use test gauge adaptors to check for proper
pressure at torch if using long hose length, or if there
are doubts about the adequacy of gas flows. Do NOT
use hose line check valves when operating No. 55
and larger heads.
2. Head size number on each welding and heating head
indicates the rated acetylene flow capacity in cubic
feet/hour (cfh). For example, No. 55A requires about
55 cfh of acetylene at the given operating pressures.
However, on heating heads designed for other fuel
gases, the size indicates the approximate equivalent heating capacity in terms of acetylene flow . For
example, note from Table 3 that No. 70A and 70FG
provide the same average heating output (102,000
Btu/Hr.) but No 70FG head really requires about 43
cfh of FG-2, 40cfh of propane, or 103cfh of natural
gas.
OPERA TING PRECAUTIONS
Backfire: Improper operation of the torch or cutting at-
tachment may cause the flame to go out with a loud
‘pop’. (If you are welding, the flame will often reignite
instantly). Such a backfire may be caused by contact of
tip or nozzle with the work, by spatter from the work, by
the use of incorrect gas pressure, or by leakage at the
cutting nozzle seats due to dirt or nicks on seats or to a
loose nozzle nut. Af ter a backfire, you can normally relight the flames immediately. However, if backfires occur repeatedly , shut off the torch. Check the ‘O’-ring seals
between the welding head or cutting attachment and the
handle, and the nozzle seats (if cutting). Readjust operating pressure and relight.
Flashback: Under certain exceptional circumstances,
the flame may not ‘pop’ out (backfire) but instead burn
back inside the torch with 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;
and (3) operating pressures are correct. Should a flashback occur, IMMEDIATEL Y shut off the torch. Allow it to
cool off for at least a minute. Then check your nozzle or
tip, gas pressures, readjust regulators if necessary , and
relight the torch. If flashback recurs, send the torch
handle and welding head or cutting attachment to your
distributor for repair.
IMPORT ANT OPERATING NOTES
For consumption purposes, the following are the
oxygen/fuel gas ratios normally required for welding and heating:
1.1 to 1.5 cfh oxygen/1.0 cfh acetylene
3.2 to 3.6 cfh oxygen/1.0 cfh FG-2
3.5 to 4.5 cfh oxygen/1.0 cfh propane
1.7 to 2.0 cfh oxygen/1.0 cfh natural gas
3. Correct pressure and flow must be maintained for
proper operation of a welding or heating head. If a
tip is “starved” due to insufficient flow of fuel gas,
the tip may overheat and cause backfire or flashback.
An acetylene or a liquefied fuel gas (LFG) cylinder
has a limited capacity for delivering fuel to the tip;
therefore, it is extremely important to manifold 2 or
more cylinders when operating larger heads to assure adequate supply of fuel gas to the tip. The rate
of withdrawal depends on type of fuel gas cylinder
size the contents remaining, and the outside temperature. T abulated below is the number of the more
commonly used cylinders recommended for
manifolding when using larger heads. If using other
cylinders or gases, check with your fuel gas supplier for recommended withdrawal rate information.
4. The tables show average values based on typical
conditions. The type and quality of steel, its surface
condition, and purity of oxygen, etc., will always have
a bearing on the end results.
4
Page 5
Head Flowrate, Min. No. of Cylinders Required*
Size cfh WKCyl (300cf) WTLCyl. (390cf)
55 55 2 1
70 70 2 2
*Based on that max. hourly flowrate should not exceed 1/7 of cylinder capacity
at 70° F. Example 1/7 (300 of WK. cyl.) = 43 cfh max.
Table 2 - W-250 Acetylene Welding Heads (Single-Flame)
Head Min. No. of Min. No. of
FG-2 (104 lb. cyl.) Propane (100 lb. cyl.)
Size Flowrate Cyl. Req’d* Flowrate Cyl. Req’d**
70 43 1 40 1
*Based on max. continuous withdrawal rate of 110cfh for 104lb. cylinder, 1/2
full @ 70° F .
**Based on max. continuous withdrawal rate of 65cfh for 100lb. cylinder, 1/2
full @ 70° F .
Withdrawal rate will increase with wind velocity and intermittant usage; reduce
with lower temperature.
Complete Steel Cleaning
Head Assembly Thickness Mixer Tip Drill
Sizeu Part No. inches Oxy. Acet. Tip Throat Mixer Extension Size
Pressure, psig Replacement Parts (See Fig. 2) Accessory Tip
2A 2214378 32 - 25 ga. 639683 621K74 42C26 — 72
4A 2214379 25ga. - 1/32 5-8 5-8 639684 621K74 622K67 — 64
6A 2214380 1/32 -1/16 639685 — 639892 — 62
15A 2214381 1/16 - 1/4 639687 621K75 622K69 — 53
30A 2214381 1/4 - 3/8 6925K58 621K76 622K70 — 45
55A 42C49 3/8 - 5/8 7 - 9 7 - 9 998060 21K77 622K71 19X42 (12") 33
70A 42C50 5/8 - 1 998061 21K78 622K72 19X42 (12") 30
u Size indicates approx. acetylene flow rate in cu. ft./hr. (cfh) at normal operating pressure.
See Important operating Notes above.
Table 3 - W-250 Standard Multiflame Heating Heads
Complete Pressure Avg. Replacement Parts Accessory Tip
Head Assembly psig Heat (See Fig. 2) Tip Cleaning
SizeK Part No. Oxy. Gas. Flames Btu/hr. Tip Throat Mixer Plated) Extension Size
For Oxy-Acetylene Use
55A 42C51 7-9 7-9 7 81,000 998070 21K77 622K71 — 19X42 (12") 59
70A 42C52 7-9 7-9 7 102,000 998071 21K78 622K72 998046 19X42 (12") 56
For Oxy-Fuel Gas Use - FG-2, propane, natural gas, etc.
70FG 42C53 16-20 7-10 7 102,000 998078 21K78 622K72 998037 19X42 (12") 54
Fuel No. of Output Mixer (Chrome- Tip Drill
u See Important Operating Notes on pg. 4
Table 3A - W-250 Rosebud Style Multiflame Heating Heads
Complete Pressure, Avg. Tip Extension
Head Assembly psig Heat Replacement Parts (See Fig. 2) (Accessory) Tip
Fuel No. of Output Tip Mixer Cleaning
SizeK Part No. Oxy. Gas Flames Btu./hr. Assy. Stem Throat Mixer Length P/N Drill Size
For Oxy-Acetylene Use
55 O-A 21310 7-9 7-9 9 81,000 998797 998792 21K77 622K71 12-in. 19Z42 61
70 O-A 21311 7-9 7-9 9 103,000 998798 998792 21K78 622K72 12-in. 19X42 57
For Oxy-Fuel Gas Use FG-2, propane, natural gas, etc.
70 O-FG 21312 13-25 6-13 8 104,000 999224 998792 21K72 622K72 12-in. 19X42 49
u See Important Operating Notes on pg. 4.
5
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Table 4 - 4202 Series Acetylene Cutting Nozzles
Nozzle Steel Pressure, psig Gas Consumption Cleaning
Size Part No. in. mm. Oxygen Acetylene Oxygen Acetylene Preheat Cutting
1/8" 638869 1/8 3 30-40 5 31 - 34 8 - 9 73 76
1/4" 16K08 1/4 6 25-30 5 42 - 45 8 - 10 73 68
1/2" 16K09 1/2 13 30-40 5 70 - 75 10 - 12 73 60
1-1/2" 16K10 3/4 19 25-30 5 95 - 100 12 - 14 69 52
4" 16K11 2 50 40-45 5 195 - 200 18 - 20 68 50
Thickness ft3/hr Drill Size
1 25 35-40 6 120 - 125 14 - 16
1-1/2 38 50-55 7 165 - 170 16 - 18
3 75 45-60 6 230 - 235 20 - 22
Table 5 - 4217 Series Fuel Gas Two-Piece Cutting Nozzles
Nozzle Sleeve Steel Pressure, p sig Gas Consumption ft3/hr. Cleaning
Nozzle (Internal) (External) Thickness Fuel Gas Fuel Gas Drill Size
Size P/N P/N in. mm. Oxygen FG-2 Propane Nat. Gas Oxygen FG-2 Propane Nat. Gas Cuttingl
1/4" 19485 19518 1/4" 6 30 4 6 7 70 8 12 30 68
1/2" 19486 19518 1/2" 13 35 4 7 8 120 9 14 32 60
1" 19487 19518 1 25 40 4 8 9 180 10 15 35 53
2" 19488 19518 2" 50 45 5 9 10 250 11 16 40 50
4" 19489 19519 4" 100 40 4 8 10 370 12 18 45 43
l Use soft-bristled brush (750F99) to clean preheat slots of internal nozzles.
NOTE: Do NOT use with Acetylene.
MAINTENANCE INSTRUCTIONS
For all repairs other than those covered below , send the
apparatus to your ESAB distributor or to ESAB
assembly. Then tilt the attachment and let the valve
spring drop out in your hand.
Remanufacturing Center, 411 S. Ebenezer Road, Florence, SC 29501. Improperly repaired apparatus is hazardous.
Now pull the lock screw off the valve stem and remove
seat and retainer from the stem. Examine the stem carefully. If either the seating surface or the cylindrical sec-
T orch Handle and Cutting Attachment Needle V alves
— Leakage around valve stem can almost always be
corrected by tightening the packing nut slightly. If necessary , replace the complete needle valve assembly as
directed below. If a valve will not shut off completely,
loosen the packing nut and unscrew the valve stem assembly from the body . Wipe the stainless steel ball seat
on the valve stem, and the seating surface in the body ,
with a clean cloth. Then reinstall the valve, retighten the
packing nut, and operate the valve several times, clos-
tion that runs in the valve screw is marred, replace the
stem with a new part. Always replace the seat with a
new part. Replace the small ‘O’-ring in the lock screw
with a new part if there has been leakage around the
valve stem. Inspect the large ‘O’-ring and replace it if it
is not in excellent condition. Place new seat on stem,
slide on the retainer, and insert stem in lock screw (be
sure the lock screw has both ‘O’-rings in position). Finally , slide valve spring into body , insert valve assembly ,
and tighten lock screw.
ing it with maximum force. If this does not end the leakage, install a new valve stem assembly. When you do
so, tighten the packing nut until you find it extremely difficult to turn the valve wheel. Set the unit aside for a few
hours to set the packing. Then loosen the packing nut
until the valve stem turns easily .
Cutting Attachment Mixer — To remove the mixer for
cleaning or replacement, back off locknut (56K09) until
it reaches the end of the threads on the adaptor (05K38).
Continue turning it with a wrench to unscrew the adaptor from the attachment body. Then remove the mixer
by grasping the end of the mixer carefully with a pair of
Cutting Valve—If leakage is detected around the cutting valve stem, or if the valve does not shut off completely when cutting oxygen valve lever is released, unscrew the lock screw (see Fig. 1) with a spanner wrench.
When the thread is fully disengaged, lift out the valve
pliers and pull it out. Clean mixer center orifice with a
No. 55 cleaning drill and the cross-drillings with a No. 66
drill or soak the mixer overnight in a solution of Nozzle
Cleaning Compound (P/N 761F00), rinse, and blow dry
with clean air.
6
Page 7
Inspect all ‘O’-rings and replace them if they are not in
good condition. Reassemble in reverse order, and tighten
locknut against body securely .
Welding Heads and Cutting Nozzles — Welding heads
and cutting nozzle orifices should be cleaned by hand,
using 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
T ables) may be used. Insert the drill carefully, and push
it back and forth. DO NOT TWIST THE DRILL.
If a welding tip requires replacement, secure the front
end of the mixer throat in a vise and unscrew the tip.
Before installing a new tip, be sure it matches the mixer
throat in size (both parts are size-stamped). Always
tighten the new tip as much as you can without bending
it.
Regulators — Each regulator is equipped with a porous metal inlet filter , P/N 71Z33, pressed into the regulator inlet nipple. No regulator should be connected to a
cylinder or station valve unless it contains this filter . You
can replace the filter if you have reason to do so. To
remove a filter, insert a No. 1 ‘EZY-OUT’ or a No. 6 wood
screw (about 2-in. long) into the filter and pull it out. Press
the new filter into the nipple with a 1/4-in. round metal
rod.
Regulators in need of repair should be returned to your
distributor or to ESAB Remanufacturing Center, 411 S.
Ebenezer Road, Florence, SC 29501.
If you have your own properly-equipped and staffed repair facility, repair parts information of this regulator is
available on request to your distributor. Request Form
15-301, which covers the regulators packed with this
outfit.
T o clean a welding head mixer , unscrew it from the mixer
throat soak it overnight in a solution of Nozzle Cleaning
Compound (761F00), rinse with clear water, dry with a
jet of air.
NOTE: Safety release device equipped on oxygen and
inert gas regulators is designed for regulator protection; not for hose or equipment downstream.
If gas escapes through the vent holes in the cap,
immediately close cylinder valve and then re-
Check the condition of ‘O’-rings on the welding heads
move the regulator for repair.
periodically . If they appear to be in poor condition, or are
so worn that the head can be inserted in the handle without noticeable resistance, replace them.
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 distributor or from ESAB Welding & Cutting Products, Customer Service Department, Florence, SC.
SPRING - 23K08
STEM - 18559
SEAT - 32Z01
RETAINER - 57K03
VALVE ASSEMBLY
08M06
“O”-RING - 14K07
NUT
21175
“O”-RING - 14K07
LOCK SCREW - 57K02
“O”-RING - 85W11
“O”-RING
14K12
ADAPTOR TUBE
05K39
ADAPTOR TUBE
05K38
“O”-RING - 14K12
ADAPTOR HEAD -
19K11 57K03
“O”-RING 85W11
“O”-RING 14K12
NUT - 802
3/4" - 20
VALVE STEM
ASSEM. 21174
ROLL PIN
1/8" x 5/8"
62350036
MIXER - 63947
“O”-RING 14K12
LEVER - 24K13
LOCKNUT 56K09
NIT - 21175
LABEL - 954098
(2) VALVE STEM - 21177
Fig. 1 - Replacement Parts - Welding Torch and Cuttting Att achment Assemblies:
CW-250 Cutting Att achment 90° Head - 21190, W-250 Welding Torch - 21189
7
Page 8
“O”-RING
85W11
“O”-RING - 14K07
MIXER
(See Table 2, 3, or 3A)
Fig. 2 - Replacement Parts - Welding and Heating Head Assemblies
“O”-RING - 86W63
MIXER THROAT
(See Table 2, 3, or 3A)
RING - 13K02
NUT - 12K15
SPRING - 19147
TIP
(See Tablel 2)
WELDING HEAD
GAUGE (DEL. PRESS.)
21938 (R-36-75-540)
21937 (R-36-15-510)
GAUGE (DEL. PRESS.)
21935 (R-36-75-540)
21934 (R-36-15-510)
TIP
(See Table
2, 3, or 3A)
MULTI-FLAME
HEA TING HEAD
PLUG - 21930
VALVE SEAT
17967 (R-36-75-540)
32Y39 (R-36-15-510)
FILTER - 71Z33
NIPPLE (includes filter)
21519 (R-36-75-540)
103Z01 (R-36-15-510)
OUTLET CONN.
3389 (R-36-75-540)
3390 (R-36-15-510)
PLUNGER - 17460
RETAINER - 21863
NUT
410 (R-36-75-540)
1369 (R-36-15-510)
DIAPHRAGM - 21828
DIAPHRAGM RING - 82Z40
DIAPHRAGM PLATE - 21827
SPRING
29Z74 (R-36-75-540)
998397 (R-36-15-510)
R-36-75-540 Illustrated
LABEL
954194 (R-36-75-540)
954193 (R-36-15-510)
PRESSURE ADJUSTING SCREW - 21942
Fig. 3 - Replacement Parts - R-36-75-540 Oxygen Regulator - P/N 21325
R-36-15-510 Acetylene Regulator - P/N 21324
SPRING PLATE - 998770
CAP - 21 18 0
OXWELD, PUROX, AND PREST-O-LITE are registered trademarks of ESAB Welding & Cutting Products.
F-15-105 5/96 8M Printed in U.S.A.
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