ESAB OXWELD C-62 Cutting Torch and Powder-Washing Attachment Troubleshooting instruction

INSTRUCTIONS for

C-62 Cutting Torch

and

Powder-Washing Attachment

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 Welding, Cutting and Heating”, Form 2035. Do not permit untrained
persons to operate this equipment. Do NOT attempt to 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-9178-K

May , 2009

OPERATION

Connecting

1. Attach regulators to the oxygen and fuel gas cylin­ders. Follow all instructions supplied with the regu­lators.

2. Attach oxygen and fuel gas hose to the regulators
and to the torch, after making sure all metal seat­ing surfaces are clean. Tighten all connection nuts
with a wrench.

3. Attach nozzle to torch head, and tighten connec­tion nut with a wrench.

Adjusting Gas Pressures
Fuel Gas: Open the fuel gas valve about one turn. Turn in

the pressure-adjusting screw on the acetylene regulator
until its delivery-pressure gauge registers the desired pres­sure (see cutting chart on page 4). Then immediately
close the acetylene valve.

Oxygen: Open the cutting oxygen valve by depressing
its valve lever fully . Turn in the pressure-adjusting screw
on the oxygen regulator until its 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 pressure as in­dicated on the scales of the regulator caps.

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 turn in
the regulator pressure-adjusting screws until the oxy­gen delivery-pressure gauge registers 60 psi and the
fuel gas delivery-pressure gauge registers 10 psi. Us­ing Leak Test Solution that is suitable for oxygen ser­vice, such as P/N 998771 (8 oz. container), check for
leaks at the cylinder valves, the cylinder-to-regulator con­nections, the regulator-to-hose connections, and the hose­to-torch connections. If bubbling at any point indicates
leakage, tighten the connection. If this does not stop 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 gas­tight.

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.

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!

Lighting

Open the preheat oxygen valve on the torch a fraction
of a turn. Open the fuel gas valve on the torch about
two turns, and light the gas at the nozzle with a friction
lighter . DO NOT USE A MATCH. Then open the cutting
oxygen valve and adjust the preheat flames by open­ing the preheat oxygen valve gradually. This will usu­ally provide maximum preheat for the nozzle in use. If
the flames burn away from the end of the nozzle, or if
less preheat is desired, close the torch fuel gas valve
until the flame inner cones shorten noticeably , and then
readjust the flames with the preheat oxygen valve. Be
sure to keep the cutting oxygen valve open during any
adjustment of the preheat flames.

Shutting Off

Release the cutting oxygen valve lever. Then close the
fuel gas valve, and finally the preheat oxygen valve.

Operating Precautions
Backfire: Improper operation of the torch may cause

the flames to go out with 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 exceptional 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; and (3) operating pressures are correct.
Should flashback occur, IMMEDIATELY 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 with nozzle in use when flashback
occurred to your distributor or to ESAB Remanufacturing
Center, Florence SC for repair.

MAINTENANCE

For all repairs other than those covered below, send
the apparatus to your ESAB Welding Products dis­tributor or to ESAB Remanufacturing Center, 411 S.
Ebenezer Road, Florence SC 29501. Improperly re­paired apparatus is hazardous.

Preheat Valves: Leakage around either valve stem can
usually be corrected by tightening the packing nut
slightly. If this does not stop the leakage, replace the
valve stem assembly.

If either preheat valve fails to shut off completely, remove
the valve stem assembly from the torch. With a clean
cloth, wipe the ball in the end of the stem. Then reinsert

valve stem assembly and tighten it several times with
maximum force. If this does not eliminate leakage, try a
new valve stem 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 valve stem assembly, tighten the
packing nut until the valve stem 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 pack­ing nut until the valve stem 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 valve fails to shut off completely,
proceed as follows:

1. Remove cutting valve lever (see pg. 3).

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.

4. Remove the internal O-ring (85W10) from the guide
and insert a new O-ring. Replace the external O­ring (638797) 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.

Mixer: To remove the mixer for cleaning or replace­ment, first unscrew the mixer chamber plug. Then let
the two springs drop out in your hand. Finally , dislodge
the mixer and its three washers (two brass, one Neo­prene) either by rapping the torch, held vertically,
against a block of soft wood, or by turning a long 10-32
machine screw into the thread in the end of the mixer
and pulling it out.

When reassembling, place the three washers (one neo­prene between two brass) on the extreme back end of
the mixer. (Be sure to use a new neoprene washer un­less the old one appears to be in equal-to-new condi­tion.) Slip mixer into torch, then insert large spring and
push it down hard to seat the forward brass washer
against shoulder in body. Then drop small spring inside
large spring, insert mixer plug, and tighten plug firmly.
Be sure the mixer chamber plug is fitted with an O-ring in
good condition (even in cases where the plug carried no
O-ring originally).

3

Cutting Valve Lever: To remove, merely drive out the
fulcrum spiral-pin, using a drill or piece of rod (7/32-in.
diam. or smaller).

ING NOZZLES. Use the OXWELD tools recommended
in the charts on page 4 or OXWELD nozzle cleaning com­pound.

Cleaning Cutting Nozzles: If the cutting nozzle does
not produce straight, uniform flames, or if any of the nozzle

To clean the preheat slots on internal nozzles, remove

the external sleeve and use a soft bristled brush.
orifices become clogged, clean them by hand with the
correct size twist drill shown in the table on page 4 or
with OXWELD tip cleaners. (The relationship between
OXWELD tip cleaners and drill sizes is shown on the tip
cleaner case.) DO NOT USE ORDINARY TWIST DRILLS

For longer life, nozzles should be cleaned periodically in

a solution of OXWELD nozzle cleaning compound (Part

No. 761F00) made up and used as directed on the jar in

which it is packed.
TO CLEAN FIN-WASHING, GOUGING OR RIVET WASH-

P ARTS INFORMA TION

All parts which can be replaced without breaking soldered or brazed joints are illustrated below or listed on the next
page. When ordering parts, please give both part number and description (including size, where appropriate).

50Z38

THUMBPIECE

DRILL AT ASSEMBLY

#52 (.0635) DRILL

PIN

6262-0009

GUIDE - 638240

“O”RING - 638797
“O”RING - 85W10

WASHER - 638241

SPRING - 29Z37

50Z37

LATCH

62399001

PIN

51Z31

INSERT

638981

LEVER ASSEMBLY

7/8-20

33A56

NUT

01Y41 (ACET .)

MIXER ASSEMBLY

77Z29

WASHER

77Z30

WASHER

77Z29

WASHER

STEM - 638930

* 77Z97

WASHER

3/8-24

(2) 54A87

STEM

ASSEM.

9/16-25

3924

SPRING

28Z43

SPRING

86W85

“O”RING

134Z55

PLUG

Fig. 1 - C-62 Torch, Part No. 02X85

4

CUTTING & SPECIAL NOZZLES INFORMATION

OPERATING DATA

OXY-ACETYLENE NOZZLES

Steel (in.) Nozzle Regulator Press. (psig)* Min.
Thickness Size Oxygen Acetylene Hose Size

CUTTING: 1502 Series

1/16 - 1/8 1/4" 25-40 5-7
1/4 - 3/8 20-40 5-7

1/2 - 5/8 1/2" 30-40 5-7 1/4-in. oxy.
3/4 - 1 1-1/2" 30-40 5-7 1/4-in. acet.

2 - 5 4" 30-60 6-8
6 - 10 8" 35-75 8-10 3/8-in. oxy.

12 12" 60-80 10-12 3/8-in. acet.

GOUGING: 1511 Series

— 13 65-75 8-9 3/8-in. oxy.
— 19 80-90 9-10 1/4-in. acet.
— 25 90-100 9-10

RIVET WASHING: 1507 Series

— 19 20-90 5-10 3/8-in. oxy.
— 25 20-90 5-10 1/4-in. acet.

OXY-FUEL GAS NOZZLES

Reg. Press. (psig)*
Steel (in.) Nozzle Fuel Gas Min.
Thickness Size Oxygen Nat. Gas Propane Hose Size

Nozzle Cleaning Data and Part Numbers

Cleaning Tool

Size Part No. Preheat Cutting

1502 SERIES ( preheat holes)

1/4" 08Z67 69 Drill 68 Drill
1/2" 15Z17 66 60
1-1/2" 15Z18 65 53
4" 15Z19 61 46
8" 15Z20 57 39
12" 15Z21 56 31

1511 SERIES (5 or 7 preheat holes)

13 15X14 5190071 5190068
19 15X15 5190072 5190069
25 15X16 5190062 5190070

1507 SERIES (6 preheat holes)

19 08Z90 62 Drill 3/16" Drill
25 15Z37 62 1/4"

1524 SERIES (10 preheat holes)

25 15X51 5190070* 5190062

1520 SERIES (10 preheat holes)

13 15X33 5190068 5190071
19 15X34 5190069 5190072
25 15X35 5190070 5190062

1539 SERIES (10 preheat holes)

CUTTING: 1534 Series

1/8 2 35-40 1-2 1-2 1/4-in. oxy.
1/4 - 3/8 3 30-40 1-2 1-2 1/4-in. fuel
1/2 4 30-35 1-2 1-2 gas
3/4 - 1-1/2 6 30-45 1-2 1-2

2 - 5 8 30-50 2-4 2-3 3/8-in. oxy.

3/8-in. F.G.

FIN WASHING: 1524 Series

— 25 50-90 24-26 18-20 3/8-in. oxy.

3/8-in. F.G.

GOUGING: 1520 Series

— 13 65-75 6-8 5-7
— 19 80-90 8-10 6-8 3/8-in. oxy.
— 25 90-100 11-14 9-11 1/4-in. F.G.

RIVET WASHING: 1539 Series

— 19 20-90 5-10 5-10 3/8-in. oxy.
— 25 20-90 5-10 5-10 3/8-in. F.G.

*Using 25 Ft. Hose Lengths.

19 65Z55 55 Drill 3/16" Drill
25 65Z56 53 1/4"

1534 SERIES (2 piece — slotted preheats)

Part No. Cleaning**

Size Internal External Tool (Cutting)

2 14Z66 14Z38 76 Drill
3 14Z50 14Z38 68
4 14Z51 14Z38 60
6 14Z52 14Z39 53
8 14Z53 14Z39 46

* 5190070 tool is also used for cleaning cutting throat.

** To clean preheat slots, remove external sleeve and use sof t bristled

brush.

5

POWDER WASHING ATTACHMENT ASSEM­BLY INSTRUCTIONS

Before attempting to use the powder attachment, read
carefully the instructions packed with your OXWELD
Powder Dispenser.

Attach to Torch

1. Insert the powder nozzle (61Y06) through the
clamp. Slip the ferrule (185W35) and nut from com­pression-type connection 185W05 over the end of
the powder nozzle. Be sure the heavy end of the
ferrule is towards the nut. Screw the connection
(185W05) into the nut. Using two wrenches, tighten
the connection.

2. Assemble the cutting nozzle in the torch as shown
in Fig. 2 below. Locate the clamp on the torch so
that the end of the powder nozzle is flush with the
end of the cutting nozzle as illustrated below.
Tighten the clamp on the torch and on the powder
nozzle.

3. Slip the ferrule 185W35 and nut from connection
185W35 onto the powder tube (147Z25) with heavy
end of ferrule toward the nut. Insert the end of the

powder tube into the connection (185W05). Using
two wrenches, tighten the connection.

4. Position the powder valve (55Y49) as shown in Fig. 2
with the lever in line with the cutting valve lever on the
torch. Connect and tighten the powder tube to the
powder valve and connect the powder inlet tube
(61Y53) to the powder valve inlet. Use two wrenches
to tighten the connections.

MAINTENANCE

ACV-2 Powder Valve: To remove the stem and seat

(33Y46) for cleaning or replacement, remove clip and
lever pin, and lift lever and washer off valve stem. Then,
unscrew valve guide from valve body. The valve stem
and seat can now be lifted out. Replace valve stem and
seat assembly and any other parts which are worn or
corroded. Blow out all loose powder from valve and re­assemble, being sure parts are in proper sequence (see
parts picture below).

Powder Adaptor: The powder nozzle (61Y06) can be
replaced by simply breaking the connection and remov­ing the nozzle from the clamp. The new nozzle is sup­plied with a ferrule and nut for easy installation.

POWDER ADAPTOR ASSEMBLY-61Y05

(2) SCREW-6134-1991
CLAMP-150Z99

NOZZLE-61Y06
CONNECTION-185W05

(2) FERRULE-185W35
POWDER TUBE-147Z25
DIAPHRAGM-30Z55

INSERT-73Z86

(SOFT SOLDER)

1/8"-27 NPT

STEM & SEAT-33Y46

PARTS SUPPLIED

WITH-55Y49

4789-NIPPLE

36Z40-NUT

SECTION “B”-“B”

(INCLUDES)

INCLUDES

RING-38Z68

CAP-31Z57

NUT-37Z25

PIN-38Z34

SPRING-28Z20

POWDER VALVE ASSEMBLY
TYPE ACV-2 - 55Y49

(SEE VIEW “A”
FOR REPLACEMENT PARTS)

SILVER SOLDER

5/8"-18

POWDER INLET TUBE-61Y53

3/16"-24"

(2) WASHER-73Z98

CONNECTION-185W04

INCLUDES

FERRULE-185W35

1"-20

“B”

ELBOW-11Z73

THUMBSCREW-6135-1052

VIEW “A”

LEVER-25Z22

CLIP-81W53

NUT-185W40
FERRULE-185W35

BODY-80Z58

SILVER SOLDER

Fig. 2 - Powder Washing Attachment for C-62 ( 61Y01)

6

7

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATIONS GUIDE - CUSTOMER SERVICES

A . CUSTOMER SERVICE QUESTIONS: Telephone [phone]/Fax: [phone]

Order Entry Product Availability Pricing Hours: 8:30 AM to 5:00 PM EST
Order Changes Saleable Goods Returns Delivery
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Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: [phone]

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: [phone]/ Fax: [phone]

E. WELDING EQUIPMENT REPAIRS: Telephone: [phone] / Fax: [phone]

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

Telephone: [phone] / Fax: [phone]
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone: [phone] Hours: 7:30 AM to 5:00 PM EST

Hours: 8:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: [phone]

Hours: 8:00 AM to 5:00 PM EST

F-9178-K 05 / 2009