INSTRUCTIONS for
October, 2003
C-65 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 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 cutting torch covered by these instructions is listed by Underwriter’s Laboratories only when using 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 parts voids the manufacturer’s warranty.
F-995-G
I. GAS SUPPL Y AND REGULATION
REQUIREMENTS
A. PRESSURES
The C-65 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.
The C-65 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
F-995-G
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.
With 75 feet of 1/2 inch hose, the approximate pressure drop will be 90 psi. The regulator must therefore
be set to a delivery pressure of approximately 135 psi.
Fuel gas hose should be 3/8 inch with “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” fitting
for torch connection, and 65-ft. of 3/8" fuel gas hose
with “B” size fittings.
C. ST ATION REGULA T OR 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 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 regula-
Be sure this information reaches the operator.
You can get extra copies through your supplier.
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.
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.
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SP-GA 10/98
tor must be at least 10 lb. per sq. inch greater — that
is, at least 145 lb. per sq. in. (135 + 10).
reduce the pressure drop between the regulator and
torch at normal operating flows.
The R-76-75-025 Fuel Gas Regulator is designed for
high flow delivery of fuel gas.
D. CENTRAL REGULA TION
If the oxygen supply is regulated from a central point in
a distribution line piping system, the R-83-40M Oxygen Station 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 Station Regulator may be
needed.
II. OPERA TING INSTRUCTIONS
A. TO CONNECT
Check that the packing nuts on the torch valves are
snug. Att ach 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
Attach an 1809, 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. TO 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 pressureadjusting screw on the regulator until the test gauge
TABLE I – Nozzle Information – 1809 Series
Nozzle Scarfing Preheat Cleaning Drill Size Replacement Parts
Path Holes
Width Wear Ring Nozzle
Size Part No. Preheat Cutting Assembly Nut
62 15X70 2-1/4” – 3-3/16” 16 1/16” 5/8” 60Y92 37Z23
(57 – 81mm)
T ABLE II
Gas Pressure & Consumption Data – 1809 Series, Size No. 62 (P/N 15X70)
(Pressure measured at the torch inlet connection)
Cutting Oxygen Natural Gas
Inlet Inlet Flow,
Pressure Flow Pressure cfh
psig (bars) cfh (m3/hr) psig (bars) (m3/hr)
20 (1.38) 4300 (123) 5 (0.35) 40 (1.13)
30 (2.07) 5600 (159) 10 (0.69) 75 (2.12)
40 (2.76) 7000 (198) 15 (1.04) 105 (2.97)
50 (3.45) 8300 (235) 20 (1.38) 130 (3.68)
60 (4.14) 9600 (272)
Oil or grease is easily ignited and burns violently in the presence of oxygen under pressure. Handle
oxygen apparatus only with clean hands or gloves. Never use oxygen as a substitute for compressed air.
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