ESAB R-89-3M-580 & R-89-4M-680 Regulators Troubleshooting instruction

INSTRUCTIONS for

F-11-447-L

January , 2001

R-89-3M-580 & R-89-4M-680 REGULATORS

CAUTION

!

These INSTRUCTIONS are for experienced operators who know the general principles and the safety precautions to be observed in
operating gas regulation equipment. If you are not certain you understand these principles fully, we urge you to read ESAB's booklet
"Precautions and Safe Practices for Welding, Cutting and Heating," (2035) which is available from any ESAB distributor. Do NOT permit
untrained persons to install, operate, or maintain this regulator. Do NOT attempt to install or operate this regulator until you have read and
fully understand these INSTRUCTIONS. If you do not fully understand these INSTRUCTIONS, contact your supplier for further information.

The regulators covered by these instructions are 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 cause damage or failure to the equipment will void the manufacturer's warranty.

IMPORTANT: 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.

OPERATING INSTRUCTIONS

TO CONNECT

1. Open the cylinder or station valve slightly, for an
instant. (This is termed "cracking the valve".) This
will blow out dust or dirt that may have collected in
the valve outlet. BE SURE to keep your face away
from the valve outlet to protect your eyes from dust
or dirt.

2. MAKE SURE that the regulator pressure-adjust-

F-11-447-L

ing screw is released. To do this, turn it to the left
(counterclockwise) until it turns freely .

3. Attach the regulator to the cylinder valve. Tighten
the connection nut with a wrench.

4. Open the cylinder valve SLOWL Y. After the cylin­der-pressure gauge hand stops moving, open the
valve fully. Never stand in front of or behind

the regulator when opening the valve. Always
stand to one side.

5. Attach the delivery line to the regulator outlet.
(Regulators are fitted with a 1/4-in. -37 degree-flare
connection).

TO ADJUST PRESSURE

1. Increase delivery pressure, turn the pressure-ad­justing screw clockwise. T o decrease delivery pres­sure, turn the pressure-adjusting screw counter­clockwise.

2. When making the initial delivery pressure adjust­ment, valve(s) downstream of the regulator must
be open or you will not get a true work-pressure
reading on the delivery-pressure gauge.

3. Close delivery line valves.

IMPORT ANT : Before starting operations, test all con-

nections with Leak Test Solution suit­able for oxygen service, such as P/N
998771 (8 oz. container). Correct any
leaks before starting work. Testing
should be performed after torch or other
gas-using device has been properly
connected, with valve(s) downstream
of regulator closed, and with maximum
delivery pressure (2000 psig) in the
delivery line.

TO RELEASE PRESSURE

If work is to be stopped for a half-hour or more, or be­fore removing a regulator from a cylinder, you should
release all pressure from the regulator. T o do this, pro­ceed as follows:

1. Close the cylinder valve.

2. Open delivery line valve(s).

3. Wait until the pressure has dropped to zero, then
turn the pressure-adjusting screw counterclock

Be sure this information reaches the operator.
Y ou can get extra copies through your supplier.

wise until it turns freely.

4. Close delivery line valves.

OPERATING HINTS

1. If the regulator is to be out of use for a few days or
more, turn in the pressure-adjusting screw enough
to move the stem off the seat. When regulator is
ready for use again, be sure to back out pressure­adjusting screw before admitting pressure into the
regulator.

2. Unless cylinders are mounted on a suitable truck,
always remove regulators before you move cylin­der.

MAINTENANCE INSTRUCTIONS

If this regulator does not operate properly, stop
work immediately and investigate the cause of the
malfunction. Maintenance work must be per­formed by an experienced person. Do not permit
untrained persons to inspect, clean, or repair this
regulator. Use only recommended replacement
parts.

For all repairs other than those covered below,
send the regulator to your ESAB welding equip­ment distributor or to ESAB Remanufacturing
Center, 411 S. Ebenezer Road, Florence SC 29501.
Improperly repaired apparatus is hazardous. Be
sure pressure has been removed and isolated from
regulator before disassembly.

A. TO REPLACE DIAPHRAGM (130Z55), VALVE

SEAT ASSEMBLY (32Y15) AND OTHER PARTS.

1. Secure regulator body in vise and back out pres­sure-adjusting screw until it turns freely.

2. Unscrew regulator cap. Diaphragm, gasket, and
parts contained inside the cap can be removed.

3. Unscrew valve seat assembly from regulator body.
Valve pin (38Z50) will slide out of the valve seat
assembly.

B. TO REASSEMBLE REGULATOR

1. Screw new valve seat assembly tightly into regu­lator body using a 3/4-in. hex socket wrench. You
may test for valve seat leakage at this point by
doing the following:
a. Connect the partially-assembled regulator to

a full cylinder.

b. Stand to one side of regulator (not in front of

the gauges or the exposed valve seat assem­bly) and slowly open the cylinder valve.

c. Apply Leak Test Solution (998771) at the cen-

ter of the valve screw and about the valve
screw threads and look for any sign of leak­age. Do not try to correct leakage while

regulator body is under pressure.

d. Close cylinder valve. Slowly loosen cylinder

connection nut to bleed out the trapped pres­sure. Remove the regulator body.

e. If leakage was noted, correct and retest. If no

leakage was detected, blow out the leak test
solution with clean compressed air or wipe out
with clean lint-free-cloth.

2. Insert valve pin into the valve screw.

3. Install new diaphragm and diaphragm gasket into
regulator.

4. Install spring washer, spring, diaphragm plate, and
diaphragm ring into regulator cap or position these
parts properly on top of diaphragm in regulator.
Screw regulator cap to regulator body tightly.

C. TO TEST THE REGULATOR FOR LEAKS

1. Connect regulator to full cylinder of gas. Back out
pressure adjusting screw. Stand to one side of
regulator and slowly open the cylinder valve.

2. Check for valve seat leakage by placing a film of
leak test solution across regulator outlet connec­tion (if not tested under B. 1. or for reassurance).

3. Blank off regulator outlet. Set regulator to maxi­mum delivery pressure of 2000 psig. Apply leak
test solution on all joints, particularly, about the
threads and vent holes of the regulator cap. Do

not correct leakage while regulator is under
pressure.

4. Close cylinder valve and release pressure through
regulator outlet. Back out pressure-adjusting
screw. If necessary, correct leakage and retest.

D. REPLACE INLET FILTER (P/N 71Z33)

1. Remove the filter from inlet nipple with a No. 1
"EZY-OUT" or a No. 6 wood screw, about 2-in. long.

2. Place the new filter in the nipple and press it into
position against the shoulder with a 1/4-in diam­eter metal rod. Never use a regulator without

this filter.

2

999445 (-580)

18641 (-680)

** CYLINDER PRESS. GAUGE -

1/2"-13

18641 (-680)

** DELIVERY PRESSURE

GAUGE - 999445 (-580)

38Z50

PIN

35Z40

SCREW

32Z42

SEAT

32Z43

STEM

*639125

6212

32Y15 SEAT ASSEM.

35Y22

CAP ASSEM.

WASHER

P.A. SCREW

PARTS INFORMATION

NIPPLE - 103Z01 (-580)

18719 - (-680)

1/4"-18 A.N.P.T.

NUT - 37Z33 (-580)

18720 (-680)

71Z33

FILTER

1/4"-18 A.N.P.T.

FITTING - 86W35

28Z32

SPRING

05Y19

SCREEN

ASSEMBLY

28Z71

SPRING

93Z26

PLATE

130Z06

RING

94Z24

GASKET

130Z55

DIAPHRAGM

R-89-3M-580 (formerly R-8962) Inert Gas Regulator - P/N 103X85

R-89-4M-680 Inert Gas Regulator - P/N 19017

All parts which can be replaced without breaking soldered or brazed joints are illustrated and listed 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, 29501.

* Includes 92Z61 bushing and ring 998289.

**Replacement Gauge Crystal - 18858. If case has 3 coarse threads (pre-1985), use 639327.

3

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

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F-11-447-L 01/01 Printed in U.S.A.