ESAB C-57-R Cutting Torch Troubleshooting instruction
- Type
- Troubleshooting instruction
ESAB C-57-R Cutting Torch is a versatile tool for oxy-fuel cutting applications. It offers precise cutting capabilities with a cutting range of 1/8" to 12" using acetylene and 1/8" to 4" using other fuel gases. The torch features easy adjustment of gas pressures, allowing you to fine-tune the flame for optimal cutting performance. With its durable construction and reliable performance, the ESAB C-57-R is a great choice for professional cutting tasks.
ESAB C-57-R Cutting Torch is a versatile tool for oxy-fuel cutting applications. It offers precise cutting capabilities with a cutting range of 1/8" to 12" using acetylene and 1/8" to 4" using other fuel gases. The torch features easy adjustment of gas pressures, allowing you to fine-tune the flame for optimal cutting performance. With its durable construction and reliable performance, the ESAB C-57-R is a great choice for professional cutting tasks.
INSTRUCTIONS for
F-9458-S
April, 2011
C-57-R CUTTING TORCH
OPERATION INSTRUCTIONS
CONNECTING
1. Attach regulators to the oxygen and fuel gas cylinders.
Follow all instructions supplied with the regulators.
2. Attach oxygen and fuel gas hoses 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.
4. Check valve packing nuts for tightness.
ADJUSTING GAS PRESSURES
Low-Pressure Fuel Gas: Be sure the torch fuel gas valve is
closed. Open the supply valve.
Medium-Pressure Fuel Gas: Open the fuel gas valve about
one turn. Turn in the pressure-adjusting screw on the fuel
gas regulator until its delivery-pressure gauge registers
the desired pressure (see cutting 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 on the
oxygen regulator until its delivery-pressure gauge registers
the desired pressure (see cutting chart on page 6). Then
release the cutting oxygen lever.
NOTE: When gaugeless regulators are used, do not
open torch valves. Merely turn in the pressure-
adjusting screws to the desired pressures as
indicated on the scales of regulator caps.
TESTING FOR LEAKS
Every cutting outt should be thoroughly tested for leaks
after it is rst hooked up, and at regular intervals thereafter.
After all connections have been made, make sure all valves
on the torch 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 suitable for oxygen
service, such as P/N 998771 (8 oz. container), check for leaks
at the cylinder valves, the cylinder-to-hose connections,
and the hose-to-torch 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 nally 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 satised that all connections are gas-tight.
After lighting the torch and adjusting the ames, use leak
test solution to check the leakage at all torch valves and at
the nozzle nut.
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 ESAB's free 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 are listed by Third Party Listed only when used in combination with cutting nozzles and parts
manufactured by ESAB Welding and Cutting Products to the specications on le with Third Party Listed, and when they are used in the gas service
for which they are designed and listed. The use of other cutting nozzles and parts voids the manufacturer's warranty.
Be sure this information reaches the operator. You can get
extra copies through your supplier.
Cutting Range using acetylene .....................................1/8" - 12" (3 - 300 mm)
Cutting Range using other fuel gases .......................... 1/8" - 4" (3 - 100 mm)
Cutting Nozzles .........................................................................................1500 series
Torch-Hose Connections .........................................ORS-size (41/64" - 18 fem.)
Torch Overall Length .....................................................................21-in. (532 mm)
Weight ......................................................................................................4-lbs. (1.8 kg)
2
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
SAVE THESE INSTRUCTIONS!
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.
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions 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 imme-
diately. 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 ser-
vice facility designated by the manufacturer.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the prin-
ciples 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.
CAUTION
USER RESPONSIBILITY
READ AND UNDERSTAND INSTRUCTION MANUAL BEFORE INSTALLING
OR OPERATING. PROTECT YOURSELF AND OTHERS!
3
4. WARNING: This product, when used for welding or
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.)
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.
MEANING OF SYMBOLS - As used throughout
this manual: Means Attention! Be Alert! Your
safety is involved.
SAFETY PRECAUTIONS
4
LIGHTING AND FLAME ADJUSTMENT
1. Open the preheat oxygen valve on the torch about two
turns.
2. Open the fuel gas valve on the torch about 1/8 turn
(about two turns if using low pressure fuel gas) and light
the gas at the nozzle with a friction lighter. DO NOT USE
A MATCH. Use of a match could seriously burn your
hand.
3. If using acetylene, open the fuel gas valve until preheat
ames leave the end of the nozzle and then close just
enough to open cutting oxygen valve and then readjust
the preheat ames to the shortest length by opening the
preheat oxygen valve gradually.
The above procedure usually provides adequate preheat
for the nozzle in use. If desiring to change the preheat
ames, always hold the cutting oxygen valve open while
readjusting the preheat oxygen and fuel gas valves.
SHUTTING OFF
Release the cutting oxygen valve lever. Then close the fuel
gas valve, and nally the preheat oxygen valve.
If operations are to be released from the torch, hoses, and
regulators do 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.
OPERATING PRECAUTIONS
Backre: Improper operation of the torch may cause the
ames to go out with a loud 'pop'. Such a backre may be
caused by contact of nozzle with 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
ame may not 'pop' out (backre) but instead burn back
inside the torch with a shrill hissing or squeal. This is called
a 'ashback'. A ashback should never occur if (1) the
equipment is in good condition; (2) preheat ports on cut-
ting nozzles or welding tips are cleaned frequently; and (3)
operating pressures are correct. Should a ashback occur,
IMMEDIATELY shut o the torch. Allow it to cool o for a
least a minute. Then check your nozzle or tip, gas pressures,
readjust regulators if necessary, and relight the torch. If
ashback recurs, send the cutting torch with nozzle to your
distributor for repair.
MAINTENANCE INSTRUCTIONS
For all repairs other than those covered below, send the ap-
paratus to your welding equipment distributor. Improperly
repaired apparatus is hazardous. Parts shown in the illustra-
tion on page 3 that require brazing operation are provided
for experienced and qualied persons engaged in the repair
of this apparatus.
Preheat Valves: Leakage around either valve stem can usu-
ally be corrected by tightening the packing nut slightly.
If either preheat valve fails to shut o 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. If then the valve does not shut o
completely, send the torch to a repair station for reseating
of the body.
After installing a new valve stem assembly, tighten the pack-
ing nut until the valve stem can be turned only with great
diculty, and set the unit aside, for three or four hours at
least, to set the packing. Then back o the packing nut until
the valve stem turns readily.
Cutting Valve Leakage: If leakage develops in the cutting
valve, replace cutting valve seat (32Z01).
To Replace Cutting Valve Seat
1. Remove (4) four screws (61608849) from the handle
(4689) and slide the handle forward as far as possible.
Remove the thumb piece (3634) from the lever (923640)
and the pusher pin (923634) from the pusher rod guide
(923635).
2. Mark the location of the pusher rod guide on the cut-
ting oxygen tube (923633). Loosen the two set screws
(6133-0907) on the pusher rod guide and slide the guide
forward as far as possible.
3. Using a spanner wrench (5190125) remove the cutting
valve assembly by unscrewing the lockscrew (57K02).
Replace both 0-rings (85W11) and (14K07) and the seat
(32Z01).
4. Replace the cutting valve assembly back in the torch and
tighten the lockscrew with the spanner wrench.
5. Locate the pusher rod guide on the markers made previ-
ously, tighten the two set screws and replace the pusher
pin in the guide.
6. Slide the handle back and replace the thumb piece on
the lever. Locate the handle over the four screw holes
and replace the screws.
5
Cleaning the Injector:
1. Remove the mixing chamber plug (35Z60) and the injec-
tor locking screw (35Z59) from the mixer body (21Z74).
2. If gentle tapping of the mixer body does not cause the
injector to fall out, screw a No. 10-32 machine screw into
the end of the injector and pull it out.
3. Clean the recess in the mixer body with a clean cloth.
4. Clean the injector orice with a No. 70 drill, wipe with a
clean cloth.
5. Examine the injector carefully. If it is nicked or marred,
on the seating surface, replace it with a new injector.
6. Insert the injector into the mixer body, and lock it se-
curely in place with locking ring.
7. Replace O-ring if necessary, and then install the mixer
chamber plug. Tighten plug rmly with a screwdriver.
Cleaning Cutting Nozzles: If the cutting nozzle does not pro-
duce straight, uniform ames, or if any of the nozzle orices
become clogged, clean them by hand with the correct size
twist drills shown in the table on page 4, or with ESAB tip
cleaners. (The relationship between ESAB tip cleaners and
drill sizes is shown on the tip cleaner case.)
6
OPERATING DATA, CLEANING DATA, AND PART 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 ft. 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 should be used. If using low-pressure
fuel gas, 3/8 in. fuel gas hose should be used for all cut-
ting operations.
2. The tables shown average values based on typical condi-
tions. The type and quality of steel, its surface condition,
the purity of oxygen, etc. will always have a bearing on
the end results.
NOTE: If using the C-57-R for fuel gases other than acetylene, see your ESAB representative.
Acetylene Cutting Nozzles
Nozzle Steel Gas Pressure, psig Gas Consumption, ft/hr Cleaning
Thickness, Drill Size
Size Part No. in. mm. Oxygen Acetylene Oxygen Acetylene Preheat Cutting
1565 Series (Low Acetylene Consumption)*
1/8 639182 1/8 3 30-40 78
1/4 639263 1/4 6 35-40 69
1/2 639264 1/2 13 55-65 5-9 73 65
3/4 639265 3/4 19 40 5-7 60-70 61
1 639266 1 25 85-95 54
2 639267 2 50 155-165 8-12 70 51
3 639268 3 75 215-230 10-12 69 47
4 639269 4 100 340-360 15-20 65 40
6 150 35-45 395-460 20-25
6 998742 8 200 55-65 8-10 545-625 30-35 57 30
10 250 40-55 8-10 630-710 40-45
10 998743 12 300 55-65 10-12 790-905 45-55 56 31
1502 Series (Medium Preheat)
3 08Z67 1/4 6 20-25 35-45 6-8 69 68
4 15Z17 1/2 13 30-35 5-7 65-75 8-10 66 60
3/4 19 30-35 120-135 14-16
6 15Z18 1 25 35-40 5-7 130-140 14-16 65 53
2 50 25-30 185-210 16-20
8 15Z19 3 75 30-40 6-8 205-255 16-20 61 46
4 100 35-45 235-285 19-22
6 150 35-45 395-460 20-25
10 15Z20 8 200 55-65 6-10 545-625 30-35 57 39
10 250 45-55 8-10 630-710 40-45
12 15Z21 12 300 55-65 10-12 790-905 45-55 56 31
* Not recommended for low-pressure acetylene.
1511 Series Gouging Nozzles
Nozzle Oxygen Avg. Gouge Approx. Nozzle
Pressure, Dimensions Speed Cleaning Tools
Size Part No. psig Width Depth ft./min. Preheat Cutting
13 15X14 65-75 5/16 3/16-1/4 1.0-1.8 5190068 5190071
19 15X15 80-90 3/8 1/4-3/8 1.6-2.2 5190069 5190072
25 15X16 90-100 1/2 1/4-7/16 1.9-2.8 5190070 5190062
1507 Series Rivet Washing Nozzles
Nozzle Oxygen Cleaning Drill Size
Pressure,
Size Part No. psig Preheat Cutting
19* 08Z90 80-90 62 3/16-in.
19* 66Z40 50-60 62 3/16-in.
25 15Z37 80-90 62 1/4-in.
*The cutting oxygen throat diameter is 0.055-in. on P/N 08Z90 and 0.125-in. on P/N 66Z40.
7
PARTS INFORMATION
All parts including those that require brazing by a trained repairman 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 welding
equipment distributor or from ESAB Welding and Cutting Products, Customer Service Department, Florence, SC.
C-57-R Cutting Torch (75° head) w/ORS -size hose ttings (illustrated) (Ser. A) .................................................................P/N 02X32
C-57 Cutting Torch (75° head) w/Std. "B" -size hose ttings (Ser. A) ......................................................................................P/N 602527
1 21Z73
2 21Z74
3 27Z10
4 923880
5 923633
6 4399
7 3634
8 923640
9 923634
10 923635
11 57K02
12 2214341
13 57K03
14 32Z01
15 23K08
16 923636
17 98C21
1 HEAD, 75"
1 BODY MIXER
2 CL + ACE TUBE
2 VALVE ASS'Y
1 CUT OXYGEN TUBE
1 ACETYLENE VALVE BODY
1 THUMB PIECE ASS'Y
1 CUT VALVE LEVER
1 PUSHER PIN
1 PUSHER ROD GUIDE
1 LOCKSCREW
1 OXYGEN CUT VALVE STEM
1 VALVE SEAT RETAINER
1 CUT VALVE SEAT
1 SPRING FOR CUT VALVE
1 OXYGEN CONNECTION
1 OXYGEN HOSE CONNECTION
18 98C23
19 42C14
20 98C24
21 923637
22 4689
23 923639
24 35Z60
25 923641
26 02Z04
27 17Z86
28 33Z58
29 35Z59
30 86W85
31 61608849
32 6133-0907
33 85W11
34 14K07
1 NIPPLE FOR OXYGEN CONNECTION
1 GAS HOSE CONNECTION NUT
1 NIPPLE FOR GAS CONNECTION
1 BODY, REAR END
1 TORCH HANDLE
1 FRONT SUPPORT BLOCK
1 CHAMBER PLUG
1 VALVE BODY
1 INJECTOR
1 MIXER TUBE
1 NOZZLE NUT
1 LOCKING SCREW
1 O-RING
4 .138 x .25 MACHINE SCREWS
2 10-32 X 3/16 SET SCREW
O-RING
O-RING
27
1
2
3
A
A
B
B
5
7
8
9
4
6
25
SECTION A-A
SECTION B-B
6
21
31
31
10
18
17
11
12 13
14
15
33
34
19 20
32
22
23
26
29
30
24
28
16
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
B. ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations
D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
ESAB Welding & Cutting Products, Florence, SC
COMMUNICATION GUIDE - CUSTOMER SERVICES
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ESAB C-57-R Cutting Torch Troubleshooting instruction
- Type
- Troubleshooting instruction
ESAB C-57-R Cutting Torch is a versatile tool for oxy-fuel cutting applications. It offers precise cutting capabilities with a cutting range of 1/8" to 12" using acetylene and 1/8" to 4" using other fuel gases. The torch features easy adjustment of gas pressures, allowing you to fine-tune the flame for optimal cutting performance. With its durable construction and reliable performance, the ESAB C-57-R is a great choice for professional cutting tasks.
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