ESAB C-59 Scarfing Torch Troubleshooting instruction

Brand: ESAB

Model: C-59 Scarfing Torch

Category: Welding System

Type: Troubleshooting instruction

INSTRUCTIONS FOR

F-6440-Y

May, 2009

C-59 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 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.

1. GAS SUPPLY AND REGULATION

REQUIREMENTS

A. Pressures

This C-59 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-59 operates most efficiently under normal con-

ditions with an oxygen pressure of 45 psi at the torch

inlet. The torch is adjusted at the factory for this con-

dition. 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 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 pres-

sure drop will be 60 psi. The regulator must there-

fore be set to a delivery pressure of approximately

105 psi.

With 75 feet of 1/2 inch hose, the approximate pres-

sure drop will be 90 psi. The regulator therefore must

be set to a delivery pressure of approximately 135

psi.

Fuel gas hose should be 3/8 inch with standard “B”

size fittings, such as P/N 2120404(50-ft).

Also available is a fitted 65-ft. Scarfing Hose Assem-

bly, P/N 2119324, which includes 50-ft. of 3/4" hose

with “D” size fitting on one end for connecting to oxy-

gen regulator spliced with 15-ft. of 1/2" hose with “C”

size fitting for torch connection, and 65 ft. of 3/8" fuel

gas hose with “B” size fittings.

C.Station Regulator Panel P/N 2119101

This regulator panel includes the R-52 Oxygen Regu-

lator (20A16) and the R-76-75-025 Fuel Gas Regula-

tor (19153) conveniently mounted on a frame for wall

mounting. The panel also includes shutoff and check

valves, oxygen line filter, and fuel gas safety valve.

The R-52 Oxygen Regulator has ample capacity to

meet gas flow requirements under normal operation

conditions. However, to obtain the required delivery

pressure at the regulator, the line pressure ahead of

the regulator must be at least 10 lb. per sq. inch

greater -- that is, at least 145 lb. per sq. in. (135 +

10).

Be sure this information reaches the operator.

You can get extra copies through your supplier.

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 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.

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!

These Safety Precautions are for your protection. They sum-

marize precautionary information from the references listed

in Additional Safety Information section. Before performing any

installation or operating procedures, be sure to read and fol-

low the safety precautions listed below as well as all other

manuals, material safety data sheets, labels, etc. Failure to ob-

serve 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 pro-

cesses 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 re-

quired.

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 non-

flammable partition or curtains.

5. Use goggles over safety glasses when chipping slag or grind-

ing. Chipped slag may be hot and can travel considerable dis-

tances. 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 non-

flammable covering. Combustible materials include wood,

cloth, sawdust, liquid and gas fuels, solvents, paints and coat-

ings, 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, par-

ticularly in confined spaces, can cause dis-

comfort or injury. Do not breathe fumes or

gases from welding or cutting, Therefore:

1. Always provide adequate ventilation in the work area by natu-

ral 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 venti-

lation 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.

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:

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.

GAS CYLINDER HANDLING - Gas cylinders, if

mishandled, can rupture or explode violently.

Sudden rupture of a cylinder, valve or relief de-

vice can injure or kill you. Therefore:

1. Use the proper gas for the process and use the proper pres-

sure reducing regulator designed to operate from the com-

pressed gas cylinder. Do not use adaptors to mount the regu-

lator on the cylinder. Maintain hoses and fittings in good con-

dition. Follow manufacturers operating instructions for mount-

ing 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 weld-

ing, cutting, or gouging operation. Never strike an arc on a

cylinder.

5. For additional information, refer to CGA Standard P-1, Pre-

cautions for Safe Handling of Compressed Gases in Cylin-

ders:, which is available from the Compressed Gas Associa-

tion, 1235 Jefferson Davis Highway, Arlington, VA 22202.

ADDITIONAL SAFETY INFORMATION - For more in-

formation on safe practices for oxy-fuel welding and

cutting equipment, ask your distributor for a copy of

Precautions and Safe Practices for Gas Welding, Cut-

ting, and Heating, Form 2035. Gas apparatus safety

guidelines are also available on video cassettes from

your distributor.

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 Prepara-

tion for Welding and Cutting of Containers and Piping That

Have Held Hazardous Substances/

3. AWS SP - Safe Practices - Reprint, Welding Handbook.

Used to call attention to immediate hazards

which, if not avoided, will result in immediate,

serious personal injury or loss of life.

Used to call attention to potential hazards

which could result in personal injury or loss of

life.

Used to call attention to hazards which could

result in minor personal injury.

This symbol appearing in this manual means

Attention! Be Alert! Your safety is involved.

SP-GA 7/97

SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for your protection. Before performing any

installation or operating procedures, be sure to read and follow the safety precau-

tions listed below. Failure to observe these Safety Precautions can result in personal

injury or death.

1. PERSONAL PROTECTION — Heat rays (infrared radiation) from an oxy-fuel

flame or hot metal can injure eyes. Therefore:

a. Wear shaded safety goggles made for gas welding and cutting purposes

for protecting your eyes from radiation burns as well as sparks or spatter.

WARN bystanders not to watch the flame and not expose themselves to the

rays of the flame or hot metal.

b. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless

trousers, high topped shoes, and a cap for hair protection, to protect

against hot sparks or hot metal. A flameproof apron may also be desirable

as protection against radiated heat and sparks.

c. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or

pockets. Sleeves and collars should be kept buttoned, and pockets

eliminated from front of clothing.

d. Protect other personnel from rays and hot sparks with a suitable

nonflammable partition.

e. Always wear safety glasses or goggles when in a work area. Use safety

glasses with side shields or goggles when chipping slag or grinding.

Chipped slag may be hot and can travel considerable distances.

Bystanders should also wear safety glasses and goggles.

f. Some gouging and cutting processes produce excessively high noise

levels and require ear protection.

2. FIRE-PREVENTION — Hot slag or sparks can cause serious fires when in contact

with combustible solids, liquids or gases. Oxygen causes fire to burn more rap-

idly. Fuel gas can explode in air or oxygen. Therefore:

a. Remove all combustible materials well away from the work area or completely

cover the materials with a protective nonflammable covering. Such combus-

tible materials include wood, clothing, sawdust, gasoline, kerosene, paints,

solvents, natural gas, acetylene, propane, and similar combustible articles.

b. Hot sparks or hot metal can fall into cracks in floors or wall openings and

cause a hidden smoldering fire. Make certain that such openings are pro-

tected from hot sparks and metal.

c. Do not weld, cut or perform other hot work until the workpiece has been

completely cleaned so that there are no substances on the workpiece which

might produce flammable or toxic vapors.

d. For fire protection, have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or portable fire extinquisher.

e. After completing operations, inspect the work area to make certain there are

no hot sparks or hot metal which could cause a later fire.

f. 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.

3. VENTILATION — Fumes, particularly in confined spaces, can cause discomfort

and physical harm. Do not breathe fumes. Therefore:

a. At all times provide adequate ventilation in the work area by natural or me-

chanical ventilation means. Do not weld, cut, or heat materials such as gal-

vanized steel, zinc, lead, beryllium, cadmium, etc. unless positive mechani-

cal ventilation is provided. Do not breathe fumes from these materials.

b. If you develop momentary eye, nose, or throat irritation while operating, this

is an indication that ventilation is not adequate. Stop work and take neces-

sary steps to improve ventilation in the work are. Do not continue to operate

if physical discomfort persists.

c. Refer to AWS Standard Z49.1 in item 5 for specific ventilation recommenda-

tions.

d. Air samples can be used to find out what respiratory protection is needed.

4. EQUIPMENT MAINTENANCE — Faulty or improperly maintained equipment can

result in poor work, but most importantly it can cause physical injury or death

through fires. Therefore:

a. Always have qualified personnel perform the installation, troubleshooting,

and maintenance work. Do not operate or repair any equipment unless you

are qualified to perform such work.

b. Keep all oxy-fuel equipment free of grease or oil. Grease, oil and other simi-

lar combustible materials once ignited can burn violently in the presence of

oxygen.

c. Maintain torches, hoses, and regulators in safe working order. Do not oper-

ate any equipment in faulty conditions.

d. Do not abuse equipment or accessories. Keep equipment away from exces-

sive heat and wet conditions, oil or grease, corrosive atmospheres and in-

clement weather.

e. Keep all safety devices in position and in good repair.

f. Use equipment for its intended purpose. Do not modify it in any manner.

5. ADDITIONAL SAFETY INFORMATION — For more information on safe practices

for setting up and operating oxy-fuel welding and cutting equipment and on good

working habits, ask your welding equipment supplier for a copy of “Precautions

and Safe Practices for Gas Welding, Cutting, and Heating”, Form 2035. The fol-

lowing publications, which are available from the American Welding Society, 550

N.W. LeJuene Rd., Miami, FL 33126, are recommended to you:

a. “Safety in Welding and Cutting” -AWSZ49.1 (ANSI)

b. “Recommended Safe Practices for the Preparation for Welding and Cutting

of Containers and Piping that have held Hazardous Substances” AWSF4.1

The R-76-75-025 Fuel Gas Regulator is designed for

high flow delivery of fuel gas.

D. Central Regulation

If the oxygen supply is regulated from a central point

in a distribution line piping system, the R-83-40M Oxy-

gen 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. OPERATING INSTRUCTIONS

NOTE: As received from the factory the starting rod

feeder is offset for right-handed operations.

For left-handed operation, see III-B, Page

A. To Connect

Check that the packing nuts on the torch valves are snug.

Attach 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 reduce

the pressure drop between the regulator and torch at

the normal operating flows.

Attach an 1806, 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 diam-

eter) 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 recom-

mended, 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 pres-

sure 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 pressure-adjusting

screw on the regulator until the test gauge shows a pres-

sure of 45 lb. per sq. in. Note the exact pressure on the

regulator gauge. Then release the pressure-adjusting

screw of the regulator, release the torch cutting oxygen

valve, and remove the test gauge from the line. Read-

just the regulator (with the torch cutting oxygen valve

open) until it shows the pressure noted during the test

and then close the cutting oxygen valve.

Fuel Gas Pressure

Open the torch fuel gas valve and adjust the fuel gas

delivery pressure at the regulator to between 10 and 20

psig.

C.To Light the Torch

Open the preheat oxygen valve just enough to provide a

slight flow of preheat oxygen. Open the fuel gas valve

one turn. Light the gas at the nozzle with a friction lighter.

Adjust the flames with the preheat oxygen valve. Then

open the cutting oxygen valve. If the flames blow away

from the nozzle or blow away as soon as lit, close the

fuel gas valve slightly, or if operations are controlled from

a main line, reduce the fuel gas line pressure.

Tables I and II give operating data as well as other use-

ful information that will be helpful in the normal use of

the C-59 torch. Cleaning drill sizes are specified as Table

I, and the oxygen and fuel gas flows for a range in oper-

ating pressure are given in Table II so as to give an indi-

cation of actual gas usage.

The cutting oxygen pressure should normally be set at

45 psi with the cutting oxygen valve wide open so as to

obtain a reasonably wide scarfing path width. The fuel

gas pressure should be set at the high end of the range,

although at times the available pressure at the supply

station will be the controlling factor. When the torch pres-

sures and torch valve adjustments (including the adjust-

ment of the preheat oxygen compensator valve) are

properly set, the preheat flames will be stable and should

not blow off the end of the nozzle as the cutting oxygen

lever is fully depressed and then released. The high

velocity flames, pale in color (oxidizing), should be just

below the flow-off point when the cutting oxygen valve is

closed.

D.To Feed the Starting Rod

With the rod adjusted until the end almost touches the

preheat flames, press the torch cutting oxygen lever

about halfway down. This movement feeds the rod, but

does not open the cutting oxygen valve. Hold the lever

at the halfway position until the rod is heated; then push

the lever all the way down to open the cutting oxygen

valve. During the latter half of the stroke, the rod re-

mains stationary.

To feed the rod independently of the cutting oxygen, limit

the movement of the valve lever to about half a stroke.

To operate the cutting oxygen valve independently of

the rod feed, confine the lever movement to the lower

half of the stroke - as would be desirable for fin burning.

The amount of rod fed at each stroke of the lever may

be regulated between 0 and a maximum of about 5/8

TABLE 1

NOZZLE INFORMATION - 1806 SERIES

Nozzle

Size Part No.

1806 Series (Fuel Gas)

62 15X44

Replacement PartsCleaning Drill SizePreheat

Holes

Scarfing

Path

Width in (mm)

2-1/4"

thru 3-3/16"

(57 - 81mm)

TABLE II

GAS PRESSURE & CONSUMPTION DATA - 1806 SERIES, SIZE 62 (P/N 15X44)

(Pressure measured at the torch inlet connection)

Cutting Oxygen

Inlet

Pressure

psig (BARS)

20 (1.38)

30 (2.07)

40 (2.76)

50 (3.45)

60 (4.14)

Flow

cfh (m

/hr)

4300 (121)

5600 (159)

7000 (198)

8300 (235)

9600 (272)

Natural Gas

Inlet

Pressure,

psig (BARS)

5 (0.35)

10 (0.69)

15 (1.04)

20 (1.38)

Flow

cfh (m

/hr)

40 (1.13)

75 (2.12)

105 (2.97)

130 (3.68)

Hose Sizes: For oxygen, use "C" size hose (1/2" I.D.), P/N 2120399 (50-ft.).

For Fuel gas, "B" size hose (3/8" I.D.), P/N 2120404.

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 OSYGEN A S A SUBSTITUTE FOR COMPRESSED AIR.

Preheat Cutting

Nozzle

Nut

37Z23

Wear Ring

Assembly

60Y92

1/16" 5/8"

inch. To make this adjustment, increase or decrease

the lever movement as the lever arm acts against the

anvil within the rod feed body. Turning the rod-feed an-

vil locknut (71Z91) further down on anvil (77Z49) will

reduce the contact distance, thus less feed is obtained.

By unscrewing the nut to increase the anvil length, the

lever will work through a greater arc for longer feeds.

IMPORTANT: Do not increase the anvil length to the

extent that the lever extension will not clear it, be-

fore the spring between the rod feed block and the

cap screw set solid.

E. To Shut Off

First close the torch fuel gas valve, then the torch oxy-

gen valve.

F. Operating Precautions

Improper handling of the torch may cause the flame to

backfire — go out with a loud snap. This may be caused

by overheating the nozzle or by dirt on the nozzle seat.

Should the flame flash back — burn back inside the torch

— immediately close the oxygen valve. Then close the

fuel gas valve. After checking the apparatus for causes

of flashback indicated above, relight the torch in the usual

manner. If flashbacks occur repeatedly, the torch should

be sent ESAB Remanufacturing Center, 411 S. Ebenezer

Rd., Florence SC 29501 for a complete checkup.

III. MAINTENANCE INSTRUCTIONS

For all repairs other than those covered below, send

the apparatus to ESAB Remanufacturing Center, Flo-

rence, SC Improperly repaired apparatus is hazard-

ous.

A. Torch

1. The Preheat-Oxygen Compensator Valve

Replacement of any of these parts will require read-

justment of the compensator valve stem, as follows:

a. Turn the adjustable stem in (clockwise) as far as it

will go.

b. Set the oxygen and fuel gas pressures, and light

the torch in the usual manner.

c. Open the fuel gas valve wide, and adjust the pre-

heat oxygen valve until a high velocity pointed flame

is obtained.

d. Open the torch cutting oxygen valve. The preheat

flames will become longer or blow off, indicating a

lack of preheat oxygen. Hold the cutting oxygen

valve open and adjust the compensator stem out-

ward (counterclockwise), until the preheat flames

show a minimum of change when the cutting oxy-

gen valve is opened and closed.

e. Any change in the cutting oxygen pressure at the

torch will require readjustment of the compensa-

tor stem. An increase in pressure will require an

inward (clockwise) adjustment, a decrease in pres-

sure will require an outward (counter clockwise)

adjustment.

2. Floating Mixer

If the mixer becomes clogged, it may be removed for

cleaning as follows:

Unscrew the body plug between the two hose con-

nections to the rear body. Remove the spring which

holds the mixer in place. Screw a standard No. 10-

32 machine screw, two inches or more in length, into

the rear of the mixer and pull out the mixer. To clean

the mixer, use a No. 35 drill (0.110 in. diameter) or a

soft brass or copper wire; other tools might enlarge

or bellmouth the orifice, hence they should not be

used. If the mixer is bent, or if its tip has been badly

nicked or marred it should be replaced by a new one.

Whenever the mixer is removed from the torch, the

"O" ring should be replaced with a new one. Apply a

light coat of soap film to the surface of the “O” ring

and then insert the mixer carefully (with a twisting mo-

tion) into the torch to avoid damage to the “O” ring.

3. To Reseat the Head

For reseating the head, use Tool No. 5230089 with

Leak Test Solution (998771) as lubricant. If the nozzle

nut threads in the head become fouled, they should

be chased with a 1-3/8 x 18 tap.

4. Fuel Gas or Preheat-Oxygen Valves

If leakage develops around the valve stems or if they

turn too easily, tighten the packing nuts. If this does

not help, remove the valve stem assembly and re-

place the sealing washer. In the original factory as-

sembly the sealing washer is a solid ring. The re-

placement sealing washer is split so that it can be

placed around the valve stem. Before inserting the

valve stem assembly into the valve body, be sure the

sealing washer is snug about the valve stem so that

the washer will start properly into the packing recess.

To seal properly, the packing material should be

molded in place. To do this, the packing nut should

be tightened until it is difficult to turn the valve. If

possible set the torch aside for 3 or 4 hours (prefer-

ably over-night), then back off the packing nut slightly

until the proper friction is obtained for satisfactory valve

adjustment. Test valve for leakage around the nut

and stem when the friction has been adjusted to

the desired amount. If either torch valve does not

shut off tightly, remove the valve stem assembly. Wipe

the seating portions of the valve stem and body with

a clean cloth. If the valve stem is damaged, the stem

assembly should be replaced. If the valve still leaks,

the valve body should be reseated at the ESAB Re-

manufacturing Center, Florence, SC or the nearest

ESAB distributor.

5. Cutting Oxygen Torch

If leakage develops through the cutting valve, replace

the valve seat. If leakage is around the valve stem,

replace the stem "O" ring seal. Proceed as follows to

replace these parts:

a. Remove cutting lever mounting nut (186W58), re-

taining screw (34Z91), and lever bushing (92Z66)

from lever (25Z56). Remove lever from torch.

b. Unscrew valve stem guide (637431) from the valve

body and carefully remove the cutting valve as-

sembly.

c.Using soapy water, moisten the cutting valve stem

(48Z67) through the stem guide and slide the stem

out of the guide.

d.Remove the “O” ring seal (85W10). spring washer

(637430), “O” ring (86W70) and valve spring

(29Z37) from the valve stem. Discard the “O” rings.

e.Remove seat retaining screw (6124-4880), washer

(94Z08), and valve seat (52Z89) from the bottom

of the valve stem. Discard the old valve seat.

f. Carefully clean and examine valve stem, spring,

guide, locknut and adjusting screw for damage and

excessive wear. Replace parts as necessary.

g.Install new valve seat(52Z89) (flat face in) and se-

cure in place with washer and screw.

h.Place new brass washer (94Z08) (countersink out)

against seat.

i. Install valve spring on top of upper valve shoulder,

and slide washer on top of the spring.

j. Apply a light coat of DuPont Krytox 240 (73585064)

on the new “O” ring seals (85W10) and (86W70)

slide the “O” rings into place.

k. Carefully slide the stem guide on the valve stem,

over the spring washer and “O” ring (85W10).

l. Insert the valve assembly in the torch valve body

and tighten the valve guide until it seats firmly.

m.Install the cutting valve lever on the torch and se-

cure with the lever bushing, retaining screw and

nut.

B.Starting Rod Feeder

1. Off-Center Adjustment

A pair of offset shims inserted between the mounting

bracket and the rod feed body locate the center line

of the starting rod approximately 1/4 in. off from the

nozzle center line. By offsetting the rod, the full ben-

efit of four to six preheat ports is obtained instead of

two, as would be the case if the rod were fed through

the nozzle center line.

The shims may be reversed to shift the body to either

side of the center line for normal right or left-hand

operation. Always reverse the shims in pairs to as-

sure proper alignment.

2. Off-the-Nozzle Adjustment

The rod feed body can be adjusted up or down for

varying the distance between the nozzle face and the

starting rod. An eccentric bolt (34Z90), bushing

(78Z96), and holding bolt (6164-1028) are provided

for this adjustment. The eccentric bolt head is turned

(with a wrench) and the eccentric bushing at the same

time. After the proper adjustment is obtained, make

sure that the bolt head and bushing engage the shims

and are against the sides of the mounting bracket

before tightening the eccentric cap nut. Then tighten

the holding bolt.

3. To Adjust the Anvil Locknut

Lift the stop nut (71Z91) clear of the broached hole

in which it is located, and turn it for proper adjust-

ment. (See Section II-D in Operating Instructions.)

4. To Replace Feed Block, Spring, and Guide Block

(Refer to View “A”)

To make these replacements, first remove the rod

feed bottom cover (31Z76) by unscrewing the guide

screw (35Z80). The remove the guide block (39Z68)

by unscrewing the attaching screw (34Z57) with a

socket wrench. Examine all parts for wear or distor-

tion, and replace where needed. Parts most frequently

requiring replacement will be feed block spring

(29Z23) and the spring (28Z82) and balls (90A13) in

guide block (39Z68). If guide block shows wear, it

should also be replaced.

Replacement of guide block spring and balls can be

accomplished by first prying the spring (28Z82) out

of the confining groove in the guide block. The two

balls should fall free of the guide block. Install two

new balls and new spring. Make sure the hole in the

spring is centered over the countersink recess in the

block groove. Carefully insert the guide block in rod

feed body recess, with center bore approach taper

facing out, and the hole in the spring and countersink

recess in the guide block in line with the screw hole

of the rod feed body. Replace attaching screw

(34Z57), making sure the point of screw enters coun-

tersink recess in block for proper engagement.

Tighten attaching screw securely, but do not over-

tighten.

5. Rod Feed Mechanism Replacements

To replace parts of the rod feed mechanism, the rod

feed body must be removed from the rod feed mount-

ing bracket. Remove the cutting oxygen valve lever

screw (34Z91) and the rod feed clevis pin (93Z42).

Slide the cutting oxygen lever from the head of the

cutting valve stem. Attach a length of string to the

rod feed sleeve for guiding purposes and remove the

rod feed eccentric bolt (34Z90) and bushing (78Z96).

Also remove the remaining rod feed body holding bolt

(6164-1028). Removal of both bolts will free the cover

plate and shims. Pull the rod feed body toward the

torch head until the lever (78Z93) and pull rod clevis

(68Z64) clears the mounting bracket (50Y59). The

pull rod clevis and lever are joined together by an

expansion pin (85W29). To remove the lever from

the pull rod clevis, drive out the expansion pin. How-

ever, to avoid distortion of clevis, the section surround-

ing the pin must be supported from the bottom. Re-

moval of the expansion pin will free the rod feed body

by snapping out the anvil spring (29Z18) and lifting

out the assembly. To remove the lever from the lever

guide block (78Z99), back up the block from the bot-

tom and drive out the rod feed lever pin (85W61).

To replace the rod feed clevis (68Z64), pull rod spring

(29Z34), or pull rod (78Z95), move the pull rod to-

ward the torch head until the offset in the pull rod

strikes the mounting bracket (50Y59). Lift the pull

rod up slightly on the clevis end and unscrew the

clevis. To remove the pull rod, push the rod toward

the rear body of the torch guiding the rod with the

string attached to the end feed sleeve.

Remove the pull rod sleeve. When the pull rod clevis

end clears the mounting bracket, the rod can be pulled

free of the torch by bending the offset end past the

mounting bracket. Reassemble the pull rod to the

torch in the reverse order. Inserting the pull rod may

cause it to bend. However, the bowed sections of the

rod (between the tube support brackets) can be

straightened out after the rod feed has been as-

sembled to the torch.

C. Replacement Parts

The 42 and 48 inch long torches are made up from the

basic 36 inch long torch. This is accomplished by

coupling the correct length extensions to the oxygen

and mixer tubes to make up the extra length. Thus

all parts shown in C-59 (36 inch) parts picture are

common to the 42 and 48 inch torches. The sketch

below shows the coupling and extensions used on

the 42 and 48 inch torches.

C-59 TORCHES

Part No. Description

02X67 36 in. Long Torch with Rod Feed Mechanism

02X68 48 in. Long Torch with Rod Feed Mechanism

02X91 42 in. Long Torch with Rod Feed Mechanism

ACCESSORIES

Part No. Description

21X48 "C"-size 200 lb. Gauge Adaptor Assembly

33Y64 C-59 Compensator Valve for conversion (In

cudes 85W10, 48Z41 and 83Z26)

163Z25 OXWELD 54 Anti-Friction Compound, for

Valve Threads

7358-5064 DuPont Krytox 240 Anti-Friction Compound,

for "O" Rings

HARDWARE

Part No. Description

6124-4880 8-32 x 1/2 in. Long Flat Socket Head Screw,

Steel

6133-2996 6-32 x 5/16 in. Long Oval Hd. Self-Tapping

Screw, Parker Kalon Type “F”

6164-1028 1/4-28 x 1-5/16 in. Long Hex. Head

Capscrew, Stainless Steel

6260-0001 1/32 x 1/2 in. Long Cotter Pin, Stainless

Steel

6430-4075 1/4 in. Standard SAE Plain Washer, Steel

Fig. 1 - C-59 Scarfing Torch - 02X68- 48 in. long

02X91- 42 in. long

MIXER TUBE EXTENSION -

OXYGEN TUBE EXTENSION -

147Z13 (02X91)

147Z15 (02X68)

147Z14 (02X91)

147Z16 (02X68)

PULL ROD -

150Z69 (02X91)

82Z05 (02X68)

MIXER TUBE AND EXTENSION MUST BOTTOM IN COUPLING

BRACKET - 151ZO6

BRACKET - 71Z94

COUPLING - 150Z56

35-1/8"

(02X91)

39-1/4" (02X68)

Fig. 2A - C-59 Scarfing Torch - 02X67 (36-in. Long)

Note: Parts for the cutting lever and arm assembly used on the Series 5 torch are not interchangeable with those used on Series 4. The series 4 can easily

be converted to accept these parts by enlarging the hole in the body lug (to which the lever is attached) with a 7/32 in. diameter drill.

BOLT - 34Z90

SCREW - 6164-1028

WASHER - 6430-4075

(2) nut - 186W59

"C"

"A"

27 1/4"

HANDLE - 24Y28

(4) SCREW - 6133-2996

"A"

SEE VIEW "E"

SILVER SOLDER

NOZZLE NUT- 37Z23

SLEEVE - 92Z67

(Included in Head - 83Z97)

1 3/8-18

HEAD - 83Z97

(Includes Sleeve - 92Z67)

SILVER SOLDER

BRACKET - 50Y59

SLEEVE

27Z88

BUSHING

78Z96

SEE VIEW "A"

PLATE - 78Z92

(2) SHIM - 78Z94

STOP - 68Z48

MIXER TUBE ASS'Y. - 16Y87

(Includes)

MIXER THROAT - 17Z75

MIXER NOZZLE ASS'Y. - 01Y43

(Includes)

0-RING - 84W85

OXYGEN TUBE - 27Z45

SILVER SOLDER

TUBE MUST BOTTOM

BODY - 80Z10

SEE VIEW "D"

LEVER - 25Z56

BOTTOM TUBE AT THIS END

PEEN TUBE BEFORE

ASSEMBLING

BRACKET - 71Z94

F-6640-Y 05 / 2009 Printed in U.S.A.

STEM - 48Z41

BODY - 83Z26

#10-32

SPRING - 28Z92

BALL - 53A61

PULL ROD

78Z95

RETAINER

68Z63

SPRING -

29Z34

LOCK - 78Z90

SPRING -

29Z18

LOCKNUT - 71Z91

ANVIL - 77Z49

SPRING -

28Z82

(2) BALL - 90A13

BLOCK - 39Z68

SCREW - 34Z57

COVER - 31Z76

PIN - 85W29

LEVER - 78Z93

BLOCK - 78Z99

PIN - 85W61

BODY - 20Y75

BLOCK - 51Z53

SPRING -

29Z23

SCREW - 35Z80

VIEW "E"

SCREW -

34Z91

BUSHING -

92Z66

NUT - 186W58

BUSHING -

2222859

7/16 - 20

"B"

SLEEVE - 77Z46

CLEVIS PIN - 93Z42

SNAP-RING - 202-8372

FUEL

CONNECTION

999082

OXYGEN

CONNECTION

10Z82

7/8 - 14

SILVER SOLDER

"O" RING - 96W97

GAS TIGHT SEAL

PLUG

35Z91

5/8 - 25

VIEW "D"

"O" RING - 84W85

(Included In Mixer

Nozzle - 01Y43)

SECTION "C" - "C"

VIEW "A"

Fig. 2B - C-59 Scarfing Torch - 0X67 (36-in. Long)

3/8 - 28

"O" RING - 85W10

#5 - 40

CLEVIS - 68Z64

NUT

186W58

BSHING

2222859

BUSHING

92Z66

SECTION "A" - "A"

LEVER SCREW - 34Z91

"O" RING - 85W10

PLATE - 637430

"O" RING - 86W70

3/4 - 20

NUT - 136Z18

GUIDE - 637431

"O" RING - 86W70

SPRING - 29Z37

STEM - 48Z67

GAS TIGHT SEAT

SCREW - 6124-4880

(2) GAS TIGHT

SEAT

ADJUSTING SCREW - 134Z0-6

9/16 -

18 (L.H.)

SEAT - 52Z89

(2) STEM ASSEMBLY - 54A87

APPLY ANTI FRICTION COMPOUND

PART NO. 163Z25

WASHER - 94Z08

SECTION "B" - "B"

SPRING

28Z91

ESAB C-59 Scarfing Torch Troubleshooting instruction

Brand: ESAB

Model: C-59 Scarfing Torch

Category: Welding System

Type: Troubleshooting instruction

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ESAB C-59 Scarfing Torch Troubleshooting instruction

ESAB C-59 Scarfing Torch Troubleshooting instruction

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