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

Brand: ESAB

Model: R-89-3M-580 & R-89-4M-680 Regulators

Type: Troubleshooting instruction

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

The ESAB R-89-3M-580 & R-89-4M-680 Regulators are designed to provide precise and consistent gas pressure regulation for a variety of applications. These regulators are ideal for use with inert gases, such as argon and helium, and are commonly used in welding, cutting, and heating operations.

With a maximum delivery pressure of 2000 psig, these regulators offer a wide range of adjustment options to meet specific requirements. The easy-to-read gauges provide clear visibility of both cylinder pressure and delivery pressure, allowing for precise monitoring and control.

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

INSTRUCTIONS for

F-11-447-L

January, 2001

Be sure this information reaches the operator.

You can get extra copies through your supplier.

F-11-447-L

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

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.

CAUTION

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-

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 SLOWLY. After the cylin-

der-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-ad-

justing screw clockwise. To decrease delivery pres-

sure, turn the pressure-adjusting screw counter-

clockwise.

2. When making the initial delivery pressure adjust-

ment, 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.

IMPORTANT: Before starting operations, test all con-

nections with Leak Test Solution suit-

able 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 be-

fore removing a regulator from a cylinder, you should

release all pressure from the regulator. To do this, pro-

ceed 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

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

the gauges or the exposed valve seat assem-

bly) 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 leak-

age. 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 pres-

sure. 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 connec-

tion (if not tested under B. 1. or for reassurance).

3. Blank off regulator outlet. Set regulator to maxi-

mum 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 diam-

eter metal rod. Never use a regulator without

this filter.

For all repairs other than those covered below,

send the regulator to your ESAB welding equip-

ment 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 pres-

sure-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 regu-

lator 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.

der.

MAINTENANCE INSTRUCTIONS

If this regulator does not operate properly, stop

work immediately and investigate the cause of the

malfunction. Maintenance work must be per-

formed by an experienced person. Do not permit

untrained persons to inspect, clean, or repair this

regulator. Use only recommended replacement

parts.

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 pressure-

adjusting screw before admitting pressure into the

regulator.

2. Unless cylinders are mounted on a suitable truck,

always remove regulators before you move cylin-

PARTS INFORMATION

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.

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

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

* Includes 92Z61 bushing and ring 998289.

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

NIPPLE - 103Z01 (-580)

18719 - (-680)

NUT - 37Z33 (-580)

18720 (-680)

71Z33

FILTER

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

** CYLINDER PRESS. GAUGE -

999445 (-580)

18641 (-680)

1/2"-13

** DELIVERY PRESSURE

GAUGE - 999445 (-580)

18641 (-680)

FITTING - 86W35

05Y19

SCREEN

ASSEMBLY

28Z32

SPRING

32Z43

STEM

32Z42

SEAT

35Z40

SCREW

38Z50

32Y15 SEAT ASSEM.

130Z55

DIAPHRAGM

94Z24

GASKET

130Z06

RING

93Z26

PLATE

28Z71

SPRING

6212

WASHER

*639125

CAP ASSEM.

35Y22

P.A. SCREW

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

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com

Hours: 7:30 AM to 5:00 PM EST

A. CUSTOMER SERVICE QUESTIONS:

Order Entry Product Availability Pricing Delivery

Order Changes Saleable Goods Returns Shipping Information

Eastern Distribution Center

Telephone: (800)362-7080 / Fax: (800) 634-7548

Central Distribution Center

Telephone: (800)783-5360 / Fax: (800) 783-5362

Western Distribution Center

Telephone: (800) 235-4012/ Fax: (888) 586-4670

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693

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: (843) 664-4452

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST

Performance Features Technical Specifications 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

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

F. WELDING EQUIPMENT TRAINING:

Telephone: (843)664-4428 / Fax: (843) 679-5864

Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 / Fax: (843) 664-4454 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

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

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

Brand: ESAB

Model: R-89-3M-580 & R-89-4M-680 Regulators

Type: Troubleshooting instruction

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

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

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

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