ESAB OXWELD C-62 User manual

INSTRUCTIONS for F-9178-K
May,2009
C-62 Cutting Torch
and
Powder-Washing Attachment
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 operate this equipment. Do NOT attempt to 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 this information reaches the operator.
You can get extra copies through your supplier.
Testing for Leaks
Everycutting outfitshould bethoroughly testedfor leaks
after it is first hooked up, and at regular intervals there-
after.After all connections have been made, make sure
all valves on the torch handle are closed. Then turn in
the regulator pressure-adjusting screws until the oxy-
gen delivery-pressure gauge registers 60 psi and the
fuel gas delivery-pressure gauge registers 10 psi. Us-
ing Leak Test Solution that is suitable for oxygen ser-
vice, such as P/N 998771 (8 oz. container), check for
leaksatthecylinder valves,thecylinder-to-regulatorcon-
nections,theregulator-to-hoseconnections,andthehose-
to-torch connections. If bubbling at any point indicates
leakage,tightentheconnection.If thisdoesnotstopleak-
age,closethe appropriatecylindervalve,open thecorre-
spondingtorchvalveto removeallpressurefrom theline,
andfinallyreleasetheregulatorpressure-adjusting screw
byturningit counterclockwise.Thenbreak theleakycon-
nection, wipe metal seating surfaces with a clean dry
cloth, and examine them for nicks and scratches. Re-
makethe connection(s)and retest.Do not tryto lightthe
torchuntil you aresatisfied thatall connections aregas-
tight.
After lighting the torch and adjusting the flames, use
leaktest solution to checkfor leakage atall torch valves
and at the nozzle nut.
OPERATION
Connecting
1. Attach regulators to the oxygen and fuel gas cylin-
ders. Follow all instructions supplied with the regu-
lators.
2. Attach oxygen and fuel gas hose to the regulators
and to the torch, after making sure all metal seat-
ing surfaces are clean. Tighten all connection nuts
with a wrench.
3. Attach nozzle to torch head, and tighten connec-
tion nut with a wrench.
Adjusting Gas Pressures
Fuel Gas: Openthefuelgasvalveaboutoneturn.Turnin
thepressure-adjusting screwon theacetylene regulator
untilitsdelivery-pressuregaugeregistersthedesiredpres-
sure (see cutting chart on page 4). Then immediately
closethe acetylenevalve.
Oxygen: Open the cutting oxygen valve by depressing
itsvalvelever fully. Turn inthe pressure-adjusting screw
onthe oxygenregulatoruntil itsdelivery-pressure gauge
registersthedesired pressure(see cuttingcharton page
4). 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 pressure as in-
dicated on the scales of the regulator caps.

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!

3
Lighting
Open the preheat oxygen valve on the torch a fraction
of a turn. Open the fuel gas valve on the torch about
two turns, and light the gas at the nozzle with a friction
lighter. DO NOT USE AMATCH. Then open the cutting
oxygen valve and adjust the preheat flames by open-
ing the preheat oxygen valve gradually. This will usu-
ally provide maximum preheat for the nozzle in use. If
the flames burn away from the end of the nozzle, or if
less preheat is desired, close the torch fuel gas valve
until the flame inner cones shorten noticeably, and then
readjust the flames with the preheat oxygen valve. Be
sure to keep the cutting oxygen valve open during any
adjustment of the preheat flames.
Shutting Off
Release the cutting oxygen valve lever. Then close the
fuel gas valve, and finally the preheat oxygen valve.
Operating Precautions
Backfire: Improper operation of the torch may cause
the flames to go out with loud ‘pop’. Such a backfire
may be caused by contact of nozzle with the work, by
spatter from the work, by the use of incorrect gas pres-
sures, 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 flame may not ‘pop’ out (backfire) but instead burn
back inside the torch with a shrill hissing or squeal. This
is called a ‘flashback’. A flashback should never occur
if (1) the equipment is in good condition; (2) preheat
ports on cutting nozzles or welding tips are cleaned
frequently; and (3) operating pressures are correct.
Should flashback occur, IMMEDIATELY shut off the
torch. Allow it to cool off for at least a minute. Then
check your nozzle or tip, gas pressures, readjust regu-
lators if necessary, and relight the torch. If flashback
recurs,send thetorchwith nozzlein usewhen flashback
occurredtoyour distributororto ESABRemanufacturing
Center,Florence SCfor repair.
MAINTENANCE
For all repairs other than those covered below, send
the apparatus to your ESAB Welding Products dis-
tributor or to ESAB Remanufacturing Center, 411 S.
Ebenezer Road, Florence SC 29501. Improperly re-
pairedapparatus is hazardous.
Preheat Valves: Leakagearound eithervalve stem can
usually be corrected by tightening the packing nut
slightly. If this does not stop the leakage, replace the
valvestem assembly.
Ifeitherpreheat valvefailsto shutoffcompletely,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 and tighten it several times with
maximum force. If this does not eliminate leakage, try a
newvalvestem assembly.Ifthen thevalvedoes notshut
off completely, send the torch to a repair station for
reseatingof the body.
After installing a new valve stem assembly, tighten the
packing nut until the valve stem can be turned only with
great difficulty, and set the unit aside, for three or four
hoursatleast, tosetthe packing.Thenback offthepack-
ing nut until the valve stem turns readily.
Cutting Valve: If leakage develops around the cutting
valve stem or between the cutting valve guide and the
torch body, or if the valve fails to shut off completely,
proceed as follows:
1. Remove cutting valve lever (see pg. 3).
2. Unscrew cutting valve guide and lift out entire valve
assembly:guide(with externaland internal O-rings),
valve stem, spring, and O-ring retaining washer.
3. Pull stem out of guide. Replace it with new part
unless the molded rubber seat appears to be in ex-
cellent condition.
4. Removethe internal O-ring (85W10) fromthe guide
and insert a new O-ring. Replace the external O-
ring (638797) if it shows distinct signs of wear.
5. Reassembleby placingretaining washerand spring
in guide, then placing stem through spring and O-
ring in guide.
6. Screw valve assembly into body. Before reassem-
bling cutting lever, connect torch to oxygen source,
apply at least 60 psi pressure, and check for leak-
agethrough thevalve, aroundthe stem,and around
the guide.
7. Reassemble cutting lever to torch.
Mixer: To remove the mixer for cleaning or replace-
ment, first unscrew the mixer chamber plug. Then let
the two springs drop out in your hand. Finally, dislodge
the mixer and its three washers (two brass, one Neo-
prene) either by rapping the torch, held vertically,
against a block of soft wood, or by turning a long 10-32
machine screw into the thread in the end of the mixer
and pulling it out.
Whenreassembling, place thethree washers(one neo-
prene between two brass) on the extreme back end of
the mixer. (Be sure to use a new neoprene washer un-
less the old one appears to be in equal-to-new condi-
tion.) Slip mixer into torch, then insert large spring and
push it down hard to seat the forward brass washer
against shoulder in body. Then drop small spring inside
large spring, insert mixer plug, and tighten plug firmly.
Besure themixerchamber plugis fittedwith anO-ring in
goodcondition (evenin cases where the plugcarried no
O-ringoriginally).

4
PARTS INFORMATION
All parts which can be replaced without breaking soldered or brazed joints are illustrated below or listed on the next
page. When ordering parts, please give both part number and description (including size, where appropriate).
50Z38
THUMBPIECE
DRILL AT ASSEMBLY
#52 (.0635) DRILL
PIN
6262-0009
50Z37
LATCH
62399001
PIN
51Z31
INSERT
638981
LEVER ASSEMBLY
7/8-20
33A56
NUT
01Y41 (ACET.)
MIXER ASSEMBLY
77Z29
WASHER
77Z30
WASHER
77Z29
WASHER
GUIDE - 638240
“O”RING - 638797
“O”RING - 85W10
WASHER - 638241
SPRING - 29Z37
STEM - 638930
* 77Z97
WASHER
3/8-24
(2) 54A87
STEM
ASSEM.
9/16-25
3924
SPRING
28Z43
SPRING
86W85
“O”RING
134Z55
PLUG
Fig. 1 - C-62 Torch, Part No. 02X85
ING NOZZLES. Use the OXWELD tools recommended
inthechartsonpage4or OXWELDnozzlecleaningcom-
pound.
To clean the preheat slots on internal nozzles, remove
the external sleeve and use a soft bristled brush.
Forlonger life,nozzles shouldbe cleanedperiodically in
asolution of OXWELDnozzle cleaningcompound (Part
No.761F00) made upand used asdirected on the jar in
which it is packed.
Cutting Valve Lever: To remove, merely drive out the
fulcrum spiral-pin, using a drill or piece of rod (7/32-in.
diam.or smaller).
Cleaning Cutting Nozzles: If the cutting nozzle does
notproducestraight,uniformflames,or ifanyofthenozzle
orifices become clogged, clean them by hand with the
correct size twist drill shown in the table on page 4 or
with OXWELD tip cleaners. (The relationship between
OXWELD tip cleaners and drill sizes is shown on the tip
cleanercase.)DONOTUSEORDINARYTWISTDRILLS
TOCLEANFIN-WASHING,GOUGINGORRIVETWASH-

5
CUTTING & SPECIAL NOZZLES INFORMATION
OPERATING DATA
OXY-ACETYLENE NOZZLES
Steel (in.) Nozzle Regulator Press. (psig)* Min.
Thickness Size Oxygen Acetylene Hose Size
CUTTING: 1502 Series
1/16 - 1/8 1/4" 25-40 5-7
1/4 - 3/8 20-40 5-7
1/2 - 5/8 1/2" 30-40 5-7 1/4-in. oxy.
3/4 - 1 1-1/2" 30-40 5-7 1/4-in. acet.
2 - 5 4" 30-60 6-8
6 - 10 8" 35-75 8-10 3/8-in. oxy.
12 12" 60-80 10-12 3/8-in. acet.
GOUGING: 1511 Series
— 13 65-75 8-9 3/8-in.oxy.
— 19 80-90 9-10 1/4-in.acet.
— 25 90-100 9-10
RIVET WASHING: 1507 Series
— 19 20-90 5-10 3/8-in. oxy.
— 25 20-90 5-10 1/4-in.acet.
Nozzle Cleaning Data and Part Numbers
Cleaning Tool
Size Part No. Preheat Cutting
1502 SERIES ( preheat holes)
1/4" 08Z67 69Drill 68 Drill
1/2" 15Z17 66 60
1-1/2" 15Z18 65 53
4" 15Z19 61 46
8" 15Z20 57 39
12" 15Z21 56 31
1511 SERIES (5 or 7 preheat holes)
13 15X14 5190071 5190068
19 15X15 5190072 5190069
25 15X16 5190062 5190070
1507 SERIES (6 preheat holes)
19 08Z90 62Drill 3/16"Drill
25 15Z37 62 1/4"
1524 SERIES (10 preheat holes)
25 15X51 5190070* 5190062
1520 SERIES (10 preheat holes)
13 15X33 5190068 5190071
19 15X34 5190069 5190072
25 15X35 5190070 5190062
1539 SERIES (10 preheat holes)
19 65Z55 55Drill 3/16"Drill
25 65Z56 53 1/4"
1534 SERIES (2 piece — slotted preheats)
Part No. Cleaning**
Size Internal External Tool (Cutting)
2 14Z66 14Z38 76Drill
3 14Z50 14Z38 68
4 14Z51 14Z38 60
6 14Z52 14Z39 53
8 14Z53 14Z39 46
* 5190070toolisalso used forcleaningcuttingthroat.
** To cleanpreheatslots, remove externalsleeveanduse softbristled
brush.
OXY-FUEL GAS NOZZLES
Reg. Press. (psig)*
Steel (in.) Nozzle Fuel Gas Min.
Thickness Size Oxygen Nat. Gas Propane Hose Size
CUTTING: 1534 Series
1/8 2 35-40 1-2 1-2 1/4-in. oxy.
1/4 - 3/8 3 30-40 1-2 1-2 1/4-in. fuel
1/2 4 30-35 1-2 1-2 gas
3/4 - 1-1/2 6 30-45 1-2 1-2
2 - 5 8 30-50 2-4 2-3 3/8-in. oxy.
3/8-in. F.G.
FIN WASHING: 1524 Series
— 25 50-90 24-26 18-20 3/8-in. oxy.
3/8-in. F.G.
GOUGING: 1520 Series
— 13 65-75 6-8 5-7
— 19 80-90 8-10 6-8 3/8-in. oxy.
— 25 90-100 11-14 9-11 1/4-in. F.G.
RIVET WASHING: 1539 Series
— 19 20-90 5-10 5-10 3/8-in. oxy.
— 25 20-90 5-10 5-10 3/8-in. F.G.
*Using 25 Ft. Hose Lengths.

6
powder tube into the connection (185W05). Using
twowrenches, tighten theconnection.
4. Positionthe powdervalve(55Y49)asshown inFig.2
withtheleverinline withthecuttingvalvelever on the
torch. Connect and tighten the powder tube to the
powder valve and connect the powder inlet tube
(61Y53)tothe powdervalveinlet.Use twowrenches
to tighten the connections.
MAINTENANCE
ACV-2 Powder Valve: To remove the stem and seat
(33Y46) for cleaning or replacement, remove clip and
leverpin, and liftleverand washer offvalve stem. Then,
unscrew valve guide from valve body. The valve stem
and seat can now be lifted out. Replace valve stem and
seat assembly and any other parts which are worn or
corroded. Blow out all loose powder from valve and re-
assemble,being sureparts arein propersequence (see
parts picture below).
Powder Adaptor: The powder nozzle (61Y06) can be
replacedby simply breakingthe connection andremov-
ing the nozzle from the clamp. The new nozzle is sup-
plied with a ferrule and nut for easy installation.
Fig. 2 - Powder Washing Attachment for C-62 ( 61Y01)
POWDERADAPTORASSEMBLY-61Y05
(INCLUDES)
INCLUDES
(2)FERRULE-185W35
NOZZLE-61Y06
CLAMP-150Z99
(2) SCREW-6134-1991
CONNECTION-185W05
POWDERTUBE-147Z25
INSERT-73Z86
(SOFT SOLDER)
DIAPHRAGM-30Z55
1/8"-27 NPT
STEM& SEAT-33Y46
PARTS SUPPLIED
WITH-55Y49
4789-NIPPLE
36Z40-NUT
SECTION “B”-“B”
SILVER SOLDER
RING-38Z68
NUT-37Z25
CAP-31Z57
PIN-38Z34
SPRING-28Z20
POWDERVALVEASSEMBLY
TYPE ACV-2 - 55Y49
(SEE VIEW “A”
FOR REPLACEMENT PARTS)
SILVER SOLDER
5/8"-18
POWDERINLETTUBE-61Y53
3/16"-24"
(2) WASHER-73Z98
CONNECTION-185W04
INCLUDES
FERRULE-185W35
1"-20
“B”
ELBOW-11Z73
THUMBSCREW-6135-1052
VIEW “A”
LEVER-25Z22
CLIP-81W53
NUT-185W40
FERRULE-185W35
BODY-80Z58
POWDER WASHING ATTACHMENT ASSEM-
BLY INSTRUCTIONS
Before attempting to use the powder attachment, read
carefully the instructions packed with your OXWELD
PowderDispenser.
Attach to Torch
1. Insert the powder nozzle (61Y06) through the
clamp.Slip the ferrule (185W35)and nut from com-
pression-type connection 185W05 over the end of
the powder nozzle. Be sure the heavy end of the
ferrule is towards the nut. Screw the connection
(185W05)into the nut. Usingtwo wrenches, tighten
the connection.
2. Assemble the cutting nozzle in the torch as shown
in Fig. 2 below. Locate the clamp on the torch so
that the end of the powder nozzle is flush with the
end of the cutting nozzle as illustrated below.
Tighten the clamp on the torch and on the powder
nozzle.
3. Slip the ferrule 185W35 and nut from connection
185W35onto the powdertube (147Z25)with heavy
end of ferrule toward the nut. Insert the end of the

7

F-9178-K 05 / 2009
IF YOU DO NOT KNOW WHOM TO CALL
Telephone:(800) ESAB-123/Fax: [phone]
Hours: 8:00 AM to 5:00 PM EST
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
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