APPARATUS REPAIR MANUAL - ESAB apparatus/arm_apparatus rep… · ESAB W elding & Cutting Products...

APPARATUSREPAIR MANUAL

SECTION H-15

REGULATORSR-36 SERIES

SECTIO

N H

-15R

-36 SeriesR

egulators

ESAB Welding & Cutting ProductsFlorence, SC

Section Item Page Date

REPAIR PROCEDURES

8. Remove pressure gauges with a 9/16-in. wrench fromthe cylinder pressure gauge port of the body.

9. If inlet nut and/or nipple are damaged, remove nippleusing an 11/16-in. deep-wall six point socket or open-end wrench and discard the damaged part(s).

NOTE: If nipple is difficult to loosen, try placing bodyin hot water for a few minutes to soften theLoctite sealant and then try to remove thenipple again while the body is still hot.

10.Remove inlet filter inside the nipple with a No. 1 “Ezy-Out” or a long No. 6 wood screw and discard filter.

11. If outlet connection is damaged, remove with a 5/8-in. wrench and discard.

CLEANINGAll parts which were not discarded during disassemblyshould be cleaned for oxygen service, even if the regu-lator is made for fuel gas or inert gas service. CleaningCompound No. 81 (P/N 73585081) is a suitable cleaningsolution. For brighter finish of brass parts, Bright-DipCompound No. 70 (P/N 73485070) may be used. Thesecompounds are available in 20 lb. containers. The solu-tions should be made up as directed on the containers.

If inlet nipple and/or outlet connection were removed,retap the 1/4-in. NPT threads in body to remove anyresidual Loctite sealant. Blow out chips with low pressuredry nitrogen. Threads must be clean. Make sure no chipsor foreign material gets into valve cavity.

REASSEMBLINGDuring reassembly, the following procedures shouldalways be observed:

1. When replacing inlet nipple or outlet connection.Loctite Grade “#242” Compound (P/N 73585435)should be used as follows:

REPAIR PROCEDURES

TOOLSIn addition to standard tools (see Section H-1; Item 4),the following are also recommended for repairing the R-36 family single-stage regulators:

Nesting Fixture, P/N 5220128Cap Spanner Wrench, P/N 5230146O-Ring Insertion Tool, P/N 5220136Spanner Wrench (RBO Adaptor) -(R-36-75-540), P/N 5250149

DISASSEMBLINGIn the parts illustrations (starting with Item 300) parts thatshould be replaced by new parts are indicated by asquare about the item number. When disassembling aregulator, examine all other parts as they are removed.If a part is damaged, it should be replaced.

To disassemble an R-36 regulator, proceed as follows:

1. Place regulator in nesting fixture (5220128) thatshould be clamped in a vise.

2. Remove pressure-adjusting screw.3. Remove cap using spanner wrench.4. Remove spring, spring washer, diaphragm slip ring

and diaphragm assembly. Discard the diaphragmassembly.

5. Remove valve seat screw with a 3/4-in. socket wrench.Remove and discard the O-ring on valve screw.Examine the seating surface about the orifice insidethe valve seat screw. If nicked or scored, discard theseat screw.

NOTE: Replacement seat screw includes O-ring.

6. Remove and discard seat-and-stem and valve clos-ing spring.

7. Remove safety release valve cap (if equipped) with a3/8-in. wrench. Remove and discard the disk and twowashers.

REGULATORS

R-36Family

H15 1 1 9/96

New Page



REPAIR PROCEDURES

a. Thread should be clean - free of grease and oil.b. Apply one drop of Loctite on the second thread

from the lead end of the male pipe threads.c. Rotate the part about 900 to encourage the

liquid compound to flow around the threads. DoNOT allow the liquid to flow to the lead end ofthe threads.

d. Assemble hand tight and then tighten with atorque wrench to 500 in.-lbs.

2. Starting from the second thread, wrap a single turn of1/4-in. wide Teflon tape around the pipe threads ofeach gauge; assemble the gauges to the propergauge port in the body; and then tighten each gaugewith a wrench until snug and properly positioned.

3. Blow out valve seat cavity in body with low pressuredry nitrogen so that all chips are removed.

4. Tap new filter into inlet nipple with a clean 1/4-in.diam. metal rod.

5. If regulator is equipped with a safety release disk,install new disk between two new washers (smoothside against the disk) in the body. Make sure Screen(17726) is in place.Assemble and tighten safetyrelease cap with a torque wrench to 20 in.-lbs.

6. Place new valve closing spring in the body and thenplace new stem-and seat on top of spring.

7. Install O-ring between the hex and threads of valveseat screw using O-ring insertion tool (5220136).Without the tool, O-ring may be damaged by thethreads of the seat screw.

8. Install valve seat screw so that stem-seat pin pro-trude through the orifice. Push down to engagethreads and then tighten seat screw with torquewrench to 300 in.-lbs. Push down on stem to makesure it moves freely.

9. Place new diaphragm assembly, slip ring, pressure-adjusting spring, and spring washer in position.

10.Assemble cap and tighten to 120 in.-lbs. usingspanner wrench (5230146).

11. Install pressure-adjusting screw turning it in onlyenough to touch the spring washer.

NOTE: If trim screw was used and removed, installin pressure-adjusting screw only a few turns.Adjustment of trim screw is made during thetesting procedures.

TESTINGAll remanufactured regulators must be tested as de-scribed in Section H-1, Item 2 using specifications inItem 2 of this section.

If trim screw was used and removed from pressure-adjusting screw, then proceed as follows:

1. With inlet gas supply set at specified pressure andwith a No. 53 orifice connected to the outlet ofregulator as described in the Section H-1, Item 2,remove trim screw, open test shutoff valve, and turnin the pressure-adjusting screw all the way. Gasshould be flowing out of the No. 53 orifice.

2. Apply one or two drops of Loctite-Super Bonder No.495 (71200434) about midway on the threads of thetrim screw and then install in pressure-adjustingscrew. Turn in trim screw until you obtain a readingslightly above the specified minimum delivery pres-sure.

3. Close test shutoff valve. Wait at least two minutesto allow adhesive on trim screw to set before turningpressure-adjusting screw. Check for leakage at alljoints while waiting.

4. Open test shutoff and proceed to the “jump-and-creep” test.

REGULATORS

R-36Family

H15 1 2 9/96

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Section Item Page DateH15 2 1 9/96

TEST SPECIFICATIONSR-36 REGULATORS

NOTE: See Section H-1, Item 2 for testing procedures

Jump & Creep TestDelivery Pressure,

Inlet Minimum psiRegulator Pressure Delivery Pressure, with Dead-Model psi psi, with flow (1) flow(1) ended

R-36-75-540 2640 75 30 36R-36-75-580

R-36-15-510 250 15(2) 10 14R-36-15-300

R-36-125-580 2640 125 100 115

R-36-500-540 2640 500 300 360

R-36-400-580 2640 400 300 360

R-36-CF-580 2640 40 cfh(3) 30 cfh 38 cfhR-36-FM-580 2640 (4) 50 62

TEST SPECIFICATIONS

(1) Gas (nitrogen) flow is through a No. 53 (0.0595-in. diam.) drilled spud, P/N 5220032.(2) With pressure-adjusting screw turned in all the way and with no flow from outlet,

delivery pressure reading should not exceed 28 psi.(3) The R-36-CF-580 is equipped with flow gauge calibrated in cubic feet/hour (cfh)

when used with spud P/N 150Z06 (installed in outlet connection of regulator).(4) Use No. 63 (0.037-in. diam.) drilled spud (P/N 5220062) instead of No. 53 drilled

spud. Adjust delivery pressure to 50 psig with inlet pressure of 1300 psig, withflowmeter valve wide open, and with nitrogen flowing through the No. 63 drilled spudattached to the outlet of flowmeter. At this setting, top of ball float in flowmeter shouldread between 56 and 64 on the argon scale.

REGULATORS

R-36Family

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PARTSREGULATORSR-36 FAMILY

R-36

H15 3 1 5/04

New Page

R-36-75-540 R-36-15-510 R-36-15-300 R-36-75-580 R-36-125-580 R-36-400-580 R-36-500-540Oxygen Acetylene Acetylene Inert Gas Inert Gas Inert Gas Oxygen

Item Description 21185 21184 21314 21313 21364 21365 215731 LABEL, Gas Service 954096 954097 954175 954174 954218 954219 954399

2 SPRING, Press. Adj. 29Z74 998397 998397 29Z74 29Z74 29Z74 29Z74

3 SEAT/STEM, Valve 17967 32Y39 32Y39 17967 17967 17967 17967

4 SPRING, Valve 19147 19147 19147 19147 19147 19147 19147

5 CONNECTION, Outlet 3389 3390 3390 74516 186W41 186W41 186W41

6 NUT, Inlet 410 1369 37Z73 37Z33 37Z33 37Z33 410

7 NIPPLE, Inlet 998386 998385 998382 998385 998385 998385 37Z33

8 GAUGE, Cyl. Press. (HP) 19082 19081 19081 19082 19082 19082 19082

9 GAUGE, Del. Press. (IP) 19079 19078 19078 19079 19080 21367 21367

10 SCREW, Press. Adj. 121181 121181 121181 121181 18789 18789 18789

◆ P.A. Screw 18789 includes: Handle-18789, Retaining Rings-950707, and Setscrew - 1/4”-20 x 1/2”.

R-36 Series "A" Family Parts Breakdown



PARTS

R-36-FM-580 (Series B) Regulator-Flowmeter - P/N 21505

Parts which should always be replaced are indicated by ❑ . NOTE: For design changes, see Sect. H-15, Item 3

New Page

❑ 11 ... SPRING, Valve ..................................... 29Z6212 ... NIPPLE, 1/4" NPT .............................. 63950113 ... FLOWMETER ASS'Y (50 psi) ........... 639749*

❑ 14 ... GAUGE, Cylinder Pressure ................. 1717615 ... NUT, Inlet Connection .......................... 37Z3316 ... NIPPLE, Inlet Connection .................. 998385

❑ 17 ... FILTER (Supplied w/item 19) ............... 71Z3318 ... CRYSTAL, Replacement Gauge ......... 1885919 ... PLUG, Hole ......................................... 950142

1 ... SCREW, Set 1/4" - 20X1/2" ........... 613070892 ... CAP ASSEMBLY ................................ 999131

❑ 3 ... LABEL ............................................... 20915704 ... PLATE, Spring .................................... 9987705 ... SPRING, Pressure-Adjusting ............... 29Z746 ... SLIP RING ............................................ 82Z40

❑ 7 ... DIAPHRAGM ASS’Y............................. 30Y118 ... SEAT SCREW (Includes O-Ring) ...... 639963

❑ 9 ... O-RING ................................................ 86W99❑ 10 ... SEAT-AND-STEM, Valve ..................... 17967

* For flowmeter parts, see Section J-1, Item 32.

REGULATORSR-36 FAMILY

R-36-FM-580

H15 580 1 9/96

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Item No. Description Part No. Item No. Description Part No.



PARTS

R-36-CF-580 (Series B) Argon Regulator - P/N 21506


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8

1 ... SCREW, Pressure-Adjusting ............... 219422 ... CAP ASSEMBLY .................................. 18791

❑ 3 ... LABEL ............................................... 20915704 ... PLATE, Spring .....................................9987705 ... SPRING, Pressure-Adjusting ............... 29Z746 ... SLIP RING ............................................. 82Z40

❑ 7 ... DIAPHRAGM ASS’Y ............................. 30Y11❑ 8 ... O-RING ................................................. 86W99

9 ... SEAT SCREW (includes O-ring) .......639963

❑ 10 ... SEAT-AND-STEM, Valve ..................... 17967❑ 11 ... SPRING, Valve ..................................... 29Z62

12 ... CONNECTION, Outlet Spud ................ 1856013 ... GAUGE, Delivery Pressure ................ 999534

❑ 14 ... GAUGE, Cylinder Pressure ................. 1717615 ... NUT, Inlet Connection .......................... 37Z3316 ... NIPPLE, Inlet Connection .................. 998385

❑ 17 ... FILTER (Supplied w/item 18) ............... 71Z33❑ 18 ... DISK, Safety Release ........................... 92Z08❑ 19 ... WASHER (2) ......................................... 92Z07

20 ... CAP ....................................................... 31Z8621 ... CRYSTAL, Replacement Gauge ......... 1885922 ... SAFETY SCREEN ................................ 17726


R-36-CF-580

H15 580 2 5/04

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PARTS

1 ... SCREW, Pressure-Adjusting.............. 219422 ... CAP ASSEMBLY .................................. 21180

❑ 3 ... LABEL ................................................. 9541754 ... PLATE, Spring .................................... 9987705 ... SPRING, Pressure-Adjusting ............... 29Z026 ... PLATE, Diaphragm............................... 218277 ... RING, Diaphragm ................................. 82Z40

❑ 8 ... DIAPHRAGM ........................................ 218289 ... RETAINER, Plunger ............................. 21863

10 ... PLUNGER ............................................. 17460❑ 11 ... SEAT-AND-STEM, Valve ..................... 32Y39

R-36-15-300 (Series B) Acetylene Regulator - P/N 21314Parts which should always be replaced are indicated by ❑ .

NOTE: For design changes, see Sect. H-15, Item 3

12 ... SPRING, Valve ..................................... 19147❑ 13 ... O-RING ................................................ 86W63

14 ... PLUG, Inlet ........................................... 2193015 ... GAUGE, Cylinder Pressure ................. 21938

❑ 16 ... GAUGE, Delivery Pressure .................. 2193417 ... NUT, Inlet Connection .......................... 37Z7318 ... NIPPLE, Inlet Connection .................... 21522

❑ 19 ... FILTER (Supplied w/item 18) ............... 71Z3320 ... CONNECTION, Outlet ............................ 339021 ... CRYSTAL, Replacement Gauge ......... 18859


R-36-15-300Series B

H15 300 B 1 9/96

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2115

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1314

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10 ... PLUNGER ............................................. 17460❑ 11 ... SEAT-AND-STEM, Valve ..................... 32Y39



❑ 16 ... GAUGE, Delivery Pressure .................. 2193417 ... NUT, Inlet Conn ...................................... 136918 ... NIPPLE, Inlet Conn ............................ 103Z01

❑ 19 ... FILTER (Supp. w/item 18) ................... 71Z3320 ... CONN., Outlet ......................................... 339021 ... CRYSTAL, Repl. Gauge ....................... 18859

R-36-15-510 (Series B) Acetylene Regulator - P/N 21184



R-36-15-510Series B

H15 510 B 1 9/96

New Page

PARTS

2115

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1112

1314

1718

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789

R-36-75-540 Series “B” Regulator illustrated

22




R-36-75-540 (Series B) Oxygen Regulator - P/N 21185


PARTS




10 ... PLUNGER ............................................. 17460❑ 11 ... SEAT & STEM, Valve ........................... 17967



❑ 16 ... GAUGE, Delivery Pressure .................. 2193517 ... NUT, Inlet Connection .............................. 41018 ... NIPPLE, Inlet Connection .................... 21519

❑ 19 ... FILTER (Supplied w/item 18) ............... 71Z3320 ... CONNECTION, Outlet ............................ 338921 ... CRYSTAL, Replacement Gauge ......... 18859


R-36-75-540Series B

H15 540 B 1 9/96

New Page

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PARTS

R-36-500-540 (Series B) Oxygen Regulator - P/N 21573





10 ... PLUNGER ............................................. 17460❑ 11 ... SEAT-AND-STEM, Valve ..................... 17967



❑ 16 ... GAUGE, Delivery Pressure .................. 2193917 ... NUT, Inlet Connection .............................. 41018 ... NIPPLE, Inlet Connection .................... 21519

❑ 19 ... FILTER (Supplied w/item 18) ............... 71Z3320 ... CONN., Outlet 1/4" flare ................... 186W4121 ... CRYSTAL, Replacement Gauge ......... 18859

❑ 22 ... O-RING .............................................. 493552


R-36-500-540Series B

H15 540 B 2 5/04

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PARTS

R-36-75-580 (Series B) Inert Gas Regulator - P/N 21313








❑ 16 ... GAUGE, Delivery Pressure .................. 2193517 ... NUT, Inlet Connection .......................... 37Z3318 ... NIPPLE, Inlet Connection .................. 103Z01

❑ 19 ... FILTER (Supplied w/item 18) ............... 71Z3320 ... CONNECTION, Outlet .......................... 74S7621 ... CRYSTAL, Replacement Gauge ......... 18859


R-36-75-580Series B

H15 580 B 1 9/96

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2115

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1112

1314

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Parts which should always be replaced are indicated by ❑ .



14 ... PLUG, Inlet ........................................... 2193015 ... GAUGE, Cylinder Pressure ................. 2193816 ... GAUGE, Delivery Pressure .................. 2193617 ... NUT, Inlet Connection .......................... 37Z3318 ... NIPPLE, Inlet Connection .................. 103Z01

❑ 19 ... FILTER (Supplied w/item 18) ............... 71Z3320 ... CONNECTION, Outlet ....................... 186W4121 ... CRYSTAL, Replacement Gauge ......... 18859

PARTS

1 ... SCREW, Pressure-Adjusting ............... 18789... (incl. items 1A, 1B & 1C

1A . HANDLE ................................................ 187901B . RING, Retaining (2) ............................ 9507071C. SETSCREW 1/4"-20 x 1/2" ............ 613350872 ... CAP ASSEMBLY .................................. 21180





H15 580 B 2 9/96

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R-36-125-580 (Series C) Inert Gas Regulator - P/N 21364

Parts which should always be replaced are indicated by ❑ .

14 ... PLUG, Inlet ............................................ 2193015 ... GAUGE, Cylinder Pressure .................. 2193816 ... GAUGE, Delivery Pressure .................. 2193617 ... NUT, Inlet Connection .......................... 37Z3318 ... NIPPLE, Inlet Connection ...................103Z01

❑ 19 ... FILTER (Supplied w/item 18) ............... 71Z3320 ... CONNECTION, Outlet ........................ 186W4121 ... CRYSTAL, Replacement Gauge ........... 18859

PARTS


❑ 3 ... LABEL ..................................................9542184 ... PLATE, Spring .....................................9987705 ... SPRING, Pressure-Adjusting ............... 225036 ... PLATE, Diaphragm ............................... 218277 ... RING, Diaphragm.................................. 82Z40

❑ 8 ... DIAPHRAGM ......................................... 218289 ... RETAINER, Plunger .............................. 21863

10 ... PLUNGER.............................................. 17460❑ 11 ... SEAT-AND-STEM, Valve ...................... 17967

12 ... SPRING, Valve ...................................... 19147❑ 13 ... O-RING ................................................. 86W63


R-36-125-580Series C

H15 580 B 2 5/04

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2115

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1314

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789


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1 ... SCREW, Pressure-Adjusting ............... 219422 ... CAP ASSEMBLY ......................... 0558005990

* 3 ... LABEL .................................................. 9542194 ... PLATE, Spring ..................................... 9987705 ... SPRING, Pressure-Adjusting................. 225036 ... PLATE, Diaphragm ................................ 218277 ... RING, Diaphragm ................................... 82Z40

* 8 ... DIAPHRAGM .......................................... 218289 ... RETAINER, Plunger ............................... 21863


Parts which should always be replaced are indicated by * . NOTE: For design changes, see Sect. H-15, Item 3

PARTS

10 ... PLUNGER .............................................. 17460* 11 ... SEAT-AND-STEM, Valve ....................... 17967

12 ... SPRING, Valve ....................................... 19147* 13 ... O-RING ................................................. 86W63

14 ... PLUG, Inlet ............................................. 2193015 ... GAUGE, Cylinder Pressure ................... 21938

* 16 ... GAUGE, Delivery Pressure .................... 2193917 ... NUT, Inlet Connection .......................... 37Z3318 ... NIPPLE, Inlet Connection .................... 103Z01

* 19 ... FILTER (Supplied w/item 18) ................. 71Z3320 ... CONN., Outlet 1/4" flare .................... 186W4121 ... CRYSTAL, Replacement Gauge ............ 18859

* 22 ... O-RING ................................................. 493552



H15 580 B 3 8/08

New Page

2115

16

1112

1314

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10

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789


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PARTS

R-36-FM-580 (Series B) Regulator-Flowmeter - P/N 21505


New Page

❑ 13 ... O-RING ................................................ 86W6314 ... PLUG, Inlet ........................................... 2193015 ... NIPPLE, 1/4" NPT .............................. 63950116 ... FLOWMETER ASS'Y (50 psi) ........... 639749*

❑ 17 ... GAUGE, Cylinder Pressure ................. 2193818 ... NUT, Inlet Connection .......................... 37Z3319 ... NIPPLE, Inlet Connection .................. 103Z01

❑ 20 ... FILTER (Supplied w/item 19) ............... 71Z3321 ... CRYSTAL, Replacement Gauge ......... 1885922 ... PLUG, Hole ......................................... 95014223 ... BUSHING .............................................. 20499

1 ... SCREW, Set 1/4" - 20X1/2" ........... 613350872 ... CAP ASSEMBLY .................................. 21180




12 ... SPRING, Valve ..................................... 19147

* For flowmeter parts, see Section J-1, Item 32.


R-36-FM-580Series B

H15 580 B 4 9/96

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PARTS

R-36-CF-580 (Series B) Argon Regulator - P/N 21506








❑ 16 ... GAUGE, Delivery Pressure .................. 2194817 ... NUT, Inlet Connection .......................... 37Z3318 ... NIPPLE, Inlet Connection .................. 103Z01

❑ 19 ... FILTER (Supplied w/item 18) ............... 71Z3320 ... CONNECTION, Outlet Spud ................ 1856021 ... CRYSTAL, Replacement Gauge ......... 18859


R-36-CF-580Series B

H15 580 B 5 9/96

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APPARATUS REPAIR MANUAL - ESAB apparatus/arm_apparatus rep… · ESAB W elding & Cutting Products...

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