owner`s manual plasma cutting torch

MANUAL NO: 80A Torch
OWNER'S
MANUAL
FOR
PLASMA CUTTING TORCH
MODEL: CT(P•Z)W(M•L)-0802
DO NOT
DESTROY
IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manual, before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safety operation of cutting
equipment. Do not allow untrained persons to install, operate or
maintain this equipment. Contact your distributor if you do not
fully understand this manual.
OTC DAIHEN Inc.
WELDING & MECHATRONICS DIVISION
Last Modified: December, 2006
CONTENTS
1. SAFETY INFORMATION ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
2
2. PLASMA ARC CUTTING SAFETY PRECAUTIONS ‥‥‥‥‥‥‥‥‥‥‥ 2
3. ACCESSORIES ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
8
4. TORCH DRAWING ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥
8
5. NOTICE AT OPERATION
‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 9
6. MAINTENANCE AND TROUBLESHOOTING ‥‥‥‥‥‥‥‥‥‥‥‥‥ 12
7. PARTS LIST
‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 16
8. SPECIFICATIONS ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 17
P. 2 / 17
1. SAFETY INFORMATION
The following safety alert symbols and signal words are used throughout this manual to
identify various hazards and special instructions.
WARNING
WARNING gives information regarding possible personal
CAUTION
CAUTION refers to minor personal injury or possible
injury or loss of life.
equipment damage.
2. PLASMA ARC CUTTING SAFETY PRECAUTIONS
WARNING
PLASMA ARC CUTTING can be hazardous.
‹ PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR
DEATH.
Be sure to:
・Keep children away.
・Keep pacemaker wearers away until consulting a doctor.
‹ Read and understand the summarized safety information given below and the
original principal information that will be found in the PRINCIPAL SAFETY
STANDARDS.
◆ Have only trained and experienced persons perform installation, operation, and
maintenance of this equipment.
◆ Use only well maintained equipment. Repair or replace damaged parts at once.
PLASMA ARC CUTTING is safe when precautions are taken.
P. 3 / 17
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work
circuits are electrically live whenever the output is on. The power line and internal circuits of
this equipment are also live when the line disconnect switch is on. When plasma cutting all
metal components in the torch and work circuits are electrically live.
1. Do not touch live electrical parts.
2. Wear dry insulating gloves and other body protection that are free of holes.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Be sure to turn off the line disconnect switch before installing, changing torch parts or
maintaining this equipment.
5. Properly install and ground this equipment according to its Owner’s Manual and national,
state, and local codes.
6. Keep all panels and covers of this equipment securely in place.
7. Do not use worn, damaged, undersized, or poorly spliced cables.
8. Do not touch electrode and any metal object if POWER switch is ON.
9. Do not wrap cables around your body.
10. Turn off POWER switch when not in use.
11. Keep away from torch tip and pilot arc when trigger is pressed.
ARC RAYS can burn eyes and skin.
NOISE can damage hearing.
Arc rays from the cutting process produce intense heat and strong ultraviolet rays that can burn
eyes and skin.
Noise from some plasma arc cutting applications can damage hearing.
1. Wear face shield with a proper shade of filter ( See ANSI Z 49.1 listed in PRINCIPAL
SAFETY STANDARDS) to protect your face and eyes when cutting or watching a cutter
work.
2. Wear approved safety goggles. Side shields recommended.
3. Use protective screens or barriers to protect others from flash and glare: warn others not to
look at the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather)
and foot protection.
5. Use approved earplugs or earmuffs if noise level is high.
P. 4 / 17
FUMES AND GASES can be hazardous to your health.
Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to
your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. Ventilate the area and / or use exhaust at the arc to remove cutting fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDS) and the manufacturer ’s instructions on
metals to be cut, consumables, coatings, and cleaners.
5. Do not cut in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to from highly toxic and irritating gases.
PLASMA ARC can cause injury
1.
2.
3.
4.
5.
6.
7.
Keep away from the torch tip.
Do not grip material near the cutting path.
The pilot arc can cause burns. Keep away from tip when trigger is pressed.
Wear proper flame-retardant clothing covering all exposed body areas.
Point torch away from your body and toward work when pressing the torch trigger.
Turn off the line disconnect switch and POWER switch on the front panel before
disassembling torch or changing torch parts.
Use only torch (‘s) specified in the Owner’s Manual.
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding can cause flying metal.
1. Wear approved face shield or safety goggles with side shields.
2. Wear proper body protection to protect skin.
3. Wear flame-resistant earplugs or earmuffs to prevent sparks from entering ears.
P. 5 / 17
CYLINDER can explode if damaged.
A shielding gas cylinder contains high-pressure gas. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the cutting process, be sure to treat them carefully.
1. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the
specific application; maintain them in good condition.
2. Protect compressed gas cylinders from excessive heat, mechanical shock, and arcs.
3. Keep the cylinder upright and securely chained to a stationary support or a rack to prevent
falling or tipping.
4. Keep cylinders away from any cutting or other electrical circuit.
5. Never touch cylinder with cutting electrode.
6. Read and follow instructions on compressed gas cylinders, associated equipment, and the
CGA publication P-1 listed in PRINCIPAL SAFETY STANDARDS.
7. Turn face away from valve outlet when opening cylinder valve.
8. Keep protective cap in place over valve except when gas cylinder is in use or connected
for use.
This equipment uses high frequency for arc starting.
High-frequency may enter nearby units as shown below, causing electromagnetic trouble.
* Input cables, signal cables, telephone cables
* Radio sets, TV sets
* Computers and other control equipment
* Industrial detectors and safety units
* Pacemakers, hearing-aid sets
For preventing electromagnetic trouble,
1. Make the cable as shortest as possible.
2. Install cables along the floor or the ground as close as possible.
3. Put the base metal side cable together with the torch side cable.
4. Do not use a common base metal ground with other machines.
5. Tightly close all of the doors and covers of this equipment, and secure them.
6. Do not press the torch switch other than when ready to start the arc.
7. When electromagnetic trouble occurs, take the measures shown in this instruction manual
until trouble is corrected.
Please contact OTC-DAIHEN , when necessary.
8. Pacemaker wearers must not come near this equipment during operation until consulting
your doctor.
Operation of the pacemakers will be affected badly by high frequency.
P. 6 / 17
Rotating parts may cause injuries. Be sure to observe the following.
If hands, fingers, hair or clothes are put near the fan’s rotating parts, injuries may occur.
1. Do not use this equipment if the case and the cover are removed.
2. When the case is removed for maintenance/inspection and repair, certified or experienced
operators must perform the work. Erect a fence, etc. around the cutting machine to keep
others away from it.
3. Do not put hands, fingers, hair or clothes near the rotating fans.
PLASMA ARC CUTTING work areas are potentially hazardous.
FALLING or MOVING machine can cause serious injury.
‹ Use both eyebolts, if installed, to lift the cutting power source.
‹ Put this equipment solidly on a flat surface.
‹ Do not pull this equipment across a floor laid with cables and hoses.
P. 7 / 17
PRINCIPAL SAFETY STANDARDS
Arc welding equipment – Installation and use, Technical Specification
IEC 62081, from International Electrotechnical Commission
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.
Government Printing Office.
Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS
C5.2, from American Welding Society.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That
Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from
American Welding Society.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards
Association, Standards Sales.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard
Z87.1, from American National Standards Institute.
Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection
Association.
Confirming Torch Package Contents
Please confirm the following components were shipped with your torch package
Plasma Cutting Torch
Included Items
Cup
Tip
Electrode
Wrench
Torch Switch
Only included with
CTPW(M)(L)-0801
Vinyl Cap
(Remove before using)
Part Names
Torch Switch
Protective Cover
Cup
Torch Body
Tip
Handle
Torch Switch
Short Handle Torch
Protective Cover
Cup
Long Handle Torch
Tip
Torch Body
Tip
Cup
Protective Cover
Handle
Power Cable / Return Water
Straight Torch
Pilot Cable / Send Water
Pilot Cable / Send Water
Torch Switch
Torch Switch
1
4
4
1
1
Operation Precaution (cont’d)
Operation Precaution
CAUTION
Observe the followings to prevent the electrical shock.
(2) During Cutting
• Do not touch live electrical parts.
• When power source is on, do not touch the tip.
If you push the torch switch, the voltage increases,
which may lead to electrical shock.
Metal Guage
• When using for gas cutting and using a metal
type gauge, the guage use insulator (Part No.
H775L00) is used to insulate between the base
material and guage.
Cup
Tip
CAUTION
If you touch plasma arc or pilot arc, you will be burned.
• Do not point the tip of the torch in direction of personnel.
• During cutting operations, when placing the torch down, do not leave
torch switch on ore place in an unstable place.
Base
Metal Guage
Material
Metal Guage
Base
Material
Please observe the following during cutting operations.
* Avoiding the following precautions will shorten the life of consumable
items and can cause damage to the torch.
• Do not start with the tip vertically on top of
the base material.
• This may create and arc inside the tip, and
may burn up the tip.
• When cutting plate thicknesses greater than
16mm, make sure the arc has completely cut to
the bottom side before moving the torch
• The proper torch angle to base metal should
be within ±5゜.
• If forward angle is too large, upwash occurs
forward of cutting direction.
• If torch leans to the right against cutting
direction, it spatters to the left, and spatters to
the right, if torch leans to the left
against cutting direction.
(1) Cutting Start
• During the start of the arc, do not touch the
side of the tip to the edge of the base material.
• This will cause a large arc to generate, and
may create a larger hole in the tip.
• Do not use a guage without an insulator. The
arc will travel to the metal gauage, causing
damage to the tip, resulting cutting faults.
Tip
Precautions during cutting operations
CAUTION
• The best distance from tip to the base material is 4mm; the maximum distance should not
exceed 5mm.
Cutting
Direction
left
right
• Keep the proper torch angle to prevent flying
spatter.
• Plasma arc flows slightly backward with
correct cutting speed, so dross can be easily
taken off from base metal.
• If it is too fast, upwash occurs forward of
cutting direction.
• Do not lift the torch cable in excess of 10m.
(Doing so will cause the coolant water to not
reach the torch tip and this may burn up the
torch)
Operation Precaution (cont’d)
Operation Precaution
CAUTION
Observe the followings to prevent the electrical shock.
(2) During Cutting
• Do not touch live electrical parts.
• When power source is on, do not touch the tip.
If you push the torch switch, the voltage increases,
which may lead to electrical shock.
Metal Guage
• When using for gas cutting and using a metal
type gauge, the guage use insulator (Part No.
H775L00) is used to insulate between the base
material and guage.
Cup
Tip
CAUTION
If you touch plasma arc or pilot arc, you will be burned.
• Do not point the tip of the torch in direction of personnel.
• During cutting operations, when placing the torch down, do not leave
torch switch on ore place in an unstable place.
Base
Metal Guage
Material
Metal Guage
Base
Material
Please observe the following during cutting operations.
* Avoiding the following precautions will shorten the life of consumable
items and can cause damage to the torch.
• Do not start with the tip vertically on top of
the base material.
• This may create and arc inside the tip, and
may burn up the tip.
• When cutting plate thicknesses greater than
16mm, make sure the arc has completely cut to
the bottom side before moving the torch
• The proper torch angle to base metal should
be within ±5゜.
• If forward angle is too large, upwash occurs
forward of cutting direction.
• If torch leans to the right against cutting
direction, it spatters to the left, and spatters to
the right, if torch leans to the left
against cutting direction.
(1) Cutting Start
• During the start of the arc, do not touch the
side of the tip to the edge of the base material.
• This will cause a large arc to generate, and
may create a larger hole in the tip.
• Do not use a guage without an insulator. The
arc will travel to the metal gauage, causing
damage to the tip, resulting cutting faults.
Tip
Precautions during cutting operations
CAUTION
• The best distance from tip to the base material is 4mm; the maximum distance should not
exceed 5mm.
Cutting
Direction
left
right
• Keep the proper torch angle to prevent flying
spatter.
• Plasma arc flows slightly backward with
correct cutting speed, so dross can be easily
taken off from base metal.
• If it is too fast, upwash occurs forward of
cutting direction.
• Do not lift the torch cable in excess of 10m.
(Doing so will cause the coolant water to not
reach the torch tip and this may burn up the
torch)
Precautions for Cutting Operation (Continued)
Precautions for Cutting Operation (Continued)
(3) End of Cutting
Do not cut down with touching tip to
base metal. Strong arc generates, and
the hole of tip can be deformed.
At cutting terminal, keep tip away from
base metal for 1~3mm, then cut it
down.
Long Handle Torch (CTZW(M・L)-0801)
Thickness greater than 16mm will
sometimes leave a small area.
5.2 About the Insulating Cover
The insulating cover serves to protect the
detective pin. Careless handling of the
torch body may cause damage to the
insulating cover. If the insulating cover
has been removed, high frequency is
emitted from the detective pin and may
cause damage to the torch body. If the
insulating cover is damaged, replace it.
(3) Straight Torch (CTPW(M・L)-0801)
5.5 Attaching the Torch Switch for CTPW(M)(L)-0801 Straight Torch
When using the attached torch switch assembly (part number K2433A00), please
follow the guidelines below.
(1) Remove the rubber
Hose Cable
Rubber
Sleeve
sleeve from the cable
Torch Handle
side of the torch
handle
(2) Expose the torch
switch cord from the
torch handle
Torch Switch Cord
5.3 Hose Cable Bend Radius
Do not bend the cable less than
300 mm in radius. In particular,
when using the torch in automated systems, causing the cable
to bend less than 300mm in radius
will cause the cable to break
sooner than the expected lifespan.
Torch Switch Assembly
Silicon Sleeve
(3) Connect the torch
switch terminals.
NOTE: Make sure to
connect the terminals
in the silicon tubes
(4) Slide rubber sleeve
back to original place
Precautions for Cutting Operation (Continued)
Precautions for Cutting Operation (Continued)
(3) End of Cutting
Do not cut down with touching tip to
base metal. Strong arc generates, and
the hole of tip can be deformed.
At cutting terminal, keep tip away from
base metal for 1~3mm, then cut it
down.
Long Handle Torch (CTZW(M・L)-0801)
Thickness greater than 16mm will
sometimes leave a small area.
5.2 About the Insulating Cover
The insulating cover serves to protect the
detective pin. Careless handling of the
torch body may cause damage to the
insulating cover. If the insulating cover
has been removed, high frequency is
emitted from the detective pin and may
cause damage to the torch body. If the
insulating cover is damaged, replace it.
(3) Straight Torch (CTPW(M・L)-0801)
5.5 Attaching the Torch Switch for CTPW(M)(L)-0801 Straight Torch
When using the attached torch switch assembly (part number K2433A00), please
follow the guidelines below.
(1) Remove the rubber
Hose Cable
Rubber
Sleeve
sleeve from the cable
Torch Handle
side of the torch
handle
(2) Expose the torch
switch cord from the
torch handle
Torch Switch Cord
5.3 Hose Cable Bend Radius
Do not bend the cable less than
300 mm in radius. In particular,
when using the torch in automated systems, causing the cable
to bend less than 300mm in radius
will cause the cable to break
sooner than the expected lifespan.
Torch Switch Assembly
Silicon Sleeve
(3) Connect the torch
switch terminals.
NOTE: Make sure to
connect the terminals
in the silicon tubes
(4) Slide rubber sleeve
back to original place
No. H1059
P. 12 / 17
6. MAINTENANCE AND TROUBLESHOOTING
WARNING
Observe followings to prevent electrical shock.
●Do not touch live electrical parts.
●Do not touch tip, when power source is on.
●Be sure to turn off the line disconnection switch before checking torch and exchanging
parts.
●Operate the maintenance check periodically, and be sure to troubleshoot and repair
immediately.
●This cutting torch must be operated by persons who understand contents of this owner’s
manual and have knowledge and skills for cutting torch safety.
CAUTION
Observe the followings to prevent burning.
●When operating, do not touch high temperature parts (tip, shield cup, and base metal just
after the operation).
●Use protectors (leather gloves, etc.) when operating.
●Exchanging torch tip parts must be done after cooling down.
CAUTION
●If parts are damaged, replace with new ones for safety and quality assurance.
●Only use OTC’s genuine parts for replacing.
6.1 Replacing of shield cup, tip, and electrode
Torch body
Shield cup
Tip
Electrode
Tip clamping part
Protection cover
For assembling and
disassembling of tip and
electrode, use a wrench
(accessory).
Wrench
Tip clamping part
(1) Installation of shield cup
Wipe dust out.
Before installing shield cup to torch body, wipe dusts out by a
peace of dry cloth.
Turn cup tightly.
Dross
If dross sticks to shield cup, wipe them out as soon as
possible, it can cause damage to it.
Maintenance & Repair (continued)
Maintenance & Repair (continued)
After performing a number of cuts, you will begin to notice some of the effects below during
cutting. When this happens, inspect the tip and electrode, and if any of the consumable parts
are in need of change, please change them.
Exchanging the Detection Pin Area
(1) CTZW(M)(L)-0801 (Long Handle Torch and CTPW(M)(L)-0801 (Straight Torch) Exchange Method
Disassembly
Handle
Please do not attempt to grind the tip or electrode
Phenomena While Cutting
Detection Area
• Pilot arc does not easily ignite, and bad starts occur
Tip, Electrode
• During the start, a loud “BAAHHHH” sound can be heard
Electrode
• Even after exchanging the tip, weird shape holes occur
Electrode
• The cutting area begins to bend aways from terminal
Tip
• The tip sticks to the base material
Tip
Torch Body
Remove rubber sleeve from handle, remove
screws from handle and body cover, and take
off handle and body cover
Rubber Sleeve
Body Cover
Exchanging the Detection Pin
Detection Pin Cover
Pull the detection
pin cover up
Handle
On the straight torch, remove the rubber tube
from the cable side, turn the handle counter
clockwise from the torch body and remove.
Exchanging the Detection Pin Assembly
Raise up the detection
pin cover
Disconnect connection terminals
Insert new detection pin
assembly inside the
groove
Cover connection
terminals with
protective tube
Detection Pin Cover
Check Item
Has the hole at the end of
the tip changed size?
T
i
p
Correct
The hole is perfectly
round
Perfect Circle
E
l
e
c
t
r
o
d
e
The hole has started to enlarge
and becomes oval shaped.
Oval Shape
Detection Pin
Detection
Pin
Cutting in this
condition will
result in less
focused cuts of
poorer quality.
Hole
Has the tip of the electrode
started to wear out?
Exchange Signs
The center area of the
electrode is less than
1.5mm.
Center area is
no more than
1.5 mm
Manually insert new
detection pin
The center area of the electrode is
greater than 1.5mm.
If the depth of the
electrode consumable area goes
beyond 1.5 mm in
depth, there
becomes the risk of
burn damage to the
torch.
Pull out detection pin
with needle nose
pliers
Insert detection pin
inside the groove
Assembly
Fasten handle and body cover with screws to
assembly the torch. Be careful not to pinch the
cables as you attach the cover. Insert the
rubber sleeve over the handle, and tighten.
Maintenance & Repair (continued)
Maintenance & Repair (continued)
After performing a number of cuts, you will begin to notice some of the effects below during
cutting. When this happens, inspect the tip and electrode, and if any of the consumable parts
are in need of change, please change them.
Exchanging the Detection Pin Area
(1) CTZW(M)(L)-0801 (Long Handle Torch and CTPW(M)(L)-0801 (Straight Torch) Exchange Method
Disassembly
Handle
Please do not attempt to grind the tip or electrode
Phenomena While Cutting
Detection Area
• Pilot arc does not easily ignite, and bad starts occur
Tip, Electrode
• During the start, a loud “BAAHHHH” sound can be heard
Electrode
• Even after exchanging the tip, weird shape holes occur
Electrode
• The cutting area begins to bend aways from terminal
Tip
• The tip sticks to the base material
Tip
Torch Body
Remove rubber sleeve from handle, remove
screws from handle and body cover, and take
off handle and body cover
Rubber Sleeve
Body Cover
Exchanging the Detection Pin
Detection Pin Cover
Pull the detection
pin cover up
Handle
On the straight torch, remove the rubber tube
from the cable side, turn the handle counter
clockwise from the torch body and remove.
Exchanging the Detection Pin Assembly
Raise up the detection
pin cover
Disconnect connection terminals
Insert new detection pin
assembly inside the
groove
Cover connection
terminals with
protective tube
Detection Pin Cover
Check Item
Has the hole at the end of
the tip changed size?
T
i
p
Correct
The hole is perfectly
round
Perfect Circle
E
l
e
c
t
r
o
d
e
The hole has started to enlarge
and becomes oval shaped.
Oval Shape
Detection Pin
Detection
Pin
Cutting in this
condition will
result in less
focused cuts of
poorer quality.
Hole
Has the tip of the electrode
started to wear out?
Exchange Signs
The center area of the
electrode is less than
1.5mm.
Center area is
no more than
1.5 mm
Manually insert new
detection pin
The center area of the electrode is
greater than 1.5mm.
If the depth of the
electrode consumable area goes
beyond 1.5 mm in
depth, there
becomes the risk of
burn damage to the
torch.
Pull out detection pin
with needle nose
pliers
Insert detection pin
inside the groove
Assembly
Fasten handle and body cover with screws to
assembly the torch. Be careful not to pinch the
cables as you attach the cover. Insert the
rubber sleeve over the handle, and tighten.
Maintenance & Repair (continued)
Maintenance & Repair (continued)
Replacing the Torch Body
Exchanging the Detection Pin Area
Disassembly
Rubber Sleeve
Handle
Tie Wrap Band
Handle
Disassembly
Replacement Method for CTW(M)(L)-0801 (Short Handle Torch)
Slide back rubber sleeve towards
cable side, cut the tie wraps and
carefully remove the torch switch.
Please refer to the assembly & disassembly figures
in 6.2 for the CTW(M)(L)-0801 Short Handle Torch
and CTPW(M)(L)-0801 Straight Torch.
Torch Body
Rubber Sleeve
Remove screws from the handle,
and and slide back handle towards
the cable side.
Remove the rubber sleeve from the handle, remove
screws from the handle and disassemble.
Body Cover
Exchanging
WARNING: The pilot cable connection opening (yellow hose) is held only by the left screw. If
you overtwist the the right screw, you risk damaging the connection opening.
Exchanging the Detection Pin
Detection
Pin Cover
Detection
Pin
Remove the protective cover and pop
off cover to detection
pin by using a small
flat-head screw driver
Remove the protective cover and pop
off cover to detection
pin by using a small
flat-head screw driver
Pull down detection pin cover and
disconnect termincal connectors.
Fix spanner to spanner holder, and
turn the nut for the power cable
counter-clockwise.
Remove detection
pin by using needlenose pliers.
Manual insert new
detection pin
Remove M6 Left screw,
remove pilot cable
Caution:
Left Screw
Insert new detection pin
assembly, snap in place,
and slide protective
cover back in place.
Reconnect connection terminals and
cover with protective tube.
Torch Switch
Rubber Sleeve
Connection power cable, pilot cable,
and detection lead wire
Exchange with new torch
body
Snap detection pin
cover back into place,
and slide protective
cover back on.
Assembly
Disconnect connection
terminal of detection lead
wire
Cover connection area
with tube
Insert handle into torch body,
tighten screws back in place, and
affix the torch switch.
Slide the rubber sleeve back in
place make sure that everything fits
nicely.
Assembly
Handle
Body
Cover
Fasten handle with screws to complete torch assembly.
Make sure not to pinch the cables inside the handle
piece.
Fasten shut by sliding the rubber sleeve into the the
handle.
Rubber Sleeve
Maintenance & Repair (continued)
Maintenance & Repair (continued)
Replacing the Torch Body
Exchanging the Detection Pin Area
Disassembly
Rubber Sleeve
Handle
Tie Wrap Band
Handle
Disassembly
Replacement Method for CTW(M)(L)-0801 (Short Handle Torch)
Slide back rubber sleeve towards
cable side, cut the tie wraps and
carefully remove the torch switch.
Please refer to the assembly & disassembly figures
in 6.2 for the CTW(M)(L)-0801 Short Handle Torch
and CTPW(M)(L)-0801 Straight Torch.
Torch Body
Rubber Sleeve
Remove screws from the handle,
and and slide back handle towards
the cable side.
Remove the rubber sleeve from the handle, remove
screws from the handle and disassemble.
Body Cover
Exchanging
WARNING: The pilot cable connection opening (yellow hose) is held only by the left screw. If
you overtwist the the right screw, you risk damaging the connection opening.
Exchanging the Detection Pin
Detection
Pin Cover
Detection
Pin
Remove the protective cover and pop
off cover to detection
pin by using a small
flat-head screw driver
Remove the protective cover and pop
off cover to detection
pin by using a small
flat-head screw driver
Pull down detection pin cover and
disconnect termincal connectors.
Fix spanner to spanner holder, and
turn the nut for the power cable
counter-clockwise.
Remove detection
pin by using needlenose pliers.
Manual insert new
detection pin
Remove M6 Left screw,
remove pilot cable
Caution:
Left Screw
Insert new detection pin
assembly, snap in place,
and slide protective
cover back in place.
Reconnect connection terminals and
cover with protective tube.
Torch Switch
Rubber Sleeve
Connection power cable, pilot cable,
and detection lead wire
Exchange with new torch
body
Snap detection pin
cover back into place,
and slide protective
cover back on.
Assembly
Disconnect connection
terminal of detection lead
wire
Cover connection area
with tube
Insert handle into torch body,
tighten screws back in place, and
affix the torch switch.
Slide the rubber sleeve back in
place make sure that everything fits
nicely.
Assembly
Handle
Body
Cover
Fasten handle with screws to complete torch assembly.
Make sure not to pinch the cables inside the handle
piece.
Fasten shut by sliding the rubber sleeve into the the
handle.
Rubber Sleeve
Parts List
Parts List (Continued)
• Please use the following as a reference for purchasing replacement parts from
either your distributor or one of our service centers.
• Regarding Part Replacement Duration
The usual minimum for part supply duration is generally 7 years after the
product goes out of production. However, parts may still be purchased
through an external part vendor.
Standard Parts List
No.
Short
Part No.
Long
Straight
Name
Quantity Included
Cap
Tip (80A)
Electrode
Torch Body
Detection Pin Assembly
Detection Pin Assembly (1)
Detection Pin Assembly (2)
Protective Cover
Detection Pin (Contact Plug)
Tie-wrap Band (Black)
Body Cover
M3x5 Small Black Bolt
Rubber Sleeve
Wrench
Handle
M4 Black Hex Cap
M4x25 Black Round Bolt
M4x10 Black Round Bolt
M4x6 Black Round Bolt
Torch Switch Assembly
Hose Cable Assembly
Electrical Plug (2P)
Electrical Plug (4P)
Remarks
Includes 4-1~4-8
Includes 4-1~4-8
Includes 4-5
Includes 4-5
10m usage
20m usage
30m usage
10m usage, Includes 10,11
20m usage, Includes 10,11
30m usage, Includes 10,11
W-W00294
Optional Parts List
No.
Part No.
Name
Quantity
H767F03 Tip (30A)
1
H767F02 Tip (50A)
1
Remark
For use on thin plate less than 1.6mm
For use on thin plate less than 4.5mm
Short Handle Torch Diagram
Parts List
Parts List (Continued)
• Please use the following as a reference for purchasing replacement parts from
either your distributor or one of our service centers.
• Regarding Part Replacement Duration
The usual minimum for part supply duration is generally 7 years after the
product goes out of production. However, parts may still be purchased
through an external part vendor.
Standard Parts List
No.
Short
Part No.
Long
Straight
Name
Quantity Included
Cap
Tip (80A)
Electrode
Torch Body
Detection Pin Assembly
Detection Pin Assembly (1)
Detection Pin Assembly (2)
Protective Cover
Detection Pin (Contact Plug)
Tie-wrap Band (Black)
Body Cover
M3x5 Small Black Bolt
Rubber Sleeve
Wrench
Handle
M4 Black Hex Cap
M4x25 Black Round Bolt
M4x10 Black Round Bolt
M4x6 Black Round Bolt
Torch Switch Assembly
Hose Cable Assembly
Electrical Plug (2P)
Electrical Plug (4P)
Remarks
Includes 4-1~4-8
Includes 4-1~4-8
Includes 4-5
Includes 4-5
10m usage
20m usage
30m usage
10m usage, Includes 10,11
20m usage, Includes 10,11
30m usage, Includes 10,11
W-W00294
Optional Parts List
No.
Part No.
Name
Quantity
H767F03 Tip (30A)
1
H767F02 Tip (50A)
1
Remark
For use on thin plate less than 1.6mm
For use on thin plate less than 4.5mm
Short Handle Torch Diagram
Parts List (Continued)
Specifications
Specifications
Cutting Torch
Rated Current
Duty Cycle
Cooling Method
Forced Cooling (Water Cooled)
Gas Type
Air
Weight
Torch Only
Dimensional Diagrams
Long Handle Torch Parts Diagram
Power Cable • Water Inlet
Air Hose
Pilot Cable • Water Outlet
Detection Lead Cable
Torch Switch
Straight Handle Torch Parts Diagram
Connection Area Diagram
(common for all machine types)
Parts List (Continued)
Specifications
Specifications
Cutting Torch
Rated Current
Duty Cycle
Cooling Method
Forced Cooling (Water Cooled)
Gas Type
Air
Weight
Torch Only
Dimensional Diagrams
Long Handle Torch Parts Diagram
Power Cable • Water Inlet
Air Hose
Pilot Cable • Water Outlet
Detection Lead Cable
Torch Switch
Straight Handle Torch Parts Diagram
Connection Area Diagram
(common for all machine types)