ESAB Cutmaster 120 - Maintenance Schedule; Common Faults

ESAB CUTMASTER 120
SERVICE Manual 0-5380
5-2
5.02 Maintenance Schedule
NOTE!
The actual frequency of maintenance may
need to be adjusted according to the oper-
ating environment.
Daily Operational Checks or Every Six Cutting
Hours:
1. Check torch consumable parts, replace if dam-
aged or worn.
2. Check plasma and secondary supply and pres-
sure/flow.
3. Purge plasma gas line to remove any moisture
build-up.
Weekly or Every 30 Cutting Hours:
1. Check fan for proper operation and adequate air
flow.
2. Inspect torch for any cracks or exposed wires,
replace if necessary.
3. Inspect input power cable for damage or ex-
posed wires, replace if necessary.
Six Months or Every 720 Cutting Hours:
1. Check the in-line air filter(s), clean or replace as
required.
2. Check cables and hoses for leaks or cracks,
replace if necessary.
3. Check all contactor points for severe arcing or
pits, replace if necessary.
4. Vacuum dust and dirt out of the entire machine.
!
CAUTION
Do not blow air into the power supply
during cleaning. Blowing air into the unit
can cause metal particles to interfere with
sensitive electrical components and cause
damage to the unit.
5.03 Common Faults
Problem - Symptom Common Cause
Insufficient Penetration 1. Cutting speed too fast.
2. Torch tilted too much.
3. Metal too thick.
4. Worn torch parts
5. Cutting current too low.
6. Non - Genuine ESAB parts used
7. Incorrect gas pressure
Main Arc Extinguishes 1. Cutting speed too slow.
2. Torch standoff too high from
workpiece.
3. Cutting current too high.
4. Work cable disconnected.
5. Worn torch parts.
6. Non - Genuine ESAB parts used
Excessive Dross
Formation
1. Cutting speed too slow.
2. Torch standoff too high from
workpiece.
3. Worn torch parts.
4. Improper cutting current.
5. Non - Genuine ESAB parts used
6. Incorrect gas pressure
Short Torch Parts Life 1. Oil or moisture in air source.
2. Exceeding system capability (material
too thick).
3. Excessive pilot arc time
4. Gas pressure too low.
5. Improperly assembled torch.
6. Non - Genuine ESAB parts used
Difficult Starting 1. Worn torch parts.
2. Non - Genuine ESAB parts used.
3. Incorrect gas pressure.