ESAB Cutmaster 120 - 02 Inspection and Replacement of Consumable Torch Parts

ESAB CUTMASTER 120
SERVICE Manual 0-5380
5T-2
5T.02 Inspection and Replacement of
Consumable Torch Parts
WARNING
Disconnect primary power to the system
before disassembling the torch or torch
leads.
DO NOT touch any internal torch parts
while the AC indicator light of the Power
Supply is ON.
Remove the consumable torch parts as follows:
NOTE!
The shield cup holds the tip and starter
cartridge in place. Position the torch with
the shield cup facing upward to prevent
these parts from falling out when the cup is
removed.
1. Unscrew and remove the shield cup from the
torch.
NOTE!
Slag built up on the shield cup that cannot
be removed may effect the performance of
the system.
2. Inspect the cup for damage. Wipe it clean or
replace if damaged.
Art # A-08067
Shield Cups
3. On torches with a shield cup body and a shield
cap or deflector, ensure that the cap or deflector
is threaded snugly against the shield cup body.
In shielded drag cutting operations (only), there
may be an O-ring between the shield cup body
and drag shield cap. Do not lubricate the O-ring.
Drag Shield Cap
Shield
Cup Body
O-Ring No. 8-3488
Art # A-03878
4. Remove the tip. Check for excessive wear
(indicated by an elongated or oversized orifice).
Clean or replace the tip if necessary.
Good Tip
Worn Tip
A-03406
Example of Tip Wear
5. Remove the starter cartridge. Check for exces-
sive wear, plugged gas holes, or discoloration.
Check the lower end fitting for free motion.
Replace if necessary.
Art # A-08064_AC
Spring-Loaded
Lower End Fitting
Full Compression
Spring-Loaded
Lower End Fitting at Reset /
Full Extension
6. PulltheElectrodestraightoutoftheTorchHead.
Check the face of the electrode for excessive
wear. Refer to the following figure.
Worn Electrode
New Electrode
Art # A-03284
Electrode Wear
7. Reinstall the Electrode by pushing it straight into
the torch head until it clicks.
8. Reinstall the desired starter cartridge and tip into
the torch head.
9. Handtightentheshieldcupuntilitisseatedon
the torch head. If resistance is felt when install-
ing the cup, check the threads before proceed-
ing.
This completes the parts replacement procedures.