ESAB Cutmaster 60 - User Manual

Questions and Answers

C
Charles SmithDec 1, 2025
What causes the ESAB Welding System's fault and 80 PSI indicators to flash with gas flow cycling ON and OFF?
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  Lori JonesDec 1, 2025
  If the fault and 80 PSI indicators are flashing and the gas flow is cycling ON and OFF on your ESAB Welding System, consider these potential causes: * The torch shield cup may be loose. Tighten it by hand, but do not overtighten. * The torch tip, electrode, or starter cartridge might be missing. Turn OFF the power supply, remove the shield cup, and install any missing parts. * The torch start cartridge could be stuck. Turn OFF the power supply, bleed down system pressure, remove the shield cup, tip, and start cartridge. Check the start cartridge lower end fitting for free movement, and replace if the fitting does not move freely. * There might be an open conductor in torch leads. Replace the torch and leads or return them to an authorized service center for repair or replacement. ...
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William KaneAug 23, 2025
What does it mean if the ESAB Cutmaster 60 Welding System's fault and 70 PSI indicators are flashing?
- X
  xbutlerAug 23, 2025
  If the fault and 70 PSI indicators are flashing on your ESAB Welding System, it could be due to the following reasons: 1. The shield cup might be loose. Hand tighten it until it is snug. 2. The torch might not be properly connected to the power supply. Ensure the torch ATC is securely fastened to the unit. 3. There might be a problem in the torch and leads PIP circuit. Replace the torch and leads or return them to an authorized service center for repair or replacement. 4. There could be failed components in the unit, requiring a return to an authorized service center for repair or replacement.
E
edwin84Aug 25, 2025
What does it mean if the ESAB Cutmaster 60 Welding System's fault and 75 PSI indicators are flashing?
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  Paul HarrisAug 25, 2025
  If the fault and 75 PSI indicators are flashing on your ESAB Welding System, it could indicate that the start signal is active when the ON/OFF switch is turned to the ON position. This can occur if the hand torch switch or hand pendant switch is held closed, or if the CNC START signal is active low. Release the START signal source. Another possibility is a problem in the torch and leads switch circuit, which would require replacing the torch and leads or returning them to an authorized service center for repair or replacement. Finally, it could be due to failed components in the unit, also requiring a return to an authorized service center for repair or replacement.
N
Neil DavisAug 26, 2025
Why is the ESAB Cutmaster 60 Welding System's temperature indicator ON and the fault indicator flashing?
- C
  carolynkennedyAug 26, 2025
  If the temperature indicator is ON and the fault indicator is flashing on your ESAB Welding System, it could be due to several reasons: * Air flow through or around the unit is obstructed. * The duty cycle of the unit has been exceeded. Allow the unit to cool. * Failed components in unit. Return to authorized service center for repair or replacement.
S
Sharon SandersAug 27, 2025
What to do if the ESAB Cutmaster 60 Welding System's pilot arc is ON but the cutting arc will not establish?
- M
  Mrs. Sharon TerryAug 27, 2025
  If the pilot arc is ON but the cutting arc will not establish on your ESAB Welding System, make sure that the work cable is connected to the work piece. If the work cable/connector is broken, replace it. It could also be due to failed components in the unit, requiring a return to an authorized service center for repair.
R
Ronald BryanSep 23, 2025
Why pilot arc is ON but cutting arc will not establish on ESAB Cutmaster 60?
- R
  Richard DavisSep 23, 2025
  If the pilot arc is ON but the cutting arc will not establish on your ESAB Welding System, consider the following: * The work cable might not be connected to the workpiece. Connect the work cable. * The work cable/connector could be broken. Replace the work cable.
N
Nancy RamosSep 17, 2025
Why TEMPERATURE indicator is ON and FAULT indicator flashing on ESAB Welding System?
- C
  Christopher MillerSep 18, 2025
  If the TEMPERATURE indicator is ON and the FAULT indicator is flashing on your ESAB Welding System, it could be due to: * Obstructed airflow through or around the unit. * Exceeding the unit's duty cycle. Allow the unit to cool.
A
Audrey SmithSep 18, 2025
How to troubleshoot diminished torch cutting on ESAB Cutmaster 60 Welding System?
- J
  Jeffery AguilarSep 18, 2025
  If the torch cutting performance is diminished on your ESAB Welding System, consider the following: * The current setting might be incorrect. Check and adjust to the proper setting. * The torch consumables could be worn. Check and replace them as needed. * There might be a poor work cable connection to the workpiece. Check the connection of the Work Lead to the workpiece. * The torch might be moving too fast. Reduce the cutting speed.
B
Brittany RichSep 7, 2025
Why is the GAS LED OFF and FAULT and MIN pressure indicators flashing on my ESAB Welding System?
- T
  travisoneillSep 7, 2025
  If the GAS LED is OFF and the FAULT and MIN pressure indicators are flashing on your ESAB Welding System, it could be due to several reasons: * The gas supply might not be connected. Ensure the gas supply is properly connected to the unit. * The gas supply may not be turned ON. Make sure to turn the gas supply ON. * The gas supply pressure could be too low. Set the air supply inlet pressure to the unit to 120 psi. * The AIR PRESSURE CONTROL regulator might be set too low. Adjust the regulator to set the air pressure.
C
Chad SimmonsSep 4, 2025
What to do if the ESAB Welding System's fault and 85 PSI indicators are flashing?
- L
  Lauren RichardsonSep 5, 2025
  If the FAULT and 85 PSI indicators are flashing on your ESAB Welding System, try turning the ON / OFF switch OFF and then back ON again. If that does not clear the fault, return to an authorized service center for repair.

Summary

SECTION 1: SAFETY

1.0 Safety Precautions

General safety guidelines and recommendations for operating the equipment.

SECTION 2 SYSTEM: INTRODUCTION

2.01 How To Use This Manual

Instructions on how to navigate and use the manual effectively.

2.02 Equipment Identification

Details on identifying the unit's model, serial number, and part numbers.

2.03 Receipt Of Equipment

Procedures for checking received equipment for completeness and damage.

2.04 Power Supply Specifications

2.05 Input Wiring Specifications

2.06 Power Supply Features

SECTION 2 TORCH: INTRODUCTION

2 T.01 Scope of Manual

Details the manual's coverage of SL60/Manual and SL100/Mechanized Plasma Cutting Torches.

2 T.02 General Description

Explains the basic design and function of plasma torches and gas flow.

2 T.03 Specifications

Provides technical specifications for torch configurations, leads, and parts.

2 T.04 Options And Accessories

2 T.05 Introduction to Plasma

SECTION 3 SYSTEM: INSTALLATION

3.01 Unpacking

Instructions for identifying and inspecting equipment after receiving it.

3.02 Lifting Options

Details on safe lifting procedures and options for the power supply unit.

3.03 Primary Input Power Connections

Guidance on connecting the primary input power, including voltage and wiring requirements.

3.04 Gas Connections

Installing Optional Two - Stage Air Filter Kit

Using High Pressure Air Cylinders

SECTION 3 TORCH: INSTALLATION

3 T.01 Torch Connections

Procedure for connecting the torch to the power supply unit.

3 T.02 Setting Up Mechanical Torch

Instructions for mounting and aligning the mechanical torch for cutting.

SECTION 4 SYSTEM: OPERATION

4.01 Front Panel Controls; Features

Description of the power supply's front panel controls and indicators for operation.

4.02 Preparations for Operation

SECTION 4 TORCH: OPERATION

4 T.01 Torch Parts Selection

Guidance on selecting appropriate torch parts for different cutting operations.

4 T.02 Cut Quality

Factors influencing cut quality and characteristics of a good cut.

4 T.03 General Cutting Information

4 T.04 Hand Torch Operation

Shield Cup With Straight Edge

Drag Cutting With a Hand Torch

Piercing With Hand Torch

4 T.05 Gouging

4 T.06 Mechanized Torch Operation

4 T.07 Parts Selection for Manual and Mechanized Torch Cutting

4 T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip

4 T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip

PATENT INFORMATION

Plasma Cutting Torch Patents

Lists US and Foreign patents covering plasma cutting torch parts.

SECTION 5 SYSTEM: SERVICE

5.01 General Maintenance

Routine maintenance tasks for the power supply unit, categorized by frequency.

5.02 Maintenance Schedule

5.03 Common Faults

5.04 Fault Indicator

5.05 Basic Troubleshooting Guide

5.06 Power Supply Basic Parts Replacement

Optional Single-Stage Filter Element Replacement

Optional Two-Stage Filter Element Replacement

SECTION 5 TORCH: SERVICE

5 T.01 General Maintenance

Procedures for cleaning and lubricating torch components for optimal performance.

5 T.02 Inspection and Replacement of Consumable Torch Parts

SECTION 6: PARTS LISTS

6.01 Introduction

Overview of the parts list breakdown and arrangement.

6.02 Ordering Information

Guidelines for ordering replacement parts, including necessary information.

6.03 Power Supply Replacement

Details on what is included with a replacement power supply unit.

6.04 Replacement Power Supply Parts

6.05 Options and Accessories

6.06 Replacement Parts for Hand Torch

6.07 Replacement Parts - for Machine Torches with Unshielded Leads

6.08 Replacement Shielded Machine Torch Leads Assemblies

6.09 Torch Consumable Parts (SL60)

6.10 Torch Consumable Parts (SL100)

APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM)

APPENDIX 2: DATA TAG INFORMATION

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

APPENDIX 4: TORCH CONNECTION DIAGRAMS

APPENDIX 5: SYSTEM SCHEMATIC, 380;400 V UNITS

APPENDIX 6: Publication History