Victor CUTMASTER 102 Service Manual

112 pages

To Next Page

100

208/230V

460V 600V

400V

VictorThermalDynamics.com

Art # A-08618_AD

Service

Manual

Revision: AM Issue Date: September 4, 2014 Manual No.: 0-4998

CUTMASTER

™

102

PLASMA CUTTING SYSTEM

Table of Contents5
Section 1: General Information7
- Notes, Cautions and Warnings7
- Important Safety Precautions7
- Publications8
- Note, Attention Et Avertissement9
- Precautions de Securite Importantes9
- Documents de Reference11
- Statement of Warranty12
Section 2 System: Introduction13
- How to Use this Manual13
- Equipment Identification13
- Receipt of Equipment13
- Power Supply Specifications14
- Input Wiring Specifications15
- Power Supply Features16
Section 2 Torch: Introduction17
- 01 Scope of Manual17
- 02 General Description17
- 03 Specifications17
- 04 Options and Accessories18
- 05 Introduction to Plasma18
Section 3 System: Installation21
- Unpacking21
- Lifting Options21
- Primary Input Power Connections21
- Gas Connections22
Section 3 Torch: Installation25
- 01 Torch Connections25
- 02 Setting up Mechanical Torch25
Section 4 System: Operation27
- Front Panel Controls / Features27
- Preparations for Operation28
Section 4 Torch: Operation31
- 01 Torch Parts Selection31
- 02 Cut Quality31
- 03 General Cutting Information32
- 04 Hand Torch Operation33
- 05 Gouging35
- 06 Mechanized Torch Operation36
- 07 Parts Selection for Manual and Mechanized Torch Cutting38
Patent Information44
Section 5 System: Service47
- General Maintenance47
- Maintenance Schedule48
- Common Faults48
- Fault Indicator49
- Basic Troubleshooting Guide51
- Circuit Fault Isolation53
- Main Input and Internal Power Problems56
- Pilot Arc Problems61
- Main Arc and Controls Problems65
- CNC Interface Problems66
- Test Procedures66
Section 5 Torch: Service81
- 01 General Maintenance81
- 02 Inspection and Replacement of Consumable Torch Parts82
Section 6: Parts Lists83
- Introduction83
- Ordering Information83
- Power Supply Replacement83
- Major External Replacement Parts84
- Front Panel Replacement Parts85
- Left Side Replacement Parts86
- Right Side Replacement Parts87
- Options and Accessories88
- Replacement Parts for Hand Torch89
- Replacement Parts - for Machine Torches with Unshielded Leads90
- Torch Consumable Parts (SL100 SV)92
Section 7: Replacement Procedures93
- Scope93
- Anti-Static Handling Procedures93
- Parts Replacement - General Information93
- Major External Parts93
- Front Panel Parts Replacement94
- Left Side Internal Parts Replacement96
- Rear Panel Parts Replacement98
- Right Side Internal Parts Replacement100
Appendix 1: Sequence of Operation (Block Diagram101
Appendix 2: Data Tag Information102
Appendix 3: Torch Pin - out Diagrams103
Appendix 4: Torch Connection Diagrams104
Appendix 5: System Schematic, 208/460V Units106
Appendix 6: System Schematic, 600V Units108
Appendix 7: Publication History110

Questions and Answers:

W
William HensonSep 13, 2025
Why is the pilot arc ON but the cutting arc won't establish on my Victor CUTMASTER 102 Welding System?
- B
  Brenda DiazSep 13, 2025
  If the pilot arc is ON but the cutting arc will not establish on your Victor Welding System, it could be due to: * The work cable not being connected to the work piece; connect the work cable. * A broken work cable/connector; replace the work cable. If the problem persists, there may be failed components in the unit, requiring you to return it to an authorized service center for repair.