Tri-Arc® Series
AIR CARBONARC
MANUAL GOUGING TORCHES
K-5,
Operating
Manual
English
Revision: AB Issue Date: June 15, 2016 Manual No.:
K-5 Torch
Tri-Arc® Series
89250019
WE APPRECIATE YOUR BUSINESS!
Congratulations on receiving your new Arcair® product. We are proud to have you as our customer
and will strive to provide you with the best service and support in the industry. This product is
backed by our extensive warranty and world-wide service network.
We know you take pride in your work and we feel privileged to provide you with this high
performance product that will help you get the job done.
For more than 60 years Arcair has provided quality products you can trust, when your reputation
is on the line.
YOU ARE IN GOOD COMPANY!
Arcair is a global brand of cutting products for ESAB. We distinguish ourselves from our
competition through market-leading innovation and truly dependable products that will stand
the test of time.
We strive to enhance your productivity, eciency and welding performance, enabling you to
excel in your craft. We design products with the welder in mind delivering- advanced features,
durability, ease of use and ergonomic comfort.
Above all, we are committed to a safer working environment within the welding industry. Your
satisfaction with this product and its safe operation is our ultimate concern. Please take the time
to read the entire manual, especially the Safety Precautions.
If you have any questions or concerns regarding your new Arcair product, please contact our
friendly and knowledgeable Customer Service Team at:
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Arcair® K-5 & Tri-Arc® Series Air Carbon-Arc Manual Gouging Torch
Operating Manual
Operating Manual Guide Number: 89250019
Published by:
ESAB Group Inc.
2800 Airport Rd.
Denton, TX. 76208
940-566-2000
www.esab.com/arcair
Copyright © 2013 ESAB All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence,
accident, or any other cause.
For Printing Material Specication refer to document 47X1920
Publication Date: August 4, 2014
Revision Date: June 15, 2016
Table of Contents
SECTION 1: INTRODUCTION .........................................................1
1.01 Air Carbon-Arc Cutting/Gouging .......................................................................... 1
1.02 History ................................................................................................................. 1
1.03 Applications ......................................................................................................... 2
SECTION 2: SAFETY AND HEALTH ..................................................3
2.01 Proper Installation, Use, and Maintenance ........................................................... 3
2.02 Electrodes ............................................................................................................ 3
2.03 Ventilation Hazards .............................................................................................. 4
2.04 Personal Protective Equipment and Clothing ....................................................... 4
2.05 Shielding Booths .................................................................................................. 5
2.06 Fire and Burn Hazards .......................................................................................... 6
2.07 Safety and Operating References ......................................................................... 7
SECTION 3: How to Use this Manual ...............................................9
3.01 Receipt of Equipment ........................................................................................... 9
SECTION 4: Installation ............................................................ 11
4.01 Tri-Arc® Series Torch Head Assembly ................................................................ 11
4.02 Installing the DC Welding Power Cable and Air Hose to the Power and Air Con-
nector ................................................................................................................. 12
4.03 Connecting to DC Welding Power Supplies ........................................................ 14
SECTION 5: Troubleshooting ...................................................... 17
SECTION 6: REPLACEMENT PARTS .............................................. 19
K-5 TORCH REPLACEMENT PARTS ........................................................................... 19
K-5 SWIVEL CABLE REPLACEMENT PARTS .............................................................. 20
TRI-ARC® TORCH REPLACEMENT PARTS ................................................................. 22
Statement of Warranty ............................................ INSIDE BACK COVER
SECTION 1: INTRODUCTION
1.01 Air Carbon-Arc Cutting/Gouging
The air carbon-arc process (CAC-A) removes metal physically, not chemically as in oxy-fuel cutting (OFC). Gouging or cutting occurs when the intense heat of the arc between the carbon electrode and the workpiece melts
part of the workpiece. Simultaneously, air passes through the arc quickly enough to blow the molten material
away.
The air carbon-arc process does not require oxidation to maintain the cut, so it can gouge or cut metals that
the OFC process cannot. Most common metals (e.g., carbon steel, stainless steel, many copper alloys and cast
irons) can be cut using the air carbon-arc process. The metal removal rate depends on the melting rate and how
eciently the air jet removes molten metal. In the process, the air must lift the molten metal clear of the arc
before the metal solidies.
1.02 History
Air carbon-arc gouging began in the 1940's, evolving from the existing carbon-arc cutting process. Myron
Stepath, a welding engineer, developed air carbon-arc gouging to remove several hundred feet of at, cracked,
stainless steel weld.
Previously, carbon-arc cutting removed overhead and vertical defective welds and rivet heads. The carbon-arc
melted the metal, then gravity moved the molten metal away.
Stepath reasoned that an air jet could provide the force to remove metal lying at. So he tried a direct-current,
electrode-negative carbon-arc with a second operator directing an air blast via air nozzle at the molten pool.
However, this attempt was unsuccessful because the arc was less stable than a carbon-welding arc. So, Stepath
tried a direct-current, electrode-positive arc, and the result was air carbon-arc gouging.
In 1948, Myron Stepath introduced the rst air carbon-arc torch to the welding industry. In 1949, Stepath and
two associates founded the Arcair® Company.
Two operators were no longer needed. The compressed air now passed through the torch and exited beneath
the electrode. This new tool saved time on weld backgouging, crack removal, and weld defect repair on carbon,
alloy, and stainless steel. Previously, these tasks were performed by grinding or chipping.
Today, the basic principle remains the same, but with improved equipment and an expanded number of applications.
1
1.03 Applications
The industry has enthusiastically adopted air carbon-arc gouging and found many uses for the process in metal
fabrication and casting nishing, chemical and petroleum technology, construction, mining, general repair, and
maintenance.
Arcair® Torches and Electrodes are used throughout the world, anywhere metal is gouged, grooved, severed, or
removed from a surface.
The air carbon-arc process is exible, ecient, and cost eective on practically any metal: carbon steel, stainless steel and other ferrous alloys; gray, malleable and ductile iron; aluminum; nickel; copper alloys and other
nonferrous metals.
2
SECTION 2: SAFETY AND HEALTH
Safe practices in welding and cutting processes, such as air carbon-arc, are covered in ANSl Z49.1, “Safety in
Welding and Cutting”, and ANSl 249.2, “Fire Prevention in Use of Welding and Cutting Processes.” Air carbon-arc
operators and their supervisors should adhere to the safe practices discussed in these documents.
Other hazards in arc welding and cutting are briey discussed in this section.
2.01 Proper Installation, Use, and Maintenance
Serious injury or death may result if gouging and cutting equipment is not properly installed, used, and maintained. Misuse of this equipment and other unsafe practices can be hazardous. The operator, supervisor, and
helper must read and understand the following safety warnings and instructions before installing or using any
air carbon-arc torch or equipment.
The gouging/cutting process is used in many potentially dangerous environments, such as elevated heights,
areas with limited ventilation, close quarters, areas around water, hostile environments, etc. The operator must
be aware of the dangers associated with working in these types of conditions. The operator must be trained in
safe practices for his work environment and be under competent supervision.
It is essential that the operator, supervisor, and others in the work area be aware of the dangers of the air
carbon-arc process. Training and proper supervision are important for a safe work place. Keep these instructions
for future use. Additional recommended safety and operating information is referenced in each section.
2.02 Electrodes
WARNING
ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH
The purchaser is responsible for the safe installation, operation, and use of all
products purchased, including compliance with all applicable ISO standards
and local codes in the country of use. Do not service or repair equipment
with power on. Do not operate equipment with protective insulators or covers removed. Service or repair to equipment must be done by qualied and/
or trained personnel only
Keep carbon electrodes dry. If electrodes become damp, bake them for 10 hours at 300˚ F (176˚ C). Wet electrodes may shatter.
Do not touch electrically live parts. Do not touch an electrode with bare skin and electrical ground at the same
time. Always wear dry welding gloves that are in good condition. Aluminized protective clothing can become
3
part of the electrical path. Keep oxygen cylinders, chains, wire ropes, cranes, hoists, and elevators away from
any part of the electrical circuit. Check all ground connections periodically to determine if they are mechanically
strong and electrically adequate for the required current.
If you are engaged in alternating current gouging/cutting under wet conditions or warm surroundings where
perspiration is a factor, use reliable automatic controls for reducing no load voltage to reduce shock hazard.
When the gouging/cutting process requires values of open circuit voltages in alternating current machines
higher than 80 volts, and direct current machines higher than 100 volts, take precautions, such as using adequate insulation, to prevent the operator from making accidental contact with the high voltage.
If you are going to suspend gouging for any substantial period of time, such as during lunch or overnight,
remove all electrodes from the torch and the put the torch in a safe location so that accidental contact cannot
occur. Disconnect the torch from the power source when it is not in use. Never immerse air carbon-arc torches or
electrodes in water.
2.03 Ventilation Hazards
WARNING
SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH
Keep smoke, fumes and gases from the breathing area. Fumes from the gouging process are of various types
and strengths, depending on the kind of base metal being worked on. To ensure your safety, do not breathe
these fumes. Ventilation must be adequate to remove smoke, fumes and gases during the operation to protect
gouging operators and others in the area.
Vapors of chlorinated solvents can form the toxic gas phosgene when they are exposed to ultraviolet radiation
from an electric arc. Remove all solvents, degreasers, and potential sources of these vapors from the operating
area.
Fumes that are produced by cutting in particularly conned places can cause discomfort and physical harm
if inhaled over an extended period of time. Provide adequate ventilation in the gouging/cutting area. Use
air-supplied respirators if there is not enough ventilation to remove all fumes and gases. Never ventilate with
oxygen, because oxygen supports and vigorously accelerates re.
2.04 Personal Protective Equipment and Clothing
WARNING
NOISE CAN DAMAGE HEARING
4
Noise from the air carbon-arc process can damage your hearing. Operators and surrounding personnel must
wear adequate protective hearing devices to ensure personal protection against noise when noise levels exceed
OSHA standards.
Duration Per Day (hours) Sound Level (dBA*) Slow Response
8 90
6 92
4 95
3 97
2 100
1-1/2 102
1 105
1/4 or less 115
* dBA = decibels
WARNING
ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE EYES AND BURN SKIN
The gouging/cutting process produces extreme localized heat and strong ultraviolet rays. Never attempt to
gouge/cut without a welding helmet with the proper lens that complies with federal guidelines.
A number 12 to 14 shade lter lens provides the best protection against arc radiation. When in a conned area,
prevent the reected arc rays from entering around the helmet. Make sure others are protected from arc rays
and sparks. Use approved shielding curtains and appropriate goggles to provide protection to others in the surrounding area and operators of nearby equipment.
Skin should also be protected from arc rays, heat and molten metal. Always wear protective gloves and clothing that will not allow skin to become exposed. Close all pockets and sew shut all cus. Wear leather aprons,
sleeves, leggings, etc. for out-of-position gouging/cutting, or for heavy metal-removal operations using large
electrodes. High top work shoes provide adequate protection from foot burns. Use leather spats for added
protection. Do not use ammable hair preparations when gouging/cutting. Wear ear plugs to protect ears from
sparks.
2.05 Shielding Booths
Where the work permits, the arc welder should be enclosed in an individual booth painted with a nish of low
reectivity—an important factor for absorbing ultraviolet radiations—such as zinc oxide and lamp black. The
welder may also be enclosed in similarly painted noncombustible screens.
5
2.06 Fire and Burn Hazards
WARNING
WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS.
Causes of re and explosion include combustibles reached by the arc, ame, ying sparks, hot slag or heated
materials. Remove combustibles from the work area and/or provide a re watch. Avoid oily or greasy clothing as
a spark may ignite them. Keep a re extinguisher nearby, and know how to use it.
Be alert to the danger of conduction or radiation. For example, if you will be gouging/cutting on a metal wall,
partition, ceiling or roof, take precautions to prevent combustibles from igniting on the other side. Do not
gouge/cut containers that have held combustibles. Vent all hollow spaces, cavities and containers before gouging/cutting to permit air or gases to escape. Purging with inert gas is recommended.
Table 2-1: Recommended Minimum Air Requirements
Recommended Compressor Rating
Type of Torch
Air
Pressure¹
psi (kPA)
Air Consumption
cfm (L/min.)
Intermittent
Use
hp (kW)
Continuous Use
hp (kW)
ASME Receiver
Size
gal (lit)
K-5
®
Tri-Arc
¹ Pressure while torch is in operation.
80 (550)
25 (708) 5 (3.7) 7.5 (5.6)
33 (934) 7.5 (5.6) 10 (7.5)
80 (303)
Use only compressed air. Using combustible compressed gases can cause explosions that may result in personal
injury or death.
6
2.07 Safety and Operating References
1. Code of Federal Regulations. (OSHA) Section 29 Part 1910.95, 132, 133, 134, 139, 251, 252, 253, 254 AND,
1000. U.S. Government Printing Oce, Washington, DC 20402
2. ANSl Z49.1 “Safety In Welding and Cutting”
3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection.”
4. ANSl Z88.2 “Standard Practice for Respiratory Protection.” American National Standards Institute, 1430
Broadway, New York, NY 10018.
5. AWS C5.3 “Recommended Practices for Air Carbon-Arc Gouging and Cutting.”
6. AWS F4.1 “Recommended Safe Practices for Welding and Cutting Containers.” The American Welding Society,
550 NW Lejeune RD., P.O. Box 351040, Miami FL. 33135
7. NFPA 51B “Fire Prevention in Cutting and Welding Processes” National Fire Protection Association, Battery
Park. Quincy MA 02269
8. CSA Standard W117.2, “Safety in Welding. Cutting and Allied Processes” Canadian Standards Association, 178
Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3
7
This Page Intentionally Blank
8
SECTION 3: HOW TO USE THIS MANUAL
!
To ensure safe operation, read the entire manual, including the chapters on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the
information provided under these headings. These special annotations are easily recognized as follows:
WARNING
A WARNING GIVES INFORMATION REGARDING POSSIBLE PERSONAL INJURY.
CAUTION
A CAUTION refers to possible equipment damage.
NOTE
A NOTE oers helpful information concerning certain operating procedures.
3.01 Receipt of Equipment
When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to le a claim.
Furnish complete information concerning damage claims or shipping errors to the location in your area listed in
the inside back cover of this manual. Include a full description of the parts in error.
9
This Page Intentionally Blank
10
SECTION 4: INSTALLATION
4.01 Tri-Arc® Series Torch Head Assembly
Install the upper and lower head assemblies into the Tri-Arc torch body by following these instructions:
1. Remove the front insulators from the body and upper arm of the assembly by using a straight blade screw
driver.
2. Apply pressure to the torch lever lifting the upper arm away from the body to allow the heads to easily be
inserted into the body and upper arm. Once both heads are in place, release the lever to hold the head assemblies in place.
3. Place the wave washer supplied with the head assemblies over the torch head screw and thread the screw
into the threaded stem on each head. Make sure this connection is tight.
4. Replace the front insulators in place and re-tighten the screws to hold the insulators in place.
PART NO. DESCRIPTION
94-378-267 Head Upper & Lower 1/2" (12.7mm) General Purpose
94-378-270 Head Upper & Lower 5/8" (15.9mm) General Purpose
94-378-273 Head Upper & Lower 3/4" (19.05mm) General Purpose
94-378-343 Head Upper & Lower 1" (25.4mm) General Purpose
94-378-286 Head Upper & Lower 1/2" (12.7mm) Padwashing
94-378-289 Head Upper & Lower 5/8" (15.9mm) Padwashing
94-378-283 Head Upper & Lower 3/4" (19.05mm) Padwashing
94-378-298 Head Upper & Lower Defect Removal
Table 4-1: Head assembly options (sold separately)
11
4.02 Installing the DC Welding Power Cable and Air Hose to the Power and Air
Connector
Part Numbers:
K-5: 61-104-007, 61-104-008
Tri-Arc® Series: 62-991-417
Follow these instructions to connect the DC Welding Power Cable and Compressed Air Line directly to the Power
and Air Connector on the Torch Swivel Cable Assembly.
1. Remove the Torch and Cable Assembly from the carton and lay the assembly in a straight and untwisted
position on a workbench or oor.
2. Slide the molded protective boot away from the female connector so there is access to connec t welding leads
and air hose to cable assembly as shown.
Figure 4-1: K-5 Figure 4-2: Tri-Arc® Series
3. Using a 1/2" - 13 X 1-1/2" hex head bolt (not supplied), position the bolt so that the threads run through the
crimped lug of the DC Welding Power Cables and through the Power and Air Connector on the Swivel Cable
Assembly. Power leads can be connected on both sides of the connector for the Tri-Arc® torch, allowing up to
four (4) 4/0 welding cables.
Figure 4-3: K-5 Figure 4-4: Tri-Arc® Series
4. Place a ½” lock washer over the bolt threads and begin to thread a ½”-13 nut down against the assembly and
tighten wrench tight. Make sure that access to the internal threads for the incoming air hose is not obstructed.
12
Figure 4-5: K-5 Figure 4-6: Tri-Arc® Series
Figure 4-7: K-5 Figure 4-8: Tri-Arc® Series
Figure 4-9: K-5 Figure 4-10: Tri-Arc® Series
5. Thread the incoming Compressed Air Line with a 3/8" pipe threaded tting into the Power and Air Connector.
This connection should be wrench tight.
Figure 4-11: K-5 Figure 4-12: Tri-Arc® Series
13
Figure 4-13: K-5 Figure 4-14 Tri-Arc® Series
6. Slide the molded protective boot back over the power and air connection so that no metal parts are protruding
out of the protective boot. Operator needs to make sure the boot stays in position over the connection to avoid
accidental arcing to a grounded work surface.
Figure 4-15: K-5 Figure 4-16: Tri-Arc® Series
7. The assembly is now ready to be used in your metal removal application.
4.03 Connecting to DC Welding Power Supplies
Gouging applications normally use three-phase welding power supplies with an open circuit voltage higher
than 60 volts, to allow for any voltage drop in the circuit.
1. Connect the Welding Power Cable that is connected to the Torch Swivel Cable to the positive terminal on the
power supply (DCEP). Refer to Figure 4-17.
2. Connect the Welding Power Cable that is connected to the negative terminal on the power supply to the
workpiece.
14
COMPRESSED AIR
WORKPIECE
WORKPIECE (-)
POWER SUPPLY
(REVERSE POLARITY)
ELECTRODE LEAD
(–)
Art# A-13069
DCEP OR AC
CONCENTRIC
CABLE
WORKPIECE LEAD
(+)
CARBON ELECTRODE
TORCH
Figure 4-17
3. Turn on the power supply and air supply to the gouging torch and cable assembly.
4. Press down on the lever of the torch to insert the air carbon-arc electrode “carbon” into the torch. When using
copper coated carbons, the bare carbon end should be down and away from the torch. This is where the arc
will be struck between the carbon and workpiece. Refer to Figure 4-17.
TORCH
STICKOUT 7" MAX
COPPER PEEL BACK
3/4" to 2"
AIR 80PSI
ALWAYS UNDER THE ELECTRODE
TRAVEL
ELECTRODE
TORCH HEADS (+)
Art# A-13070
Figure 4-18
5. Hold the electrode as shown in Figure 4-18, so that a maximum of 7” (178 mm) extends from the torch. This
extension should be 3” (76.5 mm) for aluminum.
6. While the torch valve is open, adjust the air pressure at the torch to the normal pressures range between 80
psi (551.6 kPa) and 100 psi (690 kPa); higher pressures may be used, but they do not remove metal more
eciently.
7. Adjust the welding current (Constant Current) or voltage (Constant Voltage), depending on the t ype of power
supply being used, to the suggested current range shown for the carbon diameter being used. Refer to Table
4-2.
15
Torch
Electrode Diameter DC Electrode DCEP
in (mm) min - max
5/16 (7.9) 350 - 450
K-5
3/8 (9.5) 450 - 600
1/2 (12.7) 800 - 1000
5/8 (15.9) 1000 - 1250
5/16 (7.9) 350 - 450
3/8 (9.5) 450 - 600
Tri-Arc® Series
1/2 (12.7) 800 - 1000
5/8 (15.9) 1000 - 1250
3/4 (19.1) 1250 - 1600
1 (25.4) 1600 - 2200
Table 4-2: Suggested Current Ranges (AMP) for Commonly Used Electrode Types and Sizes
8. Turn on the air jet before striking the arc. Hold the torch between a 45˚ - 60˚ work angle, so that the electrode
slopes back from the direction of travel. The air jet sweeps between the electrode and workpiece, providing
the force to remove all molten metal from the groove.
9. Lightly touch the electrode to the workpiece to establish the arc. Do not draw back the electrode once the arc
is ignited. When the correct arc voltage is being maintained, the sound of the arc and the compressed air is
loud. When the sound is mued, the arc voltage is below the recommended operating conditions. Normal
arc voltage with a handheld gouging torch is measured between 35 to 50 volts.
10. The groove’s depth is controlled by travel speed. Grooves up to 1” (25 mm) deep may be made. However, the
deeper the groove, the more experienced the operator needs to be. Slow travel speeds produce deep grooves,
and fast travel speeds produce shallow grooves. The width of the groove is determined by the size of the
electrode used and is typically about 1/8” (3.2 mm) wider than the electrode’s diameter. A wider groove may
be made with a small electrode by oscillating in a circular or weave motion.
16
SECTION 5: TROUBLESHOOTING
Problem Cause Solution
Large free-carbon deposit at the
beginning of the groove.
1. The operator either neglected
to turn on the air jet before
striking the arc or the torch
was located improperly.
1. Turn on air before striking the arc
and air should ow between the
electrode and the workpiece.
An unsteady arc, causing the
operator to use a slow travel
speed even on shallow grooves.
Erratic groove with the arc
wandering from side-to-side
and with the electrode heating
up rapidly.
Intermittent arc action resulting
in an irregular groove surface.
2. Carbon rod not positioned
properly in head assembly.
1. Not enough amperage for the
electrode diameter used (see
Table 2). While the lowest
recommended amperage may
be enough, it requires greater
operator skill. A mid-range
amperage is better.
1. The process used with DCEN
(electrode negative).
1. The travel speed was too slow
in manual gouging. The operator possibly set their hand
on other work for balance, a
tendency in shielded metalarc welding. Since the speed
of air carbon-arc gouging is
much faster than shielded
metal-arc welding, friction
between the gloved hand
and the workpiece may cause
a jerky forward motion thus
causing the gap between the
electrode and workpiece to
become too large to maintain
the arc.
2. Poor ground connection. 2. Inspect ground clamps and
2. Ensure carbon rod is seated in
groove in torch head.
1. If the desired amperage cannot
be obtained from the available
power source, use the next
smaller diameter electrode or
parallel two or more welding
power supplies.
1. Gouging process should be done
with DCEP (Electrode positive)
whenever possible. Direct current electrodes should be used
with DCEP (electrode positive)
on all metals, except for a few
copper alloys such as Superston
and Nialite.
1. The operator should stand
comfortably so their arms move
freely and their gloves do not
drag on the workpiece. If using
mechanized equipment, check
Table 4 (Page 4-24) for proper
operating conditions.
lead(s) to ensure connection
proper.
17
Problem Cause Solution
In gouging, free carbon deposits
at varying groove intervals;
in pad -washing, free carbon
deposits at various spots on the
washed surface.
Irregular groove: too deep, then
too shallow.
Slag adhering to the edges of
the groove.
1. A shorted electrode on the
workpiece. In manual gouging, this is a result of excessive
travel speed for the amperage
used and for the depth of
the groove being made. In
mechanized operations, this
is a result of excessive travel
1. Use an electrode-to-work angle
of 15° to 70°. A smaller angle increases the arcing area,reducing
the current density; this
reduction in arc-current density
requires a great decrease in arc
length, to the point of short
circuit. Keep a proper arc gap.
speed or using a at-curve,
constant-voltage power
source for a small diameter
electrode 5/16" (7,9 mm). In
padwashing, this is caused by
holding the electrode at too
small a push angle.
1. The operator was unsteady. 1. The operator should assume
a comfortable position while
gouging.
1. Slag ejection was inadequate.
To resolve, keep a proper air
pressure and ow rate (cfm).
Air pressure between 80 and
100 psi (550-690 kPa) may not
eectively eject all of the slag
if the volume is insucient.
1. To deliver adequate volume, the
air hose feeding the concentric cable assembly needs a
minimum hose ID of 3/8" (9.5
mm) for manual torches. For
automatic torches, the minimum
hose ID should be 1/2" (12.7
mm). Direct the air jet parallel to
the gouge area. Do not favor one
side unless operator wants to
minimize slag from adhering to
one side of the cut.
18
SECTION 6: REPLACEMENT PARTS
1
1
2
3
4
5
6
7
8
9
10
11
12
13
K-5 TORCH REPLACEMENT PARTS
TORCH REPLACEMENT PARTS LIST
Item Description K-5
1 Insulators & Screws 94-433-118
2 Head & Screw 94-378-370
3 Upper Arm 94-048-088
4 Spring 94-800-077
5 Torch Body 94-103-114
6 Handle 94-370-079
7 Lever & Screw 94-476-034
8 Hinge Pin 94-632-094
9 Valve Bonnet Assembly 94-104-023
10 Spool & O-Rings 94-801-021
11 O-Ring 94-710-036
12 Valve Bonnet 94-104-012
13 Bonnet Wrench 94-960-001
Complete Torch 01-104-003
19
K-5 SWIVEL CABLE REPLACEMENT PARTS
10
11
8
10
11
K-5 Cable
8
Art# A-13088
7
9
7
5
4
3
2
7
9
1
7
6
3
20
CABLE REPLACEMENT PARTS LIST
Item Description K-5
7ft. (2.1M) Swivel Cable 70-128-507
10ft. (3M) Swivel Cable 70-128-510
1 Retainer Screw
2 O-Ring
3 Male Connector 94-170-105
4 Spring Washer
5 Brass Washer
6 Swivel Sleeve 94-784-051
7 Clamp (2 Required) 98-167-012
8 7ft. (2.1M) Conductor 96-130-061
10ft. (3M) Conductor
9 7ft. (2.1M) Cover 94-171-004
10ft. (3M) Cover
10 Insulating Boot 94-105-017
11 Female Connector 94-170-087
21
TRI-ARC® TORCH REPLACEMENT PARTS
15
6
5
9
10
9
13
11
12
7
1
3
4
8
2
16
2
1
22
TORCH REPLACEMENT PARTS LIST
Item Description Part No.
Torch Only 02-991-411
1 Insulators & Screws 94-433-118
Head (Upper/Lower) & Screws
Defect Removal 94-378-298
General Purpose - 1/2” (12.7mm) 94-378-267
General Purpose - 5/8” (15.9mm) 94-378-270
General Purpose - 3/4” (19.5mm) 94-378-273
2
General Purpose - 1” (25.4mm) 94-378-344
Padwashing - 1/2” (12.7mm) 94-378-286
Padwashing - 5/8” (15.9mm) 94-378-289
Padwashing - 3/4” (19.5mm) 94-378-283
3 Upper Arm 94-048-110
4 Spring 94-800-088
5 Torch Body 94-103-221
Torch Body without Valve 94-103-237
6
7
8
9
10
11
12
13
15 Insulating Sleeve 94-784-045
16 Jumper (2 Required) 96-458-018
Handle 94-370-079
Lever & Screw 94-476-034
Hinge Pin 94-632-063
Valve & Bonnet 94-104-023
No Valve Button Kit 94-123-017
Spool & O-Rings 94-801-021
O-Ring 94-710-036
Valve Bonnet 94-104-012
Bonnet Wrench 94-960-001
23
6
e
Tri-Arc® Standard Cabl
3
5
3
7
4
Art# A-13085
2
1
CABLE ASSEMBLY REPLACEMENT PARTS LIST
340o Concentric Cable Assembly - Standard
Item Description Part No.
7ft. (2.1M) Cable 74-143-607
10ft. (3M) Cable 74-143-610
1 Male Connector 94-170-169
2 Swivel Sleeve 94-784-050
3 Clamp (2 Required) 98-167-010
4
5
6 Insulating Boot 94-105-007
7 Female Connector 94-170-095
7ft. (2.1M) Cable Conductor 96-130-063
10ft. (3M) Cable Conductor 96-130-126
7ft. (2.1M) Cable Hose Cover 94-171-006
10ft. (3M) Cable Hose Cover 94-171-140
24
6
Tri-Arc® HD Cable
3
5
3
7
8
4
Art# A-13086
2
1
CABLE ASSEMBLY REPLACEMENT PARTS LIST
Extra Heavy-Duty Cable Assembly
Item Description Part No.
7ft. (2.1M) Cable Assembly 74-161-907
1 Male Connector 94-170-176
2 Swivel Sleeve 94-784-078
3 Clamp (2 Required) 98-167-012
4 7ft. (2.1M) Cable Conductor Assembly 96-130-286
5 7ft. (2.1M) Cable Hose Cover 94-171-284
6 Insulating Boot 94-105-028
7 Female Connector 94-170-174
8 Insulating Sleeve 94-105-029
25
8
®
Water-Cooled Cable
Tri-Arc
9
2
Art# A-13087
9
5
3
9
5
9
4
9
9
1
CABLE ASSEMBLY REPLACEMENT PARTS LIST
Water-Cooled Cable Assembly
Item Description Part No.
7ft. (2.1M) Cable Assembly 74-085-207
10ft. (3M) Cable Assembly 74-085-210
1 Male Connector 94-170-171
2 Female Connector 94-170-150
3
4
5
8 Insulating Boot 94-105-032
8 Clamp (6 Required) 98-167-010
9 Insulating Sleeve 94-105-029
7ft. (2.1M) Conductor 96-130-309
10ft. (3M) Conductor 96-130-310
7ft. (2.1M) Cable Cover 94-171-273
10ft. (3M) Cable Cover 94-171-274
7ft. (2.1M) Low Pressure Hose 94-171-298
10ft. (3M) Low Pressure Hose 94-171-299
10
26
STATEMENT OF WARRANTY
LIMITED WARRANTY: ESAB warrants that its products will be free of defects in workmanship or material. Should
any failure to conform to this warranty appear within the time period applicable to the ESAB products as stated
below, ESAB shall, upon written notication thereof and substantiation that the product has been stored, installed,
operated, and maintained in accordance with ESAB’s specications, instructions, recommendations and recognized
standard industry practice, and not been subject to misuse, repair, neglect, alteration, or accident, correct such
defects by suitable repair or replacement, at ESAB’s sole option, of any components or parts of the product determined by ESAB to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION OF LIABILIT Y: ESAB shall not under any circumstances be liable for special, indirect or consequential
damages, such as, but not limited to, damage or loss of purchased or replacement goods, business interruption
or loss of prot, or claims of customers of distributor (hereinafter the “Purchaser”) for service interruption. The
remedies of the Purchaser set forth herein are exclusive and the liability of ESAB with respect to any contract, or
anything done in connection therewith such as the performance or breach thereof, or from the manufac ture, sale,
delivery, resale, or use of any goods covered by or furnished by ESAB whether arising out of contract, negligence,
strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of
the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY
IMPAIR THE SAFETY OR PERFORMANCE OF ANY ESAB PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
This warranty is eective for the time stated in the Warranty Schedule beginning on the date that the authorized
distributor delivers the products to the Purchaser.
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized ESAB repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty.
Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the
Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous
ESAB warranties.
ESAB subsidiaries and representative oces
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 70 233 075
Fax: +32 15 257 944
BULGARIA
ESAB Kft Representative Oce
Soa
Tel/Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacic
AUSTRALIA
ESAB South Pacic
Archereld BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tok yo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacic Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
Distributors
For addresses and phone numbers
to our distributors in other countries, please visit our home page
www.esab.eu
www.esab.eu
©2015 ESAB Welding and Cutting Products
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