Tweco Tri-Arc Serie User Manual [en, es, fr]
K-5, Tri-Arc® Series
OPERATING MANUAL
K-5 Torch
English
Canadien Français
Americas Español
MANUAL GOUGING TORCHES
Manual No: 89250019
Issue Date: August 4, 2014
Tri-Arc® Series
AIR CARBON-ARC
Revision: AA
VictorTechnologies.com
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 Victor Technologies™ Inc.
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, efficiency 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:
1-800-462-2782 (USA) and 1-905-827-4515 (Canada),
or visit us on the web at www.victortechnologies.com
!
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:
Victor Technologies, Inc.
2800 Airport Rd.
Denton, TX. 76208
940-566-2000
www.victortechnologies.com
Copyright © 2013 Victor Technologies, Inc. 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.
Publication Date: August 4, 2014
Table of Contents
SECTION 1: INTRODUCTION ...................................................... 1-1
1.01 Air Carbon-Arc Cutting/Gouging .......................................................................1-1
1.02 History .............................................................................................................. 1-1
1.03 Applications ...................................................................................................... 1-2
SECTION 2: SAFETY AND HEALTH ............................................... 2-1
2.01 Proper Installation, Use, and Maintenance ........................................................ 2-1
2.02 Electrodes ......................................................................................................... 2-1
2.03 Ventilation Hazards ........................................................................................... 2-2
2.04 Personal Protective Equipment and Clothing .................................................... 2-3
2.05 Shielding Booths ............................................................................................... 2-4
2.06 Fire and Burn Hazards ....................................................................................... 2-4
2.07 Safety and Operating References ...................................................................... 2-5
SECTION 3: How to Use this Manual ............................................ 3-1
3.01 Receipt of Equipment ........................................................................................ 3-1
SECTION 4: Installation ........................................................... 4-1
4.01 Tri-Arc® Series Torch Head Assembly ............................................................... 4-1
4.02 Installing the DC Welding Power Cable and Air Hose to the Power and
Air Connector ..................................................................................................... 4-2
4.03 Connecting to DC Welding Power Supplies ....................................................... 4-5
SECTION 5: Troubleshooting ..................................................... 5-1
SECTION 6: REPLACEMENT PARTS ............................................. 6-1
K-5 TORCH REPLACEMENT PARTS .......................................................................... 6-1
K-5 SWIVEL CABLE REPLACEMENT PARTS ............................................................. 6-3
TRI-ARC® TORCH REPLACEMENT PARTS ................................................................ 6-4
WARRANTY ................................................... INSIDE BACK COVER
INTERNATIONAL CONTACT INFORMATION ............................ 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
efficiently the air jet removes molten metal. In the process, the air must lift the molten
metal clear of the arc before the metal solidifies.
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 flat, 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 flat. 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 first 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
1.03 Applications
The industry has enthusiastically adopted air carbon-arc gouging and found many
uses for the process in metal fabrication and casting finishing, 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 flexible, efficient, and cost effective 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.
1-2
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 briefly 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
Install and maintain equipment in accordance with the National Electrical
Code (NFPA 70) and local codes. 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 qualified 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.
2-1
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 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 confined 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 fire.
2-2
2.04 Personal Protective Equipment and Clothing
WARNING
NOISE CAN DAMAGE HEARING
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 filter lens provides the best protection against arc radiation.
When in a confined area, prevent the reflected 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 cuffs. Wear leather aprons, sleeves, leggings, etc. for out-of-
2-3
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 flammable 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 finish of low reflectivity—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.
2.06 Fire and Burn Hazards
WARNING
WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS.
Causes of fire and explosion include combustibles reached by the arc, flame, flying
sparks, hot slag or heated materials. Remove combustibles from the work area and/or
provide a fire watch. Avoid oily or greasy clothing as a spark may ignite them. Keep a
fire 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
Air
Type of Torch
K-5
Tri-Arc
¹ Pressure while torch is in operation.
®
Pressure¹
psi (kPA)
80 (550)
Air
Consumption
cfm (L/min.)
25 (708) 5 (3.7) 7.5 (5.6)
33 (934) 7.5 (5.6) 10 (7.5)
Intermittent
Use
hp (kW)
Continuous
hp (kW)
Use
ASME
Receiver
Size
gal (lit)
80 (303)
Use only compressed air. Using combustible compressed gases can cause explosions
that may result in personal injury or death.
2-4
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 Office, 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
2-5
This Page Intentionally Blank
2-6
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 offers 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 file 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.
3-1
This Page Intentionally Blank
3-2
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 separetely)
4-1
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 floor.
2. Slide the molded protective boot away from the female connector so there is access
to connect 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
4-2
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.
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
4-3
5. Thread the incoming Compressed Air Line with a 3/8" pipe threaded fitting into the
Power and Air Connector. This connection should be wrench tight.
Figure 4-11: K-5 Figure 4-12: Tri-Arc® Series
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.
4-4
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.
COMPRESSED AIR
POWER SUPPLY
ELECTRODE LEAD
DCEP OR AC
CONCENTRIC
CABLE
WORKPIECE LEAD
CARBON ELECTRODE
TORCH
WORKPIECE
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 (+)
WORKPIECE (-)
Figure 4-18
4-5
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 pres-
sures range between 80 psi (551.6 kPa) and 100 psi (690 kPa); higher pressures
may be used, but they do not remove metal more efficiently.
7. Adjust the welding current (Constant Current) or voltage (Constant Voltage), depending on the type of power supply being used, to the suggested current range shown
for the carbon diameter being used. Refer to Table 4-2.
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 muffled,
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.
4-6
SECTION 5: TROUBLESHOOTING
Problem Cause Solution
Large free-carbon deposit at the beginning of
the groove.
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.
1. The operator either neglected to turn on the
air jet before striking
the arc or the torch was
located improperly.
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 metal-arc
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.
1. Turn on air before striking the arc and air should
flow between the electrode and the workpiece.
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.
2. Inspect ground clamps
and lead(s) to ensure
connection proper.
5-1
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 speed or using
a flat-curve, constantvoltage 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. Slag ejection was
inadequate. To resolve,
keep a proper air
pressure and flow rate
(cfm). Air pressure between 80 and 100 psi
(550-690 kPa) may not
effectively eject all of
the slag if the volume
is insufficient.
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.
1. The operator should
assume a comfortable
position while gouging.
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.
5-2
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
Complete Torch 01-104-003
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
6-1
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6-2
K-5 SWIVEL CABLE REPLACEMENT PARTS
3
8
7
7
9
10
11
6
1
2
8
3
4
5
7
7
9
11
10
K-5 Cable
CABLE REPLACEMENT PARTS LIST
Item Descripon K-5
7. (2.1M) Swivel Cable 70-128-507
10. (3M) Swivel Cable 70-128-510
10. (3M) Conductor
10. (3M) Cover
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 7. (2.1M) Conductor 96-130-061
9 7. (2.1M) Cover 94-171-004
10 Insulang Boot 94-105-017
11 Female Connector 94-170-087
6-3
TRI-ARC® TORCH REPLACEMENT PARTS
1
1
2
2
3
4
5
6
7
8
9
10
11
12
13
15
16
9
6-4
TORCH REPLACEMENT PARTS LIST
Item Descripon 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 Insulang 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 Buon 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
6-5
6
Tri-Arc® Standard Cable
3
5
3
7
4
2
1
CABLE ASSEMBLY REPLACEMENT PARTS LIST
340o Concentric Cable Assembly - Standard
Item Descripon Part No.
7. (2.1M) Cable 74-143-607
10. (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 Insulang Boot 94-105-007
7 Female Connector 94-170-095
7. (2.1M) Cable Conductor 96-130-063
10. (3M) Cable Conductor 96-130-126
7. (2.1M) Cable Hose Cover 94-171-006
10. (3M) Cable Hose Cover 94-171-140
6-6
6
Tri-Arc
®
HD Cable
3
5
3
7
4
2
1
CABLE ASSEMBLY REPLACEMENT PARTS LIST
Extra Heavy-Duty Cable Assembly
Item Descripon Part No.
7. (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 7. (2.1M) Cable Conductor Assembly 96-130-286
5 7. (2.1M) Cable Hose Cover 94-171-284
6 Insulang Boot 94-105-028
7 Female Connector 94-170-174
8 Insulang Sleeve 94-105-029
8
6-7
8
Tri-Arc® Water-Cooled Cable
9
9
2
5
3
9
5
9
4
9
9
1
CABLE ASSEMBLY REPLACEMENT PARTS LIST
Water-Cooled Cable Assembly
Item Descripon Part No.
7. (2.1M) Cable Assembly 74-085-207
10. (3M) Cable Assembly 74-085-210
1 Male Connector 94-170-171
2 Female Connector 94-170-150
3
4
5
8 Insulang Boot 94-105-032
8 Clamp (6 Required) 98-167-010
9 Insulang Sleeve 94-105-029
7. (2.1M) Conductor 96-130-309
10. (3M) Conductor 96-130-310
7. (2.1M) Cable Cover 94-171-273
10. (3M) Cable Cover 94-171-274
7. (2.1M) Low Pressure Hose 94-171-298
10. (3M) Low Pressure Hose 94-171-299
10
6-8
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