Install the torch-lead assembly to the torch receptacle

Use this information to install the torch-lead assembly to the torch receptacle. For easier installation, make sure that the connections are done in the same sequence as these steps.

  1. Unwind approximately 2 meters (6.5 feet) of the torch-end of the torch-lead assembly.
  2. Put the torch collar on the connector-end of the torch.
  3. Put the torch mounting sleeve on the torch-end of the torch-lead assembly.

    Adjust the mounting sleeve as necessary for good access to the connector ends.

    This image shows the torch mounting sleeve moving in the direction of the torch-end of the torch-lead assembly.
  4. Align the connectors in the torch-lead assembly and the torch receptacle.
    This image shows the connectors in the torch receptacle on the left and the torch lead-assembly on the right.
    1 Pilot arc
    2 Ohmic
    3 Coolant return
    4 Plasma valve
    5 Plasma Line A, black
    6 Coolant supply, green
    7 Shield gas, blue
    8 Plasma Line B, yellow
    Note:

    Good alignment keeps twisted connections to a minimum. Twisted connections can cause gas or coolant restrictions that decrease the life of the consumables or cause bad cut quality.

  5. Connect the connectors in the torch-lead assembly and the torch receptacle:
    1. Connect the pilot arc.

      Keep this connection loose for now. You can fully tighten it after the coolant-return hose installation is complete. If you fully tighten it before the coolant-return, other connections will be difficult. Use your fingers to tighten the connection, do not use tools.

      This image shows the pilot arc connector in the torch receptacle before the connection is fully tightened.
    2. Connect the ohmic cable.

      Keep this connection loose for now. You can fully tighten it after the coolant-return hose installation is complete. If you fully tighten it before the coolant-return, other connections will be difficult. Use your fingers to tighten the connection, do not use tools.

      This image shows the ohmic cable connector in the torch receptacle before the connection is fully tightened.
    3. Install the coolant-return hose and use two wrenches to tighten the nut to 16.3 N∙m –19.0 N∙m (144 lbf∙in – 168 lbf∙in).
      This image shows the coolant-return connection and the location of the nut that you tighten to 16.3 N∙m –19.0 N∙m (144 lbf∙in – 168 lbf∙in).
    4. After you install the coolant-return hose, fully tighten the pilot arc and ohmic cable connectors.

      Use your fingers to tighten the connection, do not use tools.

      This image shows the correct direction for turning the pilot arc and ohmic cable connectors to fully tighten them to the torch receptacle.
    5. Connect the plasma valve.

      Use your fingers to tighten the connection, do not use tools.

      This image shows the plasma valve connector in the torch receptacle.
    6. Push the Plasma Line A hose in the connector until it stops, approximately 13 mm (0.5 inch).

      This is a push-to-connect fitting. Make sure the hose is fully inserted and the insertion mark is no longer visible.

      This image shows the Plasma Line A connector in the torch receptacle.
    7. Push the coolant-supply hose in the connector until it stops, approximately 13 mm (0.5 inch).

      This is a push-to-connect fitting. Make sure the hose is fully inserted and the insertion mark is no longer visible.

      This image shows the coolant-supply hose in the torch receptacle.
    8. Push the shield-gas hose in the connector until it stops, approximately 13 mm (0.5 inch).

      This is a push-to-connect fitting. Make sure the hose is fully inserted and the insertion mark is no longer visible.

      This image shows the shield-gas hose in the torch receptacle.
    9. Push the Plasma Line B hose in the connector until it stops, approximately 13 mm (0.5 inch) .

      This is a push-to-connect fitting. Make sure the hose is fully inserted and the insertion mark is no longer visible.

      This image shows the Plasma Line B hose in the torch receptacle.
      This image shows how an insertion mark shows on an example hose when the hose is not fully inserted and how it does not show when a hose is fully inserted.
  6. Install the torch mounting sleeve:
    1. Move the torch mounting sleeve in the direction of the torch.
    2. Use your hands to tighten the torch mounting sleeve connection.
      Note:

      A spanner wrench is included in all of the consumable parts kits. Refer to Consumable starter kits. Do not overtighten the torch mounting sleeve if you use the spanner wrench to keep the torch stable during installation of the mounting sleeve.

      This image shows the torch mounting sleeve being installed.
  7. Put the collar in the correct position on the torch-end of the torch lead:
    1. Move the collar in the direction of the torch-end of the torch-lead assembly.
    2. Tighten the hose clamp that holds the collar in position.
      This images shows the collar in position and tightened with the hose clamp.