O-Ring Kit No. 9-9488 for XT-Series Torch Original Publication Date: 2003 Manual no.: 0-4951 Revision Date: 5/05/2014 Revision: AJ General Information This kit is for use only with Victor Thermal Dynamics XT-Series Torches. Do not use this kit with any other equipment. Read these instructions before starting the replacement procedure. Keep these instructions for future reference. Only a qualified technician should perform this procedure. Parts Supplied The kits includes: Torch O-Rings Cartridge O-Rings Cartridge Baffle O-Ring (xx-1022) Victor Thermal Dynamics Cat. No. 9-4893 O-Ring Lubricant Instructions Procedure Use only Victor Thermal Dynamics No. 9-4893 O-Ring Lubricant (Christo Lube MCG-129) with this torch part. Use of other lubricants may cause irreparable damage to the torch. Torch O-Ring Change 1. Find and open the bag labeled Torch O-Ring Kit. Verify that you have a new O-Ring for each of the ones being replaced on the Torch. See Illustration. O-Rings Cat. No. 9-9041 Cat. No. 9-3027 Cat. No. 9-3026 Cat. No. 9-3025 Installation Instructions Torch Head Baffle O-ring not shown. WARNINGS Disconnect primary power at the source and bleed down the system before starting this procedure. Torch View Art # A-04066_AC 1. If necessary, raise the torch away from the cutting table to provide working room. 2. Remove the Shield Cup Assembly (including the cartridge assembly and consumables). 2. Remove and discard each of the old O-Rings from the Torch. 3. Clean each of the O-Ring grooves with a soft bristle brush or lint free cloth. 4. Find the large yellow O-Ring and place it on the Torch where the old one was. Do Not Lubricate the yellow O-Ring. Manual 0-4951 1
5. Lubricate each of the red or purple (black on older models) O-Rings with a thin film of the lubricant provided with this kit. See earlier Caution. a. Place a small amount of lubricant on your index finger. b. Rub the lubricant between your thumb and index fingers until it becomes clear. c. Apply this lubricant to the O-Ring by rolling it between your thumb and index fingers. d. Repeat this process until the entire O-Ring is coated in a thin film of lubricant. 6. Place each of the O-Rings in the proper groove on the Torch. See Previous Illustration. Use the following Torch O-Ring scale to verify proper size. Older model torches may have brown and black O-Rings. TORCH HEAD O-RINGS Cartridge O-Ring Change 300 Amp and Less 1. Find and open the bag labeled Cartridge O-Ring Kit. Verify that you have a new O-Ring for each of the ones being replaced on the Cartridge. See Illustration. 300 Amp and Less Cartridge Retaining Ring (Cat. No. 9-9489) Inner O-Ring (Cat. No. 9-3030) Location (Under Locking Ring) Snap Ring Cartridge View O-Ring, Cat. No. 9-3029 O-Ring, Cat. No. 9-3028 Cartridge Assembly Art # A-07087_AD 9-9041 Cartridge Body Baffle O-ring Art # A-12549 Shield Cup Cartridge Baffle O-Ring 1 inch Scale 9-3027 9-3026 9-3025 For 300 and 400 Amp cartridges the Shield Cup, Baffle and Speed Lock Ring will need to be removed to access the largest of the O-Rings noted above. 2. Remove the snap ring on the cartridge assembly and slide the locking ring downward for access to the O-Ring under the retaining ring. 3. Remove and discard each of the old O-Rings from the cartridge. Remove and discard the Baffle O- ring. Art # A-07635_AB 2 Manual 0-4951
Use the following Cartridge O-Ring scale to verify proper size. CARTRIDGE O-RINGS Use only Victor Thermal Dynamics No. 9-4893 O-Ring Lubricant (Christo Lube MCG-129) with this torch part. Use of other lubricants may cause irreparable damage to the torch. 4. Lubricate each of the O-Rings with a thin film of the lubricant provided with this kit. See previous Caution. 9-3030 a. Place a small amount of lubricant on your index finger. b. Rub the lubricant between your thumb and index fingers until it becomes clear. c. Apply this lubricant to the O-Ring by rolling it between your thumb and index fingers. d. Repeat this process until the entire O-Ring is coated in a thin film of lubricant. 9-3029 5. Place the Baffle O-Ring inside the Baffle. Place each of the O-Rings in the proper groove on the Cartridge. See Previous Illustration. 6. Secure the locking ring in place by reversing step 2 above. Take extra care to insure the snap-ring is properly seated and the locking ring is secure and rotates freely. There should be a gap of 1/8 or less between the ends of the snap-ring. 1 inch Scale 9-3028 Art # A-07636_AB 7. Reinstall the Shield Cup Assembly (including the cartridge assembly and consumables) on the torch. 8. Reconnect the gas supply. Adjust gas pressure as needed. Test the system for proper operation. Manual 0-4951 3
Cartridge O-Ring Change 400 Amp 1. Find and open the bag labeled Cartridge O-Ring Kit. Verify that you have a new O-Ring for each of the ones being replaced on the Cartridge. See Illustration. Inner O-Ring (Cat. No. 9-3030) Location (Under Speed Lock Ring) Cartridge Assembly Speed Lock Ring and Threaded Ring removed for clarity Art # A-09684_AC O-Ring, Cat. No. 9-3029 O-Ring, Cat. No. 9-3028 400 Amp Only O-Ring, Cat. No. 8-0547 Outer Cartridge Cartridge View O-Ring, Cat. No. 8-0561 O-Ring, Cat. No. 9-3029 For 300 and 400 Amp cartridges the shield Cup, Baffle and Speed Lock Ring will need to be removed to access the largest of the O-Rings noted above. 2. Remove the Outer Cartridge by holding the Cartridge with the removal tool and unthreading the Outer Cartridge. Slide the Threaded Ring and Speed Lock ring off the Cartridge body for access to the O-Ring. 3. Remove and discard each of the old O-Rings from the two Cartridge sections. 4. Lubricate each of the O-Rings with a thin film of the lubricant provided with this kit. See previous Caution. a. Place a small amount of lubricant on your index finger. b. Rub the lubricant between your thumb and index fingers until it becomes clear. c. Apply this lubricant to the O-Ring by rolling it between your thumb and index finger. d. Repeat this process until the entire O-Ring is coated in a thin film of lubricant. 5. Place each of the O-Rings in the proper groove on the Cartridge sections. See Previous Illustration. 6. Secure the locking ring in place by reversing step 2 above. Be sure the tabs on the Threaded Ring go first and align with the notches before attaching the Outer Cartridge. Do not use wrenches to tighten the assembly pieces. Hand tighten ONLY. Use only Victor Thermal Dynamics No. 9-4893 O-Ring Lubricant (Christo Lube MCG-129) with this torch part. Use of other lubricants may cause irreparable damage to the torch. 4 Manual 0-4951
Use the following Cartridge O-Ring scale to verify proper size. CARTRIDGE O-RINGS 7. Reinstall the Shield Cup Assembly (including the cartridge assembly and consumables) on the torch. 8. Reconnect the gas supply. Adjust gas pressure as needed. Test the system for proper operation. 8-0547 9-3030 If O-Rings from the Torch Head and Cartridge are mixed, the O-Ring scale charts must be used to determine the correct O-Rings. Some of these O- Rings are very close in size and if they are mixed they will leak. If you are printing these pages from an electronic source, i.e. PDF, measure the 1 inch Scale provided with the illustration. If it does not measure 1, DO NOT USE IT. Many printing defaults for PDF files are set to Fit to Printer Margins. This has to be changed so that no changes or None is selected in the Page Scaling so the print out will be at 100%. 9-3029 Every effort has been made to provide complete and accurate information in this manual. However, the publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by errors or omissions in this Manual, whether such errors result from negligence, accident, or any other cause. 1 inch Scale Art # A-09683_AC 8-0561 9-3028 Manual 0-4951 5
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