Operating Instructions for Caterpillar 8T7792 Mini Torch{0679} Caterpillar

Introduction

The Caterpillar 8T7792 Mini Torch uses a specially designed exothermic rod which allows the inner components to burn slightly faster than the outer wall.

This makes it possible to reach heats up to 5538°C (10,000°F). With this high a temperature you can get a more precise cut, greater blow effect, more speed and less operator back splash.

The Mini Torch may be used for cutting all types of materials, removing bolt heads, piercing bolts, piercing track and king pins for shrinkage removal. Also, it may be used for gouging hard surfaces including T1 and T2 steel, removing bucket tooth shanks, cutting off bucket edges, precision scarfing and washing away welds

The Mini Torch can be used indoors because the noise and smoke level are low.

Caterpillar Mini Torch. 1. Exothermic rod. 2. Collet nut. 3. Shield. 4. Handle. 5. Oxygen control lever. 6. Oxygen hose. 7. Battery clip cable.

The following items are included with Caterpillar 8T7792 Mini Torch

The following items are also available to use with the Mini Torch

Operator Precautions

Show/hide table

Wear proper eye protection, arc rays can injure eyes. Use adequate ventilation and exhaust at work piece to keep fumes and gases from the general area and breathing zone. Fumes and gases can be dangerous to your health. Avoid all live electrical components, electrical shock can kill.

1. Special care should be taken when cutting plated, galvanized, or painted parts to avoid exposure to toxic fumes.

2. Wear welder's gloves when inserting rod into holder.

3. Avoid rods touching any unprotected part of the body.

4. Perform all work in an area free of combustibles

5. Read and understand the operation instructions.

Observe all safety rules (see ANS1249.1), entitled Safety in Welding and Cutting, published by American Welding Society, 2501 N. W. Seventh Street, Miami, Florida 33125 or contact your employer.

Material Needed to Operate Caterpillar 8T7792 Mini Torch

Mini torch cutting rods.Oxygen supply with a two gauge regulator.Pug tube igniter, 12-volt battery or a welding machine.Protective clothing, gloves, and tinted face shield #5 lens.

Preparing for Cutting

Mini Torch Holder Hook Up

1. Make sure the oxygen is off.

2. Fasten one end of the oxygen hose to an appropriate oxygen regulator.

3. The other end of the hose should already be connected to the torch.

NOTE: Make sure the end of the oxygen hose is free of dirt and grease before hook up.

4. Loosen collet nut assembly.

5. Insert cutting rod into the hole in the collet nut assembly. (Crimped end goes into torch).

6. Firmly tap end of cutting rod on a hard surface in order to seat it against the washer inside the torch.

7. Hand tighten the collet nut.

8. Open the oxygen cylinder valve slowly. When the high pressure gauge indicates maximum pressure, open the cylinder valve fully.

9. With the torch not in use, adjust the regulator to the working pressure recommended:

* 4.76 mm (3/16 in): 240 to 310 kPa (35 to 45 psi) recommended (3/16 WASHER MUST BE USED).

* 6.35 mm (1/4 in): 310 to 415 kPa (45 to 60 psi) recommended and up to kPa 827 kPa (120 psi) if necessary.

* 9.53 mm (3/8 in): 415 to 550 kPa (60 to 80 psi) recommended and up to 827 kPa (120 psi) if necessary.

Mini Torch Ignition Hook Up

1. Connecting to a 12 volt battery.

* Connect negative terminal to striker plate.

* Connect positive terminal to Mini Torch Holder.

2. Connecting to a welding machine.

* Connect negative lead to striker plate.

* Connect positive lead to mini torch holder.

3. Using a pug tube igniter.

* Ignite open tube end with a match.

* Insert rod 76 to 102 mm (3 to 4 in) inside tube.

* Release oxygen valve or lever so a small amount of oxygen flows. (Oxygen will enhance heat and ignite torch). It will take approximately 10 to 20 seconds.

* A pug tube will burn approximately four hours.

Preliminary Checks

1. Use only exothermic rod designed for and made available thru Caterpillar Parts System.

2. Make sure cutting rods are properly seated against washer.

3. Be sure the collet nut is tight.

4. Make sure hand guard is intact and undamaged.

5. Check for oxygen leaks.

6. Check for proper oxygen flow through lines and cutting rod prior to ignition.

7. With the power off; inspect all power cables. Dirt, grease and oil should be wiped clean from cables.

8. Be sure striker is clear of slag, grease, and dirt (tap clean).

General Operation

1. Insert crimped end of rod into holder and tighten collet. The painted end will be ignited. (Check for leaks).

2. To ignite:

* Using a 12 volt battery or a welding machine, drag r (with slight pressure) across the striker plate while releasingda small amount of oxygen by depressing the oxygen lever. The rod should immediately ignite.

* For pug tube igniter see; Mini Torch Ignition Hook Up.

3. Bring the rod to the work piece and fully depress the oxygen handle. The torch is now ready for cutting.

Gouging Procedure

The gouging technique should be very similar to the technique used in carbon arc, a sawing motion. Listed below are the parameters for gouging with or without a welding machine.

Without External Power

Ignition can be accomplished by using a 12 volt battery or a pug tube igniter

* 6.35 mm (1/4 in) Rod, use 415 to 550 kPa (60 to 80 psi).

* 9.53 mm (3/8 in) Rod, use 480 to 690 kPa (70 to 100 psi).

With a Welding Machine

Ground work piece and connect holder to (Stringer).

* 4.76 mm (3/16 in) Rod, use 310 to 345 mm (45 to 50 psi) and 150 amps.

* 6.35 mm (1/4 in) Rod, use 413 to 551 kPa (60 to 80 psi) and 150 amps.

* 9.53 mm (3/8 in) Rod, use 482 to 689 kPa (70 to 100 psi) and 150 amps.

Piercing Procedure

1. Slightly depress oxygen lever. Press the rod against the work piece, allowing it to blow a 6.35 mm (1/4 in) hole. At this point fully depress the oxygen lever.

2. Move the rod slightly in and out while piercing. This will allow oxygen pressure to blow away the molten material

Piercing Tips

* To assure accuracy on small diameter pins, weld a small piece of angle iron on the head of the pin at 90° to 270° position and use the 6.35 mm (1/4 in) rod to pierce. Once 76 mm to 102 mm (3 to 4 in) is penetrated, remove the angle iron and finish the hole.

* On normal size diameter pins 51 to 76 mm (2 to 3 in) it is best to first use the 9.53 mm (3/8 in) rod and pierce 76 to 102 mm (3 to 4 in) deep, then stop and chip away the slag. At this point change the collet and use the 6.35 mm (1/4 in) rod to finish the piercing.

Using the 9.53 mm (3/8 in) rod first allows a reservoir to be made and allows the molten metal to flow out of the hole. Once the pin is pierced, allow it to cool. The pin will then shrink by 0.25 to 0.5 mm (.010 to .020 in) and can then be removed with a hammer and drift.

* When piercing a pin longer than 179 mm (7 in), start with the 6.35 mm (1/4 in) rod and then use the 9.53 mm (3/8 in) rod to further enlarge the hole. Finish with the 6.35 mm (1/4 in) rod. This again will allow the molten metal to flow out.

Shutdown at End of Piece

1. Use a smooth motion to complete the cut.

2. Upon completing the cut, release the oxygen control lever.

NOTE: The cutting rod will continue to burn as long as oxygen is supplied.

Shutdown at End of Day

1. Release the oxygen lever to stop the torch

2. Shut off the oxygen cylinder.

3. Blow out the oxygen line by squeezing the oxygen lever on the torch.

4. Loosen collet nut.

5. Remove cutting rod.

6. Hand tighten collet nut.

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