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BEAVER
31
6 Maintenance and inspection
Refer to the following for inspection and maintenance of the machine and
use the machine under the best operating conditions at all times.
Maintenance is only to be conducted by a qualified professional.
6.1 Disassembly
6.1.1 Maintenance of the electrical equipment
(Tools to use: crosshead screwdriver, watchdriver)
1 Turn the JOX lever of the gas distributor upwards and remove the
connecting bar.
2 Remove the six fastening screws
of the machine body and loosen
the screws of the gas distributor.
(Main unit cover (L) at the same
time (do not remove the latter
screws)). Then take the main unit
cover (L) off. (Maintenance of the
electrical parts except the drive
motor can be performed when
the
cover is taken off.)
3 Fasten the main unit cover with
the six screws after the
maintenance.
figure 6 - 1
4 Insert the connecting bar in the JOX lever of the gas distributor.
6.1.2 Maintenance of the gear case
(Tools to use: crosshead screwdriver, punch, hammer).
1 Pull the torch holder out. (Revolve the pinion clockwise).
2 Turn the machine body up side down and remove the bottom cover to
see inside (Crosshead screws 4 pcs).
3 Remove the drive wheel cover. (Crosshead screws 3 pcs.)
4 Remove the drive wheel. (Crosshead screws 2 pcs).
If the drive wheel is fused to the shaft, pull the drive wheel out in the
same manner with the way of pulling a pulley out utilizing the tap hole
for attaching the drive wheel cover.
5 Remove the heat shield.
6 Remove the retainer of the casing. (While knocking them by the
punch and the hammer, revolve them counterwise).
7 Pull the axis's out and the gear will come out simultaneously.
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32
8 Pulling the axis I out will become easier if the clutch bar is removed.
9 Assemble the parts (the above items 7 to 1) in that order. That lever
(Gear II with the bearings) must be put in the gear case in advance as
it is impossible to put it in with the axis.
3
2
1
4
5
10
6 7
8
9
figure 6 - 2
1. Retainer
2. Shaft I
3. Lever
4. Gear
5. Clutch lever
6. Cover
7. Casing
8. Heat shield I
9. Heat shield II
10. Drive wheel
6.1.3 Maintenance of the drive motor and the reduction gear
(Tool to use: Crosshead screwdriver, screwdriver, L wrench)
1 Same as 1, 2 in 6.1.2
2 Remove the two screws that fasten the gear case to the main unit
cover. (Crosshead screws 2 pcs).
3 Remove four screws that fix the drive motor (Crosshead screws 4
pcs.) Motor gear, case bevel gear (I) will come out as a unit.
4 Remove the set screw (W point screw with hexagon socket head) on
the bevel gear (I) to pull out the DU washer and brush. (Tool to use: L
wrench for M3)
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33
5 The drive motor can be removed from the reduction gear taking
three screws away.
6 Assemble the parts (the above items 5 to 1) in that order. Note that the
power pinion of the gear stand (bevel gear (I) is eccentric. Put the
motor lead wire upwards when the eccentric centre is up.
1
6 5
2 3 4
7
figure 6 - 3
1. Gear case
2. Bevel gear
3. DU washer
4. Bush
5. Reduction gear
6. Motor
7. W point screw
6.2 Periodical inspection and maintenance
Carry out the periodical inspection and maintenance according to the
following instructions. Always keep your machine in good condition.
6.2.1 Daily
1 Brush all dirt, dust and chips from the rack of the cross bar and
pinion of the torch holding handle.
2 Lubricate the guide wheel shaft with machine oil.
6.2.2 Monthly or every 300 hours
1 Take apart the guide wheel and apply grease to the ball.
Caution
Take care not to loose any ball.
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34
6.2.3 Every three months or 1000 hours
1 Remove the carbon cap to check wear and tear of the carbon.
Replace them with new carbons when they are less than 3 mm in
length. Prevent breakage when putting in the new carbon.
2 Inspect the resistor. Make sure that the cabtyre cord is disconnected in
advance. Remove the resistor cover and clean the dust and chips with
a clean brush or with air blow.
6.2.4 Every six months
• Disassemble, clean and replenish the gearbox. Disassembling and
reassembling procedure as follows.
- Remove the drive wheel - detach the gearbox from the drive
motor case - clean the gears inside with a cleaning solvent.
- When reassembling the gearbox, make sure that the clutch bar is in
the lever hole. After the reassembling, apply a little grease through
the service port.
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35
7 Troubleshooting
Repairs are only to be conducted by a qualified professional.
Caution
Turn the power off.
Remove the lead wire from the polyethylene block or the stick terminal
and check the parts one by one.
1 Machine does not move (Motor does not run)
Possible cause
Action
Solution
No electrical power Check power circuit and its connection. Replace the power
supply if it is
defective.
Defective power
cord Check the cord with a circuit multimeter.
No voltage shows the cord defective.
Refer to the wiring diagram.
a-a', b-b', c-c', earth
Repair or replace
the cord.
Wrong connection See that the lead wires are properly attached to
their terminals. Improve faulty
connection.
Faulty resistor Remove the switch adapter plate and check each
terminal with a multimeter. Refer to the wiring
diagram.
e-e', e-e".
Replace faulty
resistor.
Wrong resistor
brush contact Connect the multi meter to any two resistor
terminals and turn the handle.
Wrong contact is indicated by the unsteady
multimeter needle. Refer to the wiring diagram.
Replace faulty
resistor.
Defective lead wire Check each lead wire with a multimeter Replace faulty
leadwire.
Wrong motor
carbon brush
connection
Remove the motor cap and pull the carbon out to
see if its worn out. Check also the spring
movement.
Replace worn out
brushes with new
one.
Faulty motor
windings If all the above test results are normal, the motor
itself is faulty. Repair or replace
the motor.
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36
2 Machine does not move (Motor is running)
Possible cause
Action
Solution
Faulty clutch Remove the gear box lid and check the clutch. Clean or repair the
clutch.
Reduction gear
slips Turn on the power and stop the drive wheel by
hand. Reduction gear is faulty if the motor
continues to run.
Gear is loose.
Disassemble and
replace.
3 Abnormal carriage movement
Possible cause
Action
Solution
Runs too fast 100 V Machine is connected to 200V power
source. (Take every precaution to prevent it). Check the voltage.
Will not run slowly Faulty resistor. Replace the
resistor.
Faulty wiring. Repair the wiring.
Faulty motor. Repair or replace
the motor.
Will not run fast Inadequate voltage of the power source. Check the power
source with a
tester.
Uneven speed Damaged gear. Replace the faulty
gears or do lapping
on them.
Do not damage the
gear during the
overhaul.
BEAVER
Knocking Worn gears. Replace
Bevel gears engage. Replace
Loose the reduction gear. Replace
The screws tightening the driving wheel to the shaft
are lose. Repair or replace
the screw.
Foreign material or scratch on the rail surface on
which the drive wheel runs. Remove the
hindrance or repair
the rail.
Hose or the cabtyre cord is the hindrance to the
machine movement. Use caution during
operation.
Faulty guide wheel. Repair or replace.
Foreign materials or scratches on the drive wheel
or the idle wheel. Repair or replace.
Clutch does not
work Clutch lever bar is detached from the lever in the
gear. Open the cover of
the gear case and
insert it.
37
BEAVER
38
BEAVER
39
9
8 Wiring diagram and assembly drawing
1
e'
3 e
4
B a b
5
2 a' 13
A b'
9
13
13 12
10
13
11
11
14 12
13
6 e' 7
12 e
11 e"
8
d d'
9
13
figure 8 - 1
1. 3 Lead cabtyre cord
2. Plug
3. Earth clip
4. 3P plug
5. 3P receptacle
6. Motor circuit
7. Variable resistor
8. Push-button
9. 2P polyethylene block
10. Limit switch
11. Black
12. White
13. Brown
14. Grey
Note: A = Motor circuit B = Auto stop wiring (option)
BEAVER
Assembly drawing
100 mm 144 mm 170 mm
figure 8 - 2
40
BEAVER
41
9 Parts list
9.1 Main units
6 11
7 17
8
26 18 24
15
22
21
2
5
13 23
13 14 4 3 16
25
1
19 28
12
13
29
27
BEAVER
Main units
Item no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Description Main unit cover (L)
Main unit cover (R)
Dial
Clutch lever
Clutch bar
Handle (40)
Pinion metal (A)
Pinion (A)
Name plate
Name plate
Carrier bar
Screw
Screw
Spring pin
Screw
Screw
Spring pin
Screw
Screw
Round head screw
Receptacle
Switch
Resistor
Resistor
Resistor
Resistor
Resistor
Terminal
Guide wheel assembly
Pinion assembly
Screw
Cutting oxygen lever
Cutting oxygen lever shaft
Q'ty 1
1
1
1
1
1
1
1
1
1
1
4
3
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Stock no. ZS33300
ZS33301
ZS33302
ZS33303
ZS33304
ZS30223
ZS30909
ZS30910
33305
33307
ZS33308
9968179900
9968178200
222.004.848
ZS33370
9968177200
222.004.847
ZS33370
222.004.727
222.004.743
ZS33336
ZS30547
ZS30651
ZS30651
ZS30653
30546
30544
ZS31666
ZS30503
ZS30908
ZS33370
ZS30561
ZS30562
Remarks
SR - 6 x 15
SR - 5 x 25
PR - 4 x 23
SR - 5 x 10
PR 4 x 23
SR - 5 x 35
SR - 3 x 5
100 V
120 V
200 V - 220 V
230 V - 240 V
42 V
2P
42
BEAVER
43
9
9.2 Gear case
15
23
1 32
21 22
2 45 4
34 30 39
38
18 33
46 19 47
40
42 5 44
3
25 43 24
31
6 24 20
37 17 13 28
11 16
36
14
26
7 10
27
12
35
BEAVER
Gear case
Item no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Description Gear case
Bevel gear (I)
Bevel gear (II)
Bush
Shaft (I)
Shaft (II)
Shaft (III)
Gear (I)
Gear (II)
Gear (III)
Bearing retainer
Casing
Lever
Drive wheel
Idle wheel
Heat shield (I)
Heat shield (II)
Packing
Cover
Spring
Motor
Motor
Motor
Motor
Motor
Motor
Reduction gear
Bearing
Bearing
Bearing
Bearing
Bearing
Bearing
DU bush
DU washer
Stop ring
Screw
Screw
W point screw
Screw
Q'ty 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
4
1
1
1
1
1
1
Stock no. ZS33367
ZS33310
ZS33311
ZS33312
ZS33313
ZS33314
zs33315
ZS33316
ZS33317
ZS33318
ZS33319
ZS33320
ZS33321
ZS33322
ZS33323
ZS33324
ZS33325
33326
33327
33328
33329
ZS33330
33331
ZS33332
33333
33334
ZS33335
1138352400
1138352500
1138352500
1138353600
1138357300
1138359400
33340
ZS33341
9968260400
222.004.737
222.004.738
9968272600
222.004.767
Remarks
100 V 9500 r.p.m.
120 V 9500 r.p.m.
200 V 9500 r.p.m.
220 V 9500 r.p.m.
240 V 9500 r.p.m.
42 V
6000 ZZ
608 ZZ
608 ZZ
6002 ZZ
6202 ZZ
6302 ZZ
DU 1415
RS - 8
SR - 6 x 6
SR - 6 x 18
SSW - 4 x 5
SF - 6 x 15
44
BEAVER
Gear case
Item no.
36
37
38
39
40
41
42
43
44
45
46
47
Description Screw
Screw
Screw
Screw
Screw
Spring pin
Spring pin
Spring pin
Spring pin
Spring pin
Carbon brush cap
Carbon brush cap
Q'ty 1
2
3
4
4
1
1
1
1
1
2
2
Stock no. 9968158700
222.004.734
222.004.744
9968175300
222.004.734
9968207000
222.004.846
9968207300
9968207300
222.004.845
ZS33365
ZS33366
Remarks SF - 6 x 10
SR - 6 x 8
SR - 3 x 24
SR - 4 x 15
SR - 6 x 8
PR - 3 x 20
PR - 3 x 18
PR -3 x 25
PR -3 x 25
PR -1,6 x 6
45
BEAVER
46
9.3 Torch holder and gas distributor
30 32
23
21 25
29
31 28
27
24
29 26
18
9
17 14 38
39
11
8
1
3 19 37
20
33 4
34
5
10 6 15
36 17
7
16 35
13 2 12
BEAVER
Torch holder and gas distributor
Item no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Description Holder
Vertical slide
Bar (I)
Bar (II)
Screw
Vertical guide bar
Torch holder (with shaft)
Pinion metal
Handle (40)
Graduation collar
DU bush
Wing bolt
Screw
Screw
Hexagon bolt
W-point screw
Spring pin
Connecting bar
Cutting oxygen lever
Cutting oxygen lever shaft
Screw
Nut
Distributor
Valve jet for oxygen
Valve for preheat oxygen
Valve for gas
Jet lever (small)
Jet lever shaft
Nut for oxygen
Nut for gas
Hose connector (OX)
Hose connector (GAS)
Cabtyre cord assy.
Metal socket
European plug
Torch
Hose for oxygen
Hose for preheat oxygen
Hose for gas
Q'ty 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Stock no. ZS33345
ZS33346
ZS33347
ZS33348
ZS33349
ZS33350
ZS33351
ZS30909
ZS30223
ZS30568
64000015
9968232700
ZS33370
9968179600
9968405500
222.104.208
9968204300
ZS33343
ZS30561
ZS30562
9968177500
9968123200
ZS13441
ZS15254
ZS15255
ZS15256
ZS30583
ZS30668
0866837000
0866836900
1138300100
1138300100
61004264
ZS30275
9938848900
ZS10602
ZM30511
ZM30511
ZM30513
Remarks
BS - 6 x 20
SR - 6 x 10
BH - 6 x 20
SSW - 4 x 8
SR - 2.5 x 15
SR - 5 x 15
NH – 5
USA ONLY
220 V
220 V
47
BEAVER
48
9.4 Circle cutting attachment
1
4
6
2
9
5
8 7
3
BEAVER
Circle cutting attachment
Item no.
1
2
3
4
5
6
7
8
9
Description Weight
Bar fixing base
Pivot pin
Bar
Fitting
Hexagon bolt
Nut
Hexagon bolt
Hexagon bolt
Q'ty 1
1
1
1
1
1
1
1
1
Stock no. ZS30381
30382
ZS30384
ZS30385
ZS30383
9968109500
9968123500
9968109400
9968109100
Remarks
BH - 10 x 35
NH - 10
BH - 10x30
BH - 10x20
49
BEAVER
50
9.5 Auto stop
11
10
3
7
2 4
1
8
9
5 6
BEAVER
Auto stop
Item no.
1
2
3
4
5
6
7
8
9
10
11
Description Striker
Magnet retainer
Lever
Spring
Magnet cover
Magnet
Screw
Spring Washer
Screw
Spring Washer
Screw
Spring Washer
Limit switch
Terminal
Q'ty 1
1
1
1
1
2
1
1
1
1
1
1
1
1
Stock no. 33357
33358
33359
33360
33361
33362
222.004.249
222.004.404
222.004.730
222.004.406
222.004.715
222.004.406
33337
31666
Remarks SS41
SS41
SS41
SWP
Be - 6 x 15 (HN)
SR - 4 x 45
SR - 4 x 30
2P
51
BEAVER
52
9.6 Angle tracing roller
2 11 1
12
6 5
9
7
4
4
13 3
8
10 3
Angle tracing roller
Item no.
1
2
3
4
5
6
7
8
9
10
11
12
13
Description Roller arm bracket
Bar
Roller shaft
Roller
Roller arm (A)
Roller arm shaft
Spring
Roller arm (B)
Nut
Screw
Spring pin
Spring pin
Flat Washer
Q'ty 1
1
2
1
1
1
1
1
1
1
1
1
1
Stock no. 33354
33355
30670
30671
30672
30673
33356
30675
222.004.462
222.004.121
222.004.866
222.004.865
222.004.536
Remarks
NL - 8
BH - 10 x 25
PR - 3 x 22
PR - 2 x 20
WF - 10 x 2
