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Komatsu Fine Plasma Consumables
40 Amp
90 Amp
120 Amp
300 Amp
30 kW
60 kW
Robotic
 Diagram of 90 and 120 Amp Torch
Diagram of 40 Amp Torch
Diagram of Twister 30kW (150 Amp) Torch
Diagram of Twister 60kW (300 Amp) Torch
120 Amp Process
Part Description Min.  
65-0442-002 NOZZLE 1.3 MM, G9120, 969-95-40211 10
65-0442-003 SWIRLER (Left), G9120, 969-95-40240 1
65-0442-004 SPACER RING, Swirling (crème) cut 1/4 - 3/4 in., G9120, 969-95-40250 1
65-0442-005 SHIELD CAP 120 AMP, G9120, 969-95-40270 1
65-0442-119 SPACER RING Non-Swirling Assist (brown) cut 3/4 - 1 in., G9120 1
90/120 Amp Process
Part Description Min.  
65-0434-007 NOZZLE 1.1 MM, G990/G9120, 7848-65-5180 10
65-0434-015 CAP #1, G990/G9120, 7848-65-5520 1
65-0434-016 CAP #2, G990/G9120, 7848-65-5311 1
65-0434-017 NOZZLE .8 MM, G990/G9120, 7848-65-5160 10
65-0434-018 SWIRLER (Right), G990/G9120 1
65-0434-019 SHIELD CAP 90 Amp, G990/G9120, 7848-65-5530 1
65-0434-020 CERAMIC GUIDE, G990/G9120, 969-95-40160 1
65-0434-021 O-RING Kit 1 set of 3 (small, medium, large), G990/G9120, 7848-65-9850 1
65-0434-022 SPACER RING (cut process up to 1/2 in.) Black, G990/G9120, 7848-65-5540 1
65-0434-023 O-RING Kit 10 pieces (small), G990/G9120, 7848-65-9820 1
65-0442-001 ELECTRODE, G990/G9120, 969-95-40220 10
65-0442-118 NOZZLE .6 MM, G9120, 969-95-40280 10
90/120 Amp QuickSilver SUS
Part Description Min.  
65-0438-002 NOZZLE .8 (S) MM SUS, G990/G9120, 969-95-21110 10
65-0438-003 NOZZLE 1.1 (S) MM SUS, G990/G9120, 969-95-21120 10
65-0438-004 SHIELD CAP (S) SUS, G990/G9120, 969-95-21130 1
65-0438-005 CAP #2 (S) SUS, G990/G9120, 969-95-21140 1
65-0438-009 O-RINGS (S) SUS, G990/G9120, 969-95-21150 1
40 Amp Process
Part Description Min.  
65-0400-066 CAP #2, G940, 7848-60-5410 1
65-0432-001 CAP #1, G940, 7848-60-5110 1
65-0432-002 NOZZLE .6 MM, G940, 7848-60-5130 10
65-0432-003 NOZZLE .4 MM, G940, 7848-60-5150 10
65-0432-005 ELECTRODE, G940, 7848-60-5910 10
65-0432-007 O-RING KIT, G940, 7848-60-9850 1
65-0432-013 NOZZLE .7 MM, G940, 7848-60-5160 10
65-0432-021 CERAMIC GUIDE, G940, 7848-60-5450 1
65-0432-066 SWIRLER, G940, 7848-60-5860 1
40 Amp QuickSilver SUS
Part Description Min.  
65-0436-002 ELECTRODE SUS, G940, 969-95-11470 10
65-0436-003 SWIRLER SUS, G940, 969-95-11460 1
65-0436-004 NOZZLE .7 MM SUS, G940, 969-95-11110 10
65-0436-005 CAP #1 SUS, G940, 969-95-11120 1
65-0436-006 SPACER RING SUS, G940, 969-95-11130 1
65-0436-007 SHIELD CAP SUS, G940, 969-95-11140 1
65-0436-008 CAP #2 SUS, G940, 969-95-11150 1
65-0436-012 O-RING LARGE SUS, G940, 969-95-11190 1
300 Amp Process
Part Description Min.  
65-0439-003 ELECTRODE, 300 AMP, 969-95-30160 10
65-0439-004 GUIDE, 300 AMP, 969-95-30171 1
65-0439-005 SWIRLER, 300 AMP, 969-95-30181 1
65-0439-006 NOZZLE 2.8 MM, 300 AMP, 969-95-30140 10
65-0439-007 NOZZLE 2.2 MM, 300 AMP, 969-95-30220 10
65-0439-008 NOZZLE 1.2 MM, 300 AMP, 969-95-30150 10
65-0439-009 CAP, INNER, 300 AMP, 969-95-30210 1
65-0439-010 CAP, OUTER, 300 AMP, 969-95-30110 1
65-0439-011 SPACER RING, 300 AMP, 969-95-30190 1
65-0439-012 SHIELD CAP, 300 AMP, 969-95-30130 1
65-0439-014 O-RING KIT, 300 AMP, 969-95-30560 1
Robotic Slim Tip Process
Part Description Min.  
65-0432-066 SWIRLER, G940, 7848-60-5860 1
65-0440-003 NOZZLE .6 MM, 40 AMP ROBOTIC, 7848-60-5830 10
65-0440-004 ELECTRODE, 40 AMP ROBOTIC, 7848-60-5420 10
65-0440-005 CAP #1, 40 AMP ROBOTIC, 7848-60-5850 1
65-0440-006 O-RING KIT, 40 AMP ROBOTIC 1
65-0440-007 CERAMIC GUIDE, 40 AMP ROBOTIC, 7848-60-5811 1
30kW (150 Amp) Process
Part Description Min.  
65-0444-001 Electrode (For .6 / .8 / 1.1 / 1.3 Nozzle), 969-95-24310 10
65-0444-002 Nozzle 1.3, TFP, 969-95-24130 10
65-0444-003 Nozzle 1.1, TFP, 969-95-24180 10
65-0444-004 Nozzle 0.8, TFP, 969-95-24190 10
65-0444-008 Guide A (for Nozzle 1.3, 1.1), TFP, 969-95-24320 1
65-0444-009 Ring (Swirler), TFP, 969-95-24141 10
65-0444-010 O-Ring Kit, TFP, 969-95-24390 1
65-0444-019 Outer Cap, TFP, 969-95-24470 1
65-0444-020 SHIELD CAP 150/300 AMP T 969-95-24750 NO DITCH, 969-95-24750 10
65-0444-021 Nozzle 0.6, TFP, 969-95-24770 10
65-0444-023 Guide B (for Nozzle 0.8, 0.6), TFP, 969-95-24780 1
65-0444-024 O-Ring Kit (Orange/ for Guide) [10 pcs.], TFP, 969-95-24450 1
65-0444-025 O-Ring Kit (White/ for Guide) [10 pcs.], TFP, 969-95-24730 1
65-0444-026 Shim for Outer Cap [5 pcs.], TFP, 969-95-24410 1
65-0444-027 Center Pipe, TFP, 969-94-24162 1
65-0444-028 Nozzle Contactor [2 pcs.], TFP, 969-95-24420 1
65-0444-029 Plate (for changing comsumables) [2 pcs.], TFP, 969-95-24570 1
65-0444-056 SHIELD CAP 150/300 AMP T 969-95-24810 W/DITCH, 969-95-24810 10
60kW (300 Amp) Process
Part Description Min.  
65-0444-001 Electrode (For .6 / .8 / 1.1 / 1.3 Nozzle), 969-95-24310 10
65-0444-002 Nozzle 1.3, TFP, 969-95-24130 10
65-0444-003 Nozzle 1.1, TFP, 969-95-24180 10
65-0444-004 Nozzle 0.8, TFP, 969-95-24190 10
65-0444-008 Guide A (for Nozzle 1.3, 1.1), TFP, 969-95-24320 1
65-0444-009 Ring (Swirler), TFP, 969-95-24141 10
65-0444-010 O-Ring Kit, TFP, 969-95-24390 1
65-0444-019 Outer Cap, TFP, 969-95-24470 1
65-0444-020 SHIELD CAP 150/300 AMP T 969-95-24750 NO DITCH, 969-95-24750 10
65-0444-021 Nozzle 0.6, TFP, 969-95-24770 10
65-0444-023 Guide B (for Nozzle 0.8, 0.6), TFP, 969-95-24780 1
65-0444-024 O-Ring Kit (Orange/ for Guide) [10 pcs.], TFP, 969-95-24450 1
65-0444-025 O-Ring Kit (White/ for Guide) [10 pcs.], TFP, 969-95-24730 1
65-0444-026 Shim for Outer Cap [5 pcs.], TFP, 969-95-24410 1
65-0444-027 Center Pipe, TFP, 969-94-24162 1
65-0444-028 Nozzle Contactor [2 pcs.], TFP, 969-95-24420 1
65-0444-029 Plate (for changing comsumables) [2 pcs.], TFP, 969-95-24570 1
65-0444-042 Nozzle 1.7, TFP, 969-95-26120 10
65-0444-043 Nozzle 2.2, TFP, 969-95-26110 10
65-0444-044 Electrode 60 (for 1.7 / 2.2 Nozzle), TFP, 969-95-26210 10
65-0444-045 Shield Cap 60 (for 1.7 / 2.2 Nozzle), TFP, 969-95-26140 1
65-0444-046 Inner Cap (for 1.7 / 2.2 Nozzle) , TFP, 969-95-26130 1
65-0444-047 Outer Cap 60 (for 1.7 / 2.2 Nozzle), TFP, 969-95-26160 1
65-0444-048 Outer Cap 30 (for .8 / 1.1 / 1.3 Nozzle), TFP, 969-95-26170 1
65-0444-049 O-Ring Kit 300 AMP, TFP, 969-95-26190 1
65-0444-050 Shim 60 (for 1.7 / 2.2 Nozzle) [2 pcs.], TFP, 969-95-26150 1
65-0444-056 SHIELD CAP 150/300 AMP T 969-95-24810 W/DITCH, 969-95-24810 10
65-0444-057 Inner Cap 60 (for 1.7 / 2.2 Nozzle) New April 2006, TFP 969-95-2 1
Torches
Part Description Min.  
65-0442-006 120 Amp Torch Assembly 1
65-0430-020 90 Amp Torch Assembly 1
65-0430-022 40 Amp Torch Assembly 1
65-0439-002 300 Amp Torch Assembly 1
Way Covers
Part Description Min.  
01-2002-001 5X10: LOWER RIGHT HAND 1
01-2002-002 5X10: LOWER LEFT HAND 1
01-2002-003 5X10: UPPER LEFT HAND 1
01-2002-004 5X10: UPPER RIGHT HAND 1
01-2002-005 5X10: WAYCOVER WRAP AROUND 1
01-9216-001 APS 4714,9714,12714: Y AXIS APS 1
04-1349-001 12612: X AXIS BLACK REV 1
04-1349-002 12612: X AXIS GRAY REV 1
04-1350-001 12612,12620,12624: Y AXIS REV 1
04-1350-002 12820,12812: Y AXIS REV 1
04-1454-001 APS 4714,9714,12714: X AXIS APS 1
04-1456-001 12620,12820,12624: X AXIS BLACK REV 1
04-1456-002 12620,12820,12624: X AXIS GRAY REV 1
Miscellaneous Spare Parts
Part Description Min.  
65-0430-017 TORCH SYS 1.8M 990 II/CE 969-94-49590 1
65-0430-020 TORCH ASSY G990 I/II/CE 969-94-41511/41510 1
65-0430-021 TIP SET G990 I/II 969-94-40510 1
65-0430-022 TORCH ASSY G940 I/II/CE 969-94-41010 1
65-0430-023 TIP SET/40 STD G940 I/II 969-94-40010 1
65-0432-016 TORCH TUBE (O20)KOMATSU 7848-60-2180 1
65-0432-018 TORCH & CABLE, 1.8M 940 I 7848-95-2140 1
65-0432-071 TORCH CBL.1.8M,G940 I 7848-95-6200 1
65-0434-013 1.8M TORCH CBL 90I/II 120 AMP 7848-65-6410 1
65-0434-025 TORCH TUBE, 20MM. G990 I 7848-65-2180 1
65-0438-013 COOLING TUBE G990 I/II/CE 7848-65-5670 OBSOLETE 1
65-0442-006 TORCH ASSY 120 AMP 969-94-41910 1
65-0442-007 TIPSET 120 AMP/STD 969-94-40551 1
65-0442-009 WATER TUBE 120 AMP TORCH 969-94-21110 1

90 and 120 Amp Torch Parts


Click for larger Picture
1Cap Number 2
2Shield Cap (90Amp)
2AShield Cap (120Amp)
3Spacer Ring (90Amp)
3A/3BSpacer Ring (120Amp)
4Cap Number 1
5Nozzle 0.8,1.1mm
5ANozzle 1.3mm
6Swirler
6ASwirler
7Ceramic Guide
8Electrode (90Amp)
8AElectrode (120Amp)
9Cooling Tube 90Amp
9ACooling Tube 120Amp
10O-Rings sm. med. lg.
10AO-Rings small
11Torch Body
12Torch Tube
Item 90/120 Amp Consumable Part Description Identifying Features Use with Part Number
1 Cap Number 2None90Amp120Amp 65-0434-016
2 Shield CapNone90Amp  65-0434-019
2A Shield Cap120 Ink Stamp 120Amp 65-0442-005
3 Spacer RingMade of Black Plastic90Amp  65-0434-022
3A Spacer Ring (Assist Swirler)Crème
(Formerly Red)		 120Amp 65-0442-004
3BSpacer Ring (High Heat,
Non-Swirling Assist)		Made of Brown
Phenolic		 120Amp 65-0442-119
4 Cap Number 1None90Amp120Amp 65-0434-015
5 Nozzle - 0.8mm
Nozzle - 1.1mm		0.8 Ink Stamp
1.1mm Ink Stamp		90Amp120Amp 65-0434-017
65-0434-007
5ANozzle - 1.3mm1.3 Ink Stamp 120Amp 65-0442-002
6 SwirlerNone90Amp  65-0434-018
6A Swirler120 Ink Stamp 120Amp 65-0442-003
7 Ceramic GuideNone90Amp120Amp 65-0434-020
8Electrode 90 Amp
(Obsolete: Use 120 Amp
Electrode and Cooling Tube)		None90Amp [1] 65-0434-008
8A Electrode120 Ink Stamp90Amp120Amp 65-0442-001
10O-Ring Kit 3 pc. (Sm. Med. Lg.)None90Amp120Amp 65-0434-021
10AO-Ring Kit 10 pc. SmallNone90Amp120Amp 65-0434-023

Item 90/120 Amp Repair Part Description Identifying Features Use with Part Number
9Cooling Tube 90 Amp
(Obsolete: Use 120 Amp
Electrode and Cooling Tube)		None90Amp [2] 65-0438-013
9ACooling Tube - 120 ARed Band90Amp [3] 120Amp 65-0442-009
11Torch Body - 90 Amp
(includes items 9, 10, 11, and 12 only.
Does not include any consumable parts). 		None90Amp [4]   65-0430-020
11ATorch Body Assembly: 120 Amp
Not Shown
(includes items 9A, 10, 11A, and 12 only.
Does not include any consumable parts).		None 120Amp 65-0442-006
12Torch TubeNone90Amp120Amp 65-0434-025
13Torch Leads
Not Shown		None90Amp120Amp 65-0434-013
1490 Amp Tip Set
Not Shown
Includes items 1, 2, 3, 4, 5, 6, 7, and 8		None90Amp  65-0430-021
14A120 Amp Tip Set
Not Shown
Includes items 1, 2A, 3A, 4, 5A,
6A, 7, and 8A		See Items 2A, 3A,
5A, 6A, and 8A.		 120Amp 65-0442-007
1590 Amp torch and Leads Assembly
Not Shown
Includes Items 11, 13, and 14		 90Amp   
16120 Amp Torch and Leads Assembly
Not Shown
Includes Items 11A, 13, and 14A		  120Amp 65-0430-017
Notes:
  1. Never use 90 Amp Electrode (65-0434-008) in 120 Amp Torch. Electrode water chamber is too shallow and will damage Cooling Tube and Torch (65-0442-009).
  2. NEVER use the shorter Cooling Tube (65-0438-013) in the 120 Amp Torch. Overheating and Torch failure will result.
  3. 65-0442-009 Cooling Tube can be used on the 90 Amp or 120 Amp Torch as long as the 120 electrode is used exclusively.
  4. 90 Amp Torch can be converted to 120 Amp Torch by replacing Cooling Tube 65-0438-013 with Cooling Tube 65-0442-009.

40 Amp Torch Parts

1 Cap Number 1
2 Nozzle
3 Swirler
4 Guide
5 Electrode
6 O-Ring Kit
7 Torch Body Assembly
8 Torch Tube
9 Torch Leads
Item40 Amp Torch Consumable Part DescriptionsPart Number
1Cap Number 1 65-0432-001
2 Nozzle - 0.4 mm
Nozzle - 0.6 mm
Nozzle - 0.7 mm 		65-0432-003
65-0432-002
65-0432-013
3Swirler 65-0432-066
4Guide 65-0432-021
5Electrode with O-ring 65-0432-005
6O-ring Kit 65-0432-007


Item40 Amp Torch Repair Part DescriptionsPart Number
7Torch Body Assembly
Torch Body Assembly includes Torch Body (item 7)
and Torch Tube (item 8) only
It does not include any consumable parts.		 65-0430-022
7ANot Shown - Torch Tip Set
includes item numbers 1-6
(includes 0.6 mm nozzle only).		 65-0430-023
8Torch Tube 65-0432-016
9Torch Leads 65-0432-071
10
(not shown)		 Torch Assembly with Leads
It includes all listed parts
except 0.7 mm Nozzle		 65-0432-018

Twister 30 kW (150 Amp) Torch Parts


Click for larger Picture
Komatsu Part KCT Part Description Min.  
1 969-95-24470 65-0444-019 Outer Cap 1
2 969-95-24750 65-0444-020 Shield Cap (3mm) 10
3 969-95-24141 65-0444-009 Ring 10
4 969-95-24130 65-0444-002 Nozzle 1.3mm 10
5 969-95-24180 65-0444-003 Nozzle 1.1mm 10
6 969-95-24190 65-0444-004 Nozzle 0.8mm 10
7 969-95-24770 65-0444-021 Nozzle 0.6mm 10
8-a 969-95-24320 65-0444-008 Guide A (for Nozzle 1.3, 1.1) 1
8-b 969-95-24760 65-0444-023 Guide B (for Nozzle 0.8, 0.6) 1
9 969-95-24310 65-0444-001 Electrode 10
10 969-95-24390 65-0444-010 O-Ring Kit 1
10-a 969-95-24450 65-0444-024 O-Ring Kit (Orange for Guide) [10 pcs.] 1
10-b 969-95-24730 65-0444-025 O-Ring Kit (White for Guide) [10 pcs.] 1
11 969-95-24410 65-0444-026 Shim for Outer Cap [5 pcs.] 1
12 969-94-24162 65-0444-027 Center Pipe 1
13 969-95-24420 65-0444-028 Nozzle Contactor [2 pcs.] 1
  969-95-24570 65-0444-029 Plate (for changing consumables) [2 pcs.] 1

Twister 60 kW (300 Amp) Torch Parts


Click for larger Picture
Komatsu Part KCT Part Description Min.  
1 969-95-24190 65-0444-004 Nozzle 0.8 10
2 969-95-24180 65-0444-003 Nozzle 1.1 10
3 969-95-24130 65-0444-002 Nozzle 1.3 10
4 969-95-26120 65-0444-042 Nozzle 1.7 10
5 969-95-26110 65-0444-043 Nozzle 2.2 10
6 969-95-26210 65-0444-044 Electrode 60 (For Nozzle 1.7/2.2) 10
7 969-95-24310 65-0444-001 Electrode (For Nozzle 0.8/1.1/1.3) 10
8 969-95-26140 65-0444-045 Shield Cap 60 (For Nozzle 1.7/2.2) 1
9 969-95-24750 65-0444-020 Shield Cap 30 (For Nozzle 0.8/1.1/1.3) 10
10 969-95-24320 65-0444-008 Guide A (For Nozzle 1.1/1.3/1.7/2.2) 1
11 969-95-24760 65-0444-023 Guide B (For Nozzle 0.8) 1
12 969-95-24141 65-0444-009 Ring 10
13 969-95-26130 65-0444-046 Inner Cap (For Nozzle 1.7/2.2) 1
13a 969-95-26230 65-0444-057 Inner Cap (For Nozzle 1.7/2.2) New April 2006 1
14 969-95-26160 65-0444-047 Outer Cap 60 (For Nozzle 1.7/2.2) 1
15 969-95-26170 65-0444-048 Outer Cap 30 (For Nozzle 0.8/1.1/1.3) 1
16 969-95-26190 65-0444-049 O-Ring Kit [*] 1
17 969-95-24450 65-0444-024 O-Ring Kit, Orange (For Guide) [10 pcs.] 1
18 969-95-24730 65-0444-025 O-Ring Kit, White (For Guide) [10 pcs.] 1
19 969-95-26150 65-0444-050 Shim 60 (For Nozzle 1.7/2.2) [2 pcs.] 1
20 969-95-24410 65-0444-026 Shim for Outer Cap [5 pcs.] 1
21 969-94-24162 65-0444-027 Center Pipe 1
22 969-95-24420 65-0444-028 Nozzle Contactor [2 pcs.] 1
  969-95-24570 65-0444-029 Plate (for changing consumables) [2 pcs.] 1
[*]O-Ring Kit Contents
 For torch outside: 2 kinds -2 pcs. each
 For torch inside: 5pcs.
 For Guide: 2 kinds (Black) - 2pcs. each
 For Guide: 2 kinds (Orange & White) - 5pcs. each
 For Outer Cap 30: Small, 10pcs.
 For Outer Cap 30:Big, 2pcs.
 For Inner Cap: 10pcs.
 For Shield Cap 60:10pcs.