Hypertherm Duramax 75 Degrees Manual de referencia
Duramax™ 75°/15°/HRT/HRTs –
Hand Torch Body Replacement
Torches manuelles des séries
Duramax™–Remplacement
du corps de la torche
Field Service Bulletin
Bulletin de service sur le terrain
806940 – Revision2 – June, 2012
Révision 2 – Juin, 2012
torch body replacement
Field Service Bulletin 1
Introduction
Purpose
This Field Service Bulletin describes the procedure for replacing the torch body on the Duramax™ series hand torches.
Powermax105 systems: Complete instructions for installing this repair kit are included in the Powermax105 Service
Manual. To download the Service Manual, go to www.hypertherm.com and click the “Downloads library” link.
Materials and tools
• T10 TORX screwdriver (preferred) or flat-blade screwdriver
• #1 Phillips screwdriver
• Open end wrenches (preferred) or adjustable wrenches
The following procedure requires operating knowledge of Hypertherm’s power supplies. If necessary, refer to the
system’s operator manual for detailed information on removing the torch and changing consumables.
WARNING
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance. See the
Safety and Compliance Manual included with your system for more safety
precautions.
torch body replacement
2Field Service Bulletin
Part number Description Quantity
027055 1/4 ounce tube of silicone lubricant 1
075504* Machine screw: 4-40 x 5/16 Phillips pan head 1
420017 Duramax HRTs hand torch body subassembly 1
330103 Threadlocker: Loctite®263, 0.5ml 1
Kit 228951 contents (HRTs) — Powermax1000, Powermax1250, Powermax1650 only
* Screws included with kits as spares if needed.
Part number Description Quantity
027055 1/4 ounce tube of silicone lubricant 1
075504* Machine screw: 4-40 x 5/16 Phillips pan head 1
075714* Screw: #4 x 1/2 Torx pan head 5
220779 Duramax 75° hand torch body subassembly 1
330103 Threadlocker: Loctite®263, 0.5ml 1
Kit 228714 contents (75° hand torch)
Part number Description Quantity
027055 1/4 ounce tube of silicone lubricant 1
075504* Machine screw: 4-40 x 5/16 Phillips pan head 1
075714* Screw: #4 x 1/2 Torx pan head 5
220952 Duramax 15° hand torch body subassembly (?Description?) 1
330103 Threadlocker: Loctite®263, 0.5ml 1
Kit 228715 contents (15° hand torch)
Part number Description Quantity
027055 1/4 ounce tube of silicone lubricant 1
075504* Machine screw: 4-40 x 5/16 Phillips pan head 1
220969 Duramax HRT hand torch body subassembly 1
330103 Threadlocker: Loctite®263, 0.5ml 1
Kit 228950 contents (HRT)
A replacement torch main body with a 3/8in. (9.5 mm) coupler is required if the torch lead does not have a label on it
that reads 1000/1250/1650.
torch body replacement
Field Service Bulletin 3
Part number Description Quantity
027055 1/4 ounce tube of silicone lubricant 1
075504* Machine screw: 4-40 x 5/16 Phillips pan head 1
420017 Duramax HRTs hand torch body subassembly 1
330103 Threadlocker: Loctite®263, 0.5ml 1
Kit 228809 contents (HRTs) — Powermax1000, Powermax1250, Powermax1650 only
* Screws included with kits as spares if needed.
Part number Description Quantity
027055 1/4 ounce tube of silicone lubricant 1
075504* Machine screw: 4-40 x 5/16 Phillips pan head 1
075714* Screw: #4 x 1/2 Torx pan head 5
420102 Duramax 75° hand torch body subassembly 1
330103 Threadlocker: Loctite®263, 0.5ml 1
Kit 228958 contents (75° hand torch)
Part number Description Quantity
027055 1/4 ounce tube of silicone lubricant 1
075504* Machine screw: 4-40 x 5/16 Phillips pan head 1
075714* Screw: #4 x 1/2 Torx pan head 5
420101 Duramax 15° hand torch body subassembly 1
330103 Threadlocker: Loctite®263, 0.5ml 1
Kit 228957 contents (15° hand torch)
Part number Description Quantity
027055 1/4 ounce tube of silicone lubricant 1
075504* Machine screw: 4-40 x 5/16 Phillips pan head 1
220969 Duramax HRT hand torch body subassembly 1
330103 Threadlocker: Loctite®263, 0.5ml 1
Kit 228792 contents (HRT)
torch body replacement
4Field Service Bulletin
Replace the torch body
Please refer to Figures 1 through 7 on pages 4 through 7 when performing the following procedure.
Disassemble the torch and remove the torch body
1. Turn OFF the power and disconnect the torch lead from the power supply.
2. Remove the consumables from the torch.
3. Remove the five screws from the torch handle using a T10 TORX screwdriver or a flat-blade screwdriver. Open the
handle slowly, taking care that the trigger and trigger spring do not fall out of the right side of the handle.
Note: You should wear eye protection as the spring can launch out of the handle without warning.
4. Carefully remove the trigger and trigger spring.
5. Lift the start switch off the two mounting posts in the right side of the handle.
6. The torch body fits snugly into the right side of the handle. Gently press the handle away from the torch body to
remove it.
7. Remove the cap sensor switch from the mounting post in the handle.
8. Remove the screw that secures the torch’s pilot arc wire to the torch body using a #1 Phillips screwdriver.
9. Use two wrenches to loosen the gas fitting that secures the torch body to the torch lead.
10. Remove the torch body and set aside.
torch body replacement
Field Service Bulletin 5
Right side of
handle
Left side of
handle
Torch lead
Handle
screws
Safety trigger
and spring
Torch body
Cap-sensor
switch
Start
switch
Pilot arc wire
terminal screw
Gas fitting
Torch lead
Handle
screws
Safety trigger
and spring
Torch body
Cap-sensor
switch
Right side of
handle
Left side of
handle
Start
switch
Pilot arc wire
terminal screw
Gas fitting
Figure 1 – 75° hand torch
Figure 2 – 15° hand torch
torch body replacement
6Field Service Bulletin
Reassemble the torch with the new torch lead
1. Apply Loctite®263 (Part # 330103) to the threads of the gas tube fitting on the torch body. Be very careful not to
get any Loctite on the conical surface of the gas tube fitting to avoid damage to the torch. See the figure below.
2. Thread the torch body fitting into the gas fitting of the new torch lead until snug.
3. Use two wrenches to tighten the gas fitting that secures the torch body to the torch lead. Tighten to 69 kg cm,
(60in.-lbs).
4. Tighten the screw that secures the torch’s pilot arc wire to the torch body to 5.76 kg-cm (5 in.-lbs) Using a #1
Phillips screwdriver.
Caution: Do not get any Loctite on the conical surface of the gas tube fitting to avoid causing
damage to the torch. If any Loctite does get on this surface, clean it off immediately.
Conical surface of the
gas tube fitting
Figure 3 – Torch body showing gas tube fitting
torch body replacement
Field Service Bulletin 7
5. Lay the right side of the handle on a flat surface.
6. Position the pilot wire, cap sensor wires, and cap sensor wire connector in the handle. Press the cap sensor switch
onto the mounting post in the handle while pressing the cap sensor post into the post hole in the handle.
7. Gently press the torch body into the torch handle with the gas hose fitting’s flange aligned with the slot in the
handle. Be careful not to damage the cap sensor, cap sensor wires or pilot wire in the handle. Make sure that the
strain relief rests in the slot near the rear of the handle.
Figure 4 – 75° hand torch
Figure 5 – 15° hand torch
Start switch posts
Cap sensor switch
mounting post
Cap sensor
switch post hole
Trigger’s pivot hole
Strain relief slot
Gas hose fitting slot
Gas hose fitting slot
Start switch posts
Cap sensor switch
mounting post
Cap sensor
switch post hole
Trigger’s pivot hole
Strain relief slot
torch body replacement
8Field Service Bulletin
8. Position the start switch wires beside the gas fitting flange in the handle. Gently press the start switch onto the two
mounting posts in the handle.
9. Compress the trigger spring into the trigger. Slide the trigger and the spring into place in the right side of the
handle.
10. Align the left half of the handle with the right half. Verify that the trigger pivots are both located in the trigger pivot
holes (one pivot hole in each half of the handle). Make certain the wires will not get pinched by the handle and that
the strain relief for the torch lead will be held in place by the lip on the torch handle when the handle is screwed
together.
11. Tighten the five handle screws to 14.98 kg cm (13 in-lbs) using a T10 TORX screwdriver or a flat-blade
screwdriver.
12. Replace the consumables and reconnect the torch lead to the power supply.
Cap sensor switch
Start switch
Gas fitting flange
Slot for the
strain relief
Strain relief
Spring
Cap sensor switch
Start switch
Gas fitting flange
Spring
Slot for the
strain relief
Strain relief
Figure 6 – 75° hand torch
Figure 7 – 15° hand torch
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