Hypertherm HT4001 Plasma Arc Cutting System - Manual (Page 124)

Changing Consumable Parts
OPERATION
11-96
HT4001
Instruction Manual 5-33
Inspect the consumable parts before cutting for wear, and replace when needed. Always place the consumables
on a clean, dry, oil free surface after removing. Dirty consumables can cause the torch to malfunction.
Refer to Figure 5-10.
Removal and Inspection
1. Unscrew the retaining cap. If the torch is using one of the CE retaining caps, use the CE cap tool (004732) to
remove the retaining cap.
2. Remove the nozzle from the torch. Check the ceramic portion of the nozzle for signs of wear and arcing.
3. Unscrew the electrode from the torch head using a 7/16" (11 mm) hex wrench (wrench supplied in all of the
spare parts kits). Replace the electrode if the crater in the center of the insert is in excess of .050 inch (1.3 mm)
deep.
4. Remove the swirl ring from the electrode and inspect it for plugged holes or other damage.
5. If the tip of the water tube is damaged at all, see Changing the Water Tube later in this section.
Replacement
Before replacing the consumable parts, clean the current ring in the torch – see Figure 5-10. Use a clean paper
towel or cotton swab to remove any dirt, grease, etc., from the current ring.
1. Replace the electrode by screwing it back into the torch head. Use the 7/16" (11 mm) socket wrench to tighten
down the electrode. Do not overtighten.
2. Apply a light coating of silicone grease to both O-rings of the swirl ring before installing. As a guideline, you
should be able to feel the grease on your fingers, but not see it. Do not use an excessive amount of grease.
Too much grease will plug the swirl ring ports, causing improper gas flow during operation.
When installing the swirl ring, make sure to place the smaller diameter end up toward the rear of the torch.
3. Before installing the nozzle, apply a small amount of silicone grease to the nozzle’s O-rings. As a guideline, you
should be able to feel the grease on your fingers, but not see it. Do not use an excessive amount of grease.
Insert the nozzle into the torch and push it into place.
WARNING
Always disconnect the power supply from the main power source before inspecting or changing the
torch parts.