Hypertherm MAX200 Service Manual - Manual (Page 75)

3-34 MAX200 Service Manual
MAINTENANCE
MAX200 Rev 1 90° Hand Torch Removal and Replacement
To remove and replace the hand torch main body from the torch lead, perform the following procedure and see
Figure 3-3.
Removal
1. Remove the nine (9) screws securing the two handle halves and separate.
2. Remove the torch switch from the handle switch holder and allow to hang freely.
3. On the larger leads, use a 3/8" open-end wrench to hold the torch body fittings and a 1/2" open-end wrench to
turn the torch lead fittings.
On the smaller leads, use a 5/16" open-end wrench to hold the torch body fittings and a 7/16" open-end wrench
to turn the torch lead fittings.
Turn the torch lead fittings counterclockwise (ccw) to loosen the connections. Note that the red lead fitting is
reverse threaded and must be turned in the opposite direction (clockwise).
4. Remove the torch main body.
Replacement
1. Connect the torch leads to the replacement torch main body. Thread the torch main body fittings and the torch
lead fittings together clockwise (cw). Use the size wrenches called out in the Removal procedure above. Note
that the red lead fitting is reverse threaded and must be turned in the opposite direction (counterclockwise).
2. Ensure the lead insulator is positioned over the pilot/shield gas lead fitting.
3. Insert the torch main body into one of the handle halves and then align the body and handle slots.
4. Insert the torch switch into the handle switch holder.
5. Insert the top rib of the boot into the handle just above the screw holes.
6. Align both halves of the handle, press together, and secure with the nine (9) screws.