Hypertherm MAX200 Service Manual - Manual (Page 85)

3-44 MAX200 Service Manual
1-99
MAINTENANCE
Individual Torch Leads
To remove and replace individual torch leads, perform the following procedure and see Figure 3-8. Refer to
Section 4, Parts List, pages 4-44 to 4-48 for machine torch lead assemby part numbers for different lead lengths
and other torch lead parts.
Removal
1. Disconnect the torch lead from the power supply as described in Removal under Removal and Replacement of
Machine Torch Lead Set on page 3-41.
2. Disconnect the torch from the torch lead as described in the Removal and Replacement of Machine Torch
procedure on page 3-40.
3. Lay the torch lead on the floor and stretch it out completely.
4. Cut away the heat shrink (7) and any tape underneath at both ends.
5. Remove the hose clamp (11), shield collar (10), and compression ring (9) from the torch lead at the other end.
Cut away any tape under the compression ring.
6. Holding one end of the the torch lead, pull the shield braid (8) off of the torch lead.
7. Cut the tape (every 18 inches) that holds the torch leads together.
8. Remove the lead (1-5) requiring repair or replacement.
Replacement
1. Replace the repaired or replacement lead(s) with the other leads.
2. Ensure the lead lengths (1-5) at both ends are in accordance with those called out in Figure 3-8.
3. Tape the leads together every 18 inches.
4. Slide the shield braid (8) over the torch lead ends and pull the sheath until it approximates the length
requirements called out in Figure 3-8.
5. Tape both ends of the shield braid to the torch lead.
6. Slide the heat shrink (7) over torch end of the shield braid. Heat the heat shrink until it tightly bonds around the
shield braid and torch lead.
7. Replace the compression ring (9), shield collar (10), and hose clamp (11) over the power supply end of the
shield braid. Tighten the hose clamp.
8. Connect the torch lead to the power supply.
9. Connect the torch lead to the torch.