Service manual, Pac125t torch parts removal and replacement, Aintenance – Hypertherm Powermax900 Service Manual User Manual
Page 53
M
AINTENANCE
3-26
Service Manual
Torch Lead
Figure 3-17 PAC125T Torch Main Body Removal
Torch
Main Body
Cap Sensor
Microswitch
White Wires (8)
Blue
Wires (2)
Red
Wires (2)
Cap Sensor
Microswitch
White Wires (2)
Plunger
Wire
Plunger
Nut
Plunger
Screw
Plunger
Terminal
Proper plunger
terminal mounting
angle (parallel to the
handle)
PAC125T TORCH PARTS REMOVAL AND REPLACEMENT
Torch Main Body Removal and Replacement
To remove and replace the torch main body, order the torch main body with cap-on sensor switch
and refer to the following procedure and Figures 3-17 and 3-18.
1
Set the Powermax900 power switch to O (off), unplug the power cable, and disconnect
the gas supply. Disconnect the torch lead quick disconnect from the power supply.
2.
Remove the 5 screws that secure the handle halves together and remove handles from
torch main body, torch switch and safety trigger (Fig. 3-18).
Note for step 3: Disconnect wires by pulling on terminals. Do not pull on wires.
3.
Disconnect the two lead terminals (blue wire in each terminal) from the two wires of the cap
sensor microswitch (Fig. 3-17).
4.
Disconnect the plunger wire from the torch main body by holding the plunger nut with a 1/4"
(6 mm) wrench or nut driver and removing the plunger screw (Fig. 3-17).
5.
Disconnect the torch main body and torch lead gas fittings using 3/8" (9.5 mm) and 1/2"
(13 mm) open-end wrenches.
6.
Replace the new torch main body by reversing these instructions. Note: When connecting
the plunger wire, be certain to keep the plunger wire terminal at the proper angle as shown in
the Fig. 3-17 inset. Tighten the plunger screw with 8 lb-in (9 kg-cm) of torque.
7.
Install the torch main body and torch switch back into the handle (Fig. 3-18). Be certain that
the torch switch slides into position above the safety trigger, and that trigger movement
activates the switch pushbutton and then releases. While positioning the handle halves
together, be careful not to pinch any wires.
8.
Replace the 5 screws to secure the handle halves together.
Gas Fittings