Tweco 15XC CE Merlin PAK - Manual (Page 81)

Manual 0-2529 4 - 9 SERVICE
4.6 MACHINE TORCH LEADS REPLACEMENT
WARNING
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
Machine Torch Leads
Replacement
Refer to Figure 4-D (page 4-5) and:
1. Remove the electrical tape from the end of the nylon
outer leads sleeving next to the mounting assembly.
2. Push the nylon outer sleeving back up the leads ap-
proximately one foot (0.3 m) to expose the shielded
inner leads sleeving.
3. Remove the electrical tape from the shielded inner
sleeving and push back up the leads approximately
one foot (0.3 m).
4. Unscrew the mounting assembly from the torch head.
Slide the mounting assembly back over the leads to
expose the leads connections.
5. Remove the tape that secures the lead connections
around the insulating tab. Disconnect the plasma,
secondary, coolant supply, and coolant return leads
from the torch head.
To minimize coolant leaks during torch head replacement,
perform the operation with the torch head above the level
of the coolant reservoir.
6. Connect the plasma, secondary, coolant supply, and
coolant return leads onto the replacement torch head
fittings.
7. Use electrical tape to secure the leads in place on the
insulating tab. Locate the tape over the ferrule on the
negative lead.
Make sure the insulating tab completely separates the
coolant supply lead (negative) from the plasma, secondary,
and coolant return leads.
8. Replace the mounting assembly onto the torch head.
9. Secure the shielded inner sleeving to the leads with
electrical tape. Position the end of the sleeving a few
inches back from the mounting assembly.
NOTE
CAUTION