Hypertherm Powermax350 Service Manual - Manual (Page 44)

Service Manual 3-20
M
AINTENANCE
PAC110 TORCH REPAIR
Parts and Required Tools
The PAC110 torch can be repaired in the field by removing the torch main body from the torch assembly and
installing a new torch main body and a plastic cinch strap (Tyrap). To perform the repair, the following customer-
supplied tools are required:
• #1 Phillips-head screwdriver
• 7/16 inch (11 mm) open-end wrench
• Wire cutters
• Crimping tool
WARNING
SHOCK HAZARD: Always turn off the power and unplug the cord or set the line disconnect
switch to Off before servicing the unit or changing consumable parts. In the U.S., use a "lock-
out / tag-out" procedure until the service or maintenance work is complete. In other countries,
follow appropriate national or local safety procedures.
Torch Main Body Removal and Replacement
To disassemble and repair the torch, refer to Figure 3-6 and perform the following procedure:
1. Remove the 5 screws which secure the handle halves together.
2. Remove the torch main body and torch switch from the handle halves.
3. Cut and remove the cinch strap (Tyrap).
4. Cut the 4 white wires connecting the torch lead to the plunger. Cut the wires at the butt splice.
5. Cut the 2 blue wires connecting the torch lead to the microswitch. Cut the wires at the butt splices.
6. Cut the 2 red wire connecting the torch lead to the pilot arc lead. Cut the wire at the butt splice.
7. Disconnect the torch main body and torch lead gas fitting using the 7/16 inch open-end wrench.
To install the new torch, reverse the removal procedure:
1. While holding the torch main body to keep the wires from twisting, connect the body assembly and the torch
lead gas fitting using the 7/16 inch open-end wrench.
2. Connect the 2 red wire from the torch lead to the butt splice connecting the red wire to the pilot arc fitting
using the crimping tool.
3. Connect the 2 blue wires from the torch lead to the butt splices connecting the white wires to the microswitch
using the crimping tool.
4. Connect the 4 white wires from the torch lead to the butt splice connecting the black plunger wire to the torch
main body using the crimping tool.
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