Hypertherm Powermax900 Service Manual - Manual (Page 55)

M
AINTENANCE
3-28 Service Manual
PAC125M TORCH PARTS REMOVAL AND REPLACEMENT
Repair of the PAC125M machine torch normally requires replacement of the torch main body and/or
the torch lead. Order the torch main body with switch. Refer to Figure 3-19 and perform the steps
below. See Section 7 for a complete list of the machine torch parts.
Removal
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. Unscrew the retaining cap and remove the remaining parts (nozzle, electrode and swirl ring).
3. Unscrew the positioning sleeve from the torch sleeve and slide it back along the lead and out
of the way.
4. Cut the plastic ties holding the high-current wire to the lead. Note the position of the ties for
reassembly.
5. Remove the heat shrink to expose the high-current pin and receptacle connection.
Disconnect the pin from the receptacle.
Note for step 6: Disconnect wires by pulling on terminals. Do not pull on wires.
6. Remove the heat shrink from the cap sensor microswitch connectors (blue wires from the
lead and white wires from the microswitch) to expose the terminals. Disconnect the
terminals.
7. Disconnect the torch main body and torch lead gas fitting using 3/8" (10 mm) and 1/2"
(13 mm) open-end wrenches.
8. Disconnect the torch main body from the torch sleeve by using snap-ring pliers to remove the
snap ring that holds the torch head to the sleeve. Remove the torch main body from the
torch sleeve.
Replacement
1. To replace the torch main body to the torch sleeve, line up the anti-rotation screw on the
torch head to the locating hole in the torch sleeve.
2. Insert the torch main body into the torch sleeve and using the snap-ring pliers, secure the
torch body to the sleeve with the snap ring.
3. Connect the torch main body to the torch lead gas fitting using 3/8" (10 mm) and 1/2"
(13 mm) open-end wrenches. Torque to 70 in-lbs.