Hypertherm Powermax105 Service Manual - Manual (Page 303)

Torch componenT replacemenT
powermax
105 Service Manual 10-13
Replace the torch lead
Refer to the appropriate figure on the previous page and complete the following instructions.
1. Use a Phillips screwdriver to remove the screw that secures the torch’s pilot arc wire to the torch body.
2. Use two wrenches to loosen the gas fitting that secures the torch body to the torch lead.
3. Disconnect the start switch by pressing the tab on the connector and pulling the start switch away from the
connector.
4. Disconnect the cap-sensor switch by pressing the tab on the connector and pulling the cap-sensor switch away
from the connector.
5. Apply the Loctite® 263 (330103), included in the kit, to the threads of the gas tube fitting on the torch body. Be
very careful not to get any Loctite on the conical surface of the gas tube fitting to avoid damage to the torch. See
the figure on the previous page for details.
6. Thread the torch body into the new torch lead until snug.
7. Use two wrenches to tighten the gas fitting that secures the torch body to the torch lead to 69.1 kg cm (60 in.-lbs).
8. Use a Phillips screwdriver to tighten the screw that secures the torch’s pilot arc wire to the torch body to
5.76 kg cm (5.0 in.-lbs).
Note: To prevent the pilot arc wire from being pinched between the handles, angle the pilot arc wire terminal
so it is below the torch body gas tube.
9. Connect the start switch by pressing the connector into the back of the start switch.
10. Connect the cap-sensor switch by pushing the socket into the mating plug of the connector.