Hypertherm Duramax Series Manuale di riferimento
Duramax™ Series Machine Torches –
Torch Lead Replacement
Torches machines des séries
Duramax™ – Remplacement
dufaisceau de la torche
Field Service Bulletin
Bulletin de service sur le terrain
806890 — Revision1 — June,2012
Révision1 — Juin2012
Torch lead replacemenT
Field Service Bulletin 1
Introduction
Purpose
This Field Service Bulletin describes the procedures for replacing the torch lead on the Duramax series machine torches
(M65/M65m/M85/M85m/MRT/MRT2).
This Field Service Bulletin applies to kit numbers 228730, 228731, 228732, 228733, 228734, 228786, 228787,
228928, 228929, 228930, and 228931.
Powermax105 systems: Complete instructions for installing this repair kit are included in the Powermax105 Service
Manual. To download the Service Manual, go to www.hypertherm.com and click the “Downloads library” link.
Materials and tools
• #1 Phillips screwdriver
• 1/4-inch and 3/8-inch wrenches (preferred) or adjustable wrenches
The following procedures require operating knowledge of Hypertherm’s power supplies. If necessary, refer to the
system’s operator manual for detailed information on removing the torch and changing consumables.
WARNING
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance. See the
Safety and Compliance Manual included with your system for more safety
precautions.
Part number Description Quantity
075618 Machine screw: 4-40 x 3/8 pan head 3
075754 Machine screw: 4-40 x 3/16 pan head 1
229313 Duramax full-length machine torch and mini-machine torch 15' torch lead replacement 1
Kit 228730 contents
Part number Description Quantity
075618 Machine screw: 4-40 x 3/8 pan head 3
075754 Machine screw: 4-40 x 3/16 pan head 1
229314 Duramax full-length machine torch and mini-machine torch 25' torch lead replacement 1
Kit 228731 contents
torch lead replacement
2Field Service Bulletin
Part number Description Quantity
075618 Machine screw: 4-40 x 3/8 pan head 3
075754 Machine screw: 4-40 x 3/16 pan head 1
229316 Duramax full-length machine torch and mini-machine torch 50' torch lead replacement 1
Kit 228733 contents
Part number Description Quantity
075618 Machine screw: 4-40 x 3/8 pan head 3
075754 Machine screw: 4-40 x 3/16 pan head 1
229317 Duramax full-length machine torch and mini-machine torch 75' torch lead replacement 1
Kit 228734 contents
Part number Description Quantity
075618 Machine screw: 4-40 x 3/8 pan head 3
075754 Machine screw: 4-40 x 3/16 pan head 1
229414 Duramax MRT 25' torch lead replacement 1
Kit 228786 contents - for Powermax1000/1250/1650
Part number Description Quantity
075618 Machine screw: 4-40 x 3/8 pan head 3
075754 Machine screw: 4-40 x 3/16 pan head 1
229415 Duramax MRT 50' torch lead replacement 1
Kit 228787 contents - for Powermax1000/1250/1650
Part number Description Quantity
075618 Machine screw: 4-40 x 3/8 pan head 3
075754 Machine screw: 4-40 x 3/16 pan head 1
229315 Duramax full-length machine torch and mini-machine torch 35' torch lead replacement 1
Kit 228732 contents
Torch lead replacemenT
Field Service Bulletin 3
Part number Description Quantity
075618 Machine screw: 4-40 x 3/8 pan head 3
075754 Machine screw: 4-40 x 3/16 pan head 1
229493 Duramax MRT225' torch lead replacement 1
Part number Description Quantity
075618 Machine screw: 4-40 x 3/8 pan head 3
075754 Machine screw: 4-40 x 3/16 pan head 1
229494 Duramax MRT250' torch lead replacement 1
Part number Description Quantity
075618 Machine screw: 4-40 x 3/8 pan head 3
075754 Machine screw: 4-40 x 3/16 pan head 1
229495 Duramax MRT225' torch lead replacement without quick disconnect 1
Part number Description Quantity
075618 Machine screw: 4-40 x 3/8 pan head 3
075754 Machine screw: 4-40 x 3/16 pan head 1
229496 Duramax MRT250' torch lead replacement without quick disconnect 1
Kit 228928 contents - for Powermax600/800/900/MAX42/MAX43 CSA
Kit 228929 contents - for Powermax600/800/900/MAX42/MAX43 CSA
Kit 228930 contents - for Powermax600 CE
Kit 228931 contents - for Powermax600 CE
torch lead replacement
4Field Service Bulletin
Consumables
Mounting
sleeve
Coupler
Gear rack Strain relief body*
Strain relief nut* Torch lead
Positioning sleeve
Figure 1 – Full-length machine torch
Figure 2 – Mini-machine torch
Gas supply line
connection
Torch head
Pilot wire
terminal screw
Wire connector for
cap-sensor switch
Figure 3 – Connections
Consumables
Mounting
sleeve
Coupler
Strain relief body*
Strain relief nut* Torch lead
* Kits 228930 and 228931 do not contain a strain relief body or strain relief nut.
* Kits 228930 and 228931 do not contain a strain relief body or strain relief nut.
Torch lead replacemenT
Field Service Bulletin 5
Replace the torch lead
Please refer to Figures 1, 2, and 3 on page 4 when performing the following procedure.
Disassemble the torch and remove the torch lead
1. Turn OFF the power and disconnect the torch lead from the power supply.
2. Remove the consumables from the torch.
3. If applicable, unscrew the strain relief body from the strain relief nut and slide the strain relief body back along the
torch lead.
4. If applicable, unscrew the strain relief nut from the positioning sleeve and slide the nut back along the torch lead.
5. Unscrew the positioning sleeve and coupler (Full-length machine torch) or coupler (Mini-machine torch) from the
mounting sleeve.
6. Use a #1 Phillips screwdriver to remove the three screws from the consumables end of the mounting sleeve and
slide the mounting sleeve off the front of the torch body.
7. Disconnect the wire connector for the cap-sensor switch.
8. Use a #1 Phillips screwdriver to remove the screw that secures the torch’s pilot wire to the torch body.
9. Use the 1/4-inch and 3/8-inch wrenches together (or two adjustable wrenches) to loosen the nut that secures the
gas supply line to the torch lead. Set the torch body aside.
10. Slide the positioning sleeve and coupler (Full-length machine torch) or coupler (Mini-machine torch) off the front of
the torch lead. Set the torch lead aside.
Reassemble the torch with the new torch lead
1. Unscrew the strain relief body from the strain relief nut on the new torch lead.
2. Slide the positioning sleeve and coupler (Full-length machine torch) or coupler (Mini-machine torch) over the front of
the torch lead.
3. Use the 1/4-inch and 3/8-inch wrenches together (or two adjustable wrenches) to tighten the nut that secures the
gas supply line to the torch lead.
4. Use a #1 Phillips screwdriver to tighten the screw that secures the torch’s pilot wire to the torch body to
5.76kg-cm (5 inch-pounds).
5. Connect the wire connector for the cap-sensor switch.
6. Slide the mounting sleeve over the front of the torch body, aligning the slot in the mounting sleeve with the cap
sensor plunger.
7. Use a #1 Phillips screwdriver to tighten the three mounting sleeve screws to 11.52 kg-cm (10 inch-pounds).
8. Thread the coupler (Mini-machine torch) or coupler and positioning sleeve (Full-length machine torch) into the
mounting sleeve until hand tight.
9. If applicable, thread the strain relief nut into the coupler (Mini-machine torch) or positioning sleeve (Full-length
machine torch) until hand tight.
10. If applicable, thread the strain relief body onto the strain relief nut until hand tight.
11. Install the consumables.
torch lead replacement
6Field Service Bulletin
Remplacement du faisceau de la toRche
Bulletin de service sur le terrain a-1
Introduction
Objet
Ce bulletin de service sur le terrain décrit les procédures de remplacement du faisceau de torche sur les torches
machines des séries Duramax (M65/M65m/M85/M85m/MRT/MRT2).
Il s’applique aux numéros de kit 228730, 228731, 228732, 228733, 228734, 228786, 228787, 228928, 228929,
228930 et 228931.
Systèmes Powermax105: Les instructions complètes pour l’installation de ce kit de réparation sont incluses dans
le Manuel de service du Powermax105. Pour télécharger le Manuel de service, se rendre sur www.hypertherm.com
etcliquer sur le lien «Bibliothèque des téléchargements».
Matériel et outils requis
• Tournevis cruciforme nº1
• Clés de 1/4po et de 3/8po (de préférence) ou clés ajustables
Les procédures suivantes présument une bonne connaissance du fonctionnement des sources de courant
d’Hypertherm. Si besoin, se reporter au manuel de l’opérateur du système pour obtenir des informations détaillées sur
ladépose de la torche et le remplacement des consommables.
AVERTISSEMENT
UN CHOC ÉLECTRIQUE PEUT ÊTRE MORTEL
Débrancher l’alimentation électrique avant tout entretien. Se reporter
auManuel de sécurité et de conformité compris avec votre système pour
d’autres mesures de sécurité.
Numéro
deréférence
Description Quantité
075618 Vis mécanique: tête cylindrique large de 4-40x3/8 3
075754 Vis mécanique: tête cylindrique large de 4-40x3/16 1
229313 Remplacement du faisceau de torche 15pi pour torche machine pleine longueur et mini-
torche machine Duramax
1
Contenu du kit 228730
Numéro
deréférence
Description Quantité
075618 Vis mécanique: tête cylindrique large de 4-40x3/8 3
075754 Vis mécanique: tête cylindrique large de 4-40x3/16 1
229314 Remplacement du faisceau de torche 25pi pour torche machine pleine longueur
et mini-torche machine Duramax
1
Contenu du kit 228731
Remplacement du faisceau de la toRche
a-2 Bulletin de service sur le terrain
Numéro
deréférence
Description Quantité
075618 Vis mécanique: tête cylindrique large de 4-40x3/8 3
075754 Vis mécanique: tête cylindrique large de 4-40x3/16 1
229316 Remplacement du faisceau de torche 50pi pour torche machine pleine longueur
etmini-torche machine Duramax
1
Contenu du kit 228733
Numéro
deréférence
Description Quantité
075618 Vis mécanique: tête cylindrique large de 4-40x3/8 3
075754 Vis mécanique: tête cylindrique large de 4-40x3/16 1
229317 Remplacement du faisceau de torche 75pi pour torche machine pleine ongueur
etmini-torche machine Duramax
1
Contenu du kit 228734
Numéro
deréférence
Description Quantité
075618 Vis mécanique: tête cylindrique large de 4-40x3/8 3
075754 Vis mécanique: tête cylindrique large de 4-40x3/16 1
229414 Remplacement du faisceau de torche de 25pi pour Duramax MRT 1
Contenu du kit 228786–pour les Powermax1000/1250/1650
Numéro
deréférence
Description Quantité
075618 Vis mécanique: tête cylindrique large de 4-40x3/8 3
075754 Vis mécanique: tête cylindrique large de 4-40x3/16 1
229415 Remplacement du faisceau de torche 50pi pour Duramax MRT 1
Contenu du kit 228787–pour les Powermax1000/1250/1650
Numéro
deréférence
Description Quantité
075618 Vis mécanique: tête cylindrique large de 4-40x3/8 3
075754 Vis mécanique: tête cylindrique large de 4-40x3/16 1
229315 Remplacement du faisceau de torche 35pi pour torche machine pleine longueur
etmini-torche machine Duramax
1
Contenu du kit 228732
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