Hypertherm Duramax Series Manuale di riferimento
Duramax™Series Hand Torches –
Torch Lead Replacement
Torches manuelles des séries
Duramax™–Remplacement
dufaisceai de torche
Field Service Bulletin
Bulletin de service sur le terrain
806900 — Revision 4 — January 2016
Révision4 — Janvier 2016
Hypertherm Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
800-643-9878 Tel (Technical Service)
(Technical Service Email)
800-737-2978 Tel (Customer Service)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
Hypertherm Plasmatechnik GmbH
Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax
TechnicalService-Hyper[email protected]
(Technical Service Email)
Hypertherm (Singapore) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
Hypertherm Japan Ltd.
Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
Hypertherm Korea Branch
#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
Hypertherm Europe B.V.
Vaartveld 9
4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
TechnicalService-Hyper[email protected]
(Technical Service Email)
Hypertherm (Shanghai) Trading Co., Ltd.
B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax
(Technical Service Email)
Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
55 11 2408 0462 Fax
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
(Technical Service Email)
1/26/16
© 2016 Hypertherm Inc.
All Rights Reserved
Tous droits réservés
Hypertherm, Powermax, and Duramax are trademarks of Hypertherm Inc. and may be registered in the United States and/or other countries.
Hypertherm, Powermax et Duramax sont des marques de commerce d’Hypertherm Inc., qui peuvent être déposées aux États-Unis et/ou dans d’autres pays.
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 hand torches.
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
• Assorted Phillips®and TORX®screwdrivers
• Open end 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.
Kit 228959 contents
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
210158 Label: Duramax 75°/15° hand torch lead 1
229511 25' Duramax 75°/15° hand torch lead replacement 1
330103 Threadlocker, 0.5ml 1
Kit 228960 contents
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
210158 Label: Duramax 75°/15° hand torch lead 1
229512 50' Duramax 75°/15° hand torch lead replacement 1
330103 Threadlocker, 0.5ml 1
TORCH LEAD REPLACEMENT
2Field Service Bulletin
Kit 228961 contents
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
210158 Label: Duramax 75°/15° hand torch lead 1
229513 75' Duramax 75°/15° hand torch lead replacement 1
330103 Threadlocker, 0.5ml 1
Kit 228924 contents – for Powermax600/800/900/MAX42/MAX43 CSA
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
210175 Label: Duramax retrofit hand torch lead 1
229489 25' Duramax HRT2torch lead replacement 1
330103 Threadlocker, 0.5ml 1
Kit 228925 contents – for Powermax600/800/900/MAX42/MAX43 CSA
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
210175 Label: Duramax retrofit hand torch lead 1
229490 50' Duramax HRT2torch lead replacement 1
330103 Threadlocker, 0.5 ml 1
Kit 228926 contents – for Powermax600 CE
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
210175 Label: Duramax retrofit hand torch lead 1
229491 25' Duramax HRT2torch lead replacement without quick disconnect 1
330103 Threadlocker, 0.5ml 1
Kit 228927 contents – for Powermax600 CE
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
210175 Label: Duramax retrofit hand torch lead 1
229492 50' Duramax HRT2torch lead replacement without quick disconnect 1
330103 Threadlocker, 0.5ml 1
TORCH LEAD REPLACEMENT
Field Service Bulletin 3
Kit 228952 contents – for Powermax1000/1250/1650
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
210175 Label: Duramax retrofit hand torch lead 1
229507 25' Duramax retrofit hand torch lead, coupler with 12.7mm (1/2in.) threads 1
330103 Threadlocker, 0.5ml 1
Kit 228953 contents – for Powermax1000/1250/1650
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
210175 Label: Duramax retrofit hand torch lead 1
229508 50' Duramax retrofit hand torch lead, coupler with 12.7mm (1/2in.) threads 1
330103 Threadlocker, 0.5ml 1
TORCH LEAD REPLACEMENT
4Field Service Bulletin
Right side of
handle
Left side of
handle
Torch lead
Handle
screws
Safety trigger
and spring
Torch body
Cap-sensor
switch
Start
switch
Pilot wire
terminal screw
Gas fitting
Torch lead
Handle
screws
Safety trigger
and spring
Torch body
Cap-sensor
switch
Right side of
handle
Left side of
handle
Start
switch
Pilot wire
terminal screw
Gas fitting
Figure 1 – Duramax 75°/HRT/HRT2
Figure 2 – Duramax 15°/HRTs
TORCH LEAD REPLACEMENT
Field Service Bulletin 5
Replace the torch lead
Please refer to Figures 1 and 2 on page 4 when performing the following procedure.
Disassemble the torch
1. Turn OFF the power and disconnect the torch lead from the power supply.
2. Remove the consumables from the torch.
3. Remove the 5screws from the torch handle. Open the handle slowly, taking care that the trigger and trigger spring
do not fall out of the right side of the handle.
Note: You should wear eye protection as the spring can launch out of the handle without warning.
4. Carefully remove the trigger and trigger spring.
5. Lift the start switch off the two mounting posts in the right side of the handle.
6. Disconnect the start switch from the torch lead by depressing the tab on the wire connector and pulling the switch
away from the connector.
7. The torch body fits snugly into the right side of the handle. Gently press the handle away from the torch body to
remove it.
8. Remove the cap sensor switch from the mounting post in the handle.
9. Remove the cap sensor switch from the torch lead by depressing the tab on the plug and pulling the mating socket
away from the torch lead.
10. Remove the screw that secures the torch’s pilot wire to the torch body.
11. Use two wrenches to loosen the gas fitting that secures the torch body to the torch lead.
12. Remove the torch lead and set it aside.
TORCH LEAD REPLACEMENT
6Field Service Bulletin
Reassemble the torch with the new torch lead
1. Apply Threadlocker (Part # 330103) to the threads of the gas tube fitting on the torch body. Be very careful not to
get any Threadlocker on the conical surface of the gas tube fitting to avoid damage to the torch. See the figure
below.
2. Thread the torch body fitting into the gas fitting of the new torch lead until snug.
3. Use two wrenches to tighten the gas fitting that secures the torch body to the torch lead. Tighten to 69 kg cm,
(60in.-lbs).
4. Tighten the screw that secures the torch’s pilot wire to the torch body to 5.76 kg-cm (5 inch-pounds).
5. Connect the start switch to the torch lead by aligning the tab on the wire connector with the mating slot on the start
switch and pushing the switch onto the connector until it clicks.
6. Connect the cap sensor switch to the torch lead by pushing the socket onto the mating plug of the torch lead.
Caution: Do not get any Threadlocker on the conical surface of the gas tube fitting to avoid causing
damage to the torch. If any Threadlocker does get on this surface, clean it off immediately.
Conical surface of the
gas tube fitting
TORCH LEAD REPLACEMENT
Field Service Bulletin 7
7. Lay the right side of the handle on a flat surface.
8. Position the pilot wire, cap sensor wires, and cap sensor wire connector in the handle. Press the cap sensor switch
onto the mounting post in the handle while pressing the cap sensor post into the post hole in the handle.
9. Gently press the torch body into the torch handle with the gas hose fitting’s flange aligned with the slot in the
handle. Be careful not to damage the cap sensor, cap sensor wires or pilot wire in the handle. Make sure that the
strain relief rests in the slot near the rear of the handle.
Duramax 75°/HRT/HRT2
Duramax 15°/HRTs
Start switch posts
Cap sensor switch
mounting post
Cap sensor
switch post hole
Trigger’s pivot hole
Strain relief slot
Gas hose fitting slot
Gas hose fitting slot
Start switch posts
Cap sensor switch
mounting post
Cap sensor
switch post hole
Trigger’s pivot hole
Strain relief slot
TORCH LEAD REPLACEMENT
8Field Service Bulletin
10. Position the start switch wires beside the gas fitting flange in the handle. Gently press the start switch onto the two
mounting posts in the handle.
11. Compress the trigger spring into the trigger. Slide the trigger and the spring into place in the right side of the
handle.
12. Align the left half of the handle with the right half. Verify that the trigger pivots are both located in the trigger pivot
holes (one pivot hole in each half of the handle). Make certain the wires will not get pinched by the handle and that
the strain relief for the torch lead will be held in place by the lip on the torch handle when the handle is screwed
together.
13. Tighten the five handle screws to 14.98 kg cm (13 in-lbs).
14. Replace the consumables and reconnect the torch lead to the power supply.
Cap sensor switch
Start switch
Gas fitting flange
Slot for the
strain relief
Strain relief
Spring
Cap sensor switch
Start switch
Gas fitting flange
Spring
Slot for the
strain relief
Strain relief
Duramax 75°/HRT/HRT2
Duramax 15°/HRTs
Altri manuali per Duramax Series
3
Questo manuale è adatto per i seguenti modelli
9
Indice
Lingue:
Altri manuali Hypertherm Accessori per saldatura
