Hypertherm Duramax Series Field Service Bulletin

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 5screws 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.

Hypertherm Duramax Series Specifications

General

Cooling	Air-cooled
Type	Plasma cutting torch
Series	Duramax
Compatibility	Powermax systems
Torch Lengths	15' (4.6 m), 25' (7.6 m)
Consumables	Nozzles, electrodes, shields, retaining caps, swirl rings
Torch Models	Duramax Lock
Compatible Systems	Powermax65, Powermax85, Powermax105
Nozzle Types	FineCut
Electrode Types	Standard
Shield Types	Standard
Length	15 ft (4.6 m) standard, 25 ft (7.6 m) optional