176 Powermax30 XP Service Manual 808150 Revision 0
7 – Torch Component Replacement
Install the handle
1. Lay the right side of the handle on a flat surface with the inside facing up.
If replacing the handles, apply the Duramax LT label to the left side of the torch handle.
2. Press the cap-sensor switch into its post hole and onto its mounting post. (See Figure 105.)
3. Route the cap-sensor wires as shown in Figure 106. Place the connector above the start switch’s posts with the
wires positioned below the slot for the gas hose fitting’s flange as shown.
4. Press the start switch onto the two mounting posts and position the wires below the slot for the gas fitting. The start
switch should hold the cap-sensor switch connector in place. (See Figure 105 and Figure 106.)
Figure 106
5. Press the torch body into the torch handle with the gas hose fitting’s flange aligned with the slot in the handle.
6. Align the strain relief with the strain relief slot in the handle. (See Figure 106 for the location of the strain relief slot.)
7. Compress the trigger spring into the front half of the trigger. Slide the trigger and spring
into place.
8. Being careful that the handle does not pinch the wires, align the left half of the handle with
the right half. Verify that the trigger pivots are both located in the trigger pivot holes. (See
Figure 106.)
9. Install the handle screws.
10. Install the consumables.
11. Reconnect the gas supply and power cord, and set the power switch to ON (I).
Cap-sensor switch wires
Start switch wires
1
2
4
5
3
6
1
Cap-sensor switch
2
Start switch
3
Slot for torch lead strain relief
4
Slot for gas hose fitting’s flange
5
Cap-sensor switch connector
6
Trigger’s pivot hole
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