Manual 0-2683 17 REPLACEMENT PROCEDURES
4.0 REPLACEMENT
PROCEDURES
4.1 General Information
• Failures identified on the Transformer/Inductor/
Chassis Assembly cannot be repaired - the entire
power supply must be replaced. Refer to the Parts
List for the catalog number for a replacement power
supply.
• The torch head, torch switch, and torch & leads as-
sembly are replaceable parts. The torch leads alone
are not serviceable; problems encountered in the
leads will require the torch & leads assembly to be
replaced.
• For instructions on replacing the torch & leads, work
cable & clamp, and input power cable, refer to Oper-
ating Manual 0-2682. (Refer to Appendix I, in this
manual, for leads connection diagram.)
• Most replacement hardware can be purchased lo-
cally.
• One of two harnesses has been used in this unit. For
units which are rev “C” or earlier, refer to the sche-
matic in Appendix II. For units which are rev “D” or
later, refer to the schematic in Appendix III. Check
the data tag on your unit for the rev level of your unit
and follow instructions in this section where appli-
cable, as they pertain to your unit.
WARNINGS
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
4.2 Removing Cover/Handle
1. Remove 2 screws in handle, 2 screws in end pan-
els, and four screws near base to remove cover and
handle from unit.
NOTE
When replacing cover, make sure all wires are care-
fully positioned so that the wires are not pinched
when the cover and handle are secured.
4.3 Torch Head Assembly
Replacement
WARNINGS
Disconnect primary power to the system before dis-
assembling the torch or power supply.
Torch parts may get quite hot during normal opera-
tion. Always wear light cutting gloves when chang-
ing torch parts just after operating the Drag-Gun
system.
To Remove Torch Head Assembly:
NOTE
Refer to Figure 4-1 for parts identification.
1. Remove consumable parts from front end of torch.
2. Remove six screws from torch handle assembly
(A).
3. Remove both torch handle halves from the torch
and leads assembly , then complete the following:
a. Disconnect positive pilot lead connection at
torch head by removing pilot lead screw (B).
b. Cut tie wrap from torch hose (C).
c. Using X-acto knife or other small cutting tool,
cut torch lead 1" (2.54 cm) from the end of black
sleeve (D) to reveal butt splice.
4. Pull torch head away from torch lead to expose
1/2"-3/4" of cable.
5. Clamp down with vise grips on black sleeve of
lead so that cable cannot spring back into lead (E).
6. Cut cable at end of butt splice and remove torch
head assembly (F).
7. Remove orange insulating sleeving from torch head
gas input (G). Note: Sleeving is optional. Some
torch assemblies may not have sleeving.
8. Remove torch O-ring from torch split holder (H).
9. Remove the two screws from the torch head split
holder and separate the halves (I).
10. Remove the torch head from the holder. Do not
disturb PIP connections.
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