Hypertherm Duramax Series Reference manual

Duramax™ Series Machine Torches –
Torch Sleeve, Coupler, and Gear Rack
Replacement
Les torches machines des séries
Duramax – Gaine de torche,
coupleuret crémaillère d’engrenage
de rechange
Field Service Bulletin
Bulletin de service sur le terrain
807050 — Revision1 — June,2012
Révision1 — Juin2012

Torch sleeve, coupler, and Gear rack replacemenT
Field Service Bulletin 1
Introduction
Purpose
This Field Service Bulletin describes the procedures for replacing the mounting sleeve, coupler, positioning sleeve, and
gear rack on the Duramax™ series machine torches.
This Field Service Bulletin applies to kit numbers 228735, 228736, 228737, and 228738.
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 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.

Torch sleeve, coupler, and gear rack replacemenT
2Field 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
Figure 3 – Connections
Consumables
Mounting
sleeve
Coupler
Strain relief body*
Strain relief nut* Torch lead
Gas supply line
connection
Torch body
Pilot wire
terminal screw
Wire connector for
cap-sensor switch
Mounting sleeve
screws (3)
Mounting sleeve
* MRT2torches for Powermax600 CE systems do not have a strain relief nut or strain relief body.
* MRT2torches for Powermax600 CE systems do not have a strain relief nut or strain relief body.

Torch sleeve, coupler, and Gear rack replacemenT
Field Service Bulletin 3
Disassemble the torch and remove the mounting sleeve
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 (Full-length machine torch) and slide the nut
back along the torch lead.
5. Unscrew the positioning sleeve (Full-length machine torch) from the coupler.
6. Unscrew the coupler from the mounting sleeve.
7. 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.
Reassemble the torch with the new mounting sleeve
1. Slide new mounting sleeve over the front of the torch body, aligning the slot in the mounting sleeve with the cap
sensor plunger.
2. Use a #1 Phillips screwdriver to tighten the three mounting sleeve screws to 11.52 kg-cm (10 inch-pounds).
3. Thread the coupler into the mounting sleeve until hand tight.
4. Thread the positioning sleeve (Full-length machine torch) into the coupler until hand tight.
5. If applicable, thread the strain relief nut into the positioning sleeve (Full-length machine torch) until hand tight.
6. If applicable, thread the strain relief body onto the strain relief nut until hand tight.
7. Install the consumables.
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
220956 Torch mounting sleeve 1
Kit 228735 contents
Replace the machine torch mounting sleeve
Please refer to Figures 1, 2, and 3 on page 2 when performing the following procedure.

Torch sleeve, coupler, and gear rack replacemenT
4Field Service Bulletin
Kit 228736 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
220808 Machine torch coupler 1
Disassemble the torch and remove the coupler
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 (Full-length machine torch) and slide the nut
back along the torch lead.
5. Unscrew the positioning sleeve (Full-length machine torch) from the coupler.
6. Unscrew the coupler from the mounting sleeve.
7. 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. Set the mounting sleeve aside.
8. Disconnect the wire connector for the cap-sensor switch.
9. Use a #1 Phillips screwdriver to remove the screw that secures the torch’s pilot wire to the torch body.
10. Use the 1/4-inch and 3/8-inch wrenches or two adjustable wrenches together, to loosen the nut that secures the
gas supply line to the torch lead. Set the torch body aside.
11. Slide the coupler off the front of the torch lead.
Reassemble the torch with the new coupler
1. Slide the new coupler over the front of the torch lead.
2. Use the 1/4-inch and 3/8-inch wrenches or two adjustable wrenches together, to tighten the nut that secures the
gas supply line to the torch lead.
3. Use a #1 Phillips screwdriver to tighten the screw that secures the torch’s pilot wire to the torch body to
5.76kg-cm (5 inch-pounds).
4. Connect the wire connector for the cap-sensor switch.
5. Slide the mounting sleeve over the front of the torch body, aligning the slot in the mounting sleeve with the cap
sensor plunger.
Replace the machine torch coupler
Please refer to Figures 1, 2, and 3 on page 2 when performing the following procedure.

Torch sleeve, coupler, and Gear rack replacemenT
Field Service Bulletin 5
6. Use a #1 Phillips screwdriver to tighten the three mounting sleeve screws to 11.52 kg-cm (10 inch-pounds).
7. Thread the coupler into the mounting sleeve until hand tight.
8. Thread the positioning sleeve (Full-length machine torch) into the coupler until hand tight.
9. If applicable, thread the strain relief nut into the 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.
Kit 228737 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
220809 Torch positioning sleeve 1
Replace the machine torch positioning sleeve (for the full length machine
torch only)
Please refer to Figures 1 and 2 on page 2 when performing the following procedure.
Disassemble the torch and remove the positioning sleeve
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 from the coupler.
6. Unscrew the coupler from the mounting sleeve.
7. 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. Set the mounting sleeve aside.
8. Disconnect the wire connector for the cap-sensor switch.
9. Use a #1 Phillips screwdriver to remove the screw that secures the torch’s pilot wire to the torch body.
10. Use the 1/4-inch and 3/8-inch wrenches or two adjustable wrenches together, to loosen the nut that secures the
gas supply line to the torch lead. Set the torch body aside.
11. Slide the coupler off the front of the torch lead.
12. Slide the positioning sleeve off the front of the torch lead.

Torch sleeve, coupler, and gear rack replacemenT
6Field Service Bulletin
Reassemble the torch with the new positioning sleeve
1. Slide the new positioning sleeve over the front of the torch lead.
2. Slide the coupler over the front of the torch lead.
3. Use the 1/4-inch and 3/8-inch wrenches or two adjustable wrenches together, 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
5.76kg-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 into the mounting sleeve until hand tight.
9. Thread the positioning sleeve into the coupler until hand tight.
10. If applicable, thread the strain relief nut into the positioning sleeve until hand tight.
11. If applicable, thread the strain relief body onto the strain relief nut until hand tight.
12. Install the consumables.
Kit 228738 contents
Part number Description Quantity
220850 Torch gear rack 1
Disassemble the torch and remove the gear rack
1. Turn OFF the power and disconnect the torch lead from the power supply.
2. If applicable, unscrew the strain relief body from the strain relief nut and slide the strain relief body back along the
torch lead.
3. If applicable, unscrew the strain relief nut from the positioning sleeve and slide the nut back along the torch lead.
4. Unscrew the positioning sleeve from the coupler and slide the positioning sleeve back along the torch lead.
5. Remove the gear rack by sliding it out of the groove in the positioning sleeve.
Replace the machine torch gear rack (for the full length machine torch only)
Please refer to Figure 1 on page 2 when performing the following procedure.

Torch sleeve, coupler, and Gear rack replacemenT
Field Service Bulletin 7
Reassemble the torch with the new gear rack
1. Slide the new gear rack into the groove in positioning sleeve until it stops at the end of the groove.
2. Thread the positioning sleeve into the coupler until hand tight.
3. If applicable, thread the strain relief nut into the positioning sleeve until hand tight.
4. If applicable, thread the strain relief body onto the strain relief nut until hand tight.

Torch sleeve, coupler, and gear rack replacemenT
8Field Service Bulletin