Torch lead replacemenT
Field Service Bulletin 5
Replace the torch lead
Please refer to Figures 1, 2, and 3 on page 4 when performing the following procedure.
Disassemble the torch and remove the torch lead
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 and coupler (Full-length machine torch) or coupler (Mini-machine torch) from the
mounting sleeve.
6. 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.
7. Disconnect the wire connector for the cap-sensor switch.
8. Use a #1 Phillips screwdriver to remove the screw that secures the torch’s pilot wire to the torch body.
9. Use the 1/4-inch and 3/8-inch wrenches together (or two adjustable wrenches) to loosen the nut that secures the
gas supply line to the torch lead. Set the torch body aside.
10. Slide the positioning sleeve and coupler (Full-length machine torch) or coupler (Mini-machine torch) off the front of
the torch lead. Set the torch lead aside.
Reassemble the torch with the new torch lead
1. Unscrew the strain relief body from the strain relief nut on the new torch lead.
2. Slide the positioning sleeve and coupler (Full-length machine torch) or coupler (Mini-machine torch) over the front of
the torch lead.
3. Use the 1/4-inch and 3/8-inch wrenches together (or two adjustable wrenches) 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
5.76kg-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 (Mini-machine torch) or coupler and positioning sleeve (Full-length machine torch) into the
mounting sleeve until hand tight.
9. If applicable, thread the strain relief nut into the coupler (Mini-machine torch) or 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.
