Hypertherm H65 User manual

H65/H65s/H85/H85s/HRT Torch Lead
Replacement
Remplacement du faisceau de torche
H65/H65s/H85/H85s/HRT
Field Service Bulletin
Bulletin de service sur le terrain
806900 — Revision 0 — January 2011
Révision0 — janvier2011

H65/H65S/H85/H85S/HRT TORCH LEAD REPLACEMENT
Field Service Bulletin 1
Introduction
Purpose
This Field Service Bulletin describes the procedures for replacing the torch lead on the Duramax series hand torches
(H65/H65s/H85/H85s/HRT).
This Field Service Bulletin applies to kit numbers 228723, 228724, 228725, 228727, 228728, 228729, 228784, and
228785.
Materials and tools
• T10 TORX screwdriver (preferred) or flat-blade screwdriver
• #1 Phillips screwdriver
• 5/16-inch and 1/2-inch wrenches (preferred) 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.
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
229310 25’ H65/H85 torch lead replacement 1
Kit 228723 contents
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
229311 50’ H65/H85 torch lead replacement 1
Kit 228724 contents

H65/H65S/H85/H85S/HRT TORCH LEAD REPLACEMENT
2 Field Service Bulletin
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
229357 25’ H65s/H85s torch lead replacement 1
Kit 228727 contents
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
229358 50’ H65s/H85s torch lead replacement 1
Kit 228728 contents
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
229359 75’ H65s/H85s torch lead replacement 1
Kit 228729 contents
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
229412 25’ Duramax HRT torch lead replacement 1
Kit 228784 contents
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
229413 50’ Duramax HRT torch lead replacement 1
Kit 228785 contents
Part number Description Quantity
075504 Machine screw: 4-40 x 5/16 pan head 1
229312 75’ H65/H85 torch lead replacement 1
Kit 228725 contents

H65/H65S/H85/H85S/HRT TORCH LEAD REPLACEMENT
Field Service Bulletin 3
Right side of
handle
Left side of
handle
Torch lead
Handle
screws
Safety trigger
and spring
Torch head
Cap-sensor
switch
Start
switch
Pilot wire
terminal screw
Gas fitting
Torch lead
Handle
screws
Safety trigger
and spring
Torch head
Cap-sensor
switch
Right side of
handle
Left side of
handle
Start
switch
Pilot wire
terminal screw
Gas fitting
Figure 1 – H65/H85/HRT
Figure 2 – H65s/H85s

H65/H65S/H85/H85S/HRT TORCH LEAD REPLACEMENT
4 Field Service Bulletin
Replace the torch lead
Please refer to Figures 1 and 2 on page 3 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. Use a T10 TORX screwdriver or a flat-blade screwdriver to 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 head fits snugly into the right side of the handle. Gently press the handle away from the torch head 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. Use a #1 Phillips screwdriver to remove the screw that secures the torch’s pilot wire to the torch body.
11. Use the 5/16-inch and 1/2-inch wrenches together (or two adjustable wrenches) to loosen the gas fitting that
secures the torch head to the torch lead. Set the torch lead aside.

H65/H65S/H85/H85S/HRT TORCH LEAD REPLACEMENT
Field Service Bulletin 5
Reassemble the torch with the new torch lead
1. Thread the torch head fitting into the gas fitting of the new torch lead.
2. Use the 5/16-inch and 1/2-inch wrenches together (or two adjustable wrenches) to tighten the gas fitting that
secures the torch head 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 inch-
pounds (5.76 kg-cm).
4. Connect the start switch to the torch lead by aligning the tab on the wire connector with the mating slot on the start
switch and pushing the switch onto the connector until it clicks.
5. Connect the cap sensor switch to the torch lead by pushing the socket onto the mating plug of the torch lead.
6. Lay the right side of the handle on a flat surface.
7. Position the pilot wire, cap sensor wires, and cap sensor wire connector in the handle. Press the cap sensor switch
onto the mounting post in the handle while pressing the cap sensor post into the post hole in the handle.
8. Gently press the torch head into the torch handle with the gas hose fitting’s flange aligned with the slot in the
handle. Be careful not to damage the cap sensor, cap sensor wires or pilot wire in the handle. Make sure that the
strain relief rests in the slot near the rear of the handle.
H65/H85/HRT
H65s/H85s
Start switch posts
Cap sensor switch
mounting post
Cap sensor
switch post hole
Trigger’s pivot hole
Strain relief slot
Gas hose fitting slot
Gas hose fitting slot
Start switch posts
Cap sensor switch
mounting post
Cap sensor
switch post hole
Trigger’s pivot hole
Strain relief slot

H65/H65S/H85/H85S/HRT TORCH LEAD REPLACEMENT
6 Field Service Bulletin
9. Position the start switch wires beside the gas fitting flange in the handle. Gently press the start switch onto the two
mounting posts in the handle.
10. Compress the trigger spring into the trigger. Slide the trigger and the spring into place in the right side of the
handle.
11. Align the left half of the handle with the right half. Verify that the trigger pivots are both located in the trigger pivot
holes (one pivot hole in each half of the handle). Make certain the wires will not get pinched by the handle and that
the strain relief for the torch lead will be held in place by the lip on the torch handle when the handle is screwed
together.
12. Replace the 5 screws.
13. Replace the consumables and reconnect the torch lead to the power supply.
Cap sensor switch
Start switch
Gas fitting flange
Slot for the
strain relief
Strain relief
Spring
Cap sensor switch
Start switch
Gas fitting flange
Spring
Slot for the
strain relief
Strain relief
H65/H85/HRT
H65s/H85s

REMPLACEMENT DU FAISCEAU DE TORCHE H65/H65S/H85/H85S/HRT
Bulletin de service sur le terrain a-1
Introduction
Objet
Ce bulletin de service sur le terrain décrit les procédures de remplacement du faisceau de torche sur les torches
manuelles de la série Duramax (H65/H65s/H85/H85s/HRT).
Il s'applique aux numéros de kit 228723, 228724, 228725, 228727, 228728, 228729, 228784 et 228785.
Matériel et outils requis
• Tournevis TORX T10 (méthode préférée) ou un tournevis plat
• Tournevis cruciforme n°1
• Clés de 5/16po et de 1/2po (de préférence) ou clés ajustables
Les procédures suivantes présument une bonne connaissance du fonctionnement des sources de courant
d'Hypertherm. Si besoin, reportez-vous au manuel du système de l'opérateur pour obtenir des informations
détaillées sur la dépose de la torche et le remplacement des consommables.
AVERTISSEMENT
LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS
Débrancher l’alimentation électrique avant tout entretien. Se reporter au
Manuel de sécurité et de conformité compris avec votre système pour
d’autres précautions de sécurité.
Numéro de
référence
Description Quantité
075504 Vis mécanique: tête cylindrique large de 4-40x5/16 1
229310 Faisceau de torche de rechange de 7,62m pour H65/H85 1
Contenu du kit228723
Numéro de
référence
Description Quantité
075504 Vis mécanique: tête cylindrique large de 4-40x5/16 1
229311 Faisceau de torche de rechange de 15,24m pour H65/H85 1
Contenu du kit228724

REMPLACEMENT DU FAISCEAU DE TORCHE H65/H65S/H85/H85S/HRT
a-2 Bulletin de service sur le terrain
Numéro de
référence
Description Quantité
075504 Vis mécanique: tête cylindrique large de 4-40x5/16 1
229357 Faisceau de torche de rechange de 7,62m pour H65s/H85s 1
Contenu du kit228727
Numéro de
référence
Description Quantité
075504 Vis mécanique: tête cylindrique large de 4-40x5/16 1
229358 Faisceau de torche de rechange de 15,24m pour H65s/H85s 1
Contenu du kit228728
Numéro de
référence
Description Quantité
075504 Vis mécanique: tête cylindrique large de 4-40x5/16 1
229359 Faisceau de torche de rechange de 22,9m pour H65s/H85s 1
Contenu du kit228729
Numéro de
référence
Description Quantité
075504 Vis mécanique: tête cylindrique large de 4-40x5/16 1
229412 Faisceau de torche de rechange de 7,62m pour Duramax HRT 1
Contenu du kit228784
Numéro de
référence
Description Quantité
075504 Vis mécanique: tête cylindrique large de 4-40x5/16 1
229413 Faisceau de torche de rechange de 15,24m pour Duramax HRT 1
Contenu du kit228785
Numéro de
référence
Description Quantité
075504 Vis mécanique: tête cylindrique large de 4-40x5/16 1
229312 Faisceau de torche de rechange de 22,9m pour H65/H85 1
Contenu du kit228725