ESAB HandyPlasma 250, Instruction Manual

Page: 34 / 48

34
SECTION 4 MAINTENANCE
BEFORE ANY MAINTENANCE IS AT-
TEMPTED ON THIS TORCH, MAKE
SURE THE POWER SWITCH ON THE
POWER SOURCE IS IN THE OFF PO-
SITION AND THE PRIMARY INPUT
POWER IS DEENERGIZED.
1. To disassemble the front end, hold the torch with the shield in an upright position.
This will prevent the nozzle, electrode, and swirl baffle from falling free when the
shield is removed.
The gas flow check valve is part of the safety interlock and is permanently as-
sembled in the torch head. The head must be replaced if this valve malfunctions.
The light spring force used to close the ball check can be felt by pushing on the
electrode when assembling the front end components.
2. Periodically check the heat shield, electrode, nozzle, and swirl baffle. Replace if
worn or damaged.
3. Do not continue to use if the electrode end erodes to a length shorter than 0.63"
(16mm) as shown in Fugure 4-3 below.
4. Apply a small amount of lubricant P/N 17672, supplied in spare parts kit, to the
heat shield as shown in Figure 4-3 below or to the o-ring. Check o-ring for dam-
age whenever the shield is removed. Replace if necessary.
Figure 4-3 O-ring and Electrode Maintenance
1.13" (28.6mm)
Minimum
Double-ended Electrode
Replace electrode when both
ends wear to 0.63" (16mm) long.
Lubricant can be applied to
O-ring or Heat Shield
5. The power cable and switch leads in the service line should be inspected periodi-
cally. If there are any cuts through the protective sheath or if gas leaks are noted,
replace the damaged component.
By following Steps 1, 2, and 3 in Subsection 4.5 the service line can be removed from
the torch. To disassemble the service line, lay the line out straight, remove the tape
from around the switch lead splices, and free the switch by cutting the leads close to
the splices. Replacement switches have extra long leads to make up for any loss due
to cutting. Remove the rubber boot from the inlet end of the cable and remove the
tape that secures the sheath at each end. Pull the sheath off the cable (over small
fitting at torch end). Note that the switch leads wrapped around the power cable are
secured with tape several places along the cable. The leads, switch cord plug, and
strain relief can now be removed. DO NOT remove the white tape that forms a band
around the power cable at each end. The sheath is taped to the cable in front of the
band which acts as a shoulder to prevent the sheath from sliding back on the cable.
Replacement cables have this tape in place. If the switch leads are to be replaced,
replace with 16 AWG STRANDED COPPER, 600- VOLT, 90
°
C (194
°
F) INSULATED WIRE.
Reassemble in reverse order.
6. To reposition the switch on the torch, slide the flex support back, remove the tape
securing the spliced leads to the power cable, reposition switch, retape the leads,
and pull the flex support back in place.
NOTE: A thin film of silicone lubricant P/N 17672, supplied with the spare parts kit,
applied inside of the flex support will ease the assembly of this part.
4.4 PT-31XL TORCH MAINTENANCE
WARNING