ESAB PT-25, Instruction Manual

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5.4 REMOVAL AND REPLACEMENT OF THE
TORCH HEAD
Note the position of all components and tape locations
before performing disassembly to ensure proper position-
ing of components and tape during reassembly. Refer to
Figure 5.1.
1. Slide the flex support rearward, onto the cable sleev-
ing until it is approximately 450mm to the rear of the
handle.
2. Remove the tape near the end of the torch handle.
3. Slide the switch band and switch rearward and off of
the handle.
4. Slide the cable sleeving rearward to expose the tube
union for the safety sensor tube. Remove the torch
end of the tube by pressing on the end of the union
and pulling on the tube at the same time.
5. Unthread the handle from the torch head and slide it
rearward to expose the torch cable connections.
6. Using two wrenches at each connection, unthread the
two torch connections. The wrench sizes required are
3/8" (10mm) and 7/16" (11mm).
7. Pull the torch head away from the cable assembly,
including the short piece of safety sensor tubing at-
tached. Position the new torch head and safety sensor
tube back into the assembly.
8. Using two wrenches at each connection, tighten the
two torch connections securely. The torque value used
at the factory for this step is 30 - 35 kg-cm.
9. Thread the handle back onto the torch head. Make sure
the safety sensor tube on the torch passes through the
handle.
10. Push the safety sensor tube into the union until it stops.
Slide the switch band and switch onto the handle until
it is 50mm from the torch head. The red splice connec-
tions for the switch lead should be located just behind
the handle end.
11. Pull the cable sleeving forward and tape in place behind
the handle using vinyl electrical tape.
12. Slide the flex support back onto the handle until it
contacts the switch band.
5.5 REMOVAL AND REPLACEMENT OF TORCH
CABLES
1. Disconnect the torch cable assembly from the power
source. Refer to your power source instruction booklet
for detailed instructions.
2. Remove the torch head from the cable assembly as
described in Steps 1 through 7 of the previous section.
Also remove the handle and flex support from the cable
assembly.
3. Lay the cable assembly out straight. This should be done
in an area about 1-1/2 times the length of the cables.
4. Using a piece of cord or sturdy twine about 1/2 the
length of the torch cables, secure one end of the cord
around all of the torch cables at the torch end and se-
cure the other end of the cord to a stationary object.
5. Remove the tape from the cable sleeving at the power
source end of the cables.
6. Push the switch out of the switch band and slide the
handle, switch band and flex support to the far end of
the cord used in Step 4. Secure the power source end
of the cables and pull the cable sleeving completely
onto the cord.
7. Untie the cord from the cables and replace the dam-
aged cable or cables. Be sure to replace the rubber boot
on the power cable
8. Resecure the torch ends of the cables with the cord and
pull the cable sleeving back onto the cables. Temporar-
ily secure the sleeving to the cables near the torch head
end with vinyl electrical tape.
9. Pull the flex support, switch band and handle back
off the cord and onto the cable sleeving. Remove the
tape.
10. Untie the cord from the cables and follow Steps 7
through 12 of the previous section to secure the torch
head to the cable assembly.
11. Secure the cable sleeving to the cables at the power
source end with vinyl electrical tape.
SECTION 5 MAINTENANCE