Hypertherm Duramax 228735, Field Service Bulletin

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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.