Hypertherm Duramax 228735, Field Service Bulletin

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Torch sleeve, coupler, and gear rack replacemenT
6 Field Service Bulletin
Reassemble the torch with the new positioning sleeve
1. Slide the new positioning sleeve over the front of the torch lead.
2. Slide the coupler over the front of the torch lead.
3. Use the 1/4-inch and 3/8-inch wrenches or two adjustable wrenches together, 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
5.76 kg-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 into the mounting sleeve until hand tight.
9. Thread the positioning sleeve into the coupler until hand tight.
10. If applicable, thread the strain relief nut into the positioning sleeve until hand tight.
11. If applicable, thread the strain relief body onto the strain relief nut until hand tight.
12. Install the consumables.
Kit 228738 contents
Part number Description Quantity
220850 Torch gear rack 1
Disassemble the torch and remove the gear rack
1. Turn OFF the power and disconnect the torch lead from the power supply.
2. If applicable, unscrew the strain relief body from the strain relief nut and slide the strain relief body back along the
torch lead.
3. If applicable, unscrew the strain relief nut from the positioning sleeve and slide the nut back along the torch lead.
4. Unscrew the positioning sleeve from the coupler and slide the positioning sleeve back along the torch lead.
5. Remove the gear rack by sliding it out of the groove in the positioning sleeve.
Replace the machine torch gear rack (for the full length machine torch only)
Please refer to Figure 1 on page 2 when performing the following procedure.