Hypertherm Duramax Hyamp Series, Service Manual

Page: 47 / 102

Duramax Hyamp Long Handheld Torches Service Manual 808290 47
4 – Component Replacement
Install the handle
1. Lay the right side of the handle under the torch assembly with the inside of the handle facing up.
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If you are installing a new handle, apply the “H” label to the right side of the handle and
the “Duramax Hyamp” label to the left side of the handle.
2. Clamp the torch lead in place, with the white wires facing up, to keep the lead from moving.
3. Press the start switch onto the 2 mounting posts in the handle. See Figure 4 on page 48.
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Putting the start switch in the handle at this point helps to correctly position the pilot arc
and cap-sensor wires.
4. The right side of the handle contains 4 posts around the slot for the gas tube fitting’s flange. (See Figure 4 .) Position
the wires around these posts as follows:
a. Route the blue and orange cap-sensor switch wires and the purple start switch wire below the bottom 2 posts.
 Gently push the cap-sensor switch connector into the extension tube. Position the connector
between the gas tube and the side of the extension tube that will be closest to the right handle.
b. Route the red pilot arc wire above the top 2 posts.
 Gently push the pilot terminal screw (encased in heatshrink) into the extension tube. Position the
screw between the gas tube and the side of the extension tube that will be closest to the left handle.
c. Make sure the wires do not run over the gas tube or across the slot for the gas tube fitting’s flange. All 4 wires
must sit behind the gas tube in the torch handle, as shown in
Figure 4 .