Hypertherm Duramax Hyamp Series, Service Manual

Page: 73 / 102

Duramax Hyamp Long Handheld Torches Service Manual 808290 73
4 – Component Replacement
10. Straighten the pilot arc wire and the cap-sensor wires towards the end of the gas tube. Do not pull the wires too
tight, and make sure the wires are not knotted or twisted.
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Leave a small amount of slack in the wires so you can position them as needed around
the gas tube and to prevent too much stress on connection points.
11. Apply the first foam strip. Grip the gas tube, pilot arc wire, and cap-sensor wires below the front shell. Hold the wires
in place as you wrap a new foam strip from the kit around the gas tube and the wires.
 0.6 m (2 foot) torches: Apply the foam strip at the position you marked in step 5 in the previous procedure.
(See Figure 27 on page 70.) Skip to step 14 .
 1.2 m (4 foot) and 1.8 m (6 foot) torches: Apply the foam strip at the position closest to the torch head. (See
Figure 27 on page 70.) Continue with the next step.
12. Apply the second foam strip. Straighten out the wires below the foam strip you just applied. Grip the gas tube and
wires below the foam strip, and wrap another foam strip from the kit around the gas tube and the wires. Apply the
foam strip at the second of the positions you marked in
step 5 in the previous procedure.
 1.2 m (4 foot) torches: Skip to step 14 .
 1.8 m (6 foot) torches: Continue to the next step.
13. 1.8 m (6 foot) torches: Straighten out the wires below the foam strip you just applied. Grip the gas tube and wires
below the foam strip, and wrap another foam strip from the kit around the gas tube and the wires. Apply the foam
strip at the third of the positions you marked in
step 5 in the previous procedure. Continue to the next step.
14. Reinstall the torch body. See Install the torch body on page 65.
15. Reinstall the front shell. See Install the front shell on page 53.
16. Reinstall the rest of the torch components and the torch handle. See Install the handle on page 47.