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Duramax Hyamp Long Handheld Torches

Service Manual 808290

4 – Component Replacement

Install the quick disconnect housing

Place the new latch into the quick disconnect housing.

Hold up the end of the latch and insert the new spring under the latch.

Use a blade screwdriver to push the spring into the recess until it clicks into place.

Install the new shell halves onto the torch lead, making sure the strain relief fits in the slot of the shell and the wires
are not pinched or do not interfere with the latch.

Install and tighten the screws.

Summary of Contents for Duramax Hyamp Series

Page 1: ...Duramax Hyamp Long Handheld Torches 45 and 90 0 6 m 2 feet 1 2 m 4 feet and 1 8 m 6 feet Service Manual 808290 Revision 1 English ...

Page 2: ...w hypertherm com registration for easy and fast registration If you experience any problems with the product registration process please contact registration hypertherm com For your records Serial number __________________________________________________________________________ Purchase date __________________________________________________________________________ Distributor ____________________...

Page 3: ...Hypertherm Inc Hanover NH 03755 USA www hypertherm com Duramax Hyamp Long Handheld Torches Service Manual 808290 Revision 1 English March 2018 ...

Page 4: ...apan 81 6 6225 1183 Tel 81 6 6225 1184 Fax HTJapan info hypertherm com Main Office Email TechSupportAPAC hypertherm com Technical Service Email Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 0 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Service technicalservice emea hypertherm com Technical Servi...

Page 5: ...ngshandleiding 80669C Het niet volgen van de veiligheidsinstructies kan resulteren in persoonlijk letsel of schade aan apparatuur De handleidingen kunnen in elektronische en gedrukte vorm met het product worden meegeleverd De handleidingen elke handleiding beschikbaar in alle talen zijn ook verkrijgbaar via de Documentenbibliotheek op www hypertherm com DANSK DANISH ADVARSEL Inden Hypertherm udsty...

Page 6: ... din cadrul secţiunii Bibliotecă documente aflată pe site ul www hypertherm com TÜRKÇE TURKISH UYARI Bir Hypertherm ekipmanını çalıştırmadan önce ürün kullanım kılavuzunda ve Güvenlik ve Uyumluluk Kılavuzu nda 80669C yer alan güvenlik talimatlarını okuyun Güvenlik talimatlarına uyulmaması durumunda kişisel yaralanmalar veya ekipman hasarı meydana gelebilir Kılavuzların kopyaları elektronik ve bası...

Page 7: ...uipment SC 11 Cutting cables SC 11 Equipotential bonding SC 11 Earthing of the workpiece SC 12 Screening and shielding SC 12 Warranty SC 13 Attention SC 13 General SC 13 Patent indemnity SC 13 Limitation of liability SC 13 National and local codes SC 13 Liability cap SC 14 Insurance SC 14 Transfer of rights SC 14 Waterjet product warranty coverage SC 14 Product SC 14 Parts coverage SC 14 1 Specifi...

Page 8: ...es 25 Connecting the torch lead 27 3 Operation 29 Using the hand torch 29 Operate the safety trigger 30 Hand torch cutting guidelines 31 Start a cut from the edge of the workpiece 32 Pierce a workpiece 33 Gouge a workpiece 35 Gouge profile 36 Varying the gouge profile 37 125 A gouging profile chart 37 Common hand cutting faults 39 4 Component Replacement 41 Duramax Hyamp 45 long handheld torch com...

Page 9: ...ance tasks 88 Inspect the consumables 89 Basic troubleshooting 90 Duramax Hyamp long handheld torch replacement parts 92 Full torch assembly 45 torch 92 External components 45 torch 93 Internal components 45 torch 94 Full torch assembly 90 torch 96 External components 90 torch 97 Internal components 90 torch 98 Duramax Hyamp hand torch consumables 100 Drag cutting 100 Maximum Removal gouging 100 F...

Page 10: ...10 Duramax Hyamp Long Handheld Torches Service Manual 808290 Contents ...

Page 11: ...nt User shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of th...

Page 12: ...ies where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note The cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury for example by allowing parallel ...

Page 13: ...horized Hypertherm repair facility all costs insurance and freight pre paid by the customer Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph and with Hypertherm s prior written consent The warranty set forth above is exclusive and is in lieu of all other warranties express implied statutory o...

Page 14: ...erein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise Waterjet product warranty coverage Consumable parts are not covered by this warranty Consumable parts include but are not limited to high pressure water seals check valves cylinders bleed down valves low pressure seals high pressure tubing low and high pressure water filters and ab...

Page 15: ...to be used with the Powermax125 but they can also be used with the Powermax45 XP Powermax65 Powermax85 and Powermax105 with the exception of the torches with the 46 m 150 foot leads The Duramax Hyamp long handheld torches with 46 m 150 foot torch leads must be used with a Powermax125 Duramax Hyamp long handheld torches with 46 m 150 foot leads cannot be used with any other Powermax systems IMPORTA...

Page 16: ...plications require the use of multiple torches The torches are cooled by ambient air and do not require special cooling procedures Duramax Hyamp long handheld torches comply with IEC 60974 7 They are not suitable for cutting under water or for use in the rain or snow WARNING Do not submerge the torch in water while cutting Putting the torch head under water while there is an active arc can result ...

Page 17: ...1 4 pounds 45 Duramax Hyamp 1 2 m 4 foot torch with 15 2 m 50 foot lead 7 9 kg 17 3 pounds 45 Duramax Hyamp 1 2 m 4 foot torch with 46 m 150 foot lead for Powermax125 only 18 3 kg 40 3 pounds 90 Duramax Hyamp 0 6 m 2 foot torch with 7 6 m 25 foot lead 4 2 kg 9 2 pounds 90 Duramax Hyamp 0 6 m 2 foot torch with 15 2 m 50 foot lead 6 9 kg 15 1 pounds 90 Duramax Hyamp 1 2 m 4 foot torch with 7 6 m 25 ...

Page 18: ...ns will vary depending on the type of consumables installed This figure shows handheld shielded consumables installed 45 3 5 cm 1 4 inches 3 5 cm 1 4 inches 74 cm 29 inches with 0 6 m extension 145 cm 57 inches with 1 2 m extension 9 6 cm 3 8 inches 8 0 cm 3 2 inches 51 cm 20 inches with 0 6 m extension 122 cm 48 inches with 1 2 m extension ...

Page 19: ...consumables installed This figure shows handheld shielded consumables installed 90 3 5 cm 1 4 inches 3 5 cm 1 4 inches 71 cm 28 inches with 0 6 m extension 142 cm 56 inches with 1 2 m extension 203 cm 80 inches with 1 8 m extension 12 4cm 4 9 inches 8 0 cm 3 2 inches 51 cm 20 inches with 0 6 m extension 122 cm 48 inches with 1 2 m extension 183 cm 72 inches with 1 8 m extension ...

Page 20: ...20 Duramax Hyamp Long Handheld Torches Service Manual 808290 1 Specifications ...

Page 21: ...ng handheld torch with any of the following Powermax systems Refer to your system s Operator Manual for operation maintenance troubleshooting and parts information related to the power supply Powermax45 XP 809240 Powermax65 806650 Powermax85 806650 Powermax105 807390 Powermax125 808080 You can download these manuals from www hypertherm com by clicking the Documents library link and searching for t...

Page 22: ...ting cuts from the edge Proper torch to work distance when gouging Proper pierce height Whether you are cutting in continuous pilot arc mode or normal mode Cutting with a continuous pilot arc causes more consumable wear Under normal conditions the nozzle will wear out first when hand cutting As general rule a set of consumables lasts approximately 1 to 3 hours of actual arc on time for 105 125 A h...

Page 23: ... Duramax Hyamp 45 and 90 long handheld torches ship without consumables installed Duramax Hyamp 45 long handheld torch Duramax Hyamp 90 long handheld torch Consumables Safety trigger Extension tube 0 6 m 2 feet or 1 2 m 4 feet Safety trigger Consumables Extension tube 0 6 m 2 feet 1 2 m 4 feet or 1 8 m 6 feet ...

Page 24: ... Also notice that specific consumables are not available for cutting at 85 A Use the standard drag cutting 105 125 A consumables to cut at 85 A For higher cut quality on thin materials approximately 4 mm 10 GA or less you may prefer to use FineCut consumables or use a 45 A nozzle and reduce the amperage to that setting More consumables are available for this torch but can require testing to find t...

Page 25: ...wirl ring and electrode Torches ship without consumables installed Pull off the vinyl cap before installing your consumables WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch trigger is activated Make sure the power is OFF before changing consumables 420112 Shield 220977 Retaining cap 420001 Nozzle 220997 Swirl ring 220971 Electrode...

Page 26: ... Duramax Hyamp Long Handheld Torches Service Manual 808290 2 Torch Setup With the power switch in the OFF O position install the torch consumables as shown Shield Retaining cap Nozzle Electrode Swirl ring ...

Page 27: ...a quick disconnect system for connecting and disconnecting handheld and machine torch leads When connecting or disconnecting a torch first turn OFF the system To connect the torch push the connector into the receptacle on the front of the power supply To remove the torch press the red button on the connector and pull the connector out of the receptacle Red button ...

Page 28: ...28 Duramax Hyamp Long Handheld Torches Service Manual 808290 2 Torch Setup ...

Page 29: ... workpiece and keep your hands clear of the cutting path Never point the torch toward yourself or others WARNING CAREFULLY OPERATE AND STORE THE LONG TORCH Beware of hot falling debris when cutting at waist height or higher Keep the cutting area clear to avoid injury or property damage Make sure that conditions are safe before cutting in difficult to access areas where visibility is poor Always ac...

Page 30: ... 3 Operation Operate the safety trigger The long hand torches are equipped with a safety trigger to prevent accidental firings When you are ready to use the torch flip the trigger s safety cover forward toward the torch head and press the red torch trigger 1 2 3 ...

Page 31: ...orch more slowly or set the output current higher With either hand torch hold the torch nozzle perpendicular to the workpiece so that the nozzle is at a 90 angle to the cutting surface Observe the cutting arc as the torch cuts If you fire the torch unnecessarily you will shorten the life of the nozzle and electrode Pulling or dragging the torch along the cut is easier than pushing it For straight ...

Page 32: ...ouging techniques shown are the same for the Duramax Hyamp long handheld torches 1 With the ground clamp attached to the workpiece hold the torch nozzle perpendicular 90 to the edge of the workpiece 2 Press the torch s trigger to start the arc Pause at the edge until the arc has cut completely through the workpiece 3 Drag the torch tip lightly across the workpiece to proceed with the cut Maintain ...

Page 33: ...mm 1 16 inch of the workpiece before firing the torch 2 Fire the torch while still at an angle to the workpiece Slowly rotate the torch to a perpendicular 90 position WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle sparks and hot metal will spray out from the nozzle Point the torch away from yourself and others Always wear proper protective equipment in...

Page 34: ...al 808290 3 Operation 3 Hold the torch in place while continuing to press the trigger When sparks exit below the workpiece the arc has pierced the material 4 When the pierce is complete drag the nozzle lightly along the workpiece to proceed with the cut ...

Page 35: ... gouge Refer to Varying the gouge profile on page 37 and 125 A gouging profile chart on page 37 4 Maintain the same angle to the workpiece as you feed into the gouge Push the plasma arc in the direction of the gouge you want to create Keep a small distance between the torch tip and the molten metal to avoid reducing consumable life or damaging the torch WARNING SPARKS AND HOT METAL CAN INJURE EYES...

Page 36: ...ging profile for reference but the tips in Varying the gouge profile below apply regardless of the power output Refer to the Powermax45 XP Powermax65 Powermax85 or Powermax105 Operator Manual for more information on gouging with those power supplies Typical gouging profile 125 A Metal removal rate on mild steel 12 5 kg hour 27 pounds hour Speed Standoff Angle Operating parameters 125 A Speed 508 1...

Page 37: ...r supply will increase width and increase depth Decreasing the current of the power supply will decrease width and decrease depth 125 A gouging profile chart The following tables show the 125 A gouging profile at 30 and 35 on mild steel These settings are intended to serve as a starting point to help you determine the best gouging profile for a given cutting job Adjust these settings as needed for...

Page 38: ...idth inches Width depth ratio 30 0 25 20 0 31 0 33 1 06 30 0 26 0 30 1 16 40 0 22 0 26 1 21 50 0 17 0 24 1 38 0 40 20 0 30 0 39 1 30 30 0 24 0 34 1 43 40 0 19 0 29 1 50 50 0 17 0 28 1 66 35 0 25 20 0 30 0 27 0 92 30 0 23 0 26 1 13 40 0 18 0 22 1 26 50 0 17 0 21 1 24 0 40 20 0 29 0 32 1 12 30 0 23 0 30 1 30 40 0 23 0 25 1 12 50 0 18 0 24 1 35 ...

Page 39: ...hick for the amperage The wrong consumables are being used gouging consumables are installed instead of drag cutting consumables for example The torch is moving too quickly or too slowly The arc sputters and consumable life is shorter than expected The causes can be Moisture in the gas supply Incorrect gas pressure Consumables incorrectly installed The consumables are worn The consumables show une...

Page 40: ...40 Duramax Hyamp Long Handheld Torches Service Manual 808290 3 Operation ...

Page 41: ...0 torch However the procedures are the same for both the 45 and 90 torches unless otherwise noted WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance The maintenance procedures in this section must be performed by a qualified service technician See the Safety and Compliance Manual 80669C for more safety precautions ...

Page 42: ... shell right side 2 Cap sensor switch 3 Torch body torch head plus gas tube 4 Consumables 5 Pilot arc wire 6 Pilot terminal screw 2 7 Extension tube 8 Trigger 9 Spring 10 Gas tube fitting s flange 11 Start switch 12 Cap sensor switch connector 13 Strain relief 14 Torch lead 15 Front shell left side 16 Screws for front shell 8 17 Handle left side 18 Screws for handle 9 19 Handle right side ...

Page 43: ... shell right side 2 Cap sensor switch 3 Torch body torch head plus gas tube 4 Consumables 5 Pilot arc wire 6 Pilot terminal screw 2 7 Extension tube 8 Trigger 9 Spring 10 Gas tube fitting s flange 11 Start switch 12 Cap sensor switch connector 13 Strain relief 14 Torch lead 15 Front shell left side 16 Screws for front shell 8 17 Handle left side 18 Screws for handle 9 19 Handle right side ...

Page 44: ...Replacement Disconnect the power gas supply and torch 1 Turn the plasma power supply switch to OFF O 2 Turn the line disconnect switch to OFF O 3 Disconnect the gas supply hose from the plasma power supply 4 Disconnect the torch from the plasma power supply Figure 1 1 3 4 2 ...

Page 45: ... 2 Place the torch on a flat surface with the left handle facing up The left handle is the side with the screws 3 Clamp the torch lead in place to keep it from moving 4 Remove the screws from the left handle 5 Insert a blade screwdriver between the handles and gently twist the screwdriver to pry up the left handle Being careful to keep the trigger spring from launching out of the handle lift the l...

Page 46: ...the trigger and spring up and out of the handle Set them aside 7 The handle fits snugly around the extension tube While holding the extension tube gently press the right side of the handle away from the extension tube and torch lead to remove it 8 Use a blade screwdriver to pry the start switch off the 2 mounting posts Figure 3 ...

Page 47: ...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 wi...

Page 48: ... top and shown bottom 3 Pilot arc wire red Cap sensor switch wires blue orange Start switch wires purple 5 4 1 2 6 6 7 8 9 1 Cap sensor switch connector 2 Pilot terminal screw 3 Trigger s pivot hole 4 Start switch 5 Slot for gas tube fitting s flange 6 Posts for routing the wires 7 Slot for torch lead strain relief 8 Gas tube 9 Torch lead strain relief ...

Page 49: ...e wires properly positioned If the handle does not align with the flat grooves on the extension tube as shown in Figure 5 you can grip the extension tube with one hand and the gas tube and torch handle with the other and then rotate slightly until the handle and tube align properly Figure 5 7 Align the gas hose fitting s flange with the slot in the handle See Figure 4 on page 48 Bend the gas tube ...

Page 50: ...that the handle and gas fitting flange do not pinch the wires align the left half of the handle with the right half 12 Install the handle screws loosely and verify that the Trigger pivots are both located in the trigger pivot holes by pulling the trigger a few times See Figure 4 on page 48 Flat square grooves on the extension tube align with where the handles meet See Figure 5 on page 49 Wires are...

Page 51: ...he shell 1 Turn OFF O the power disconnect the gas supply and disconnect the torch 2 Remove the consumables from the torch 3 Place the torch on a flat surface with the left front shell facing up The left shell is the side with the screws 4 Clamp the torch lead in place to keep it from moving 5 Remove the screws from the left front shell 6 Lift the left side of the front shell away from the torch F...

Page 52: ... tube fit snugly into the right side of the front shell While holding the extension tube gently press the right side of the shell away from the extension tube and torch body to remove it 8 Slide the cap sensor switch off its mounting post Figure 8 Remove cap sensor switch from 45 top and 90 bottom front shell 45 90 ...

Page 53: ... 3 kg cm 15 inch pounds 2 Make sure the consumables have been removed from the torch 3 Lay the right side of the front shell on a flat surface with the inside facing up 4 Clamp the torch lead in place to keep it from moving 5 Press the cap sensor switch into its post hole and onto its mounting post in the shell Figure 9 Install cap sensor switch in 45 top and 90 bottom front shell 45 90 ...

Page 54: ...the gas tube and above the protective foam that is wrapped around the gas tube 90 torches Position the wires underneath or behind the gas tube and below the protective foam that is wrapped around the gas tube Figure 10 Wire routing in 45 top and 90 bottom front shell 1 2 3 1 45 90 1 Slot for torch head 2 Cap sensor switch 3 Slot for foam strip wrapped around the gas tube ...

Page 55: ...rch head and shell with the other and then rotate slightly until the shell and tube align properly Figure 11 9 Make sure the pilot arc wire is angled toward the gas tube and that the wire terminal is not pressed against the ribs or plastic housing in the right front shell 10 Being careful that the front shell does not pinch the wires align the left half of the shell with the right half Make sure t...

Page 56: ...to keep it from moving 4 Remove the screws from the left handle 5 Insert a blade screwdriver between the handles and gently twist the screwdriver to pry up the left handle Being careful to keep the trigger spring from launching out of the handle lift the left side of the handle away from the torch Figure 12 6 While holding the spring in place slide the trigger and spring up and out of the handle K...

Page 57: ...tshrink are completely inside the extension tube 4 Being careful that the handle and gas fitting flange do not pinch the wires align the left half of the handle with the right half 5 Install the handle screws loosely and verify that the Trigger pivots are both located in the trigger pivot holes by pulling the trigger a few times See Figure 4 on page 48 Flat square grooves on the extension tube ali...

Page 58: ... the screws 3 Clamp the torch lead in place to keep it from moving 4 Remove the screws from the left handle 5 Insert a blade screwdriver between the handles and gently twist the screwdriver to pry up the left handle Being careful to keep the trigger spring from launching out of the handle lift the left side of the handle away from the torch Figure 14 Kit Description 428162 Kit Duramax Hyamp hand t...

Page 59: ...the spring in place slide the trigger and spring up and out of the handle Set them aside 7 Use a blade screwdriver to pry the start switch off the 2 mounting posts Figure 15 8 Disconnect the start switch by pushing the tab and pulling the start switch away from the connector Figure 16 Start switch Tab ...

Page 60: ... handle as shown in Figure 17 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 handle Figure 17 Wires and start switch positioned in handle with gas tube and torch lead hidden top and shown bottom 3 Pilot arc wire red Cap sensor switch wires blue orange Start switch wires purple 5 4 1 2 6 6 7 8 9 1...

Page 61: ...minal screw encased in heatshrink are completely inside the extension tube 9 Being careful that the handle and gas fitting flange do not pinch the wires align the left half of the handle with the right half 10 Install the handle screws loosely and verify that the Trigger pivots are both located in the trigger pivot holes by pulling the trigger a few times See Figure 17 above Flat square grooves on...

Page 62: ...extension tube by pressing the tab on the connector and pulling the connector apart Figure 18 Kit Description 428282 Kit Duramax Hyamp 45 long handheld torch body replacement torch head plus gas tube 0 6 m 2 feet includes pilot arc wire cap sensor switch and foam strips 428284 Kit Duramax Hyamp 45 long handheld torch body replacement torch head plus gas tube 1 2 m 4 feet includes pilot arc wire ca...

Page 63: ... heatshrink at the trigger end of the extension tube to reveal the pilot terminal screw and nut Remove the pilot terminal screw and nut and set them aside Figure 19 6 Disconnect the start switch by pushing the tab and pulling the start switch away from the connector Figure 20 1 2 3 1 2 3 Start switch Tab ...

Page 64: ...ll the torch body out of the extension tube 10 Make sure the torch head and cap sensor switch have been removed from the front shell Figure 21 The 0 6 m 2 foot torches contain only 1 foam strip around the middle of the torch body the 1 2 m 4 foot torches pictured above contain 2 foam strips around the middle of the torch body the 1 8 m 6 foot torches contain 3 foam strips around the middle of the ...

Page 65: ...ing to remove any dried or loose threadlocker Apply a fresh drop of threadlocker to the threads of the gas tube fitting on the torch body If you are installing a new torch body be careful not to get any threadlocker on the conical surface of the gas tube fitting to prevent damage to the torch Apply a drop of threadlocker included in the kit to the threads of the gas tube fitting on the new torch b...

Page 66: ...igure 23 7 Use 2 wrenches to tighten the gas fitting that secures the torch body to the torch lead to 69 1 kg cm 60 inch pounds 8 Remove the electrical tape from the pilot arc wire and cap sensor wires that you applied in step 1 above 9 Use the pilot terminal screw and nut you removed in step 5 on page 63 to connect the red pilot arc wire from the torch lead with the red pilot arc wire from the to...

Page 67: ...heat gun to warm the heatshrink until it adheres to the screw c Close the end of the heatshrink by crimping it with a pair of pliers Figure 24 11 Connect the cap sensor switch to the torch lead by pushing the mating plug on the torch lead wires into the socket near the trigger end of the extension tube Figure 25 CAUTION Do not apply heat to the wires Heating the wires can damage the connections in...

Page 68: ...ement 12 Connect the start switch by pushing the mating plug into the socket Figure 26 13 Reinstall the front shell See Install the front shell on page 53 14 Reinstall the rest of the torch components and the torch handle See Install the handle on page 47 Start switch Mating plug ...

Page 69: ...ding the consumables See Remove the handle on page 45 and Remove the front shell on page 51 3 Remove the torch body from the rest of the torch See Remove the torch body on page 62 Kit Description 428290 Kit Duramax Hyamp long handheld torch pilot arc wire replacement with screws 0 6 m 2 feet 428291 Kit Duramax Hyamp long handheld torch pilot arc wire replacement with screws 1 2 m 4 feet 428823 Kit...

Page 70: ... 6 foot torches Mark where the 3 foam strips are wrapped around the middle of the torch body s gas tube so that you can install new strips in the same place Do not remove the foam strip at the top of the gas tube near the torch head Figure 27 The 0 6 m 2 foot torches contain only 1 foam strip around the middle of the torch body the 1 2 m 4 foot torches pictured above contain 2 foam strips around t...

Page 71: ...torch head Angle the pilot arc wire towards the gas tube Carefully bend the wire terminal as needed Keep in mind that the pilot arc wire terminal must not press against the ribs or plastic housing in the right front shell when the torch is put back together Tighten the screw to 17 3 kg cm 15 inch pounds Figure 28 4 Lay the right side of the front shell on a flat surface with the inside facing up 5...

Page 72: ...e the gas tube and above the protective foam that is wrapped around the gas tube 90 torches Position the wires to run under the foam strip and to remain behind the gas tube Figure 29 Wire routing in 45 top and 90 bottom front shell 8 Press the torch body into the front shell Align the torch head with the slot in the shell See Figure 29 9 Make sure the pilot arc wire terminal is not pressed against...

Page 73: ...t 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 fo...

Page 74: ...you can install new strips in the same place 1 8 m 6 foot torches Mark where the 3 foam strips are wrapped around the middle of the torch body s gas tube so that you can install new strips in the same place Do not remove the foam strip at the top of the gas tube near the torch head 5 Peel the foam strip or strips off of the gas tube and discard Also discard the cap sensor switch Figure 30 The 0 6 ...

Page 75: ...ensor switch in the shell at this point ensures the switch is positioned properly before you wrap the new foam strips around the cap sensor wires 5 Position the cap sensor wires as shown in Figure 31 45 torches Position the wires above the gas tube and above the protective foam that is wrapped around the gas tube 90 torches Position the wires to run under the foam strip and to remain behind the ga...

Page 76: ... Continue with the next step 9 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 4 in the previous procedure 1 2 m 4 foot torches Skip to step 11 1 8 m 6 foot torch...

Page 77: ...n removed from the torch 2 Make sure that the pilot terminal screw on the torch head is tightened to 17 3 kg cm 15 inch pounds 3 Install the new extension tube as you reinstall the torch body See Install the torch body on page 65 4 Reinstall the front shell See Install the front shell on page 53 5 Reinstall the rest of the torch components and the torch handle See Install the handle on page 47 Kit...

Page 78: ...Disconnect the cap sensor switch at the trigger end of the extension tube by pressing the tab on the connector and pulling the connector apart Figure 32 Kit Description 428159 Kit Duramax and Duramax Hyamp hand torch lead replacement 7 6 m 25 feet 428160 Kit Duramax and Duramax Hyamp hand torch lead replacement 15 m 50 feet 428762 Kit Duramax Hyamp hand torch lead replacement 46 m 150 feet The 46 ...

Page 79: ... heatshrink at the trigger end of the extension tube to reveal the pilot terminal screw and nut Remove the pilot terminal screw and nut and set them aside Figure 33 6 Disconnect the start switch by pushing the tab and pulling the start switch away from the connector Figure 34 1 2 3 1 2 3 Start switch Tab ...

Page 80: ...e a heat gun to slowly heat only the fitting until you can easily loosen the fitting Figure 35 8 Cover the end of the gas line on the torch lead with tape to keep dirt and other contaminants from getting in the gas line CAUTION Do not apply heat to the wires Heating the wires can damage the connections in the torch lead CAUTION Always use 2 wrenches to properly loosen and tighten the hex nuts and ...

Page 81: ...Clamp the new torch lead in place with the white wires facing up to keep the lead from moving 3 Remove the tape that you placed over the end of the gas line on the torch lead in step 8 on page 80 4 Thread the conical end of the gas tube into the new torch lead until snug The lead s white wires must be facing up Figure 37 CAUTION Do not get any threadlocker on the conical surface of the gas tube fi...

Page 82: ...he torch body Tighten the screw to 17 3 kg cm 15 inch pounds Keep in mind that the pilot arc wire from the torch lead must be routed under the gas tube when the torch handle is put back together 7 Cover the pilot terminal screw and nut with the heatshrink included in the kit a Leave 10 mm 3 8 inch excess heatshrink above the screw b Use a heat gun to warm the heatshrink until it adheres to the scr...

Page 83: ... near the trigger end of the extension tube Figure 39 9 Connect the start switch by pushing the mating plug into the socket Figure 40 10 Reinstall all of the torch components that you removed in step 2 on page 78 See Install the handle on page 47 11 Connect the new torch lead to the power supply 12 Reconnect the gas supply and turn ON I the power Cap sensor switch Mating plug Start switch Mating p...

Page 84: ...ure 41 3 Remove the 2 shell halves 4 Remove the latch by using a blade screwdriver to press down firmly on the latch tab while pushing the tab down and out toward the lead 5 Pull the spring out of the quick disconnect housing Figure 41 Kit Description 428260 Kit Duramax and Duramax Hyamp torch FastConnect replacement 1 2 3 4 5 6 7 8 9 10 1 Top shell half 2 Latch tab 3 Quick disconnect housing 4 Bo...

Page 85: ...sing 2 Hold up the end of the latch and insert the new spring under the latch 3 Use a blade screwdriver to push the spring into the recess until it clicks into place 4 Install the new shell halves onto the torch lead making sure the strain relief fits in the slot of the shell and the wires are not pinched or do not interfere with the latch 5 Install and tighten the screws ...

Page 86: ...86 Duramax Hyamp Long Handheld Torches Service Manual 808290 4 Component Replacement ...

Page 87: ...al 808290 87 Section 5 Maintenance and Parts Routine maintenance and troubleshooting WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance See the Safety and Compliance Manual 80669C for more safety precautions ...

Page 88: ...lation and wear Every 3 months Replace any damaged labels Inspect the trigger for damage Inspect the torch body for cracks and exposed wires Inspect the extension tube for cracks or other damage Replace any damaged parts Inspect the power cord and plug Replace if damaged Inspect the torch lead Replace if damaged Every 6 months or Clean the inside of the power supply with clean dry oil free and moi...

Page 89: ...e pit depth is greater than 1 6 mm 1 16 inch deep Swirl ring The surface inside the swirl ring for damage or wear and the gas holes for blockages Replace the swirl ring if the surface is damaged or worn or any of the gas holes are blocked The O ring for damage or wear If the O ring is worn or damaged replace it 428253 The length of the swirl ring If the length of the 220997 or 420159 swirl ring is...

Page 90: ...kpiece to ensure a good metal to metal connection Inspect the ground clamp for damage and repair as necessary The pierce height distance may be too large Move the torch closer to the workpiece and fire the torch again The arc blows out but re ignites when the torch trigger is pressed again Inspect the consumable parts and replace them if they are worn or damaged See Inspect the consumables on page...

Page 91: ...Duramax Hyamp Long Handheld Torches Service Manual 808290 91 5 Maintenance and Parts ...

Page 92: ...5 IMPORTANT If your Powermax125 has a serial number of 125 007943 or lower you must install a new DSP board 428119 Make sure that the DSP board is at Revision C or higher See the Duramax Hyamp 46 m 150 foot Torch and Torch Leads Field Service Bulletin 810260 for more information Part Number Description 059562 Duramax Hyamp 45 long handheld torch assembly with 0 6 m 2 foot extension and 7 6 m 25 fo...

Page 93: ...n 1 428278 Kit Duramax Hyamp 45 long handheld torch front shell replacement 2 428280 Kit Duramax Hyamp long handheld torch extension tube replacement 0 6 m 2 feet 2 428281 Kit Duramax Hyamp long handheld torch extension tube replacement 1 2 m 4 feet 3 428286 Kit Duramax Hyamp long handheld torch auxiliary handle replacement with screws 4 428287 Kit Duramax Hyamp torch handle screws 5 428156 Kit Du...

Page 94: ... 2 428282 Kit Duramax Hyamp 45 long handheld torch body replacement torch head plus gas tube 0 6 m 2 feet includes pilot arc wire cap sensor switch and foam strips 2 428284 Kit Duramax Hyamp 45 long handheld torch body replacement torch head plus gas tube 1 2 m 4 feet includes pilot arc wire cap sensor switch and foam strips 3 428253 Kit Duramax Hyamp O ring replacement 5 2 3 6 1 4 5 The 0 6 m 2 f...

Page 95: ...ld Service Bulletin 810260 for more information 4 428290 Kit Duramax Hyamp long handheld torch pilot arc wire replacement with screws 0 6 m 2 feet 4 428291 Kit Duramax Hyamp long handheld torch pilot arc wire replacement with screws 1 2 m 4 feet 5 428162 Kit Duramax Hyamp hand torch start switch replacement 6 428159 Kit Duramax and Duramax Hyamp hand torch lead replacement 7 6 m 25 feet 6 428160 K...

Page 96: ...tension and 7 6 m 25 foot lead 059580 Duramax Hyamp 90 long handheld torch assembly with 0 6 m 2 foot extension and 15 m 50 foot lead 059568 Duramax Hyamp 90 long handheld torch assembly with 1 2 m 4 foot extension and 7 6 m 25 foot lead 059582 Duramax Hyamp 90 long handheld torch assembly with 1 2 m 4 foot extension and 15 m 50 foot lead 059668 Duramax Hyamp 90 long handheld torch assembly with 1...

Page 97: ...ll replacement 2 428280 Kit Duramax Hyamp long handheld torch extension tube replacement 0 6 m 2 feet 2 428281 Kit Duramax Hyamp long handheld torch extension tube replacement 1 2 m 4 feet 2 428820 Kit Duramax Hyamp long handheld torch extension tube replacement 1 8 m 6 feet 3 428286 Kit Duramax Hyamp long handheld torch auxiliary handle replacement with screws 4 428287 Kit Duramax Hyamp torch han...

Page 98: ...replacement torch head plus gas tube 1 2 m 4 feet includes pilot arc wire cap sensor switch and foam strips 2 428821 Kit Duramax Hyamp 90 long handheld torch body replacement torch head plus gas tube 1 8 m 6 feet includes pilot arc wire cap sensor switch and foam strips 3 428253 Kit Duramax Hyamp O ring replacement 5 4 428290 Kit Duramax Hyamp long handheld torch pilot arc wire replacement with sc...

Page 99: ...at the DSP board is at Revision C or higher See the Duramax Hyamp 46 m 150 foot Torch and Torch Leads Field Service Bulletin 810260 for more information 5 428162 Kit Duramax Hyamp hand torch start switch replacement 6 428159 Kit Duramax and Duramax Hyamp hand torch lead replacement 7 6 m 25 feet 6 428160 Kit Duramax and Duramax Hyamp hand torch lead replacement 15 m 50 feet 6 428762 Kit Duramax Hy...

Page 100: ... A 420169 Duramax Hyamp nozzle 65 A 220975 Duramax Hyamp nozzle 105 125 A 220971 Duramax Hyamp electrode 220997 Duramax Hyamp swirl ring Part Number Description 420112 Duramax Hyamp gouging shield 220977 Duramax Hyamp retaining cap 420001 Duramax Hyamp gouging nozzle 220971 Duramax Hyamp electrode 220997 Duramax Hyamp swirl ring Part Number Description 420152 Duramax Hyamp FineCut shield 220977 Du...

Page 101: ... 101 5 Maintenance and Parts Accessory parts Part Number Description 127169 Leather cutting gloves 127103 Face shield shade 8 lens 017031 Helmet shade 8 12 auto dim with glasses 127105 Replacement lens for face shield shade 8 428809 Kit Skeleton cutting sled ...

Page 102: ...102 Duramax Hyamp Long Handheld Torches Service Manual 808290 5 Maintenance and Parts ...

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