Hypertherm MAX42, Service Manual

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MAINTENANCE
Page 3-18 MAX42 Service Manual
PAC121T TORCH PARTS REMOVAL AND REPLACEMENT
Repair of the PAC121T torch normally requires that either the torch main body or the torch
switch be replaced. Refer to Section 4,
Parts List for a torch parts breakdown.
Torch Main Body Removal and Replacement
To remove and replace the torch main body, order the PAC121T torch main body with switch
(020932) and refer to the following procedure and Figure 3-1.
1. Ensure the MAX42 power switch is positioned to OFF (0), unplug the power cable, and
disconnect the gas supply.
2. Remove the five (5) screws which secure the handle halves together.
3. Remove the torch main body and torch switch from the handle halves.
4. Remove the Tyrap that holds wiring bundle in place.
5. Disconnect the black plunger wire and two white wires of the cap sensor
microswitch from the torch leads.
Note: Disconnect wires by pulling on terminals. Do not pull on wires.
6. Disconnect the red wire attached to the pilot arc tab.
7. Disconnect torch main body and torch lead gas fittings using 5/16" and 7/16" wrenches.
8. Connect and tighten the new torch main body with the torch lead gas fittings.
9. Connect the terminal of the two white wires from the torch lead to the black plunger wire
terminal of the torch main body.
10. Connect the bullet receptacles and plugs connecting the two blue wires from the torch
lead to the white wires from the cap sensor microswitch.
11. Connect the red wire from torch leads to the pilot arc tab.
12. Bundle wires and attach Tyrap as necessary.
13. Install the torch main body and torch switch back into handle. Be certain that torch switch
slides into position above safety trigger, and that trigger movement activates the button of
the switch and then releases.
14. Position the handle halves together (be careful not to pinch any wires)and replace the five
(5) screws to secure the handle halves together.