Hypertherm Duramax Hyamp Series Service Manual
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Hypertherm Duramax Hyamp Series Service Manual

Hypertherm Duramax Hyamp Series Service Manual

Long handheld torches
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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

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Summary of Contents for Hypertherm 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 All other trademarks are the property of their respective holders. Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We are striving to reduce the environmental impact of everything we do. For more information: www.hypertherm.com/environment.
  • Page 3 Duramax Hyamp Long Handheld Torches Service Manual 808290 Revision 1 English March 2018 Hypertherm Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 México, D.F. C.P. 01780 (Technical Service Email) 52 55 5681 8109 Tel 52 55 5683 2127 Fax South America & Central America: Hypertherm Brasil Ltda. Soporte.Tecnico@hypertherm.com (Technical Service Email) Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP – Brasil...
  • Page 5 한국어 / KOREAN product worden meegeleverd. De handleidingen, elke handleiding 경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 beschikbaar in alle talen, zijn ook verkrijgbaar via de “Documentenbibliotheek” 준수 설명서 (80669C)에 나와 있는 안전 지침을 읽으십시오. 안전 지침을...
  • Page 6 Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú alebo tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch, sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.

  • Page 7: Table Of Contents

    Contents Electromagnetic Compatibility (EMC) ................SC-11 Introduction ....................................SC-11 Installation and use .................................SC-11 Assessment of area ................................SC-11 Methods of reducing emissions ............................SC-11 Mains supply ..................................SC-11 Maintenance of cutting equipment .............................SC-11 Cutting cables ..................................SC-11 Equipotential bonding ..............................SC-11 Earthing of the workpiece .............................SC-12 Screening and shielding ...............................SC-12 Warranty ..........................
  • Page 8 Contents 45° Duramax Hyamp long handheld torch dimensions ....................... 18 90° Duramax Hyamp long handheld torch dimensions ....................... 19 2 Torch Setup ..........................21 Consumable life .................................... 22 Long handheld torch components ............................23 Duramax Hyamp 45° long handheld torch ........................23 Duramax Hyamp 90°...
  • Page 9 Contents Replace the torch lead ................................78 Replace the quick disconnect housing ........................... 84 5 Maintenance and Parts ......................87 Routine maintenance and troubleshooting ..........................87 Perform routine maintenance tasks ..........................88 Inspect the consumables ..............................89 Basic troubleshooting ................................90 Duramax Hyamp long handheld torch replacement parts ....................
  • Page 10 Contents Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 11: Electromagnetic Compatibility (Emc

    Introduction Methods of reducing emissions Mains supply Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in Cutting equipment must be connected to the mains supply according to accordance with the information below to achieve electromagnetic the manufacturer’s recommendations.

  • Page 12: Earthing Of The Workpiece

    Electromagnetic Compatibility (EMC) Earthing of the workpiece Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship’s hull or building steel work, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances.

  • Page 13: Warranty

    Hypertherm not in strict conformity herein and as follows: if Hypertherm is notified of a defect (i) with respect with Hypertherm’s specifications and in cases of designs, processes,...

  • Page 14: Liability Cap

    At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products.

  • Page 15: Specifications

    Section 1 Specifications Introduction The Duramax Hyamp torch line includes 45° long handheld torches fitted with either 0.6 m (2 foot) or 1.2 m (4 foot) extensions and 90° long handheld torches fitted with 0.6 m (2 foot), 1.2 m (4 foot), or 1.8 m (6 foot) extensions. The extensions offer increased reach in difficult to access areas.
  • Page 16 1 – Specifications Hypertherm’s FastConnect™ system makes it easy to remove the torch for transport or to switch from one torch to another if your cutting applications require the use of multiple torches. The torches are cooled by ambient air and do not require special cooling procedures.

  • Page 17: Torch Configurations And Weights

    1 – Specifications Torch configurations and weights The Duramax Hyamp long handheld torches ship in one of the configurations shown in Table 1. Table 1 lists each configuration and its corresponding weight.  These weights do not include consumables. Table 1 Torch configuration Weight 45°...

  • Page 18: 45° Duramax Hyamp Long Handheld Torch Dimensions

    45° Duramax Hyamp long handheld torch dimensions 74 cm (29 inches) with 0.6 m extension 145 cm (57 inches) with 1.2 m extension 51 cm (20 inches) with 0.6 m extension 122 cm (48 inches) with 1.2 m extension 8.0 cm 9.6 cm (3.2 inches) (3.8 inches)

  • Page 19: 90° Duramax Hyamp Long Handheld Torch Dimensions

    90° Duramax Hyamp long handheld torch dimensions 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 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 8.0 cm (3.2 inches)
  • Page 20 1 – Specifications Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 21: Torch Setup

    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 the part numbers listed above. Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 22: Consumable Life

    2 – Torch Setup Consumable life How often you need to change the consumables on your torch will depend on a number of factors:  The thickness of the metal being cut.  The average length of the cut.  The air quality (presence of oil, moisture, or other contaminants).

  • Page 23: Long Handheld Torch Components

    2 – Torch Setup Long handheld torch components The Duramax Hyamp 45° and 90° long handheld torches ship without consumables installed. Duramax Hyamp 45° long handheld torch Extension tube, 0.6 m (2 feet) or Consumables Safety trigger 1.2 m (4 feet) Duramax Hyamp 90°...

  • Page 24: Choose The Hand Torch Consumables

    2 – Torch Setup Choose the hand torch consumables Hypertherm includes a starter consumable kit (428099) with your Duramax Hyamp torch. The 45° and 90° long handheld torches use the same consumables. Hand torches use shielded consumables. Therefore, you can drag the torch tip along the metal.

  • Page 25: Maximum Removal Gouging Consumables

    2 – Torch Setup Maximum Removal gouging consumables 420112 220977 420001 220997 220971 Shield Retaining cap Nozzle Swirl ring Electrode FineCut consumables 420152 220977 420151 420159 220971 Shield Retaining cap Nozzle Swirl ring Electrode Install the hand torch consumables WARNING! INSTANT-ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch trigger is activated.
  • Page 26 2 – Torch Setup With the power switch in the OFF (O) position, install the torch consumables as shown. Electrode Swirl ring Nozzle Retaining cap Shield Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 27: Connecting The Torch Lead

    2 – Torch Setup Connecting the torch lead The Powermax systems and torches are equipped with FastConnect, 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.
  • Page 28 2 – Torch Setup Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 29: Operation

    Section 3 Operation Using the hand torch WARNING! INSTANT-ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch trigger is activated. The plasma arc will cut quickly through gloves and skin.  Wear correct and appropriate protective equipment.

  • Page 30: Operate The Safety Trigger

    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. Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 31: Hand Torch Cutting Guidelines

    3 – Operation Hand torch cutting guidelines  Drag the torch tip lightly along the workpiece to maintain a steady cut.  While cutting, make sure that sparks exit from the bottom of the workpiece. The sparks should lag slightly behind the torch as you cut (15 –...

  • Page 32: Start A Cut From The Edge Of The Workpiece

    3 – Operation Start a cut from the edge of the workpiece  The photographs in this section show a regular Duramax hand torch; however, the cutting, piercing, and gouging techniques shown are the same for the Duramax Hyamp long handheld torches.

  • Page 33: Pierce A Workpiece

    3 – Operation Pierce a workpiece 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 including gloves and eye protection.
  • Page 34 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. Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 35: Gouge A Workpiece

    3 – Operation Gouge a workpiece 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 including gloves and eye protection.

  • Page 36: Gouge Profile

    3 – Operation Gouge profile You can vary the gouge profile by varying the:  Speed of the torch over the workpiece  Torch-to-work standoff distance  Angle of the torch to the workpiece  Current output of the power supply Speed Angle Standoff...

  • Page 37: Varying The Gouge Profile

    3 – Operation Varying the gouge profile Follow these recommendations to change the gouge profile as needed:  Increasing the speed of the torch will decrease width and decrease depth.  Decreasing the speed of the torch will increase width and increase depth. ...
  • Page 38 3 – Operation Table 3 – English Standoff Speed Depth Width Width/depth Torch angle (inches) (ipm) (inches) (inches) ratio 0.31 0.33 1.06 0.26 0.30 1.16 0.25 0.22 0.26 1.21 0.17 0.24 1.38 30° 0.30 0.39 1.30 0.24 0.34 1.43 0.40 0.19 0.29 1.50...

  • Page 39: Common Hand-Cutting Faults

    3 – Operation Common hand-cutting faults The torch does not cut completely through the workpiece. The causes can be:  The cut speed is too fast.  The consumables are worn.  The metal being cut is too thick for the selected amperage. ...
  • Page 40 3 – Operation Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 41: Component Replacement

    Section 4 Component Replacement 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: Duramax Hyamp 45° Long Handheld Torch Components

    Duramax Hyamp 45° long handheld torch components 1 Front shell, right side 8 Trigger 15 Front shell, left side 2 Cap-sensor switch 9 Spring 16 Screws for front shell (8) 3 Torch body (torch head plus gas tube) 10 Gas tube fitting’s flange 17 Handle, left side 4 Consumables 11 Start switch...

  • Page 43: Duramax Hyamp 90° Long Handheld Torch Components

    Duramax Hyamp 90° long handheld torch components 1 Front shell, right side 8 Trigger 15 Front shell, left side 2 Cap-sensor switch 9 Spring 16 Screws for front shell (8) 3 Torch body (torch head plus gas tube) 10 Gas tube fitting’s flange 17 Handle, left side 4 Consumables 11 Start switch...

  • Page 44: Disconnect The Power, Gas Supply, And Torch

    4 – Component 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.

  • Page 45: Replace The Handle

    4 – Component Replacement Replace the handle Description 428277 Kit: Duramax Hyamp long handheld torch handle replacement Remove the handle All replacement procedures for the Duramax Hyamp long handheld torches require the removal of the handle that surrounds the trigger. To replace the handle, you need to remove the internal components from the handle. 1.
  • Page 46 4 – Component Replacement 6. While holding the spring in place, slide 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.
  • Page 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.  If you are installing a new handle, apply the “H” label to the right side of the handle and the “Duramax Hyamp”...
  • Page 48 4 – Component Replacement Figure 4 – Wire routing in handle with gas tube and torch lead hidden (top) and shown (bottom) Pilot arc wire (red) Cap-sensor switch wires (blue, orange) Start switch wires (purple) 1 Cap-sensor switch connector 6 Posts for routing the wires 2 Pilot terminal screw 7 Slot for torch lead strain relief 3 Trigger’s pivot hole...
  • Page 49 4 – Component Replacement 5. Line up the right handle with the extension tube. The small ribs in the molding of the handle will rest in the flat square grooves on the extension tube, as shown in Figure 5. 6. Press the extension tube into the torch handle while guiding the gas tube and strain relief into the handle. Keep the wires properly positioned.
  • Page 50 4 – Component Replacement 9. Compress the trigger spring into the front half of the trigger. Slide the trigger and spring into place. Figure 6 10. Make sure the cap-sensor switch connector and the pilot terminal screw (encased in heatshrink) are completely inside the extension tube.

  • Page 51: Replace The Front Shell

    4 – Component Replacement Replace the front shell Description 428278 Kit: Duramax Hyamp 45° long handheld torch front shell replacement 428279 Kit: Duramax Hyamp 90° long handheld torch front shell replacement Remove the front shell Several replacement procedures for the Duramax Hyamp long handheld torches require the removal of the front shell that surrounds the torch head.
  • Page 52 4 – Component Replacement 7. The torch body and extension 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.
  • Page 53 4 – Component Replacement Install the front shell 1. Make sure that the pilot terminal screw on the torch head is tightened to 17.3 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.
  • Page 54 4 – Component Replacement 6. Route the cap-sensor wires as shown in Figure 10.  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 underneath (or behind) the gas tube and below the protective foam that is wrapped around the gas tube.
  • Page 55 4 – Component Replacement 7. Line up the right front shell with the extension tube. The small ribs in the molding of the shell will rest in the flat square grooves on the extension tube, as shown in Figure 11. 8.

  • Page 56: Replace The Trigger Assembly

    4 – Component Replacement Replace the trigger assembly Description 428156 Kit: Duramax Hyamp hand torch trigger replacement (with spring) Remove the trigger assembly 1. Turn OFF (O) the power, disconnect the gas supply, and disconnect the torch. 2. Place the torch on a flat surface with the left handle facing up. ...
  • Page 57 4 – Component Replacement Install the trigger assembly 1. Clamp the torch lead in place, with the white wires facing up, to keep the lead from moving. 2. Compress the new trigger spring into the front half of the new trigger. Slide the trigger and spring into place. Figure 13 3.

  • Page 58: Replace The Start Switch

    4 – Component Replacement Replace the start switch Description 428162 Kit: Duramax Hyamp hand torch start switch replacement Remove the start switch 1. Turn OFF (O) the power, disconnect the gas supply, and disconnect the torch. 2. Place the torch on a flat surface with the left handle facing up. ...
  • Page 59 4 – Component Replacement 6. While holding 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.
  • Page 60 4 – Component Replacement Install the start switch 1. Clamp the torch lead in place, with the white wires facing up, to keep the lead from moving. 2. Connect the new start switch by pushing the mating plug into the socket. 3.
  • Page 61 4 – Component Replacement 5. Verify the gas hose fitting’s flange aligns with the slot in the handle. See Figure 17, above. 6. Verify the strain relief aligns with the strain relief slot in the handle. See Figure 17, above. 7.

  • Page 62: Replace The Torch Body

    4 – Component Replacement Replace the torch body 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) –...
  • Page 63 4 – Component Replacement 5. Carefully cut the heatshrink at the trigger end of the extension tube to reveal the pilot terminal screw and . 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 Start switch Duramax Hyamp Long Handheld Torches Service Manual 808290...
  • Page 64 4 – Component Replacement 7. Use 2 wrenches to loosen the gas fitting that secures the torch body’s gas tube to the torch lead . Separate the torch body from the torch lead. (See Figure 21.)  Heating the gas fitting can help loosen the threadlocker and make removing the torch body easier.
  • Page 65 4 – Component Replacement Install the torch body 1. Use a small strip of electrical tape to temporarily secure the very ends of the pilot arc wire and cap-sensor wires to the gas tube. 2. Slide the extension tube over the torch body and up to the torch head. 3.
  • Page 66 4 – Component Replacement 4. Clamp the torch lead in place, with the white wires facing up, to keep the lead from moving. 5. Remove the tape that you placed over the end of the gas line on the torch lead in step 8 on page 64. 6.
  • Page 67 4 – Component Replacement 10. Cover the pilot terminal screw and nut with the heatshrink included in the kit, as follows: 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 screw. c.
  • Page 68 4 – Component Replacement 12. Connect the start switch by pushing the mating plug into the socket. Figure 26 Start switch Mating plug 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. Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 69: Replace The Pilot Arc Wire

    4 – Component Replacement Replace the pilot arc wire 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: Duramax Hyamp long handheld torch pilot arc wire replacement (with screws), 1.8 m...
  • Page 70 4 – Component Replacement 4. Remove the pilot terminal screw from the torch head. 5. 0.6 m (2 foot) torches: Mark where the foam strip is wrapped around the middle of the torch body’s gas tube so that you can install a new strip in the same place. 1.2 m (4 foot) torches: Mark where the 2 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.
  • Page 71 4 – Component Replacement Install the pilot arc wire 1. Make sure the consumables have been removed from the torch. 2. Locate a new pilot terminal screw, included in the kit. 3. Use the new screw to attach the new pilot arc wire to the torch head. ...
  • Page 72 4 – Component Replacement 6. Press the cap-sensor switch into its post hole and onto its mounting post in the front shell. (See Figure 29.)  Putting the cap-sensor 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.
  • Page 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.  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.

  • Page 74: Replace The Cap-Sensor Switch

    4 – Component Replacement Replace the cap-sensor switch Description 428288 Kit: Duramax Hyamp long handheld torch cap-sensor switch replacement, 0.6 m (2 feet) 428289 Kit: Duramax Hyamp long handheld torch cap-sensor switch replacement, 1.2 m (4 feet) 428822 Kit: Duramax Hyamp long handheld torch cap-sensor switch replacement, 1.8 m (6 feet) Remove the cap-sensor switch 1.
  • Page 75 4 – Component Replacement Install the cap-sensor switch 1. Lay the right side of the front shell on a flat surface with the inside facing up. 2. Clamp the torch lead in place, with the white wires facing up, to keep the lead from moving. 3.
  • Page 76 4 – Component Replacement 7. 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.  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.

  • Page 77: Replace The Extension Tube

    4 – Component Replacement Replace the extension tube Description 428280* Kit: Duramax Hyamp long handheld torch extension tube replacement, 0.6 m (2 feet) 428281* Kit: Duramax Hyamp long handheld torch extension tube replacement, 1.2 m (4 feet) 428820* Kit: Duramax Hyamp long handheld torch extension tube replacement, 1.8 m (6 feet) * The extension tubes cannot be used to convert from one torch length to another torch length .

  • Page 78: Replace The Torch Lead

    4 – Component Replacement Replace the torch lead 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-m (150-foot) torch leads must be used with a Powermax125.
  • Page 79 4 – Component Replacement 5. Carefully cut the heatshrink at the trigger end of the extension tube to reveal the pilot terminal screw and . 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 Start switch Duramax Hyamp Long Handheld Torches Service Manual 808290...
  • Page 80 4 – Component Replacement 7. Use 2 wrenches to loosen the gas fitting that secures the torch body’s gas tube to the torch lead . Separate the torch body assembly from the torch lead. See Figure 35.  Heating the gas fitting can help loosen the threadlocker and make removing the torch body easier.
  • Page 81 4 – Component Replacement Install the torch lead 1. Clean the conical surface of the gas tube fitting 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. ...
  • Page 82 4 – Component Replacement 5. Use 2 wrenches to tighten the gas fitting that secures the torch body to the new torch lead to 69.1 kg∙cm (60 inch∙pounds). 6. Use the pilot terminal screw and nut you removed in step 3 on page 78 to connect the red pilot arc wire from the torch lead with the red pilot arc wire from the torch body.
  • Page 83 4 – Component Replacement 8. 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 39 Mating plug Cap-sensor switch 9.

  • Page 84: Replace The Quick Disconnect Housing

    4 – Component Replacement Replace the quick disconnect housing Description 428260 Kit: Duramax and Duramax Hyamp torch FastConnect replacement Remove the quick disconnect housing 1. Turn OFF (O) the power, disconnect the gas supply, and disconnect the torch. 2. Remove the screws from the bottom half of the shell. (See Figure 41.) 3.
  • Page 85 4 – Component Replacement Install the quick disconnect housing 1. Place the new latch into the quick disconnect housing. 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.
  • Page 86 4 – Component Replacement Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 87: Maintenance And Parts

    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. Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 88: Perform Routine Maintenance Tasks

    5 – Maintenance and Parts Perform routine maintenance tasks Every use: Inspect the consumables for proper installation and wear. Check indicator lights and fault icons. Correct any fault conditions. Every 3 months: Inspect the trigger for damage. Inspect the torch body for cracks and exposed wires.

  • Page 89: Inspect The Consumables

    5 – Maintenance and Parts Inspect the consumables Part Inspect Action The center hole for roundness. Replace the shield if the hole is no longer round. The gap between the shield and the Remove the shield and clean away any nozzle for accumulated debris.

  • Page 90: Basic Troubleshooting

    If you are unable to fix the problem by following this basic troubleshooting guide, or if you need further assistance: 1. Call your Hypertherm distributor or authorized Hypertherm repair facility. 2. Call the nearest Hypertherm office listed in the front of this manual. Table 4 – Troubleshooting guide...
  • Page 91 5 – Maintenance and Parts Duramax Hyamp Long Handheld Torches Service Manual 808290...

  • Page 92: Duramax Hyamp Long Handheld Torch Replacement Parts

    5 – Maintenance and Parts Duramax Hyamp long handheld torch replacement parts The entire Duramax Hyamp long handheld torch assembly with lead can be replaced, or individual component parts can be replaced. Full torch assembly, 45° torch Use the following part numbers to replace the entire Duramax Hyamp 45° long handheld torch assembly. ...

  • Page 93: External Components, 45° Torch

    External components, 45° torch Item Part Number Description 428278 Kit: Duramax Hyamp 45° long handheld torch front shell replacement 428280* Kit: Duramax Hyamp long handheld torch extension tube replacement, 0.6 m (2 feet) 428281* Kit: Duramax Hyamp long handheld torch extension tube replacement, 1.2 m (4 feet) 428286 Kit: Duramax Hyamp long handheld torch auxiliary handle replacement (with screws) 428287...

  • Page 94: Internal Components, 45° Torch

    Internal components, 45° torch The 0.6 m (2 foot) torch body contains 1 foam strip around the middle; the 1.2 m (4 foot) torch body contains 2 foam strips around the middle. Item Part Number Description 428288 Kit: Duramax Hyamp long handheld torch cap-sensor switch replacement, 0.6 m (2 feet) 428289 Kit: Duramax Hyamp long handheld torch cap-sensor switch replacement, 1.2 m (4 feet) 428282...
  • Page 95 Item Part Number 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) 428162 Kit: Duramax Hyamp hand torch start switch replacement 428159 Kit: Duramax and Duramax Hyamp hand torch lead replacement, 7.6 m (25 feet) 428160...

  • Page 96: Full Torch Assembly, 90° Torch

    5 – Maintenance and Parts Full torch assembly, 90° torch Use the following part numbers to replace the entire Duramax Hyamp 90° long handheld torch assembly.  The torch assembly does not include consumables. See Duramax Hyamp hand torch consumables on page 100 for a list of consumable part numbers. Part Number Description 059563...

  • Page 97: External Components, 90° Torch

    External components, 90° torch Item Part Number Description 428279 Kit: Duramax Hyamp 90° long handheld torch front shell replacement 428280* Kit: Duramax Hyamp long handheld torch extension tube replacement, 0.6 m (2 feet) 428281* Kit: Duramax Hyamp long handheld torch extension tube replacement, 1.2 m (4 feet) 428820* Kit: Duramax Hyamp long handheld torch extension tube replacement, 1.8 m (6 feet) 428286...

  • Page 98: Internal Components, 90° Torch

    Internal components, 90° torch The 0.6 m (2 foot) torch body contains 1 foam strip around the middle; the 1.2 m (4 foot) torch body contains 2 foam strips around the middle; the 1.8 m (6 foot) torch body contains 3 foam strips around the middle Item Part Number...
  • Page 99 Item Part Number Description 428162 Kit: Duramax Hyamp hand torch start switch replacement 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-m (150-foot) torch leads must be used with a Powermax125.

  • Page 100: Duramax Hyamp Hand Torch Consumables

    5 – Maintenance and Parts Duramax Hyamp hand torch consumables Drag cutting Part Number Description 420172 Duramax Hyamp shield 45/65 A 420000 Duramax Hyamp shield 105/125 A 220977 Duramax Hyamp retaining cap 420158 Duramax Hyamp nozzle 45 A 420169 Duramax Hyamp nozzle 65 A 220975 Duramax Hyamp nozzle 105/125 A 220971...

  • Page 101: Accessory Parts

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

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