Hypertherm SmartSYNC 059719 Procedure Manual
  1. Manuals
  2. Brands
  3. Hypertherm Manuals
  4. Flashlight
  5. SmartSYNC 059719
  6. Procedure manual
Hypertherm SmartSYNC 059719 Procedure Manual

Hypertherm SmartSYNC 059719 Procedure Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

SmartSYNC™ Torches
Service Parts and Procedures Guide
810460 – REVISION 0
ENGLISH

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SmartSYNC 059719 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Hypertherm SmartSYNC 059719

Summary of Contents for Hypertherm SmartSYNC 059719

  • Page 1 SmartSYNC™ Torches Service Parts and Procedures Guide 810460 – REVISION 0 ENGLISH...
  • Page 2 Powermax, SYNC, SmartSYNC, FastConnect, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and other countries. All other trademarks are the property of their respective holders. Environmental stewardship is one of Hypertherm’s core values. www.hypertherm.com/environment...
  • Page 3 SmartSYNC Torches Service Parts and Procedures Guide 810460 REVISION 0 ENGLISH Original instructions August 2022 Hypertherm, Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 31 165 596901 Fax 31 165 596908 Tel (Marketing) 31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service) technicalservice.emeia@hypertherm.com (Technical Service) For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at www.hypertherm.com/hci.
  • Page 5 Salinan elektronik juga tersedia di situs web kami. Berbagai manual tersedia dalam beberapa bahasa di www.hypertherm.com/docs. DE (DEUTSCH/GERMAN) WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die IT (ITALIANO/ITALIAN) Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla...
  • Page 6 NO (NORSK/NORWEGIAN) SV (SVENSKA/SWEDISH) ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet og efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för Waterjet samsvar (80669C), håndboken om vannjet sikkerhet og samsvar (80943C), (80943C) och varningsmanualen för radiofrekvenser (80945C) för viktig...

  • Page 7: Table Of Contents

    Contents 1 Before You Begin........................11 2 Service Parts ..........................13 Hand torch parts ..............................14 75° and 15° hand torch assemblies ....................14 75° and 15° hand torch exterior parts....................15 75° and 15° hand torch controls ......................16 75°...
  • Page 8 Prevent damage to the RF torch PCB ......................38 Disconnect the power from the cutting system ................... 39 Remove the Hypertherm cartridge ........................39 Put a clamp on the torch lead .......................... 40 Remove the left side of the torch handle or shell ..................41 Get a photograph of the torch .........................
  • Page 9 6 Mini Machine and Robotic Torch Part Replacement Procedures........77 Disassemble the mini machine or robotic torch................... 78 Before you begin ............................. 78 Remove the components from the torch shell.................. 79 Disconnect the torch components...................... 80 Assemble the mini machine or robotic torch ....................82 Connect the torch components......................
  • Page 10 810460 Service Parts and Procedures SmartSYNC...

  • Page 11: Before You Begin

    1. Get the serial number for your torch from the data plate that is on the torch. 2. Contact your Hypertherm distributor or authorized repair facility. 3. Contact the nearest Hypertherm office shown in the front of this manual. For related information, refer to the following documents: Powermax65/85/105 SYNC Troubleshooting Guide (810430) ...
  • Page 12 Before You Begin 810460 Service Parts and Procedures SmartSYNC...

  • Page 13: Service Parts

    Service Parts Genuine Hypertherm parts are factory-recommended parts for your Hypertherm system. Any damage caused by the use of parts that are not from Hypertherm may not be covered by the Hypertherm warranty. Hypertherm recommends that service centers keep all of these parts available for repairs because these parts are parts necessary for safety or are usually exposed to continuous wear.

  • Page 14: Hand Torch Parts

    Service Parts Hand torch parts 75° and 15° hand torch assemblies Item Part number Description 059726 75° hand torch assembly with 7.6 m (25 foot) lead* 059727 75° hand torch assembly with 15 m (50 foot) lead* 059728 75° hand torch assembly with 23 m (75 foot) lead* 059723 15°...

  • Page 15: 75° And 15° Hand Torch Exterior Parts

    Service Parts 75° and 15° hand torch exterior parts Part Item Description and kit contents number 428856 Kit: Handle for 75° hand torch 101453 Handle for 75° hand torch 075714 Screws for torch handle* (7) 428855 Kit: Handle for 15° hand torch 101452 Handle for 15°...

  • Page 16: 75° And 15° Hand Torch Controls

    Service Parts 75° and 15° hand torch controls Part Item Description and kit contents number 428873 Kit: Amperage-adjustment control for 75° or 15° hand torch 229847 Amperage-adjustment control for 75° or 15° hand torch 428871 Kit: Torch-lock slider for 75° or 15° hand torch 229846 Torch-lock slider for 75°...

  • Page 17: 75° And 15° Hand Torch Body And O-Ring

    Service Parts 75° and 15° hand torch body and O-ring Part Item Description and kit contents number 528066 Kit: Torch contact ring (for torch head) 420931 Torch contact ring (2) 428950 Kit: O-rings for torch body 058021 O-ring for any torch (5) SmartSYNC 428858...

  • Page 18: 75° And 15° Hand Torch Lead And Terminal Screw

    Service Parts 75° and 15° hand torch lead and terminal screw Part Item Description and kit contents number 075903 Terminal screw (1/4 inch) for pilot arc wire 428852 Kit: Lead for hand torch, 7.6 m (25 foot) 428853 Kit: Lead for hand torch, 15 m (50 foot) 428854 Kit: Lead for hand torch, 23 m (75 foot) 229849...

  • Page 19: 75° And 15° Hand Torch Switches And Pcb

    Service Parts 75° and 15° hand torch switches and PCB Part Item Description and kit contents number 428958 Kit: Start switch 005684 Start switch for hand torch 428869 Kit: Radio-frequency (RF) torch PCB for hand torch 141463 RF torch PCB for hand torch 428877 Kit: Clip for RF wires 104912...

  • Page 20: Full-Length Machine Torch Parts

    Service Parts Full-length machine torch parts Full-length machine torch assemblies Part Item Description number 059719 Full-length machine torch assembly with 7.6 m (25 foot) lead* 059720 Full-length machine torch assembly with 10.7 m (35 foot) lead* 059721 Full-length machine torch assembly with 15 m (50 foot) lead* 059722 Full-length machine torch assembly with 23 m (75 foot) lead* * The torch assembly does not include a cartridge.

  • Page 21: Full-Length Machine Torch Exterior Parts

    Service Parts Full-length machine torch exterior parts Part Item Description and kit contents number 428874 Kit: Shell for full-length machine torch* 101457 Shell for full-length machine torch 075714 Screws for shell** (7) 075418 Screws for gear rack (2) 428863 Kit: Quick-disconnect shell (shell with button – does not include torch lead or connector) 420565 Shell for torch quick-disconnect 220681...

  • Page 22: Full-Length Machine Torch Body And O-Ring

    Service Parts Full-length machine torch body and O-ring Item Part number Description and kit contents 528066 Kit: Torch contact ring for torch head 420931 Torch contact ring (2) 428950 Kit: O-rings for torch body 058021 O-ring for any torch (5) SmartSYNC 428859 Kit: Body for full-length machine torch...

  • Page 23: Full-Length Machine Torch Switches And Pcb

    Service Parts Full-length machine torch switches and PCB Item Part number Description and kit contents 428866 Kit: Cap-sensor switch for full-length machine torch 005711 Cap-sensor switch for full-length machine torch 428870 Kit: RF torch PCB for full-length, mini machine, or robotic torch 141466 RF torch PCB for full-length, mini machine, or robotic torch 428868...

  • Page 24: Full-Length Machine Torch Lead And Terminal Screw

    Service Parts Full-length machine torch lead and terminal screw Item Part number Description and kit contents 075903 Terminal screw (1/4 inch) for pilot arc wire 428848 Kit: Lead for full-length machine torch, 7.6 m (25 foot) 428849 Kit: Lead for full-length machine torch, 10.7 m (35 foot) 428850 Kit: Lead for full-length machine torch, 15 m (50 foot) 428851...

  • Page 25: Mini Machine And 180° Robotic Torch Parts

    Service Parts Mini machine and 180° robotic torch parts Mini machine and 180° robotic torch assemblies Item Part number Description 059733 Mini machine and 180° robotic torch assembly with 4.6 m (15 foot) lead* 059734 Mini machine and 180° robotic torch assembly with 7.6 m (25 foot) lead* 059735 Mini machine and 180°...

  • Page 26: Mini Machine And 180° Robotic Torch Exterior Parts

    Service Parts Mini machine and 180° robotic torch exterior parts Item Part number Description and kit contents 428896 Kit: Shell for mini machine and180° robotic torch 101458 Shell for mini machine and180° robotic torch 075714 Screws for shell* (5) 428863 Kit: Quick-disconnect shell (shell with button –...

  • Page 27: Mini Machine And 180° Robotic Torch Lead And Terminal Screw

    Service Parts Mini machine and 180° robotic torch lead and terminal screw Item Part number Description and kit contents 075903 Terminal screw (1/4 inch) for pilot arc wire 428901 Kit: Lead for mini machine and robotic torch, 4.6 m (15 foot) 428900 Kit: Lead for mini machine and robotic torch, 7.6 m (25 foot) 428903...

  • Page 28: Mini Machine And 180° Robotic Switch And Pcb

    Service Parts Mini machine and 180° robotic switch and PCB Item Part number Description 428867 Kit: Cap-sensor switch for mini machine and180° robotic torch 005723 Cap-sensor switch for mini machine and180° robotic torch 428870 Kit: RF torch PCB for full-length, mini machine, or robotic torch 141466 RF torch PCB for full-length, mini machine, or robotic torch 428899...

  • Page 29: Mini Machine And 180° Robotic Torch Body And O-Ring

    Service Parts Mini machine and 180° robotic torch body and O-ring Item Part number Description 528066 Kit: Torch contact ring (for torch head) 420931 Torch contact ring (2) 428950 Kit: O-rings for torch body 058021 O-ring for any torch (5) SmartSYNC 428860 Kit: Body for mini machine and180°...

  • Page 30: 90° And 45° Robotic Torch Parts

    Service Parts 90° and 45° robotic torch parts 90° and 45° robotic torch assemblies Item Part number Description 059731 90° robotic torch assembly with 7.6 m (25 foot) lead* 059732 90° robotic torch assembly with 15 m (50 foot) lead* 059767 90°...

  • Page 31: 90° And 45° Robotic Torch Exterior Parts

    Service Parts 90° and 45° robotic torch exterior parts Item Part number Description and kit contents 428898 Kit: Shell for 90° robotic torch 101481 Shell for 90° robotic torch 075714 Screws for shell* (5) 428897 Kit: Shell for 45° robotic torch 101480 Shell for 45°...

  • Page 32: 90° And 45° Robotic Torch Lead And Terminal Screw

    Service Parts 90° and 45° robotic torch lead and terminal screw Item Part number Description and kit contents 075903 Terminal screw (1/4 inch) for pilot arc wire 428900 Kit: Lead for mini machine and robotic torch, 7.6 m (25 foot) 428903 Kit: Lead for mini machine and robotic torch,15 m (50 foot) 428904...

  • Page 33: 90° And 45° Robotic Switch And Pcb

    Service Parts 90° and 45° robotic switch and PCB Item Part number Description 428867 Kit: Cap-sensor switch for mini machine or robotic torch 005723 Cap-sensor switch for mini machine or robotic torch 428870 Kit: Torch RF PCB for full-length, mini machine, or robotic torch 141466 RF torch PCB for full-length, mini machine, or robotic torch 428899...

  • Page 34: 90° And 45° Robotic Torch Body And O-Ring

    Service Parts 90° and 45° robotic torch body and O-ring Item Part number Description 528066 Kit: Torch contact ring (for torch head) 420931 Torch contact ring (2) 428950 Kit: O-rings for torch body 058021 O-ring for any torch (5) SmartSYNC 428862 Kit: Body for 90°...

  • Page 35: Find Torch Replacement Parts By Part Number

    Find torch replacement parts by part number Use this list to find the page number for a part number in Service Parts on page 13. Part number ....................Page 059719......................20 059720......................20 059721......................20 059722......................20 059723......................14 059724......................14 059725......................14 059726......................14 059727......................14 059728......................14 059729......................30 059730......................30 059731......................30 059732......................30...
  • Page 36 428861......................34 428862......................34 428863..................15, 21, 26, 31 428864......................19 428865......................19 428866......................23 428867.....................28, 33 428868......................23 428869......................19 428870..................... 23, 28, 33 428871......................16 428872......................23 428873......................16 428874......................21 428877..................19, 23, 28, 33 428896......................26 428897......................31 428898......................31 428899.....................28, 33 428900.....................27, 32 428901......................27 428903.....................27, 32 428904......................32 428950..................17, 22, 29, 34 428958......................19 528066..................

  • Page 37: Prepare To Do The Part Replacement

    Prepare to Do the Part Replacement These steps must be completed before you start installing a replacement part. Get the replacement part kit Do one of the following: If you already have the kit, continue with this section.  If you need to order the kit, refer to Service Parts on page 13.

  • Page 38: Prevent Injury To Yourself And Others

    Prepare to Do the Part Replacement Prevent injury to yourself and others The following precautions apply to all of the procedures in this manual. WARNING ELECTRIC SHOCK CAN KILL Disconnect electric power before doing installation or maintenance. You can get a serious electric shock if electric power is not disconnected. Electric shock can seriously injure or kill you.

  • Page 39: Disconnect The Power From The Cutting System

    2. Set the power switch on the plasma power supply to OFF (O). 3. Disconnect the power cord from the power source. 4. Disconnect the gas supply. Remove the Hypertherm cartridge To prevent damage to the cap-sensor switch, always remove the cartridge before you start any replacement procedure.

  • Page 40: Put A Clamp On The Torch Lead

    Prepare to Do the Part Replacement Put a clamp on the torch lead 1. Put the torch on a flat surface so that the left side of the torch handle or shell points up. The left side of the torch handle is the side with the screws. 2.

  • Page 41: Remove The Left Side Of The Torch Handle Or Shell

    Prepare to Do the Part Replacement Remove the left side of the torch handle or shell 1. Remove the screws from the torch handle. 2. Lift the left side of the torch handle away from the torch. For a hand torch, do not let the trigger spring eject from the torch handle.
  • Page 42 Prepare to Do the Part Replacement 810460 Service Parts and Procedures SmartSYNC...

  • Page 43: Hand Torch Part Replacement Procedures

    Hand Torch Part Replacement Procedures Figure 3 – 15° and 75° hand torch components This example shows a 15° torch. The components are the same for the 75° torch. 75° torch 1 Amperage-adjustment control 7 Radio-frequency (RF) wire and clip 2 Trigger and trigger spring 8 RF torch PCB 3 Torch lead...

  • Page 44: Disassemble The Hand Torch

    Prepare to Do the Part Replacement on page 37: Disconnect the power from the cutting system on page 39. Remove the Hypertherm cartridge on page 39. Put a clamp on the torch lead on page 40. Remove the left side of the torch handle or shell on page 41.
  • Page 45 Hand Torch Part Replacement Procedures 2. Keep the trigger spring compressed with your finger while you remove the trigger and spring from the right side of the torch handle. Do not let the trigger spring eject from the torch handle. 3.

  • Page 46: Disconnect The Torch Components

    Hand Torch Part Replacement Procedures 7. Push the metal lever against the start switch, and then lift the start switch off of the mounting posts. 8. Pull the cap-sensor switch off of the cap-sensor switch mounting stud. 75° hand torch 15°...
  • Page 47 Hand Torch Part Replacement Procedures 3. Remove the wires from the 2-pin receptacles on the RF torch PCB. One wire at a time, push the lever on the 2-pin wire receptacle while you pull the wire straight out of the receptacle. It can be necessary to use some force, or push the wire into the receptacle before you pull it out.
  • Page 48 6. Use a 1/2-inch wrench and a 5/8-inch wrench to disconnect the gas fitting. The gas fitting is assembled in the factory using thread locker. Hypertherm recommends that you use some heat to loosen the gas fitting. Do not overheat the torch wires.

  • Page 49: Assemble The Hand Torch

    Hand Torch Part Replacement Procedures Assemble the hand torch This procedure shows how to fully assemble the torch. This includes installation of all of the torch components into the right side of the torch handle, and how to connect all of the wires. It is not always necessary to fully disassemble the torch to the do the part replacement procedure.
  • Page 50 Hand Torch Part Replacement Procedures d. Make sure that the white wires of the torch lead point up. 1 Flat sides of the torch body 2 White wires e. Use a 1/2-inch wrench and a 5/8-inch wrench to tighten the gas fitting. Tighten to 6.78 N∙m (60 lbf∙in).
  • Page 51 Hand Torch Part Replacement Procedures 3. Install the pilot terminal screw as follows: a. Make sure that the routing of the pilot arc wire is correct. b. Align the ring terminal of the pilot arc wire with the slot in the torch body. c.

  • Page 52: Install The Torch Components Into The Torch Handle

    Hand Torch Part Replacement Procedures 6. Push the start-switch wire connector into the start switch until you hear a click. Install the torch components into the torch handle 1. Put the cap-sensor switch onto the cap-sensor mounting stud in the right side of the torch handle.
  • Page 53 Hand Torch Part Replacement Procedures 2. Push the metal lever against the start switch, and then push the start switch onto the mounting studs in the torch handle. 3. Align the RF torch PCB with the PCB mounting posts in the right side of the torch handle, and push the PCB loosely into the torch handle.
  • Page 54 Hand Torch Part Replacement Procedures 4. Push the pilot arc wire and start-switch wires into the torch handle. Make sure that the routing of the wires is correct, as shown. Bend the wires as necessary, and use the wire routing studs. 1 Pilot arc wire 2 Start-switch wires 5.
  • Page 55 Hand Torch Part Replacement Procedures 8. Push the RF torch PCB and cap-sensor wires into the torch handle. Make sure that the RF torch PCB wires go around the screw boss. 9. Use the wire routing studs to make sure that the routing of all of the wires is correct, as shown. 1 RF torch PCB wires 4 Pilot arc wire 2 Screw boss...
  • Page 56 Hand Torch Part Replacement Procedures 13. Put the RF wire through the routing post and into the slot in the RF wire clip. 75° hand torch 15° hand torch 1 RF wire 3 2 mounting studs 2 RF wire clip 4 Routing post 14.
  • Page 57 Hand Torch Part Replacement Procedures 16. Put the amperage-adjustment control into the torch handle. a. Put the 2 tabs of the amperage-adjustment control into the 2 recesses in the torch handle. b. Align the switch recess on the amperage-adjustment control with the amperage-adjustment switch on the RF torch PCB.

  • Page 58: Do A Check Of The Component Positions And Wire Routing

    Hand Torch Part Replacement Procedures Do a check of the component positions and wire routing 1. Make sure that all of the torch components are in the correct positions in the right side of the torch handle. Compare the appearance of the torch components with the photograph you got page 41, or with Figure...
  • Page 59 Hand Torch Part Replacement Procedures Figure 8 – Wire routing in correct positions 75° hand torch 15° hand torch 4 Start switch wires 1 RF torch PCB wires 2 Cap-sensor switch wires 5 RF wires 3 Pilot arc wire SmartSYNC Service Parts and Procedures 810460...

  • Page 60: Install The Left Side Of The Torch Handle

    Hand Torch Part Replacement Procedures Install the left side of the torch handle Do not cause damage to the wires inside the torch as you install the left side of the torch handle. 1. Align the left side of the torch handle with the right side of the torch handle. Push the left side of the torch handle onto the torch at the torch body end of the torch.
  • Page 61 Hand Torch Part Replacement Procedures 3. Attach the left side of the torch handle to the right side of the torch handle with the 7 screws. Install the screws in the following sequence: a. The middle of the torch. b. The torch-body end of the torch. c.
  • Page 62 Hand Torch Part Replacement Procedures 810460 Service Parts and Procedures SmartSYNC...

  • Page 63: Full-Length Machine Torch Part Replacement Procedures

    Full-Length Machine Torch Part Replacement Procedures Figure 9 – Full-length machine torch components 1 Torch lead 6 Switch assembly for torch-lock slider 2 Torch body 7 RF wires and clip 3 Radio-frequency (RF) torch PCB 8 RF torch PCB wires and connector 4 Cap-sensor switch 9 Pilot terminal screw 5 Torch-lock slider...

  • Page 64: Disassemble The Full-Length Machine Torch

    Prepare to Do the Part Replacement on page 37: Disconnect the power from the cutting system on page 39. Remove the Hypertherm cartridge on page 39. Put a clamp on the torch lead on page 40. Remove the left side of the torch handle or shell on page 41.
  • Page 65 Full-Length Machine Torch Part Replacement Procedures 3. Lift the RF wire out of the RF wire routing post and the RF wire clip. 4. Remove the RF wire clip. 5. Pull the cap-sensor switch off of the cap-sensor switch mounting stud. 6.

  • Page 66: Disconnect The Torch Components

    Full-Length Machine Torch Part Replacement Procedures Disconnect the torch components 1. Remove the 6-wire connector from the receptacle on the RF torch PCB. Do not pull the wires. Refer to Figure 10 on page 66 for location. 2. Remove the wires from the 2-pin receptacles on the RF torch PCB. One wire at a time, push the lever on the 2-pin wire receptacle while you pull the wire straight out of the receptacle.
  • Page 67 Full-Length Machine Torch Part Replacement Procedures 5. Remove the pilot terminal screw. 6. Use a 1/4-inch wrench and a 3/8-inch wrench to disconnect the gas fitting. Do not strip the gas fitting. 3/8 inch 1/4 inch To prevent damage to the torch, always use 2 wrenches to loosen or tighten the gas fitting. SmartSYNC Service Parts and Procedures 810460...

  • Page 68: Assemble The Machine Torch

    Full-Length Machine Torch Part Replacement Procedures Assemble the machine torch This procedure shows how to fully assemble the torch. This includes installation of all of the torch components into the right side of the torch shell, and how to connect all of the wires. It is not always necessary to fully disassemble the torch to the do the part replacement procedure.
  • Page 69 Full-Length Machine Torch Part Replacement Procedures e. Use a 1/4-inch wrench and a 3/8-inch wrench to tighten the gas fitting to 6.78 N∙m (60 lbf∙in). Make sure that the torch body and torch lead stay aligned. Do not tighten too much.
  • Page 70 Full-Length Machine Torch Part Replacement Procedures 3. Install the torch-lock switch connector into the receptacle. Put the blue and black torch-lock switch wires into the notch in the RF torch PCB. Refer to Figure 11 on page 70 for location. 4.

  • Page 71: Install Torch Components Into The Torch Shell

    Full-Length Machine Torch Part Replacement Procedures Install torch components into the torch shell 1. Put the torch-lock switch onto the stud in the right side of the torch shell. 2. Put the cap-sensor switch onto the cap-sensor mounting stud in the right side of the torch shell. Keep the cap-sensor switch flat in relation to the torch shell.
  • Page 72 Full-Length Machine Torch Part Replacement Procedures 9. Make sure that the routing of all the wires is correct, as shown. 1 RF torch PCB wires 3 Pilot arc wire 2 Cap-sensor wires 4 Torch-lock switch wires 10. Push the torch body fully into the torch shell. 11.
  • Page 73 Full-Length Machine Torch Part Replacement Procedures 13. Push the RF wire clip onto the torch body. Make sure that the RF wire clip points up. 14. Put the RF wire through the routing post and into the slot in the RF wire clip. 1 RF wire 3 Routing post 2 RF wire clip...

  • Page 74: Do A Check Of The Component Positions And Wire Routing

    Full-Length Machine Torch Part Replacement Procedures Do a check of the component positions and wire routing 1. Make sure that all of the torch components are in the correct positions in the right side of the torch shell. Compare the appearance of the torch components with the photograph you got on page 41, or with Figure 12...

  • Page 75: Install The Left Side Of The Torch Shell

    Full-Length Machine Torch Part Replacement Procedures Install the left side of the torch shell Do not cause damage to the wires inside the torch as you install the left side of the torch shell. 1. Align the left side of the torch shell with the right side of the torch shell. Push the left side of the torch shell onto the torch at the torch-body end of the torch.
  • Page 76 Full-Length Machine Torch Part Replacement Procedures 3. Attach the left side of the torch shell to the right side of the torch shell with the 7 screws. Install the screws in the following sequence: a. The middle of the torch. b.

  • Page 77: Mini Machine And Robotic Torch Part Replacement Procedures

    Mini Machine and Robotic Torch Part Replacement Procedures Figure 14 – Mini machine / 180° robotic torch components 1 Torch lead 5 RF wires and clip 2 Torch body 6 RF torch PCB wires and connector 3 Radio-frequency (RF) torch PCB 7 Pilot terminal screw 4 Cap-sensor switch 8 Gas fitting...

  • Page 78: Disassemble The Mini Machine Or Robotic Torch

    Prepare to Do the Part Replacement on page 37: Disconnect the power from the cutting system on page 39. Remove the Hypertherm cartridge on page 39. Put a clamp on the torch lead on page 40. Remove the left side of the torch handle or shell on page 41.

  • Page 79: Remove The Components From The Torch Shell

    Mini Machine and Robotic Torch Part Replacement Procedures Remove the components from the torch shell 1. Carefully lift the torch lead, body, PCB, and attached wires from the right side of the torch shell. Use a screwdriver as a lever under the torch body to help you remove the torch body. Do not bend the gas tube or torch lead.

  • Page 80: Disconnect The Torch Components

    Mini Machine and Robotic Torch Part Replacement Procedures Disconnect the torch components 1. Remove the 6-wire connector from the receptacle on the RF torch PCB. Do not pull on the wires. Refer to Figure 16 on page 80 for location. 2.
  • Page 81 Mini Machine and Robotic Torch Part Replacement Procedures 5. Remove the pilot terminal screw. 6. Use a 1/2-inch wrench and a 5/8-inch wrench to disconnect the gas fitting. Do not strip the gas fitting. 5/8 inch 1/2 inch 5/8 inch 1/2 inch To prevent damage to the torch, always use 2 wrenches to loosen or tighten the gas fitting.

  • Page 82: Assemble The Mini Machine Or Robotic Torch

    Mini Machine and Robotic Torch Part Replacement Procedures Assemble the mini machine or robotic torch This procedure shows how to fully assemble the torch. This includes installation of all of the torch components into the right side of the torch shell, and how to connect all of the wires. It is not always necessary to fully disassemble the torch to the do the part replacement procedure.
  • Page 83 Mini Machine and Robotic Torch Part Replacement Procedures c. Make sure that the flat sides of the torch body point up and that the RF wire is in the correct position as shown. d. Make sure that the white wires of the torch lead are on the opposite side from the RF torch PCB and that the RF torch PCB wires point to the PCB.
  • Page 84 Mini Machine and Robotic Torch Part Replacement Procedures e. Use a 1/2-inch wrench and a 5/8-inch wrench to tighten the gas fitting. Tighten to 6.78 N∙m (60 lbf∙in). Make sure that the torch body and torch lead stay aligned. Do not tighten too much.
  • Page 85 Mini Machine and Robotic Torch Part Replacement Procedures 2. Install the pilot terminal screw as follows: a. Make sure that the routing of the pilot arc wire is correct. b. Align the ring terminal of the pilot arc wire with the slot in the torch body. c.

  • Page 86: Install The Torch Components Into The Torch Shell

    Mini Machine and Robotic Torch Part Replacement Procedures Install the torch components into the torch shell 1. Put the cap-sensor switch onto the cap-sensor mounting stud in the right side of the torch shell. Keep the cap-sensor switch flat in relation to the torch shell. Mini machine / 180°...
  • Page 87 Mini Machine and Robotic Torch Part Replacement Procedures 7. Make sure that the routing of all the wires is correct, as shown. Mini machine / 180° robotic torch 45° robotic torch 1 RF torch PCB wires 3 Pilot arc wire 2 Cap-sensor wires 8.
  • Page 88 Mini Machine and Robotic Torch Part Replacement Procedures 10. Push the RF wire clip onto the torch body. Make sure that the RF wire clip points up. 11. Put the RF wire through the routing post and into the slot in the RF wire clip. Mini machine / 180°...

  • Page 89: Do A Check Of The Component Positions And Wire Routing

    Mini Machine and Robotic Torch Part Replacement Procedures Do a check of the component positions and wire routing 1. Make sure that all of the torch components are in the correct positions in the right side of the torch shell. Compare the appearance of the torch components with the photograph you got on page 41, or with Figure...
  • Page 90 Mini Machine and Robotic Torch Part Replacement Procedures Figure 21 – Wire routing in correct positions Mini machine / 180° robotic torch 45° robotic torch Mini machine / 180° robotic torch 90° robotic torch 45° robotic torch 1 RF torch PCB wires 3 Pilot arc wire 2 Cap-sensor switch wires 4 RF wires...

  • Page 91: Install The Left Side Of The Torch Shell

    Mini Machine and Robotic Torch Part Replacement Procedures Install the left side of the torch shell Do not cause damage to the wires inside the torch as you install the left side of the torch shell. 1. Align the left side of the torch shell with the right side of the torch shell. Push the left side of the torch shell onto the torch at the torch body end of the torch.
  • Page 92 Mini Machine and Robotic Torch Part Replacement Procedures 4. Tighten the screw in the middle of the torch shell again. 1 Middle of the torch 3 Lead-end of the torch 2 Torch-body end of the torch 4 Middle of the torch 5.

  • Page 93: Torch Lead Replacement Procedures

    Torch Lead Replacement Procedures Replace the torch quick-disconnect shell Before you begin Complete the following procedures: Disconnect the power from the cutting system on page 39. 2. Disconnect the torch (page 95). Put a clamp on the torch lead on page 40. Remove the torch quick-disconnect shell 1.

  • Page 94: Install The Torch Quick-Disconnect Shell

    Torch Lead Replacement Procedures 3. Remove the latch with the red button from the torch quick-disconnect housing: a. Push and hold the red button. b. Use a blade screwdriver to push on the latch tab while you pull the latch out of the torch quick-disconnect housing.

  • Page 95: Replace The Torch Assembly With Lead

    Torch Lead Replacement Procedures 5. Make sure that the strain relief fits in the slot of the shell and the wires are not pinched and do not cause interference with the latch. 6. Install the 4 screws to attach the torch quick-disconnect shell. 7.
  • Page 96 Torch Lead Replacement Procedures 810460 Service Parts and Procedures SmartSYNC...

  • Page 97: Do A Check Of The Torch Assembly

    Do a Check of the Torch Assembly Do a check of the following components to make sure that the torch is assembled correctly: 1. Torch-lock switch: Unlock the torch. You must hear a click. 2. Trigger: Pull the trigger. You must hear a click. 3.
  • Page 98 Do a Check of the Torch Assembly 810460 Service Parts and Procedures SmartSYNC...

This manual is also suitable for:

Smartsync 059720Smartsync 059721Smartsync 059722Smartsync 059723Smartsync 059724Smartsync 059725 ... Show all

Table of Contents