Removing Cover/Handle; Torch Head Assembly Replacement - Firepower FP-18 Service Manual

• For instructions on replacing the torch & leads, work
cable & clamp, and input power cable, refer to Oper-
ating Manual 0-2691. (Refer to Appendix I, in this
manual, for leads connection diagram.)
• Most replacement hardware can be purchased locally.
• One of two harnesses has been used in this unit. For
units which are rev "C" or earlier, refer to the sche-
matic in Appendix II. For units which are rev "D" or
later, refer to the schematic in Appendix III. Check
the data tag on your unit for the rev level of your unit
and follow instructions in this section where aplicable,
as they pertain to your unit.
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.

4.2 Removing Cover/Handle

1. Remove 2 screws in handle, 2 screws in end pan-
els, and four screws near base to remove cover and
handle from unit.
NOTE
When replacing cover, make sure all wires are care-
fully positioned so that the wires are not pinched
when the cover and handle are secured.
4.3 Torch Head Assembly
Replacement
Disconnect primary power to the system before dis-
assembling the torch or power supply.
Torch parts may get quite hot during normal op-
eration. Always wear light cutting gloves when
changing torch parts just after operating the FP-
18 System.
To Remove Torch Head Assembly:
NOTE
Refer to Figure 4-1 for parts identification.
1. Remove consumable parts from front end of torch.
2. Remove six screws from torch handle assembly (A).
3. Remove both torch handle halves from the torch
and leads assembly , then complete the following:
Service Manual 0-2692
WARNINGS
WARNINGS
a. Disconnect positive pilot lead connection at
torch head by removing pilot lead screw (B).
b. Cut tie wrap from torch hose (C).
c. Using X-acto knife or other small cutting tool,
cut torch lead 1" (2.54 cm) from the end of black
sleeve (D) to reveal butt splice.
4. Pull torch head away from torch lead to expose 1/
2"-3/4" of cable.
5. Clamp down with vise grips on black sleeve of
lead so that cable cannot spring back into lead (E).
6. Cut cable at end of butt splice and remove torch
head assembly (F).
7. Remove orange insulating sleeving from torch head
gas input (G). Note: Sleeving is optional. Some
torch assemblies may not have sleeving.
8. Remove torch O-ring from torch split holder (H).
9. Remove the two screws from the torch head split
holder and separate the halves (I).
10. Remove the torch head from the holder. Do not
disturb PIP connections.
Cut Tie Wrap
C
Washer
B
Remove Pilot
Lead Screw
Remove Screws
H
I
O-Ring
Orange Torch
Sleeving
(Optional)
Figure 4-1 Removing Torch HeadAssembly
13
Remove Six Screws
A
Switch
Cut Black
Hose
1.000
D
Place Vise
Grips Here
E
Cut Cable Here
F
A-02295
G
Firepower FP-18 Plasma Cutter