MAINTENANCE
3-34
Service Manual
PAC121MS TORCH PARTS REMOVAL AND REPLACEMENT
Repair of the PAC121MS machine torch normally requires replacement of the torch main body and/or
the torch lead. Order the torch main body with switch. Refer to Figure 3-9 and perform the steps
below. See page 4-11 for a complete torch parts list.
Removal
1. Set the Powermax800 power switch to O (off), unplug the power cable, and
disconnect the gas supply. Disconnect the torch lead quick disconnect from the
power supply.
2. Unscrew the retaining cap and remove the remaining parts (nozzle, electrode and swirl ring).
3. Remove the O-ring from the torch main body.
4. Remove the three screws securing the torch sleeve to the torch main body.
5. Unscrew the torch position sleeve from the torch sleeve and slide it back out of the way.
6. Remove the screw securing the red wires from the torch lead to the torch main body.
Note for steps 7 and 8: Disconnect wires by pulling on terminals. Do not pull on wires.
7. Disconnect the two lead terminals (four white wires in each terminal) from the two black
plunger wire terminals of the torch main body.
8. Disconnect the two lead terminals (blue wire in each terminal) from the two white wires of the
cap sensor microswitch.
9. Disconnect the torch main body and torch lead gas fitting using the 5/16" (8 mm) and 7/16"
(11 mm) open-end wrenches.
Replacement
1. Remove the O-ring from the replacement torch main body.
Caution: Use caution when removing the O-ring, it can easily be damaged.
2. Connect the torch main body to the torch lead gas fitting using open-end wrenches.
3. Connect the two lead terminals (blue wire in each terminal) to the two white wires of the cap
sensor microswitch.
4. Connect the two lead terminals (four white wires in each terminal) to the two black plunger
wires of the torch main body.
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