INSTRUCTIONS for
RETROFITTING PT-25 TORCH
TO PCM-100/PCM-150 POWER SOURCES
F-15-278
January, 1996
KIT P/N 21932
The PT-25 Retrofit Kit, P/N 21932, includes the following components:
1 - Pressure Switch Assembly, P/N 21933
1 - Bulkhead Adaptor, B/I-GF x 1/4 NPTM, P/N 58V58
1 - Male Spade Terminal
1 - Union Tube
2 - Ty-Wrap, large
5 - Ty-Wrap, medium
4-ft. - T ubing, 5/32" O.D.
Be sure to shut off primary power to the power
source before installing the kit.
Tools Required:
1 1/32" Nut Driver
Stubby Phillips or Square Driver
8" Adjustable Wrench
12" Adjustable Wrench
Bench Vise
Wire Cutters
Terminal Crimping Tool
INSTALLATION
Remove top and side panels from the PCM-100 or PCM150 and proceed as follows:
1. Using the 8" adjustable wrench, loosen and remove
the gas hose fitting from the elbow fitting attached
to the back of the bulkhead “POS” torch fitting. See
Fig. 1. Move the hose and its captive fitting out of
the way .
2. Using the 11/32" nut driver, remove the nut on the
inside screw of the “POS” bulkhead fitting. Slip the
two black leads and one yellow lead from the screw
where the nut was attached.
3. Using the stubby Phillips or square driver and working within the torch connection compartment, (see
Fig. 1), remove the two screws holding the “POS”
bulkhead fitting in place and slide the fitting backwards to remove it from the power source.
4. Place the bulkhead fitting in the bench vise and remove the straight union fitting from the bulkhead fitting using the 12" adjustable wrench, leaving the
threaded elbow fitting in place.
5. Install the new fitting (P/N 58V58) in place of the
original fitting by reversing steps 1 through 4. Make
sure to get all the gas hose fitting connections tight
and free of leaks.
6. Place the torch safety pressure switch (TSPS) assembly from the retrofit kit onto the right side panel
support bracket with the switch leads facing the front
of the power source and the hose connection facing
the rear. See Fig. 2.
7. Remove the gray lead from the cooling gas pressure switch (CGPS) and place red lead of the TSPS
in its place. See Fig. 3.
8. Cut the fork terminal from the gray CGPS lead and
crimp the male spade terminal (950904) in its place.
9. Connect the male spade terminal on the gray lead
of the CGPS to the female spade terminal on the
black lead of the TSPS.
10. Secure the TSPS to the side panel support bracket
with the 6" wire tie supplied in the kit. Secure the
switch leads to the wire harness using a 4 1/2" wire
tie.
11. Push one end of the plastic tubing from the kit into
the tube fitting on the TSPS. Route the tubing along
the two larger tubes which run from the gas solenoid valves to the torch connections at the front of
the power source.
12. Push the free end of the tubing through one of the
small holes in the sheet metal which forms the torch
connection chamber. Push the tubing into one end
of the union fitting from the kit. (See Fig. 1)
13. Secure the small diameter safety tube just installed
to the two larger gas tubes using the 4 1/2" wire ties
supplied in the kit. See Fig. 2.
14. Reassemble the power source side panels and top.
The power source is now ready to accept the PT-25
torch. Keep this document together with your
power source literature.
Be sure this information reaches the operator.
Y ou can get extra copies through your supplier.
TORCH CONNECTION
COMPARTMENT
UNION
"POS" BULKHEAD
FITTING
Fig. 1 - Location of tubing and union inside of torch connection chamber. Note tubing passes through small hole in sheet metal.
NOTE TUBE ROUTING
TORCH SAFETY PRESSURE
SWITCH
(TSPS) ASSEMBLY
COOLING GAS PRESSURE SWITCH (CGPS)
Fig. 2 - Location of torch safety pressure switch (TSPS), and coolong gas pressure switch (CGPS). Note view is from right side of power source.
TO HARNESS
TSPS
SPADE
TERMINAL
GRY
BLK
RED
CGPS
BLUE LEADS
Fig. 3- Location red lead of TSPS leading to center terminal of CGPS. Also shows spade terminal connection of black and grey leads.
F-15-278 1/96 Printed in
U.S.A.
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