Hypertherm Duramax Hyamp User Manual
Duramax™ and Duramax Hyamp Robotic
Torches
45°, 90°, 180°
Service Manual
807460 | Revision 2 | English
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© 2014 Hypertherm Inc.
Duramax /Duramax Hyamp Robotic Torches
Service Manual
807460
Revision 2
English
March 2014
Hypertherm Inc.
Hanover, NH 03755 USA
Hypertherm Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
technical.service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
return.materials@hypertherm.com (RMA email)
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
65 6841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building
495 ShangZhong Road
Shanghai, 200231
PR China
86-21-60740003 Tel
86-21-60740393 Fax
Hypertherm Europe B.V.
Vaartveld 9
4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
Hypertherm Japan Ltd.
Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP - Brasil
CEP 07115-030
55 11 2409 2636 Tel
55 11 2408 0462 Fax
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
Hypertherm Korea Branch
#3904 Centum Leaders Mark B/D,
1514 Woo-dong, Haeundae-gu, Busan
Korea, 612-889
82 51 747 0358 Tel
82 51 701 0358 Fax
Safety information
Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included
with your product for important safety information.
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-12
Cutting cables .........................................................................................................................................................................SC-12
Equipotential bonding ....................................................................................................................................................SC-12
Earthing of the workpiece .............................................................................................................................................SC-12
Screening and shielding .......................................................................................................................................................SC-12
Warranty .................................................................................................................................. SC-13
Attention ....................................................................................................................................................................................SC-13
General .....................................................................................................................................................................................SC-13
Patent indemnity .....................................................................................................................................................................SC-14
Limitation of liability ................................................................................................................................................................SC-14
National and local codes .......................................................................................................................................................SC-14
Liability cap ..............................................................................................................................................................................SC-14
Insurance ..................................................................................................................................................................................SC-14
Transfer of rights .....................................................................................................................................................................SC-14
1 Specifications .............................................................................................................................. 15
Introduction .................................................................................................................................................................................... 15
Duramax component weights .................................................................................................................................................... 16
Duramax Hyamp component weights ...................................................................................................................................... 16
Torch dimensions ......................................................................................................................................................................... 17
Duramax 180° robotic torch dimensions ......................................................................................................................... 17
Duramax/Duramax Hyamp Robotic Torches Service Manual 807460 7
Contents
Duramax 90° robotic torch dimensions ........................................................................................................................... 17
Duramax 45° robotic torch dimensions ........................................................................................................................... 18
Duramax Hyamp 180° robotic torch dimensions .......................................................................................................... 18
Duramax Hyamp 90° robotic torch dimensions ............................................................................................................. 19
Duramax Hyamp 45° robotic torch dimensions ............................................................................................................. 19
2 Torch Setup .................................................................................................................................. 21
Robotic torch components ......................................................................................................................................................... 21
Install the torch .............................................................................................................................................................................. 22
Disassemble the robotic torch .................................................................................................................................................. 23
Mount the torch ............................................................................................................................................................................. 30
Consumable life ............................................................................................................................................................................ 33
Choosing the consumables ....................................................................................................................................................... 34
Duramax robotic torches ..................................................................................................................................................... 34
Duramax consumables ........................................................................................................................................................ 34
Duramax mechanized shielded 105 A* .................................................................................................................... 34
Duramax mechanized shielded 45 A, 65 A, 85 A* ................................................................................................ 34
Duramax FineCut shielded 105 A* ........................................................................................................................... 34
Duramax FineCut shielded 65 A, 85 A* .................................................................................................................. 35
*Ohmic-sensing retaining cap ................................................................................................................................... 35
Duramax mechanized unshielded 105 A ................................................................................................................. 35
Duramax mechanized unshielded 45 A, 65 A, 85 A ............................................................................................. 35
Duramax FineCut unshielded 105 A ........................................................................................................................ 35
Duramax FineCut unshielded 65 A, 85 ................................................................................................................... 36
Duramax gouging 105 A ............................................................................................................................................. 36
Duramax gouging 65 A, 85 A .................................................................................................................................... 36
Duramax Hyamp robotic torches ....................................................................................................................................... 37
Duramax Hyamp consumables .......................................................................................................................................... 37
Duramax Hyamp mechanized shielded 105 A/125 A* ........................................................................................ 37
Duramax Hyamp mechanized shielded 45 A, 65 A* ............................................................................................. 37
Duramax Hyamp FineCut shielded* .......................................................................................................................... 37
*Ohmic-sensing retaining cap ................................................................................................................................... 37
Duramax Hyamp gouging ............................................................................................................................................ 37
Installing the consumables ................................................................................................................................................. 38
Connecting the torch lead .......................................................................................................................................................... 39
Connecting a remote-start pendant ......................................................................................................................................... 40
Connecting the machine interface cable ................................................................................................................................ 41
Machine interface pinout ..................................................................................................................................................... 43
Setting the five-position voltage divider .....................................................................................
Using the cut charts ..................................................................................................................................................................... 45
..................................... 44
8 Duramax/Duramax Hyamp Robotic Torches Service Manual 807460
Contents
3 Operation ...................................................................................................................................... 47
Using the robotic torch ................................................................................................................................................................ 47
Using the Duramax robotic teach tool .............................................................................................................................. 48
Understand and optimize cut quality ................................................................................................................................ 49
Cut or bevel angle ........................................................................................................................................................ 49
Dross ................................................................................................................................................................................ 49
Straightness of the cut surface .................................................................................................................................. 50
Piercing a workpiece using the robotic torch ................................................................................................................ 50
Common machine-cutting faults ....................................................................................................................................... 51
4 Component Replacement ........................................................................................................ 53
Duramax and Duramax Hyamp robotic torch overview ........................................................................................................ 53
Disconnect the power, gas supply, and torch ....................................................................................................................... 55
Replacing the positioning barrel ............................................................................................................................................... 56
Replacing the torch body ............................................................................................................................................................ 59
Replacing the cap-sensor switch ............................................................................................................................................. 61
Replacing the torch lead ............................................................................................................................................................. 62
5 Maintenance and Parts ............................................................................................................. 65
Perform routine maintenance ..................................................................................................................................................... 65
Routine maintenance tasks ................................................................................................................................................. 66
Inspect the consumables ............................................................................................................................................................ 67
Duramax robotic torch replacement parts ............................................................................................................................... 68
Duramax 180° robotic torch ............................................................................................................................................... 68
Duramax 90° robotic torch ................................................................................................................................................. 69
Duramax 45° robotic torch ................................................................................................................................................. 70
Duramax Hyamp robotic torch replacement parts ................................................................................................................ 71
Duramax Hyamp 180° robotic torch ................................................................................................................................. 71
Duramax Hyamp 90° robotic torch ................................................................................................................................... 72
Duramax Hyamp 45° robotic torch ................................................................................................................................... 73
Accessory parts ............................................................................................................................................................................ 74
Duramax/Duramax Hyamp Robotic Torches Service Manual 807460 9
Contents
10 Duramax/Duramax Hyamp Robotic Torches Service Manual 807460
Electromagnetic Compatibility (EMC)
Introduction
Hypertherm’s CE-marked equipment is built in compliance
with standard EN60974-10. The equipment should be
installed and used in accordance with the information
below to achieve electromagnetic compatibility.
The limits required by EN60974-10 may not be adequate
to completely eliminate interference when the affected
equipment is in close proximity or has a high degree of
sensitivity. In such cases it may be necessary to use other
measures to further reduce interference.
This cutting equipment is designed for use only in an
industrial environment.
Installation and use
The user is responsible for installing and using the plasma
equipment according to the manufacturer’s instructions.
If electromagnetic disturbances are detected then it shall
be the responsibility of the user to resolve the situation
with the technical assistance of the manufacturer. In some
cases this remedial action may be as simple as earthing
the cutting circuit, see Earthing of the work piece. In other
cases, it could involve constructing an electromagnetic
screen enclosing the power source and the work
complete with associated input filters. In all cases,
electromagnetic disturbances must be reduced to the
point where they are no longer troublesome.
Assessment of area
Before installing the equipment, the user shall make an
assessment of potential electromagnetic problems in the
surrounding area. The following shall be taken into
account:
a. Other supply cables, control cables, signaling
and telephone cables; above, below and adjacent
to the cutting equipment.
b. Radio and television transmitters and receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example guarding of
industrial equipment.
e. Health of the people around, for example the use
of pacemakers and hearing aids.
f. Equipment used for calibration or measurement.
g. Immunity of other equipment in the environment.
User shall ensure that other equipment being
used in the environment is compatible. This may
require additional protection measures.
h. Time of day that cutting or other activities are to
be carried out.
The size of the surrounding area to be considered will
depend on the structure of the building and other activities
that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
Methods of reducing emissions
Mains supply
Cutting equipment must be connected to the mains
supply according to the manufacturer’s recommendations.
If interference occurs, it may be necessary to take
additional precautions such as filtering of the mains
supply.
Consideration should be given to shielding the supply
cable of permanently installed cutting equipment, in
metallic conduit or equivalent. Shielding should be
electrically continuous throughout its length. The shielding
should be connected to the cutting mains supply so that
good electrical contact is maintained between the conduit
and the cutting power source enclosure.
Safety and Compliance SC-11
Electromagnetic Compatibility (EMC)
Maintenance of cutting equipment
The cutting equipment must be routinely maintained
according to the manufacturer’s recommendations. All
access and service doors and covers should be closed
and properly fastened when the cutting equipment is in
operation. The cutting equipment should not be modified
in any way, except as set forth in and in accordance with
the manufacturer’s written instructions. For example, the
spark gaps of arc striking and stabilizing devices should
be adjusted and maintained according to the
manufacturer’s recommendations.
Cutting cables
The cutting cables should be kept as short as possible
and should be positioned close together, running at or
close to the floor level.
Equipotential bonding
Bonding of all metallic components in the cutting
installation and adjacent to it should be considered.
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. Care should be
taken to prevent the earthing of the workpiece increasing
the risk of injury to users, or damage to other electrical
equipment. Where necessary, the connection of the
workpiece to earth should be made by a direct connection
to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be
achieved by suitable capacitances selected according to
national regulations.
Note: The cutting circuit may or may not be earthed for
safety reasons. Changing the earthing arrangements
should only be authorized by a person who is competent
to assess whether the changes will in crease the risk of
injury, for example, by allowing parallel cutting current
return paths which may damage the earth circuits of other
equipment. Further guidance is provided in IEC 60974-9,
Arc Welding Equipment, Part 9: Installation and Use.
However, metallic components bonded to the workpiece
will increase the risk that the operator could receive a
shock by touching these metallic components and the
electrode (nozzle for laser heads) at the same time.
The operator should be insulated from all such bonded
metallic components.
Screening and shielding
Selective screening and shielding of other cables and
equipment in the surrounding area may alleviate problems
of interference. Screening of the entire plasma cutting
installation may be considered for special applications.
SC-12 Safety and Compliance
Warranty
Attention
Genuine Hypertherm parts are the factory-recommended
replacement parts for your Hypertherm system. Any
damage or injury caused by the use of other than genuine
Hypertherm parts may not be covered by the Hypertherm
warranty, and will constitute misuse of the Hypertherm
Product.
You are solely responsible for the safe use of the Product.
Hypertherm does not and cannot make any guarantee or
warranty regarding the safe use of the product in your
environment.
General
Hypertherm, Inc. warrants that its Products shall be free
from defects in materials and workmanship for the specific
periods of time set forth herein and as follows: if
Hypertherm is notified of a defect (i) with respect to the
plasma power supply within a period of two (2) years from
the date of its delivery to you, with the exception of
Powermax brand power supplies, which shall be within a
period of three (3) years from the date of delivery to you,
and (ii) with respect to the torch and leads within a period
of one (1) year from its date of delivery to you, and with
respect to torch lifter assemblies within a period of one (1)
year from its date of delivery to you, and with respect to
Automation products one (1) year from its date of delivery
to you, with the exception of the EDGE Pro CNC,
EDGE Pro Ti CNC, MicroEDGE Pro CNC, and
ArcGlide THC, which shall be within a period of two (2)
years from the date of delivery to you, and (iii) with respect
to HyIntensity fiber laser components within a period of
two (2) years from the date of its delivery to you, with the
exception of laser heads and beam delivery cables, which
shall be within a period of one (1) year from its date of
delivery to you.
Hypertherm provides repair, replacement or adjustment of
the Product as the sole and exclusive remedy, if and only if
the warranty set forth herein properly is invoked and
applies. Hypertherm, at its sole option, shall repair,
replace, or adjust, free of charge, any defective Products
covered by this warranty which shall be returned with
Hypertherm’s prior authorization (which shall not be
unreasonably withheld), properly packed, to Hypertherm’s
place of business in Hanover, New Hampshire, or to an
authorized Hypertherm repair facility, all costs, insurance
and freight pre paid by the customer. Hypertherm shall not
be liable for any repairs, replacement, or adjustments of
Products covered by this warranty, except those made
pursuant to this paragraph and with Hypertherm’s prior
written consent.
The warranty set forth above is exclusive and is in lieu of all
other warranties, express, implied, statutory, or otherwise
with respect to the Products or as to the results which
may be obtained therefrom, and all implied warranties or
conditions of quality or of merchantability or fitness for a
particular purpose or against infringement. The foregoing
shall constitute the sole and exclusive remedy for any
breach by Hypertherm of its warranty.
Distributors/OEMs may offer different or additional
warranties, but Distributors/OEMs are not authorized to
give any additional warranty protection to you or make any
representation to you purporting to be binding upon
Hypertherm.
This warranty shall not apply to any Powermax brand
power supplies that have been used with phase
converters. In addition, Hypertherm does not warranty
systems that have been damaged as a result of poor
power quality, whether from phase converters or incoming
line power. This warranty shall not apply to any product
which has been incorrectly installed, modified, or
otherwise damaged.
Safety and Compliance SC-13
Warranty
Patent indemnity
Except only in cases of products not manufactured by
Hypertherm or manufactured by a person other than
Hypertherm not in strict conformity with Hypertherm’s
specifications and in cases of designs, processes,
formulae, or combinations not developed or purported to
be developed by Hypertherm, Hypertherm will have the
right to defend or settle, at its own expense, any suit or
proceeding brought against you alleging that the use of
the Hypertherm product, alone and not in combination
with any other product not supplied by Hypertherm,
infringes any patent of any third party. You shall notify
Hypertherm promptly upon learning of any action or
threatened action in connection with any such alleged
infringement (and in any event no longer than fourteen
(14) days after learning of any action or threat of action),
and Hypertherm’s obligation to defend shall be
conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the
defense of the claim.
Limitation of liability
In no event shall Hypertherm be liable to any
person or entity for any incidental, consequential
direct, indirect, punitive or exemplary damages
(including but not limited to lost profits) regardless
of whether such liability is based on breach of
contract, tort, strict liability, breach of warranty,
failure of essential purpose, or otherwise, and even
if advised of the possibility of such damages.
National and local codes
Liability cap
In no event shall Hypertherm’s liability, if any,
whether such liability is based on breach of
contract, tort, strict liability, breach of warranties,
failure of essential purpose or otherwise, for any
claim, action, suit or proceeding (whether in court,
arbitration, regulatory proceeding or otherwise)
arising out of or relating to the use of the Products
exceed in the aggregate the amount paid for the
Products that gave rise to such claim.
Insurance
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.
Transfer of rights
You may transfer any remaining rights you may have
hereunder only in connection with the sale of all or
substantially all of your assets or capital stock to a
successor in interest who agrees to be bound by all of the
terms and conditions of this Warranty. Within thirty (30)
days before any such transfer occurs, you agree to notify
in writing Hypertherm, which reserves the right of
approval. Should you fail timely to notify Hypertherm and
seek its approval as set forth herein, the Warranty set forth
herein shall be null and void and you will have no further
recourse against Hypertherm under the Warranty or
otherwise.
National and local codes governing plumbing and
electrical installation shall take precedence over any
instructions contained in this manual. In no event shall
Hypertherm be liable for injury to persons or property
damage by reason of any code violation or poor work
practices.
SC-14 Safety and Compliance
Section 1
Specifications
Introduction
The Duramax robotic torch line consists of 3 torches: 180°, 90°, and 45°, designed for use with the Powermax65®,
Powermax85, and Powermax105 systems. The Duramax robotic torches are not compatible with the Powermax125
system. These torches use only Duramax consumables.
The Duramax Hyamp robotic torch line also consists of 3 torches: 180°, 90°, and 45°, designed for use with the
Powermax65, Powermax85, Powermax105, and Powermax125 systems. These torches use only Duramax Hyamp
consumables.
Both lines of torches are designed for use in robotic applications. They can also be used in other mechanized
applications where careful positioning of the torch and the ability to approach the workpiece at an angle are important
considerations.
The FastConnect™ quick-disconnect system makes it easy to remove the torch for transport or to switch from one torch
to the other if your applications require the use of different torches. The torches are cooled by ambient air and do not
require special cooling procedures.
Duramax and Duramax Hyamp robotic torches comply with IEC 60974-7 and are not suitable for use in the rain or snow.
Duramax/Duramax Hyamp Robotic Torches Service Manual 807460 15
1 – Specifications
76 mm
(3.0 inches)
76 mm
(3.0 inches)
152 mm
(6.0 inches)
Diameter = 2 x Radius = 152 mm (6.0 inches)
10 2 m m
(4.0 inches)
10 2 m m
(4.0 inches)
204 mm
(8.0 inches)
Diameter = 2 x Radius = 204 mm (8.0 inches)
Duramax component weights
180° Duramax robotic torch with 7.6 m (25 foot) lead 3.3 kg (7.2 pounds)
90° Duramax robotic torch 7.6 m (25 foot) lead 3.3 kg (7.2 pounds)
45° Duramax robotic torch 7.6 m (25 foot) lead 3.3 kg (7.2 pounds)
Each Duramax robotic torch weighs 0.43 kg/m (0.29 pounds/foot).
The recommended minimum bend radius for the Duramax torch lead is 76 mm (3.0 inches). See Figure 1.
Figure 1 – Duramax bend radius
Duramax Hyamp component weights
180° Duramax Hyamp robotic torch with 7.6 m (25 foot) lead 3.5 kg (7.8 pounds)
90° Duramax Hyamp robotic torch 7.6 m (25 foot) lead 3.5 kg (7.8 pounds)
45° Duramax Hyamp robotic torch 7.6 m (25 foot) lead 3.5 kg (7.8 pounds)
Each Duramax Hyamp robotic torch weighs 0.46 kg/m (0.31 pounds/foot).
The recommended minimum bend radius for the Duramax Hyamp torch lead is 102 mm (4.0 inches). See Figure 2.
Figure2–Duramax Hyamp bend radius
16 Duramax/Duramax Hyamp Robotic Torches Service Manual 807460
Torch dimensions
25.1 cm (9.89 inches)*
3.5 cm
(1.38 inches)
2.5 cm
(1.0 inch)
19.1 cm (7.50 inches)
12.2cm (4.82inches)*
16.6 cm (6.54 inches)*
21.0cm (8.27inches)*
14.2cm (5.58inches)*
20.1 cm (7.90 inches)
3.5 cm
(1.38 inches)
10 .1 c m
(3.97 inches)*
2.5 cm
(1.0 inch)
90°
5.41 cm
(2.13 inches)*
9.78 cm (3.85 inches)*
Duramax 180° robotic torch dimensions
1 – Specifications
Duramax 90° robotic torch dimensions
Duramax/Duramax Hyamp Robotic Torches Service Manual 807460 17
1 – Specifications
19.6 cm (7.72 inches)
3.51 cm
(1.38 inches)
8.0 cm
(3.15 inches)*
2.5 cm
(1.0 inch)
45°
9.88 cm (3.89 inches)*
14.3 cm (5.61 inches)*
18.6 cm (7.34 inches)*
27.1 cm (10.7 inches)*
3.5 cm
(1.38 inches)
3.5 cm
(1.38 inches)
20.8 cm (8.15 inches)
14.1 cm (5.57 inches)*
18.5 cm (7.30 inches)*
22.9cm (9.02inches)*
4.5 cm
(1.8 inches)
Duramax 45° robotic torch dimensions
Duramax Hyamp 180° robotic torch dimensions
18 Duramax/Duramax Hyamp Robotic Torches Service Manual 807460
Duramax Hyamp 90° robotic torch dimensions
22.4 cm (8.80 inches)
3.5 cm
(1.38 inches)
12.2 cm
(4.79 inches)*
3.5 cm
(1.38 inches)
7.2cm (2.83inches)*
11.6 cm (4.55 inches)*
16.0cm (6.28inches)*
90°
21.8 cm (8.57 inches)
3.5 cm
(1.38 inches)
9.3 cm
(3.66 inches)*
3.5 cm
(1.38 inches)
45°
11.8 cm (4.66 inches)*
16.2cm (6.39inches)*
20.6 cm (8.11 inches)*
1 – Specifications
Duramax Hyamp 45° robotic torch dimensions
* Torch dimensions will vary depending on the type of consumables installed. The preceding figures show the mechanized shielded
consumables installed.
Duramax/Duramax Hyamp Robotic Torches Service Manual 807460 19
1 – Specifications
20 Duramax/Duramax Hyamp Robotic Torches Service Manual 807460
Robotic torch components
1 2 3 4
1 Consumables
2 Positioning barrel
3 Strain relief
4 Tor ch l ead
Duramax 180° is shown.
Section 2
Torch Setu p
Before using any robotic torch, you must:
Install and mount the torch.
Choose and install the consumables.
Attach the torch lead to the power supply.
Set up the power supply for remote starting with either the remote-start pendant or a machine interface cable.
Duramax/Duramax Hyamp Robotic Torches Service Manual 807460 21
2 – Torch Setup
1
2
3
4
5
6
4.20 cm
(1.65 inches)
3.68 cm
(1.45 inches)
1 Disconnect button
2 Ta b
3 Top shell
4 Strain relief
5 Bottom shell
6 Mounting screws (4)
Install the torch
Depending on the type of torch, robot, and installation method, you may need to disassemble the FastConnect plug or
torch to install the torch. For the outside mounting method, it is not necessary to disassemble the torch. The torch can be
mounted per the instructions in Mount the torch on page 30.
For the through-arm mounting method, see Figure 3 to determine if the robot’s through-arm cavity is large enough to
accept the torch lead’s FastConnect plug as assembled or with the 2 shells removed. If the through-arm cavity is large
enough for the FastConnect plug as assembled, route the torch lead through the through-arm cavity. Then, mount the
torch to the robot arm per the instructions in Mount the torch on page 30.
Figure 3
22 Duramax/Duramax Hyamp Robotic Torches Service Manual 807460
2 – Torch Setup
If the through-arm cavity is large enough for the disassembled FastConnect plug (see Figure 3 for dimensions), complete
the following instructions.
1. Remove the mounting screws from the bottom shell and pull the 2 shells apart.
The red disconnect button and tab on top of the FastConnect plug are spring loaded and
self-adjust below the surface of the plug while being routed through the through-arm
cavity.
2. Cover the end of the FastConnect plug with tape to keep dirt and other contaminants from getting into the gas line.
3. Route the torch lead through the through-arm cavity.
4. Install the 2 shells by aligning them over the torch lead, making sure the strain relief is held in place by the slot in the
FastConnect shells.
5. Tighten the mounting screws.
6. Mount the torch to the robot arm per the instructions in Mount the torch on page 30.
Disassemble the robotic torch
If the through-arm cavity is not large enough to accept the FastConnect plug at all (see Figure 3 for dimensions),
complete the following instructions to disassemble, install, and reassemble the torch.
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance.
The maintenance procedures in this section must be performed by a qualified
technician.
See the Safety and Compliance Manual (80669C) for more safety
precautions.
The instructions to disassemble and reassemble all 3 models of robotic torches are the same. The 45° robotic torch
is shown in the figures that follow.
Duramax/Duramax Hyamp Robotic Torches Service Manual 807460 23
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