Hypertherm Manual Family Service Manual (SM)

SmartSYNC™ Torches

Service Parts and Procedures Guide

810460 – REVISION 0

ENGLISH

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

© 2022 Hypertherm, Inc. 100% Associate-owned.

SmartSYNC Torches

Service Parts and Procedures Guide

810460

REVISION 0

ENGLISH

Original instructions

August 2022

Hypertherm, Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Hypertherm, Inc.

21 Great Hollow Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[e-mail] (Main Office)

800-643-9878 Tel (Technical Service)

[e-mail] (Technical Service)

800-737-2978 Tel (Customer Service)

[e-mail] (Customer Service)

Hypertherm México, S.A. de C.V.

52 55 5681 8109 Tel
52 55 5681 7978 Tel
[e-mail] (Technical Service)

Hypertherm Plasmatechnik GmbH

Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax

31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)

[e-mail] (Technical Service)

Hypertherm (Singapore) Pte Ltd.

Solaris @ Kallang 164
164 Kallang Way #03-13
Singapore 349248, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[e-mail] (Marketing)
[e-mail] (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
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm Europe B.V.

Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)

31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)

[e-mail] (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax

86-21-80231128 Tel (Technical Service)

[e-mail] (Technical Service)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
[e-mail] (Technical Service)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[e-mail] (Marketing)
[e-mail] (Technical Service)

Hypertherm Pty Limited

GPO Box 4836
Sydney NSW 2001, Australia
61 7 3103 1695 Tel
61 7 3219 9010 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at

www.hypertherm.com/hci.

ENGLISH

WARNING! Before operating any Hypertherm equipment, read the safety
instructions in your product’s manual, the Safety and Compliance Manual (80669C),

Waterjet Safety and Compliance Manual (80943C), and Radio Frequency Warning
Manual (80945C). Failure to follow safety instructions can result in personal injury

or in damage to equipment.
Copies of the manuals can come with the product in electronic and printed formats.

Electronic copies are also on our website. Many manuals are available in multiple
languages at www.hypertherm.com/docs.

BG (БЪЛГAPCКИ/BULGARIAN)

ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване
Hypertherm, прочетете инструкциите за безопасност в ръководството на вашия
продукт, „Инструкция за безопасност и съответствие“ (80669C), „Инструкция
за безопасност и съответствие на Waterjet“ (80943С) и „Инструкция
за предупреждение за радиочестота“ (80945С).

Продуктът може да е съпроводен от копия на ръководствата в електронен
и в печатен формат. Тези в електронен формат са достъпни също на уебсайта
ни. Много ръководства са налице на няколко езика
на адрес www.hypertherm.com/docs.

CS (ČESKY/CZECH)

VAROVÁNÍ! Před uvedením jakéhokoli zařízení Hypertherm do provozu si přečtěte
bezpečnostní pokyny v příručce k produktu a v Manuálu pro bezpečnost

a dodržování předpisů (80669C), Manuálu pro bezpečnost a dodržování
předpisů při řezání vodním paprskem (80943C) a Manuálu varování ohledně
rádiových frekvencí (80945C).

Kopie příruček mohou být součástí dodávky produktu, a to v elektronické i tištěné
formě. Elektronické kopie jsou k dispozici i na našich webových stránkách. Mnoho
příruček je k dispozici v různých jazycích na stránce www.hypertherm.com/docs.

DA (DANSK/DANISH)

ADVARSEL! Inden Hypertherm udstyr tages i brug skal sikkerhedsinstruktionerne
i produktets manual og i Manual om sikkerhed og overholdelse af krav (80669C),
Manual om sikkerhed og overholdelse af krav for vandstråleskæring (80943C),
og Manual om radiofrekvensadvarsel (80945C), gennemlæses.

Kopier af manualerne kan leveres med produktet i elektronisk og trykt format.
Elektroniske kopier findes også på vores hjemmeside. Mange manualer
er tilgængelige på flere sprog på www.hypertherm.com/docs.

DE (DEUTSCH/GERMAN)

WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die
Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit

und Übereinstimmung (80669C), das Handbuch für Sicherheit und Compliance bei
Wasserstrahl-Schneidanlagen (80943C) und das Handbuch für Hochfrequenz­Warnung (80945C).

Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer Form
oder als Druckversion beiliegen. In elektronischer Form liegen sie auch auf unserer
Website vor. Viele Handbücher stehen in verschiedenen Sprachen auf

www.hypertherm.com/docs zur Verfügung.

ES (ESPAÑOL/SPANISH)

¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, lea las
instrucciones de seguridad del manual de su producto, del Manual de seguridad

y cumplimiento (80669C), del Manual de seguridad y cumplimiento en corte con
chorro de agua (80943C) y del Manual de advertencias de radiofrecuencia

(80945C).
El producto puede incluir copias de los manuales en formato digital e impreso.

Las copias digitales también están en nuestra página web. Hay diversos manuales
disponibles en varios idiomas en www.hypertherm.com/docs.

ET (EESTI/ESTONIAN)

HOIATUS! Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote
kasutusjuhendis olevad ohutusjuhised ning Ohutus- ja vastavusjuhend (80669C),
Veejoa ohutuse ja vastavuse juhend (80943C) ja Raadiosageduse hoiatusjuhend
(80945C). Ohutusjuhiste eiramine võib põhjustada vigastusi ja kahjustada
seadmeid.

Juhiste koopiad võivad tootega kaasas olla elektrooniliselt või trükituna.
Elektroonilised koopiad on saadaval ka meie veebilehel. Paljud kasutusjuhendid
on erinevates keeltes saadaval veebilehel www.hypertherm.com/docs.

FI (SUOMI/FINNISH)

VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen
käyttöoppaassa olevat turvallisuusohjeet, turvallisuuden ja vaatimustenmukaisuuden

käsikirja (80669C), vesileikkauksen turvallisuuden ja vaatimustenmukaisuuden
käsikirja (80943C) ja radiotaajuusvaroitusten käsikirja (80945C).

Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa
muodossa. Sähköiset kopiot ovat myös verkkosivustollamme. Monet käyttöoppaat
ovat myös saatavissa useilla kielillä www.hypertherm.com/docs.

FR (FRANÇAIS/FRENCH)

AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les consignes
de sécurité dumanuel de votre produit, duManuel de sécurité et de conformité
(80669C), du Manuel de sécurité et de conformité du jet d’eau (80943C)
et du Manuel d'avertissement relatif aux radiofréqunces (80945C).

Les exemplaires des manuels qui accompagnent le produit peuvent être sous forme
électronique ou papier. Les manuels sous forme électronique se trouvent également
sur notre site Internet. Plusieurs manuels sont offerts en plusieurs langues
à www.hypertherm.com/docs.

GR (ΕΛΛΗΝΙΚΆ/GREEK)

ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της
Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος και στο

εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C), στο εγχειρίδιο ασφάλειας και
συμμόρφωσης του waterjet (80943C) και στο εγχειρίδιο προειδοποιήσεων για τις
ραδιοσυχνότητες (80945C).

Το προϊόν μπορεί να συνοδεύεται από αντίγραφα των εγχειριδίων σε ηλεκτρονική
και έντυπη μορφή. Τα ηλεκτρονικά αντίγραφα υπάρχουν επίσης στον ιστότοπό μας.
Πολλά εγχειρίδια είναι διαθέσιμα σε διάφορες γλώσσες στο

www.hypertherm.com/docs.

HU (MAGYAR/HUNGARIAN)

VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne,
olvassa el a biztonsági információkat a termék kézikönyvében, a Biztonsági

és szabálykövetési kézikönyvben (80669C), a Vízsugaras biztonsági
és szabálykövetési kézikönyvben (80943C) és a Rádiófrekvenciás
figyelmeztetéseket tartalmazó kézikönyvben (80945C).

A termékhez a kézikönyv példányai elektronikus és nyomtatott formában is mellékelve
lehetnek. Az elektronikus példányok webhelyünkön is megtalálhatók. Számos
kézikönyv áll rendelkezésre több nyelven a www.hypertherm.com/docs weboldalon.

ID (BAHASA INDONESIA/INDONESIAN)

PERINGATAN! Sebelum mengoperasikan peralatan Hypertherm, bacalah petunjuk
keselamatan dalam manual produk Anda, Manual Keselamatan dan Kepatuhan
(80669C), Manual Keselamatan dan Kepatuhan Jet Air (80943C), dan Manual
Peringatan Frekuensi Radio (80945C). Kegagalan mengikuti petunjuk keselamatan
dapat menyebabkan cedera pribadi atau kerusakan pada peralatan.

Produk mungkin disertai salinan manual atau petunjuk dalam format elektronik
maupun cetak. Salinan elektronik juga tersedia di situs web kami. Berbagai manual
tersedia dalam beberapa bahasa di www.hypertherm.com/docs.

IT (ITALIANO/ITALIAN)

AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla
sicurezza nel manuale del prodotto, nel Manuale sulla sicurezza e la conformità
(80669C), nel Manuale sulla sicurezza e la conformità Waterjet (80943C) e nel
Manuale di avvertenze sulla radiofrequenza(80945C).

Copie del manuale possono accompagnare il prodotto in formato cartaceo
o elettronico. Le copie elettroniche sono disponibili anche sul nostro sito web. Molti
manuali sono disponibili in diverse lingue all’indirizzo www.hypertherm.com/docs.

JA (日本語/JAPANESE)

警告 ! Hypertherm 機器を操作する前に、この製品説明書にある安全情報、「安全
とコンプライアンスマニュアル」 (80669C) 、「ウォータージェットの安全とコ
ンプライアンス」 (80943C)、「高周波警告」 (80945C) をお読みください。

説明書のコピーは、電子フォーマット、または印刷物として製品に同梱されて
います。電子コピーは当社ウェブサイトにも掲載されています。説明書の多く
は www.hypertherm.com/docs にて複数の言語でご用意しています。

KO (뼑뼑霢꽩 KOREAN)

陲隕+\SHUWKHUP녚ꟹꌱꩡ끞뼍韥놹꾅뇑븽꫙ꐺ꫑꿵껽놹ꗄ鞑뇊늵ꯍ
꫙ꐺ꫑&낁뫥뇤껽놹ꗄ鞑뇊늵ꯍ꫙ꐺ꫑&鞭ꍡ隕ꓩ꫕늱볁ꯍ
陲隕꫙ꐺ꫑&꾅驍꿵넽鱉껽놹덵렝냹넲냱겢겑꿙

놹녅뿊겒隱넭ꭹ鷑뿊겒냱ꈑ꫙ꐺ꫑ꩡꚭ넩뇑븽隱뼝颍뇑險鷕ꯍ넽걪鱽鲙
놹녅ꩡꚭ鵹+\SHUWKHUP낮ꩡ넩뱭꾅꫑ꚩ겙ꯍ넽냱ꐥ꫙ꐺ꫑ꩡꚭ냵

www.hypertherm.com/docs꾅꫑꾡ꆡ꽭꽩ꈑ뇑險鷞鱽鲙

NE (NEDERLANDS/DUTCH)

WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt
de veiligheidsinstructies in de producthandleiding, in de Veiligheids-

en nalevingshandleiding (80669C) in de Veiligheids- en nalevingshandleiding
voor waterstralen (80943C) en in de Waarschuwingshandleiding radiofrequentie

(80945C).
De handleidingen kunnen in elektronische en gedrukte vorm met het product worden

meegeleverd. Elektronische versies zijn ook beschikbaar op onze website. Veel
handleidingen zijn in meerdere talen beschikbaar via www.hypertherm.com/docs.

NO (NORSK/NORWEGIAN)

ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese
sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet og
samsvar (80669C), håndboken om vannjet sikkerhet og samsvar (80943C),
og håndboken om radiofrekvensadvarsler (80945C).

Eksemplarer av håndbøkene kan følge med produktet i elektronisk og trykt form.
Elektroniske eksemplarer finnes også på nettstedet vårt. Mange håndbøker
er tilgjengelig i flere språk på www.hypertherm.com/docs.

PL (POLSKI/POLISH)

OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu
firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi
w podręczniku produktu, w podręczniku bezpieczeństwa i zgodności (80669C),
podręczniku bezpieczeństwa i zgodności systemów strumienia wody (80943C)
oraz podręczniku z ostrzeżeniem o częstotliwości radiowej (80945C).

Do produktu mogą być dołączone podręczniki użytkownika wformie elektronicznej
idrukowanej. Kopie elektroniczne znajdują się również wnaszej witrynie internetowej.
Wiele podręczników jest dostępnych wróżnych językach pod adresem

www.hypertherm.com/docs.

PT (PORTUGUÊS/PORTUGUESE)

ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm,
leia as instruções de segurança no manual do seu produto, no Manual

de Segurança e de Conformidade (80669C), no Manual de Segurança
e de Conformidade do Waterjet (80943C) e no Manual de Advertência
de radiofrequência (80945C).

Cópias dos manuais podem vir com o produto nos formatos eletrônico e impresso.
Cópias eletrônicas também são encontradas em nosso website. Muitos manuais
estão disponíveis em vários idiomas em www.hypertherm.com/docs.

RO (ROMÂNĂ/ROMANIAN)

AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți
instrucțiunile de siguranță din manualul produsului, manualul de siguranță
și conformitate (80669C), manualul de siguranță și conformitate Waterjet (80943C)
și din manualul de avertizare privind radiofrecvența (80945C).

Produsul poate fi însoțit de copii ale manualelor în format tipărit și electronic.
Exemplarele electronice sunt disponibile și pe site-ul nostru web.
Numeroase manuale sunt disponibile în mai mult limbi la adresa:

www.hypertherm.com/docs.

RU (PУССКИЙ/RUSSIAN)

БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm ознакомьтесь
с инструкциями по безопасности, представленными в руководстве, которое
поставляется вместе с продуктом, в Руководстве по безопасности и

соответствию (80669С), в Руководстве по безопасности и соответствию для
водоструйной резки (80943C) и Руководстве по предупреждению о
радиочастотном излучении (80945С).

Копии руководств, которые поставляются вместе с продуктом, могут быть
представлены в электронном и бумажном виде. Электронные копии также
доступны на нашем веб-сайте. Целый ряд руководств доступны на нескольких
языках по ссылке www.hypertherm.com/docs.

SK (S LOVENČI NA/SLOVAK)

VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm si
prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia a v Manuáli

o bezpečnosti a súlade s normami (80669C), Manuáli o bezpečnosti a súlade
snormami pre systém rezania vodou (80943C) avManuáli sinformáciami
orádiofrekvencii (80945C).

Návod na obsluhu sa dodáva spolu sproduktom velektronickej atlačenej podobe.
Jeho elektronický formát je dostupný aj na našej webovej stránke. Mnohé znávodov
na obsluhu sú dostupné vo viacjazyčnej mutácii na stránke

www.hypertherm.com/docs.

SL (S LOVENŠČINA/S LOVENIAN)

OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite varnostna
navodila v priročniku vašega izdelka, v Priročniku za varnost in skladnost (80669C),
v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom (80943C)
in v Priročniku Opozorilo o radijskih frekvencah (80945C).

Izvodi priročnikov so lahko izdelku priloženi v elektronski in tiskani obliki. Elektronski
izvodi so na voljo tudi na našem spletnem mestu. Številni priročniki so na voljo
v različnih jezikih na naslovu www.hypertherm.com/docs.

SR (SRPSKI/SERBIAN)

UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom pročitajte
uputstva o bezbednosti u svom priručniku za proizvod, Priručniku o bezbednosti

i usaglašenosti (80669C), Priručniku o bezbednosti i usaglašenosti Waterjet
tehnologije (80943C) i Priručniku sa upozorenjem o radio-frekvenciji (80945C).

Уз производ се испоручују копије приручника у електронском или штампаном
формату. Електронске копије су такође доступне на нашем веб-сајту. Многи
приручници су доступни на више језика на адреси www.hypertherm.com/docs.

SV (SVENSKA/SWEDISH)

VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och
efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för Waterjet

(80943C) och varningsmanualen för radiofrekvenser (80945C) för viktig
säkerhetsinformation innan du använder eller underhåller Hypertherm-utrustning.

Kopior av manualerna kan medfölja produkten i elektroniskt och tryckt format.
Elektroniska kopior finns också på vår webbplats. Många manualer finns på flera
språk på www.hypertherm.com/docs.

THࡗࡩࡠࡩࡷࡎ࡙THAI

࠻ࢀࡩࡳࡌ࡮ࡤࡐ࠸ᕍࡤࡐ࠸ࡩ࡚ࡶࡁᕎ࠾ࡩࡐࡤ࡯ࡒ࠸࡚ࡊᕑ࠹ࡤ࠾+\SHUWKHUPࡎࡨࡼ࠾ࡢࡘࡋࡵࡒ࡚ࡋࡤᕍࡩࡐ࠻ࢀࡩࡴࡐࡧࡐࢀࡩࡋᕎࡩࡐ࠻࡞ࡩࡘ
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TR (TÜRKÇE/TURKISH)

UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürününüzün kullanım
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ve Uyumluluk Kılavuzu’nda (80943C) ve Radyo Frekansı Uyarısı Kılavuzu’nda
(80945C) yer alan güvenlik talimatlarını okuyun.

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www.hypertherm.com/docsᇭ

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° and 15° hand torch body and O-ring ......................................................................................... 17

75° and 15° hand torch lead and terminal screw............................................................................ 18

75° and 15° hand torch switches and PCB ..................................................................................... 19

Full-length machine torch parts ....................................................................................................................... 20

Full-length machine torch assemblies................................................................................................ 20

Full-length machine torch exterior parts............................................................................................. 21

Full-length machine torch body and O-ring...................................................................................... 22

Full-length machine torch switches and PCB.................................................................................. 23

Full-length machine torch lead and terminal screw......................................................................... 24

Mini machine and 180° robotic torch parts .................................................................................................. 25

Mini machine and 180° robotic torch assemblies ........................................................................... 25

Mini machine and 180° robotic torch exterior parts........................................................................ 26

Mini machine and 180° robotic torch lead and terminal screw.................................................... 27

Mini machine and 180° robotic switch and PCB ............................................................................ 28

Mini machine and 180° robotic torch body and O-ring ................................................................. 29

SmartSYNC Service Parts and Procedures 810460 7

90° and 45° robotic torch parts....................................................................................................................... 30

90° and 45° robotic torch assemblies ............................................................................................... 30

90° and 45° robotic torch exterior parts............................................................................................ 31

90° and 45° robotic torch lead and terminal screw........................................................................ 32

90° and 45° robotic switch and PCB ................................................................................................ 33

90° and 45° robotic torch body and O-ring ..................................................................................... 34

Find torch replacement parts by part number .............................................................................................. 35

3 Prepare to Do the Part Replacement .................................................................................... 37

Get the replacement part kit............................................................................................................................. 37

Get the tools ........................................................................................................................................................ 37

Prevent injury to yourself and others .............................................................................................................. 38

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 ......................................................................................................................... 41

4 Hand Torch Part Replacement Procedures .......................................................................... 43

Disassemble the hand torch............................................................................................................................. 44

Before you begin..................................................................................................................................... 44

Remove the components from the torch handle.............................................................................. 44

Disconnect the torch components...................................................................................................... 46

Assemble the hand torch .................................................................................................................................. 49

Connect the torch components........................................................................................................... 49

Install the torch components into the torch handle......................................................................... 52

Do a check of the component positions and wire routing......................................................................... 58

Install the left side of the torch handle ........................................................................................................... 60

5 Full-Length Machine Torch Part Replacement Procedures .............................................. 63

Disassemble the full-length machine torch................................................................................................... 64

Before you begin..................................................................................................................................... 64

Remove the components from the torch shell.................................................................................. 64

Disconnect the torch components...................................................................................................... 66

Assemble the machine torch............................................................................................................................ 68

Connect the torch components........................................................................................................... 68

Install torch components into the torch shell.................................................................................... 71

Do a check of the component positions and wire routing......................................................................... 74

Install the left side of the torch shell ............................................................................................................... 75

8 810460 Service Parts and Procedures SmartSYNC

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........................................................................................................... 82

Install the torch components into the torch shell............................................................................. 86

Do a check of the component positions and wire routing......................................................................... 89

Install the left side of the torch shell ............................................................................................................... 91

7 Torch Lead Replacement Procedures.................................................................................... 93

Replace the torch quick-disconnect shell..................................................................................................... 93

Before you begin..................................................................................................................................... 93

Remove the torch quick-disconnect shell ......................................................................................... 93

Install the torch quick-disconnect shell.............................................................................................. 94

Replace the torch assembly with lead ........................................................................................................... 95

8 Do a Check of the Torch Assembly ........................................................................................ 97

SmartSYNC Service Parts and Procedures 810460 9

10 810460 Service Parts and Procedures SmartSYNC

Before You Begin

This manual helps you do the following:

 Install replacement parts that you already have

 Refer to Prepare to Do the Part Replacement on page 37.

 Find the part number that you need to order

 Refer to Service Parts on page 13.

 Refer to Find torch replacement parts by part number on page 35.

For assistance with repairing or replacing internal components, do the following:

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)

 Powermax65/85 SYNC Service Parts and Procedures Guide (810440)

 Powermax105 SYNC Service Parts and Procedures Guide (810450)

Technical documentation is available at www.hypertherm.com/docs.

Technical documentation is current as of the date of its release.



Subsequent revisions are possible.

SmartSYNC Service Parts and Procedures 810460 11

Before You Begin

1

12 810460 Service Parts and Procedures SmartSYNC

Service Parts

NOTICE

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.

Cartridges are not included in this manual. For a list of the cutting and



gouging cartridges available, refer to the Powermax65/85/105 SYNC
Parts Guide (810490).

To find part numbers with kit contents, refer to the following:

 Hand torch parts on page 14

 Full-length machine torch parts on page 20

 Mini machine and 180° robotic torch parts on page 25

 90° and 45° robotic torch parts on page 30

To see a list of parts in order by part number, refer to Find torch replacement parts by part

number on page 35.

SmartSYNC Service Parts and Procedures 810460 13

Service Parts

2

1

2

Hand torch parts

75° and 15° hand torch assemblies

Item Part number Description

1 059726 75° hand torch assembly with 7.6 m (25 foot) lead*

1 059727 75° hand torch assembly with 15 m (50 foot) lead*

1 059728 75° hand torch assembly with 23 m (75 foot) lead*

2 059723 15° hand torch assembly with 7.6 m (25 foot) lead*

2 059724 15° hand torch assembly with 15 m (50 foot) lead*

2 059725 15° hand torch assembly with 23 m (75 foot) lead*

* The torch assembly does not include a cartridge. For a full list of the cutting and gouging cartridges available, refer

to the Powermax65/85/105 SYNC Parts Guide (810490).

14 810460 Service Parts and Procedures SmartSYNC

2

75° and 15° hand torch exterior parts

1

2

3

4

4

4

4

1

3

4

2

Service Parts

Item

1 428856 Kit: Handle for 75° hand torch

2 428855 Kit: Handle for 15° hand torch

3 428863 Kit: Quick-disconnect shell (shell with button – does not include torch lead or connector)

4 428148 Kit: Screws for torch handle or quick-disconnect shell

* Can also be ordered separately as kit 428148 (quantity: 7)

Part

number

Description and kit contents

101453 Handle for 75° hand torch

075714 Screws for torch handle* (7)

101452 Handle for 15° hand torch

075714 Screws for torch handle* (7)

420565 Shell for torch quick-disconnect

220681 Latch with red button

127197 Lever for latch

075714 Screws for shell* (4)

075714 Screws for torch handle or quick-disconnect shell (7)

SmartSYNC Service Parts and Procedures 810460 15

Service Parts

2

1

3

2

1

3

2

1

2

3

4

75° and 15° hand torch controls

Item

Part

number

Description and kit contents

1 428873 Kit: Amperage-adjustment control for 75° or 15° hand torch

229847 Amperage-adjustment control for 75° or 15° hand torch

2 428871 Kit: Torch-lock slider for 75° or 15° hand torch

229846 Torch-lock slider for 75° or 15° hand torch (with yellow and green label)

3 428156 Kit: Trigger

002554 Trigger

027254 Spring for trigger*

005684 Start switch**

075714 Screws for torch handle*** (7)

4 428182 Kit: Spring for trigger

027254 Spring for trigger (5)

* Can also be ordered separately as kit 428182 (quantity: 5).

** Can also be ordered separately as kit 428958 (quantity: 1).

*** Can also be ordered separately as kit 428148 (quantity: 7).

16 810460 Service Parts and Procedures SmartSYNC

2

75° and 15° hand torch body and O-ring

3

4

3

4

1

1

2

2

2

1

Service Parts

Item

Part

number

Description and kit contents

1 528066 Kit: Torch contact ring (for torch head)

420931 Torch contact ring (2)

2 428950 Kit: O-rings for torch body

058021 O-ring for any SmartSYNC torch (5)

3 428858 Kit: Body for 75° hand torch

420582 Main body replacement for 75° hand torch

075903 Terminal screw (1/4 inch) for pilot arc wire*

075714 Screws for torch handle** (7)

027055 Silicone lubricant, 7.4 ml (0.25 fl oz)***

330103 Thread locker, 0.5 ml (0.017 fl oz)

4 428857 Kit: Body for 15° hand torch

420630 Main body replacement for 15° hand torch

075903 Terminal screw (1/4 inch) for pilot arc wire*

075714 Screws for torch handle** (7)

027055 Silicone lubricant, 7.4 ml (0.25 fl oz)***

330103 Thread locker, 0.5 ml (0.017 fl oz)

* Can also be ordered separately as part number 075903 (quantity: 1).

** Can also be ordered separately as kit 428148 (quantity: 7).

*** Can also be ordered separately as part number 027055 (quantity: 1).

SmartSYNC Service Parts and Procedures 810460 17

Service Parts

2

2

1

2

1

2

75° and 15° hand torch lead and terminal screw

Item

1 075903 Terminal screw (1/4 inch) for pilot arc wire

2 428852

* Can also be ordered separately as part number 075903 (quantity: 1).

Part

number

428853
428854

Description and kit contents

Kit: Lead for hand torch, 7.6 m (25 foot)
Kit: Lead for hand torch, 15 m (50 foot)
Kit: Lead for hand torch, 23 m (75 foot)

229849 Lead for kit 428852, 7.6 m (25 foot)

229850 Lead for kit 428853, 15 m (50 foot)

229851 Lead for kit 428854, 23 m (75 foot)

210735 Data plate: SmartSYNC torch (not shown)

210729 Label: SmartSYNC torch lead (not shown)

075903 Terminal screw (1/4 inch) for pilot arc wire*

330103 Thread locker, 0.5 ml (0.017 fl oz)

18 810460 Service Parts and Procedures SmartSYNC

2

75° and 15° hand torch switches and PCB

3

4

2

1

3

5

2

1

1

2

3

4

5

Service Parts

Item

Part

number

Description and kit contents

1 428958 Kit: Start switch

005684 Start switch for hand torch

2 428869 Kit: Radio-frequency (RF) torch PCB for hand torch

141463 RF torch PCB for hand torch

3 428877 Kit: Clip for RF wires

104912 Clip for RF wires (2)

4 428865 Kit: Cap-sensor switch for 75° hand torch

5 428864 Kit: Cap-sensor switch for 15° hand torch

005710 Cap-sensor switch for 75° hand torch

005722 Cap-sensor switch for 15° hand torch

SmartSYNC Service Parts and Procedures 810460 19

Service Parts

2

1

Full-length machine torch parts

Full-length machine torch assemblies

Item

1 059719 Full-length machine torch assembly with 7.6 m (25 foot) lead*

1 059720 Full-length machine torch assembly with 10.7 m (35 foot) lead*

1 059721 Full-length machine torch assembly with 15 m (50 foot) lead*

1 059722 Full-length machine torch assembly with 23 m (75 foot) lead*

* The torch assembly does not include a cartridge. For a full list of the cutting and gouging cartridges available, refer

Part

number

to the Powermax65/85/105 SYNC Parts Guide (810490).

Description

20 810460 Service Parts and Procedures SmartSYNC

2

Full-length machine torch exterior parts

1

2

3

4

2

3

1

4

4

Service Parts

Item

1 428874 Kit: Shell for full-length machine torch*

2 428863 Kit: Quick-disconnect shell (shell with button – does not include torch lead or connector)

3 428703 Kit: Removable gear rack with screws

4 428148 Kit: Screws for torch handle or quick-disconnect shell

* Does not include gear rack.

Part

number

Description and kit contents

101457 Shell for full-length machine torch

075714 Screws for shell** (7)

075418 Screws for gear rack (2)

420565 Shell for torch quick-disconnect

220681 Latch with red button

127197 Lever for latch

075714 Screws for shell** (4)

420504 Gear rack for full-length machine torch

075418 Screws for gear rack (2)

075714 Screws for torch handle or quick-disconnect shell (7)

** Can also be ordered separately as kit 428148 (quantity: 7).

SmartSYNC Service Parts and Procedures 810460 21

Service Parts

2

1

3

1

2

3

2

Full-length machine torch body and O-ring

Item Part number Description and kit contents

1 528066 Kit: Torch contact ring for torch head

420931 Torch contact ring (2)

2 428950 Kit: O-rings for torch body

058021 O-ring for any SmartSYNC torch (5)

3 428859 Kit: Body for full-length machine torch

420544 Main body replacement for full-length machine torch

075903 Terminal screw (1/4 inch) for pilot arc wire*

075714 Screws for torch handle (7)**

027055 Silicone lubricant, 7.4 ml (0.25 fl oz)***

* Can also be ordered separately as part number 075903 (quantity: 1).

** Can also be ordered separately as kit 428148 (quantity: 7).

*** Can also be ordered separately as part number 027055 (quantity: 1).

22 810460 Service Parts and Procedures SmartSYNC

2

Full-length machine torch switches and PCB

1

2

3

4

5

1

2

3

4

5

Service Parts

Item Part number Description and kit contents

1 428866 Kit: Cap-sensor switch for full-length machine torch

005711 Cap-sensor switch for full-length machine torch

2 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

3 428868 Kit: Switch assembly for torch-lock slider for full-length machine torch

005712 Switch assembly for torch-lock slider for full-length machine torch

4 428872 Kit: Torch-lock slider for full-length machine torch

229848 Torch-lock slider for full-length machine torch (with yellow and green

label)

5 428877 Kit: Clip for RF wires

104912 Clip for RF wires (2)

SmartSYNC Service Parts and Procedures 810460 23

Service Parts

2

1

2

Full-length machine torch lead and terminal screw

Item Part number Description and kit contents

1 075903 Terminal screw (1/4 inch) for pilot arc wire

2 428848

428849
428850
428851

* Can also be ordered separately as part number 075903 (quantity: 1).

Kit: Lead for full-length machine torch, 7.6 m (25 foot)
Kit: Lead for full-length machine torch, 10.7 m (35 foot)
Kit: Lead for full-length machine torch, 15 m (50 foot)
Kit: Lead for full-length machine torch, 23 m (75 foot)

229853 Lead for kit 428848, 7.6 m (25 foot)

229854 Lead for kit 428849, 10.7 m (35 foot)

229855 Lead for kit 428850, 15 m (50 foot)

229856 Lead for kit 428851, 23 m (75 foot)

210735 Data plate: SmartSYNC torch (not shown)

210729 Label: SmartSYNC torch lead (not shown)

075903 Terminal screw (1/4 inch) for pilot arc wire*

24 810460 Service Parts and Procedures SmartSYNC

2

Mini machine and 180° robotic torch parts

1

Mini machine and 180° robotic torch assemblies

Item Part number Description

1 059733 Mini machine and 180° robotic torch assembly with 4.6 m (15 foot) lead*

1 059734 Mini machine and 180° robotic torch assembly with 7.6 m (25 foot) lead*

1 059735 Mini machine and 180° robotic torch assembly with 15 m (50 foot) lead*

Service Parts

* The torch assembly does not include a cartridge. For a full list of the cutting and gouging cartridges available, refer

to the Powermax65/85/105 SYNC Parts Guide (810490).

SmartSYNC Service Parts and Procedures 810460 25

Service Parts

2

2

3

2

3

3

1

1

Mini machine and 180° robotic torch exterior parts

Item Part number Description and kit contents

1 428896 Kit: Shell for mini machine and180° robotic torch

101458 Shell for mini machine and180° robotic torch

075714 Screws for shell* (5)

2 428863 Kit: Quick-disconnect shell (shell with button – does not include torch lead or connector)

420565 Shell for torch quick-disconnect

220681 Latch with red button

127197 Lever for latch

075714 Screws for shell* (4)

3 428148 Kit: Screws for torch shell

075714 Screws for torch handle or quick-disconnect shell (7)

* Can also be ordered separately as kit 428148 (quantity: 7).

26 810460 Service Parts and Procedures SmartSYNC

2

Mini machine and 180° robotic torch lead and terminal screw

2

1

2

Item Part number Description and kit contents

1 075903 Terminal screw (1/4 inch) for pilot arc wire

Service Parts

2 428901

428900
428903

* Can also be ordered separately as part number 075903 (quantity: 1).

Kit: Lead for mini machine and robotic torch, 4.6 m (15 foot)
Kit: Lead for mini machine and robotic torch, 7.6 m (25 foot)
Kit: Lead for mini machine and robotic torch, 15 m (50 foot)

229966 Lead for kit 428901, 4.6 m (15 foot)

229967 Lead for kit 428900, 7.6 m (25 foot)

229969 Lead for kit 428903,15 m (50 foot)

210735 Data plate: SmartSYNC torch (not shown)

210729 Label: SmartSYNC torch lead (not shown)

075903 Terminal screw (1/4 inch) for pilot arc wire*

SmartSYNC Service Parts and Procedures 810460 27

Service Parts

2

1

2

3

4

123

4

Mini machine and 180° robotic switch and PCB

Item Part number Description

1 428867 Kit: Cap-sensor switch for mini machine and180° robotic torch

005723 Cap-sensor switch for mini machine and180° robotic torch

2 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

3 428899 Kit: Jumper wire for RF torch PCB for mini machine or robotic torch*

005724 Jumper wire for RF torch PCB for mini machine or robotic torch

4 428877 Kit: Clip for RF wires

104912 Clip for RF wires (2)

* Does not include RF torch PCB.

28 810460 Service Parts and Procedures SmartSYNC

2

Mini machine and 180° robotic torch body and O-ring

1

2

1

2

3

3

Item Part number Description

1 528066 Kit: Torch contact ring (for torch head)

420931 Torch contact ring (2)

2 428950 Kit: O-rings for torch body

058021 O-ring for any SmartSYNC torch (5)

Service Parts

3 428860 Kit: Body for mini machine and180° robotic torch

420754 Main body replacement for mini machine and180° robotic torch

075903 Terminal screw (1/4 inch) for pilot arc wire*

075714 Screws for torch handle** (5)

027055 Silicone lubricant, 7.4 ml (0.25 fl oz)***

* Can also be ordered separately as part number 075903 (quantity: 1).

** Can also be ordered separately as kit 428148 (quantity: 7).

*** Can also be ordered separately as part number 027055 (quantity: 1).

SmartSYNC Service Parts and Procedures 810460 29

Service Parts

2

1

2

90° and 45° robotic torch parts

90° and 45° robotic torch assemblies

Item Part number Description

1 059731 90° robotic torch assembly with 7.6 m (25 foot) lead*

1 059732 90° robotic torch assembly with 15 m (50 foot) lead*

1 059767 90° robotic torch assembly with 23 m (75 foot) lead*

2 059729 45° robotic torch assembly with 7.6 m (25 foot) lead*

2 059730 45° robotic torch assembly with 15 m (50 foot) lead*

2 059766 45° robotic torch assembly with 23 m (75 foot) lead*

* The torch assembly does not include a cartridge. For a full list of the cutting and gouging cartridges available, refer

to the Powermax65/85/105 SYNC Parts Guide (810490).

30 810460 Service Parts and Procedures SmartSYNC

2

90° and 45° robotic torch exterior parts

3

4

3

4

4

1

1

4

4

3

2

2

Service Parts

Item Part number Description and kit contents

1 428898 Kit: Shell for 90° robotic torch

101481 Shell for 90° robotic torch

075714 Screws for shell* (5)

2 428897 Kit: Shell for 45° robotic torch

101480 Shell for 45° robotic torch

3 428863 Kit: Quick-disconnect shell (shell with button – does not include torch lead or connector)

075714 Screws for shell* (5)

420565 Shell for torch quick-disconnect

220681 Latch with red button

127197 Lever for latch

075714 Screws for shell* (4)

4 428148 Kit: Screws for torch shell

075714 Screws for torch handle or quick-disconnect shell (7)

* Can also be ordered separately as kit 428148 (quantity: 7).

SmartSYNC Service Parts and Procedures 810460 31

Service Parts

2

2

1

2

2

1

90° and 45° robotic torch lead and terminal screw

Item Part number Description and kit contents

1 075903 Terminal screw (1/4 inch) for pilot arc wire

2 428900

428903
428904

* Can also be ordered separately as part number 075903 (quantity: 1).

Kit: Lead for mini machine and robotic torch, 7.6 m (25 foot)
Kit: Lead for mini machine and robotic torch,15 m (50 foot)
Kit: Lead for mini machine and robotic torch, 23 m (75 foot)

229967 Lead for kit 428900, 7.6 m (25 foot)

229969 Lead for kit 428903, 15 m (50 foot)

229970 Lead for kit 428904, 23 m (75 foot)

210735 Data plate: SmartSYNC torch (not shown)

210729 Label: SmartSYNC torch lead (not shown)

075903 Terminal screw (1/4 inch) for pilot arc wire*

32 810460 Service Parts and Procedures SmartSYNC

2

90° and 45° robotic switch and PCB

1

2

3

4

1

2

3

4

1

2

3

4

Service Parts

Item Part number Description

1 428867 Kit: Cap-sensor switch for mini machine or robotic torch

005723 Cap-sensor switch for mini machine or robotic torch

2 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

3 428899 Kit: Jumper wire for RF torch PCB for mini machine or robotic torch*

005724 Jumper wire for RF torch PCB for mini machine or robotic torch

4 428877 Kit: Clip for RF wires

104912 Clip for RF wires (2)

* Does not include RF torch PCB.

SmartSYNC Service Parts and Procedures 810460 33

Service Parts

2

1

2

1

3

2

4

90° and 45° robotic torch body and O-ring

Item Part number Description

1 528066 Kit: Torch contact ring (for torch head)

420931 Torch contact ring (2)

2 428950 Kit: O-rings for torch body

058021 O-ring for any SmartSYNC torch (5)

3 428862 Kit: Body for 90° robotic torch

420756 Main body replacement for 90° robotic torch

075903 Terminal screw (1/4 inch) for pilot arc wire*

075714 Screws for torch handle** (5)

027055 Silicone lubricant, 7.4 ml (0.25 fl oz)***

4 428861 Kit: Body for 45° robotic torch

420755 Main body replacement for 45° robotic torch

075903 Terminal screw (1/4 inch) for pilot arc wire*

075714 Screws for torch handle** (5)

027055 Silicone lubricant, 7.4 ml (0.25 fl oz)***

* Can also be ordered separately as part number 075903 (quantity: 1).

** Can also be ordered separately as kit 428148 (quantity: 7).

*** Can also be ordered separately as part number 027055 (quantity: 1).

34 810460 Service Parts and Procedures SmartSYNC

2

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

059733............................................................................................................25

059734............................................................................................................25

059735............................................................................................................25

059766............................................................................................................30

059767............................................................................................................30

075903......................................................................................18, 24, 27, 32

428148......................................................................................15, 21, 26, 31

428156............................................................................................................16

428182............................................................................................................16

428703............................................................................................................21

428848............................................................................................................24

428849............................................................................................................24

428850............................................................................................................24

428851............................................................................................................24

428852............................................................................................................18

428853............................................................................................................18

428854............................................................................................................18

428855............................................................................................................15

428856............................................................................................................15

428857............................................................................................................17

428858............................................................................................................17

428859............................................................................................................22

428860............................................................................................................29

SmartSYNC Service Parts and Procedures 810460 35

2

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......................................................................................17, 22, 29, 34

36 810460 Service Parts and Procedures SmartSYNC

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.

Get the tools

 Assorted TORX

 Blade screwdriver

 Clamp

 Grounded wrist strap (or similar grounding accessory)

 Anti-static container to store PCB

 Eye protection

 1/4-inch, 3/8-inch, 1/2-inch, and 5/8-inch wrenches (for torch body or torch lead

®

screwdrivers

replacement only)

SmartSYNC Service Parts and Procedures 810460 37

Prepare to Do the Part Replacement

3

Prevent injury to yourself and others

The following precautions apply to all of the procedures in this manual.

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.

All work that requires removal of the plasma power supply outer cover or
panels must be done by a qualified technician.

Refer to the Safety and Compliance Manual (80669C) for more safety
information.

WAR N ING

Wear eye protection. The trigger spring can eject from the right side of the torch handle.

Prevent damage to the RF torch PCB

The following precaution applies to all of the procedures in this manual.

NOTICE

Static electricity can cause damage to printed circuit boards (PCBs). Use correct
precautions when you touch PCBs.

Keep PCBs in antistatic containers.

Put on a grounded wrist strap when you touch PCBs.

CAUTI ON

38 810460 Service Parts and Procedures SmartSYNC

3

Disconnect the power from the cutting system

1

2

3

4

1. Lock the torch.

2. Set the power switch on the plasma power supply to OFF (O).

3. Disconnect the power cord from the power source.

Prepare to Do the Part Replacement

4. Disconnect the gas supply.

Remove the Hypertherm cartridge

NOTICE

To prevent damage to the cap-sensor switch, always remove the cartridge before you start any
replacement procedure.

Turn the cartridge counter-clockwise to remove the cartridge.

SmartSYNC Service Parts and Procedures 810460 39

Prepare to Do the Part Replacement

3

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. Put a clamp on the torch lead to hold the torch in position. Put the clamp 150 mm – 300 mm
(6 inches – 12 inches) from the torch handle or shell.

Figure 1 – 75° hand torch with clamp



This figure shows a 75° hand torch but the procedure is the same for all
torches.

Figure 2 – Full-length machine torch with clamp

This figure shows a full-length machine torch but the procedure is the



same for all torches.

40 810460 Service Parts and Procedures SmartSYNC

3

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.

3. Remove the left side of the torch handle.

Prepare to Do the Part Replacement

Get a photograph of the torch

If possible, get a photograph of the torch components in their
correct positions. You can use the photograph as a reference as
you replace parts.

SmartSYNC Service Parts and Procedures 810460 41

Prepare to Do the Part Replacement

3

42 810460 Service Parts and Procedures SmartSYNC

Hand Torch Part Replacement Procedures

This example shows a 15° torch. The
components are the same for the 75°
torch.

75° torch

7

8

9

1

2

3

4

5

6

9

1

0

1

1

1 Amperage-adjustment control
2 Trigger and trigger spring

3 Tor c h le ad

4 Torch body
5 Torch-lock slider

6 Start switch

7 Radio-frequency (RF) wire and clip
8 RF torch PCB

9 Cap-sensor switch

10 Pilot terminal screw
11 Gas fitting

Figure 3 – 15° and 75° hand torch components

SmartSYNC Service Parts and Procedures 810460 43

Hand Torch Part Replacement Procedures

4

Disassemble the hand torch

This procedure shows how to fully disassemble the torch. This includes removal of all of the torch
components from the right side of the torch handle, and how to disconnect all of the wires.

It is not always necessary to fully disassemble the torch. Only remove and disconnect the
components and wires that you must for each replacement part.

Before you begin

Complete the procedures in Prepare to Do the Part Replacement on page 37:

1. Disconnect the power from the cutting system on page 39.

2. Remove the Hypertherm cartridge on page 39.

3. Put a clamp on the torch lead on page 40.

4. Remove the left side of the torch handle or shell on page 41.

5. Get a photograph of the torch on page 41.

Remove the components from the torch handle

1. Lift the amperage-adjustment control out of the torch handle.

44 810460 Service Parts and Procedures SmartSYNC

Hand Torch Part Replacement Procedures

4

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. Carefully lift the torch lead, body, PCB, and attached wires from the right side of the torch
handle. Use a screwdriver as a lever under the torch body to help you remove the torch body.

Do not bend the gas tube. Do not pinch wires between the screwdriver and the torch
handle.

4. Remove the torch-lock slider.

5. Lift the RF wire out of the RF wire routing post and RF wire clip.

6. Remove the RF wire clip.

SmartSYNC Service Parts and Procedures 810460 45

Hand Torch Part Replacement Procedures

4

75° hand torch 15° hand torch

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.

Disconnect the torch components

1. Remove the wire connector from the start switch. Push the plastic lever, and pull the wire
connector out of the start switch.

2. Remove the 6-wire connector from the receptacle on the RF torch PCB. Do not pull the wires.
Refer to Figure 4 on page 47 for location.

46 810460 Service Parts and Procedures SmartSYNC

Hand Torch Part Replacement Procedures

4

1

3

4

4

2

3

1 6-wire connector

2 2-pin wire receptacle

3 Blue and black cap-sensor switch wires

4 Red RF wires

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. Refer to

Figure 4 on page 47 for location.

a. Remove the blue and black cap-sensor switch wires from the receptacle.

b. Remove the 2 red RF wires from the receptacle.

Figure 4 – RF torch PCB connections for hand torch

4. Put the RF torch PCB in an anti-static container, unless you are replacing the RF torch PCB.

5. Remove the pilot terminal screw.

SmartSYNC Service Parts and Procedures 810460 47

Hand Torch Part Replacement Procedures

4

5/8 inch

1/2 inch

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.

NOTICE

To prevent damage to the torch, always use 2 wrenches to loosen or tighten the gas fitting.

NOTICE

Do not bend the gas tube. If you bend the gas tube, you will not be able to install the torch body in the
torch handle again because it will not fit correctly.

NOTICE

To prevent damage to the torch wires, do not overheat the torch wires.

48 810460 Service Parts and Procedures SmartSYNC

4

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. Do only the steps that are applicable.

Connect the torch components

1. Apply a small quantity of thread locker to the first 2 or 3 threads of the gas fitting on the torch
body. Do not get thread locker on the conical surface of the fitting.

Hand Torch Part Replacement Procedures

2. Attach the torch body to the torch lead as follows:

a. Tighten the gas fitting with your hand.

b. Put the torch body and torch lead on a flat surface.

c. Make sure that the flat sides of the torch body point up.

SmartSYNC Service Parts and Procedures 810460 49

Hand Torch Part Replacement Procedures

4

1

2

1

1 Flat sides of the torch body 2 White wires

5/8 inch

1/2 inch

d. Make sure that the white wires of the torch lead point up.

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). Do not tighten too much. Make sure that the torch body and torch lead stay
aligned.

NOTICE

To prevent damage to the torch, always use 2 wrenches to loosen or tighten the gas fitting.

NOTICE

Do not bend the gas tube. If you bend the gas tube, you will not be able to install the torch body in the
torch handle again because it will not fit correctly.

50 810460 Service Parts and Procedures SmartSYNC

Hand Torch Part Replacement Procedures

4

1

3

4

4

2

3

1 6-wire connector

2 2-pin wire receptacle

3 Blue and black cap-sensor switch wires

4 Red RF wires

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. Attach the pilot arc wire to the torch body with the pilot terminal screw. Tighten to 1.13 N∙m

(10 lbf∙in).

4. Install the wires into the 2-pin receptacles on the RF torch PCB. Refer to Figure 5 on page 51
for location.

a. Push both wires of the cap-sensor switch into the 2-pin receptacle at the same time.

b. Push both red RF wires into the 2-pin receptacle at the same time.

5. Install the 6-wire connector into the receptacle on the RF torch PCB. Refer to Figure 5 on

page 51 for location.

Figure 5 – RF torch PCB connections for hand torch

SmartSYNC Service Parts and Procedures 810460 51

Hand Torch Part Replacement Procedures

4

75° hand torch 15° hand torch

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.

NOTICE

Keep the cap-sensor switch flat in relation to the torch handle, especially with the 15° torch. The fit is
tight, and you can break the cap-sensor switch if you use force.

52 810460 Service Parts and Procedures SmartSYNC

Hand Torch Part Replacement Procedures

4

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.

SmartSYNC Service Parts and Procedures 810460 53

Hand Torch Part Replacement Procedures

4

1

2

1 Pilot arc wire 2 Start-switch wires

1

2

3

1 Torch-lock slider

2 Recess in the torch-lock slider

3 Torch-lock slider switch

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.

5. Make sure that the torch-lock slider switch on the RF torch PCB is in the lock position.

6. Put the torch-lock slider on the torch-lock slider switch, with the yellow lock (X) label pointing to

the torch body. Make sure that the torch-lock slider switch aligns with the recess in the bottom
of the torch-lock slider.

7. Hold the torch-lock slider in position and push the RF torch PCB fully into the torch handle.

54 810460 Service Parts and Procedures SmartSYNC

Hand Torch Part Replacement Procedures

4

1

3

4

5

2

1 RF torch PCB wires

2 Screw boss

3 Cap-sensor wires

4 Pilot arc wire

5 Start-switch wires

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.

10. Push the torch body fully into the torch handle.

11 . Push the torch lead fully into the torch handle.

 Push the gas hose fitting flange onto the support in the handle.

 Align the torch lead strain relief with the recess in the handle, and push the strain relief into

position.

12. Push the RF wire clip onto the torch body. Make sure that the RF wire clip points up, and that
the prong of the RF wire clip is between the 2 mounting studs inside the torch handle.

SmartSYNC Service Parts and Procedures 810460 55

Hand Torch Part Replacement Procedures

4

1

2

3

4

1

2

3

4

75° hand torch 15° hand torch

1 RF wire

2 RF wire clip

3 2 mounting studs

4 Routing post

1

2

3

1 Trigger spring

2 Mounting stud

3 Trigger assembly

13. Put the RF wire through the routing post and into the slot in the RF wire clip.

14. Put the trigger spring on the mounting stud in the trigger.

15. Fully compress the trigger spring. Keep the trigger spring compressed as you push the trigger

assembly into the torch handle. Do not let the trigger spring eject from the torch handle.

56 810460 Service Parts and Procedures SmartSYNC

Hand Torch Part Replacement Procedures

4

1

2

3

4

1 2 tabs
2 2 recesses

3 Switch recess
4 Amperage-adjustment switch

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. Then put the amperage-adjustment control into position on the
RF torch PCB and in the handle.

SmartSYNC Service Parts and Procedures 810460 57

Hand Torch Part Replacement Procedures

4

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
on page 41, or with Figure 6, Figure 7, and Figure 8.

Figure 6 – 75° hand torch components in correct positions

Figure 7 – 15° hand torch components in correct positions

2. Make sure that the routing of all of the wires is correct, as shown.

58 810460 Service Parts and Procedures SmartSYNC

Hand Torch Part Replacement Procedures

4

1

5

3

4

5

2

3

3

75° hand torch 15° hand torch

1 RF torch PCB wires

2 Cap-sensor switch wires
3 Pilot arc wire

4 Start switch wires

5 RF wires

Figure 8 – Wire routing in correct positions

SmartSYNC Service Parts and Procedures 810460 59

Hand Torch Part Replacement Procedures

4

1

2

1 Torch-body end of the left torch handle 2 Torch-lead end of the left torch handle

Install the left side of the torch handle

NOTICE

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. Continue to push the left and
right sides of the torch handle fully together.

2. Make sure that no wires are pinched between the handles. Make sure that the handles stay
aligned.

60 810460 Service Parts and Procedures SmartSYNC

Hand Torch Part Replacement Procedures

4

1

2

3

4

1 Middle of the torch
2 Torch-body end of the torch

3 Torch-lead of the torch
4 Middle of the torch

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. The torch-lead end of the torch.

4. Tighten the screw in the middle of the torch handle again.

5. Do a Check of the Torch Assembly on page 97.

SmartSYNC Service Parts and Procedures 810460 61

Hand Torch Part Replacement Procedures

4

62 810460 Service Parts and Procedures SmartSYNC

Full-Length Machine Torch Part

7

8

9

1

2

3

4

5

6

1

0

7

1 Tor c h le ad

2 Torch body
3 Radio-frequency (RF) torch PCB

4 Cap-sensor switch

5 Torch-lock slider

6 Switch assembly for torch-lock slider

7 RF wires and clip
8 RF torch PCB wires and connector

9 Pilot terminal screw

10 Gas fitting

Replacement Procedures

Figure 9 – Full-length machine torch components

SmartSYNC Service Parts and Procedures 810460 63

Full-Length Machine Torch Part Replacement Procedures

5

Disassemble the full-length machine torch

This procedure shows how to fully disassemble the torch. This includes removal of all of the torch
components from the right side of the torch shell, and how to disconnect all of the wires.

It is not always necessary to fully disassemble the torch. Only remove and disconnect the
components and wires that you must for each replacement part.

Before you begin

Complete the procedures in Prepare to Do the Part Replacement on page 37:

1. Disconnect the power from the cutting system on page 39.

2. Remove the Hypertherm cartridge on page 39.

3. Put a clamp on the torch lead on page 40.

4. Remove the left side of the torch handle or shell on page 41.

5. Get a photograph of the torch on page 41.

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

pinch wires between the screwdriver and the torch shell.

2. Remove the torch-lock slider.

64 810460 Service Parts and Procedures SmartSYNC

Full-Length Machine Torch Part Replacement Procedures

5

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. Pull the switch assembly for the torch-lock slider off of the switch mounting stud.

SmartSYNC Service Parts and Procedures 810460 65

Full-Length Machine Torch Part Replacement Procedures

5

5

1

2

3

4

6

6

1 6-wire connector
2 2-pin wire receptacle

3 Blue and black cap-sensor switch wires

4 Red RF wires
5 Notch in the RF torch PCB

6 Torch-lock switch connector

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. It can be
necessary to use some force, or push the wire into the receptacle before you pull it out. Refer to

Figure 10 on page 66 for location.

a. Remove the blue and black cap-sensor switch wires from the receptacle.

b. Remove the 2 red RF wires from the receptacle.

3. One wire at a time, remove the blue and black torch-lock switch wires from the notch in the RF

torch PCB. Then pull the torch-lock switch connector out of the receptacle. Use your fingernails
to pull out the connector. Do not pull the wires. Refer to Figure 10 on page 66 for location.

Figure 10 – RF torch PCB connections for full-length machine torch

4. Put the RF torch PCB in an anti-static container, unless you are replacing the RF torch PCB.

66 810460 Service Parts and Procedures SmartSYNC

Full-Length Machine Torch Part Replacement Procedures

5

3/8 inch

1/4 inch

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.

NOTICE

To prevent damage to the torch, always use 2 wrenches to loosen or tighten the gas fitting.

SmartSYNC Service Parts and Procedures 810460 67

Full-Length Machine Torch Part Replacement Procedures

5

1

2

1

3

1 Flat sides of the torch body

2 RF wire

3 White wires

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. Do only the steps that are applicable.

Connect the torch components

1. Attach the torch body to the torch lead as follows:

a. Tighten the gas fitting with your hand.

b. Put the torch body and torch lead on a flat surface.

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.

68 810460 Service Parts and Procedures SmartSYNC

Full-Length Machine Torch Part Replacement Procedures

5

3/8 inch

1/4 inch

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. Do not strip the gas fitting.

NOTICE

To prevent damage to the torch, always use 2 wrenches to loosen or tighten the gas fitting.

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. Attach the pilot arc wire to the torch body with the pilot terminal screw. Tighten to 1.13 N∙m

(10 lbf∙in).

SmartSYNC Service Parts and Procedures 810460 69

Full-Length Machine Torch Part Replacement Procedures

5

5

1

2

3

4

6

6

1 6-wire connector

2 2-pin wire receptacle
3 Blue and black cap-sensor switch wires

4 Red RF wires

5 Notch in the RF torch PCB
6 Torch-lock switch connector

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. Install the wires into the 2-pin receptacles on the RF torch PCB. Refer to Figure 11 on page 70
for location.

a. Push both wires of the cap-sensor switch into the 2-pin receptacle at the same time.

b. Push both red RF wires into the 2-pin receptacle at the same time.

5. Install the 6-wire connector into the receptacle on the RF torch PCB. Refer to Figure 11 on

page 70 for location.

Figure 11 – RF torch PCB connections for full-length machine torch

70 810460 Service Parts and Procedures SmartSYNC

5

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.

Full-Length Machine Torch Part Replacement Procedures

3. Align the RF torch PCB with the PCB mounting posts in the shell, and push the PCB into the
torch shell.

4. Put the torch body and lead loosely into position in the shell.

5. Put the torch-lock switch wires into the shell. Hold them down with your finger.

6. Push the cap-sensor wires into the shell.

7. Push the pilot arc wire below the torch body and torch lead in the shell.

8. Push the RF torch PCB wires into the shell.

SmartSYNC Service Parts and Procedures 810460 71

Full-Length Machine Torch Part Replacement Procedures

5

2

3

4

1

1 RF torch PCB wires

2 Cap-sensor wires

3 Pilot arc wire

4 Torch-lock switch wires

9. Make sure that the routing of all the wires is correct, as shown.

10. Push the torch body fully into the torch shell.

11 . Align the torch lead strain relief with the recess in the shell, and push the strain relief into

position.

12. Install the torch-lock slider into the torch shell, with the yellow lock (X) label pointing to the torch

72 810460 Service Parts and Procedures SmartSYNC

body.

Full-Length Machine Torch Part Replacement Procedures

5

2

3

1

1 RF wire

2 RF wire clip

3 Routing post

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.

SmartSYNC Service Parts and Procedures 810460 73

Full-Length Machine Torch Part Replacement Procedures

5

2

1

3

4

5

3

2

1 RF torch PCB wires
2 Cap-sensor switch wires

3 Pilot arc wire

4 Torch-lock switch wires
5 RF wires

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 / Figure 13.

Figure 12 – Full-length machine torch components in correct positions

2. Make sure that the routing of all of the wires is correct, as shown.

Figure 13 – Wire routing in correct positions

74 810460 Service Parts and Procedures SmartSYNC

Full-Length Machine Torch Part Replacement Procedures

5

1

2

1 Torch-body end of the left torch shell 2 Torch-lead end of the left torch shell

Install the left side of the torch shell

NOTICE

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. Continue to push the left and right
sides of the torch shell fully together.

2. Make sure that no wires are pinched between the shells. Make sure that the torch-lock
switch is aligned correctly and can move freely. Make sure that the shells stay aligned.

SmartSYNC Service Parts and Procedures 810460 75

Full-Length Machine Torch Part Replacement Procedures

5

1

2

3

4

1 Middle of the torch
2 Torch-body end of the torch

3 Torch-lead end of the torch
4 Middle of the torch

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. The torch-body end of the torch.

c. The torch-lead end of the torch.

4. Tighten the screw in the middle of the torch shell again.

5. Make sure that the seam between the left and right sides of the torch shell is even. Make sure

that the torch-lock slider moves freely.

6. Do a Check of the Torch Assembly on page 97.

76 810460 Service Parts and Procedures SmartSYNC

Mini Machine and Robotic Torch Part

7

8

1

2

3

4

5

6

5

1 Tor c h le ad

2 Torch body
3 Radio-frequency (RF) torch PCB

4 Cap-sensor switch

5 RF wires and clip

6 RF torch PCB wires and connector
7 Pilot terminal screw

8 Gas fitting

Replacement Procedures

Figure 14 – Mini machine / 180° robotic torch components

SmartSYNC Service Parts and Procedures 810460 77

Mini Machine and Robotic Torch Part Replacement Procedures

6

7

8

1

2

3

4

5

6

5

This example shows a 90° torch.
The components are the same
for the 45° torch.

45° torch

4

1 Tor c h le ad

2 Torch body

3 RF torch PCB
4 Cap-sensor switch

5 RF wires and clip

6 RF torch PCB wires and connector

7 Pilot terminal screw
8 Gas fitting

Figure 15 – 90° and 45° robotic torch components

Disassemble the mini machine or robotic torch

This procedure shows how to fully disassemble the torch. This includes removal of all of the torch
components from the right side of the torch shell, and how to disconnect all of the wires.

It is not always necessary to fully disassemble the torch. Only remove and disconnect the
components and wires that you must for each replacement part.

Before you begin

Complete the procedures in Prepare to Do the Part Replacement on page 37:

1. Disconnect the power from the cutting system on page 39.

2. Remove the Hypertherm cartridge on page 39.

3. Put a clamp on the torch lead on page 40.

78 810460 Service Parts and Procedures SmartSYNC

4. Remove the left side of the torch handle or shell on page 41.

5. Get a photograph of the torch on page 41.

Mini Machine and Robotic Torch Part Replacement Procedures

6

90° robotic torch 45° robotic torchMini machine / 180° torch

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. Do not pinch wires between the screwdriver and the
torch shell.

2. Lift the RF wire out of the RF wire routing post and the RF wire clip.

3. Remove the RF wire clip.

4. Pull the cap-sensor switch off of the cap-sensor switch mounting stud.

SmartSYNC Service Parts and Procedures 810460 79

Mini Machine and Robotic Torch Part Replacement Procedures

6

1

2

3

4

5

5

1 6-wire connector

2 2-pin wire receptacle
3 Blue and black cap-sensor switch wires

4 Red RF wires

5 Jumper wire connector

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. 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. Refer to

Figure 16 on page 80 for location.

a. Remove the blue and black cap-sensor switch wires from the receptacle.

b. Remove the 2 red RF wires from the receptacle.

3. Pull the jumper wire connector out of the receptacle. Do not pull on the wire. Refer to Figure 16

on page 80 for location.

Figure 16 – RF torch PCB connections for mini machine and robotic torch

4. Put the RF torch PCB in an anti-static container, unless you are replacing the RF torch PCB.

80 810460 Service Parts and Procedures SmartSYNC

Mini Machine and Robotic Torch Part Replacement Procedures

6

5/8 inch

1/2 inch

5/8 inch

1/2 inch

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.

NOTICE

To prevent damage to the torch, always use 2 wrenches to loosen or tighten the gas fitting.

NOTICE

Do not bend the gas tube. If you bend the gas tube, you will not be able to install the torch body in the
torch shell again because it will not fit correctly.

SmartSYNC Service Parts and Procedures 810460 81

Mini Machine and Robotic Torch Part Replacement Procedures

6

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. Do only the steps that are applicable.

Connect the torch components

1. Attach the torch body to the torch lead.

a. Tighten the gas fitting with your hand.

b. Put the torch body and torch lead on a flat surface.

82 810460 Service Parts and Procedures SmartSYNC

Mini Machine and Robotic Torch Part Replacement Procedures

6

1

3

1

1

3

1

4

4

2

2

1 Flat sides of the torch body

2 RF wire

3 White wires

4 RF torch PCB wires

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.

SmartSYNC Service Parts and Procedures 810460 83

Mini Machine and Robotic Torch Part Replacement Procedures

6

5/8 inch

1/2 inch

5/8 inch

1/2 inch

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. Do not strip the gas fitting.

NOTICE

To prevent damage to the torch, always use 2 wrenches to loosen or tighten the gas fitting.

NOTICE

Do not bend the gas tube. If you bend the gas tube, you will not be able to install the torch body in the
torch shell again because it will not fit correctly.

84 810460 Service Parts and Procedures SmartSYNC

Mini Machine and Robotic Torch Part Replacement Procedures

6

1

2

3

4

5

5

1 6-wire connector

2 2-pin wire receptacle
3 Blue and black cap-sensor switch wires

4 Stripped red RF wires

5 Jumper wire connector

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. Attach the pilot arc wire to the torch body with the pilot terminal screw. Tighten to 1.13 N∙m

(10 lbf∙in).

3. Install the jumper wire connector into the receptacle. Refer to Figure 17 on page 85 for location.

4. Install the wires into the 2-pin receptacles on the RF torch PCB. Refer to Figure 17 on page 85

for location.

a. Push both wires of the cap-sensor switch into the 2-pin receptacle at the same time.

b. Push both red RF wires into the 2-pin receptacle at the same time.

5. Install the 6-wire connector into the receptacle on the RF torch PCB. Refer to Figure 17 on

page 85 for location.

Figure 17 – RF torch PCB connections for mini machine and robotic torch

SmartSYNC Service Parts and Procedures 810460 85

Mini Machine and Robotic Torch Part Replacement Procedures

6

90° robotic torch 45° robotic torchMini machine / 180° torch

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.

2. Align the RF torch PCB with the PCB slot in the shell, and push the PCB into the torch shell.

3. Put the torch body and lead loosely into position in the shell.

4. Push the cap-sensor wires into the shell. Make sure that the wires go around the stud.

5. Push the pilot arc wire below the torch body and lead in the shell.

6. Push the RF torch PCB wires into the shell.

86 810460 Service Parts and Procedures SmartSYNC

Mini Machine and Robotic Torch Part Replacement Procedures

6

2

3

1

2

1

3

Mini machine / 180° robotic torch

45° robotic torch

1 RF torch PCB wires

2 Cap-sensor wires

3 Pilot arc wire

7. Make sure that the routing of all the wires is correct, as shown.

8. Push the torch body fully into the torch shell.

9. Align the torch lead strain relief with the recess in the shell, and push the strain relief into

position.

SmartSYNC Service Parts and Procedures 810460 87

Mini Machine and Robotic Torch Part Replacement Procedures

6

2

3

1

Mini machine / 180° robotic torch

45° robotic torch

90° robotic torch

2

3

1

2

3

1

1 RF wire
2 RF wire clip

3 Routing post

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.

88 810460 Service Parts and Procedures SmartSYNC

Mini Machine and Robotic Torch Part Replacement Procedures

6

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 18, Figure 19, and Figure 20.

Figure 18 – Mini machine and 180° robotic torch components in correct positions

Figure 19 – 90° robotic torch components in correct positions

Figure 20 – 45° robotic torch components in correct positions

2. Make sure that the routing of all of the wires is correct, as shown.

SmartSYNC Service Parts and Procedures 810460 89

Mini Machine and Robotic Torch Part Replacement Procedures

6

1

4

2

3

2

3

Mini machine / 180° robotic torch

45° robotic torch

90° robotic torch

2

3

2

3

Mini machine / 180° robotic torch

45° robotic torch

4

4

1

2

3

1 RF torch PCB wires

2 Cap-sensor switch wires

3 Pilot arc wire

4 RF wires

Figure 21 – Wire routing in correct positions

90 810460 Service Parts and Procedures SmartSYNC

Mini Machine and Robotic Torch Part Replacement Procedures

6

1

2

1 Torch-body end of the left torch shell 2 Torch-lead end of the left torch shell

Install the left side of the torch shell

NOTICE

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. Continue to push the left and right
sides of the torch shell fully together.

2. Make sure that no wires are pinched between the shells. Make sure that the shells are still
aligned.

3. Attach the left side of the torch shell to the right side of the torch shell with the 5 screws. Install
the screws in the following sequence:

a. The middle of the torch.

b. The torch-body end of the torch.

c. The torch-lead end of the torch.

SmartSYNC Service Parts and Procedures 810460 91

Mini Machine and Robotic Torch Part Replacement Procedures

6

123

4

1 Middle of the torch
2 Torch-body end of the torch

3 Lead-end of the torch
4 Middle of the torch

4. Tighten the screw in the middle of the torch shell again.

5. Make sure that the seam between the left and right sides of the torch shell is even.

6. Do a Check of the Torch Assembly on page 97.

92 810460 Service Parts and Procedures SmartSYNC

Torch Lead Replacement Procedures

Replace the torch quick-disconnect shell

Before you begin

Complete the following procedures:

1. Disconnect the power from the cutting system on page 39.

2. Disconnect the torch (page 95).

3. Put a clamp on the torch lead on page 40.

Remove the torch quick-disconnect shell

1. Remove the 4 screws from the torch quick-disconnect shell.

2. Remove the torch quick-disconnect shell. The shell is 2 pieces.

SmartSYNC Service Parts and Procedures 810460 93

Torch Lead Replacement Procedures

7

1

2

1 Red button 2 Latch tab

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.

4. Remove the lever from the torch quick-disconnect housing.

Install the torch quick-disconnect shell

1. Put the latch with the red button into the torch quick-disconnect housing.

2. Hold the latch up and put the lever under the latch.

3. Push the lever into the torch quick-disconnect housing until it clicks into place.

4. Put the 2 new torch quick-disconnect shell pieces onto the torch lead.

94 810460 Service Parts and Procedures SmartSYNC

7

5. Make sure that the strain relief fits in the slot of the shell and the wires are not pinched and do

Red button

not cause interference with the latch.

6. Install the 4 screws to attach the torch quick-disconnect shell.

7. Connect the torch (page 95).

Replace the torch assembly with lead

Torch Lead Replacement Procedures

1. Disconnect the power from the cutting system on page 39.

2. Disconnect the torch. Push the red button on the torch quick-disconnect and pull the connector

out of the receptacle on the front panel of the plasma power supply.

3. Connect the torch. Push the torch quick-disconnect into the receptacle. The connector makes a
click when it is fully engaged.

SmartSYNC Service Parts and Procedures 810460 95

Torch Lead Replacement Procedures

7

96 810460 Service Parts and Procedures SmartSYNC

Do a Check of the Torch Assembly

1

2

3

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. Cap-sensor tab in torch body: Use a blade screwdriver to push

down the cap-sensor tab inside the torch body. You must hear a
click.

SmartSYNC Service Parts and Procedures 810460 97

Do a Check of the Torch Assembly

8

98 810460 Service Parts and Procedures SmartSYNC