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MAIN TRANSFORMER DISASSEMBLY
1.Perform Lift Bail Removal Procedure.
2.Remove lead #271 from resistor R3 (located near the input contactor).
3.Separate the
4.Remove lead #256 from the choke thermostat.
5.Remove lead #220 from the reed switch (3CR).
6.Cut any necessary cable ties or restraints and clear the leads nec- essary for the removal of the top transformer iron.
7.Using a 3/8” socket wrench, remove two screws mounting the input con- tactor bracket to the case back assembly. With leads attached, carefully pull assembly up and out of the way. Set assembly aside.
8.Using a 1/2” socket wrench, move 16 screws (8 on each side) from the transformer side brackets. Taking note of placement, remove the four brackets and two bottom spacers. See Figure F.26.
9.Using a 3/4” wrench, remove the six nuts and lock washers from the transformer threaded rods. It may be necessary to hold the threaded rods to keep them from turning.
10.Using a hoist, carefully lift the top iron from the assembly. Note the placement of shims and insulators.
NOTE: Some prying and jolting may be necessary to free the iron from the coils. Replace any coils that may be faulty. If any heavy aluminum secondary coils are to be replaced, identify and label all leads to the transformer. The leads will have to be cut and then TIG welded upon reassembly.
COIL REMOVAL AND
REPLACEMENT
1Label and disconnect leads to the coils that are being removed or replaced (see Wiring Diagram).
2Refer to Figure F.26 for proper coil locations (top, bottom, left, right, and center) of primary and sec- ondary coils. If secondary coils are to be replaced, it will be necessary to cut the leads and TIG weld upon reassembly.
3.Remove the coils:
a.Some prying and jolting may be necessary to free the coils from the iron.
b.Note placement of insulation and wedges for reassembly (especially primary coil to lami- nation insulation and secondary to primary insulation).
4.Replace the coils:
a.Be sure to replace all insulation and wedges that were removed (lamination to coils, and primary to secondary coils).
b.Using a high temperature industrial epoxy, such as Lincoln E1603, glue the coils in place by applying the epoxy to the coil sides along the lamina- tion, cell insulation, and wedges.
c.Glue the secondary coils in place from the iron to the coil sides.
5.
6.When reconnecting any aluminum leads, apply a thin layer of Dow Corning 340 Heat Sink Compound to mating surfaces.
