6.Install the replacement Transformer Assembly by reversing the above procedure.

C.Main Contactor (W1 or W2) Replacement

NOTE

The Main Contactors, W1 and W2, are replaced in the same manner.

1.Depending on which Main Contactor Assembly is to be replaced, remove the Left or Right Side Panel per Section 5.04-B.

2.Label all the wiring connected to the Main Contac- tor Assembly.

3.Disconnect the wires from the Main Contactor As- sembly terminals.

4.Remove the two screws and star washers securing the Main Contactor Assembly to the Base.

5.Install the replacement Main Contactor Assembly by reversing the above procedure.

D.Motor (M1) Assembly Replacement

1.Remove the Left and Right Side Panels per Section 5.04-B.

2.Loosen the allen set screw securing the Coupling to the shaft of the Motor Assembly.

3.Remove the two bolts and nuts securing the Pilot Resistors, air cooled 4.5 ohms, to the left Pilot Re- sistor Mounting Support.

4.Remove the two bolts securing the Pilot Resistor Mounting Support to the Base.

5.Carefully suspend the free end of the Pilot Resis- tors with string to prevent damage to the resis- tors.

6.Disconnect the Motor Assembly wiring.

7.Remove the four bolts securing the Motor Assem- bly to the Base.

8.Remove the complete Motor Assembly out the left side of the unit.

9.Install the replacement Motor Assembly by revers- ing the above procedure.

E.Pump Assembly Replacement

1.Remove the Right Side Panel per Section 5.04-B.

2.Disconnect the two Hose Assemblies at the fittings on the Pump Assembly.

3.Loosen the allen set screw securing the Coupling to the Pump Assembly shaft.

4.Note the orientation of the Pump Assembly to the Pump Mounting Plate.

5.Remove the three nuts securing the Pump Assem- bly to the Pump Mounting Plate.

6.Remove the Pump Assembly from the unit.

7.Install the replacement Pump Assembly by revers- ing the above procedure and noting the follow- ing:

•Remove the Fittings from the old Pump Assem- bly and install on the replacement Pump As- sembly.

•Be sure to align the Pump Assembly to the Pump Mounting Plate as noted in Step 4 above.

5.09Upper Chassis Parts Replacement

NOTE

Refer to Section 6.08, Upper Chassis Replacement Parts, for parts list and overall detail drawing.

A. Power Driver PC Board Kit Replacement

The Power Driver PC Board Replacement Kit is a di- rect parts replacement for the failed Driver PC Board and Switching Transistor (Q1) Assemblies in the Power Supply.

WARNING

Disconnect primary power at the source before as- sembling or disassembling power supply, torch parts, or torch and leads assemblies.

1.Turn OFF main input power to the Power Supply both at the Power Supply ON/OFF switch and at the main power disconnect.

2.Wait at least two minutes to allow the input ca- pacitors to discharge.

3.Remove the top panel of the Power Supply. To remove the top panel of the Power Supply requires the removal of several phillips head screws. Care- fully remove all the screws before attempting to remove the top panel.

4.Locate the old Driver PC Board Assembly on the inside left side, behind the front panel, as viewed from the front of the unit.

REPLACEMENT PROCEDURES

40

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Thermal Comfort 3000 Upper Chassis Parts Replacement, Main Contactor W1 or W2 Replacement, Motor M1 Assembly Replacement
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3000 specifications

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