Items referenced in Table D - Service Parts, page 4.
(1) Item 4.
(2) Items 4, 6, 8, 9, 10, 11, 13, 14.
The following steps are
recommended when servicing those service parts listed
in Table D - Service Parts, page 4.
Preferred service tools are:
• Screw driver TX 15 and TX 10
• Solder SN62
• Needle nose pliers, small tip
• Solder iron, electronic type
• Volt/ohm meter (VOM)
• Cleaning solvent, Chemtronics 2000 ES 1601
• Torque wrench, 0-50 in•lb (0-66 N•m)
REPLACING COVER AND/OR
ELECTRICAL CONNECTOR
1.
Wipe down external surface to ensure that loose
contaminants will not fall inside the housing.
2.
Place the valve in a firm position at 45° with the electrical
connector tilted upwards (PCPs built after 1988 are filled
with a silicon oil). Locate and remove the four connector
screws (Item 9 if MS connector, or Item 11 if Packard
connector).
3.
Hold the electrical connector and untwist wires by rotating
the connector CCW two turns while gently pulling away
from the housing.
4.
Clean the solder connections inside connection of the
electrical connector with degreaser. Unsolder the wires,
noting which pin goes to which wire color (i.e., Pin A to
black, Pin B to red, Pin C to brown, etc.). With the
connector held firmly, place the solder iron against the
base solder cup if MS, and pin if Packard, until the wires
can be gently pulled away.
5.
The cover can now be removed and replaced if required.
Be sure the cover gasket (Item 3) is firmly seated into the
cover base and is in good condition before cover is
installed. Torque cover screws to 12-15 in•lb (16-20
N•m).
6.
Verify that wire to pin connections are correct before
soldering wires. Also ensure that the connector gasket
(see Table D - Service Parts, Item 3, page 4) is in place
before soldering.
7a. For the MS style connector, ensure that the cups have
sufficient solder (approximately level). If additional
solder is required, place solder iron against the base of
the cup and add solder. While solder is still liquid, place
wire in the cup, remove iron and let cool for several
seconds while holding wire firmly.
SERVICE PARTS
(continued)
DO NOT Remove Cover Screws, unless replacing cover.
WARNING
7b. For the Packard style connector, the wire should extend
around and contact the terminal post for at least 180° (1/
2 wrap to a maximum of 270°). When ready to solder,
heat the terminal and add solder, remove iron, and let
cool for several seconds while holding wire firmly.
8.
After soldering, ensure that terminals and wires do not
contact one another.
9.
If silicone oil is to be added, do so at this step with the
connector not yet attached to cover. Tilt cover upward
and add 45-cc of oil from container. The container (P/N
K21436) holds enough for 3 fills.
10. Before attaching the connector to the cover, rotate
connector CW two turns. This will bundle the wires
together, finishing with the notch up when viewed from
the outward side of the MS connector, and lead wires
down for Packard connector (see MS Connector Pin
Orientation, page 9). Insert connector screws and
torque to 8-10 in•lb (11-13 N•m).
11. With a VOM, check for proper coil resistance between
terminals A and B, and between C and D if PCP is a dual
coil.
© Danfoss, 2014-05
11152452 • Rev AA • May 2014
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