Service
5-4
6600-0361-000
08/10/02
5-4
Replacing the Bulb Bracket and Thermostat
(See Figure 5-3)
1.
Remove the front cover, EMI shield, gooseneck and bulb.
2.
Use a 7mm wrench to remove the 3 screws that secure the bracket.
3.
Pop the seal out of its groove. To remove the mirror, use a 2mm hex key to remove the 2 screws that hold
it in position.
4.
To remove the thermostat, disconnect its connector from J4 on the LED board.
5.
Cut the 2 cable ties that secure the thermostat to the cable tie holder and remove the thermostat. If you
are replacing the thermostat, remember to order 2 new cable ties to hold it in position.
6.
Remove the wire bulb retainer by removing the nut that secures it on the mounting stud. When replacing
or reinstalling the bulb retainer, position it from 0.45 to 0.5 inches from the bulb bracket to maintain ad-
equate spring load on the bulb.
Replacing the Ballast
(See Figure 5-3)
WARNING
w
Shock hazard. The ballast emits high voltage pulses. Disconnect the unit from power
source and use extreme care when servicing it. It is not recommended to measure the
voltages at the lamp: this may damage measuring equipment.
1.
Disconnect all the wire harnesses coming from the ballast.
2.
Disconnect the bulb connector from the bulb.
3.
Cut the cable tie strain relief. Order a new cable tie (6600-0384-400) when you replace the ballast.
4.
Using a 2mm hex key, remove the 4 M3 screws that secure the ballast and remove the ballast.
Removing other components
(See Figure 5-5 and 5-6)
To replace the components located in the lower portion of the unit it is necessary to first remove the large U
shaped bracket at the bottom of the unit. To remove the bracket use a 7mm wrench to remove the 2 nuts that
hold the bracket to the back cover. It may be necessary to carefully move or remove ballast fan bracket to
access the other components.
Power Supply-
To remove the power supply, first disconnect its wire harness, then use a Phillips head screw-
driver to remove the 4 screws that secure it to the back cover.
Main Fan-
To remove, first remove the fan guard and filter from the bottom of the unit, then disconnect the fan
from J2 on the LED board. Use a Phillips head to turn the 4 screws and a 5.5mm wrench to hold the 4 nuts
that secure it to the U bracket.
Indicator Board-
To remove the LED Board, first disconnect the boards wire harnesses, then pop the board
off its standoffs.
Circuit Breakers-
to remove the circuit breakers disconnect their wire harnesses then unscrew the knurled nut
that holds them to the U bracket.
Power Switch, Line Filter and Hour Meter-
To remove any of these components simply disconnect their wire
harnesses and pop them out of their cutout in the U bracket. The line filter is secured by two screws.
When removing the power switch, you must also remove its clear plastic drip cover. When replacing the
hour meter, you must also replace its label on the front cover.
