Thermal Arc ULTIMA 150, Service Manual

Page: 40 / 64

SECTION 4: REPAIRS & REPLACEMENT 34 Manual 0-2503
4.09 Hose Assembly Replacements
This subsection describes the replacement of the various
Hose Assemblies used in the ULTIMA-150 Plasma Welder.
Refer to Section 5, Replacement Parts for the part num-
ber and location of each part. For a block diagram of the
ULTIMA-150 Plasma Welding Hose Assemblies refer to
Appendix V.
A. Coolant Supply Hose (Reservoir to Coolant
Filter) Assembly Replacement
The Coolant Supply Hose Assembly goes from the Cool-
ant Reservoir to the Coolant Filter Assembly mounted
on the rear panel. Replace the Hose Assembly using the
following procedure:
1. Drain the coolant from the Coolant Reservoir per the
following procedure:
a. Disconnect the input hose at the rear panel
Coolant Filter Assembly. The hose goes from
the bottom of the reservoir to the Coolant Fil-
ter Assembly.
b. Place the end of the hose into a container to
catch the coolant as it flows from the reser-
voir.
NOTE
Do Not run the pump as the coolant will gravity
feed from the reservoir.
CAUTION
Handle and dispose of the used coolant per recom-
mended procedures.
2. Disconnect the other end of the Hose Assembly
from the Coolant Reservoir.
3. Remove the Hose Assembly from the unit.
4. Install the replacement Hose Assembly by revers-
ing the above steps.
5. Refill the ULTIMA-150 Plasma Welder with Ther-
mal Arc® Torch Coolant before applying power.
B. Coolant Supply Hose (Coolant Filter to
Pump) Assembly Replacement
The Coolant Supply Hose Assembly goes from the rear
panel Coolant Filter Assembly to the Pump Assembly.
Replace the Hose Assembly using the following proce-
dure:
1. Remove the Enclosure Cover per Section 4.04.
2. Disconnect the Hose Assembly from the Coolant Fil-
ter Assembly on the rear panel.
3. Remove the other end of the Hose Assembly from
the Pump Assembly.
4. Remove the Hose Assembly from the unit.
5. Install the replacement Hose Assembly by reversing
the above steps.
C. Coolant Return Hose (TORCH Connector to
Radiator) Assembly Replacement
The Coolant Return Hose Assembly goes from the
TORCH Connector to the upper side of the Radiator.
Replace the Hose Assembly using the following proce-
dure:
1. Remove the Enclosure Cover per Section 4.04.
2. Disconnect the other end of the Hose Assembly from
the check valve on the rear panel TORCH connector.
3. Locate the end of the Coolant Return Hose Assembly
connected to the upper part of the radiator.
4. With a screwdriver loosen the Hose Clamp around
the Hose Assembly.
5. Pull the Hose Assembly from the Radiator.
6. Remove the Hose Assembly from the unit.
7. Install the replacement Hose Assembly by reversing
the above steps.
NOTE
It is very important that this hose goes between
the two gas hoses.