Thermal Dynamics MERLIN 6000 Service Manual Download Page 56

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REPLACEMENT PROCEDURES

Manual 0-2569

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-A.

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.

F. Thermostat Assembly Replacement

There are three Thermostat Assemblies mounted to
the 29KVA Transformer. The Thermostat Assemblies
are all replaced in the same way. To replace a Ther-
mostat Assembly use the following procedure:

1. Remove the Left and Right Panels per Section

5.04-A.

2. Locate the Thermostat Assembly to be replaced

and place a clean rag under the copper support.
This will prevent debris from getting into the trans-
former coil.

3. Remove the tie-wrap securing the glass sleeving

over the Thermostat Assembly.

4. Slide the glass sleeving back over the wiring har-

ness (see NOTE) to expose the Thermostat Assem-
bly connections.

NOTE

To make it easier to slide the glass sleeving back far
enough, it may be necessary to remove a second
tie-wrap on the wiring harness.

5. Disconnect the wiring connections at the Thermo-

stat Assembly.

6. The Thermostat Assembly has Loctite on the threads

and requires heat to break the seal. At the copper
support carefully use a propane torch to heat the
base and exposed threads of the Thermostat As-
sembly for 30 to 60 seconds.

7. Carefully use a wrench to remove the Thermostat

Assembly. If resistance is felt, apply more heat (see
NOTE).

NOTE

Using excessive force will cause the Thermostat
Assembly mounting stud to shear off.

8. Clean the Thermostat Assembly contact surface area

of the copper support.

9. Install the replacement Thermostat Assembly by

reversing the above procedure and noting the fol-
lowing:

• Carefully bend the tabs on the replacement Ther-

mostat Assembly 90° the same as the removed
part.

• Apply Loctite 290 or equivalent to the Thermo-

stat Assembly stud threads.