Thermal Dynamics PAK Master 150XL, Service Manual

Page: 52 / 90

REPLACEMENT PROCEDURES 5-14 Manual 0-2728
D. Main Contactor Assembly (W) Replacement
NOTE
The Main Contactor was located in the Base on
earlier units and on the Center Chassis for current
units.
1. Remove the Left Side Panel per Section 5.04-A.
2. Note orientation of the Main Contactor and loca-
tion of all wires and cables connected to the
Contactor Assembly.
3. Disconnect wires and cables at Main Contactor.
4. Remove the two nuts securing the Contactor As-
sembly to the two mounting studs in the unit.
5. Install the replacement Main Contactor Assem-
bly by reversing the above steps, connecting wires
as follows:
a. Connect ground wire as shown.
A-02291
Side
Panel
Ground
Main
Harness
Ground
Input
Board
Ground
3-Star
Washers
2-Brass
Nuts
b. Attach main harness wires #55 and #59 to the
coil of the Contactor.
L1
L2
L3
Main Contactor
(MC1)
A-02453
Coil
Wire #59
Coil
Wire #55
c. Attach the main harness wires #4 & #5 to the
inner prong of L1 & L2 respectively of the main
contactor.
d. Connect cables 1, 2, and 3 to T1, T2, and T3
respectively.
E. Motor (M5) / Fan / Pump Replacement
The simplest way to replace the Motor is to remove the
Motor, Fan and Pump together, then replace the Motor.
The procedure below describes how to remove the Mo-
tor/Fan Pump Assembly to replace the Motor. To replace
the Fan, continue with the procedures outlined in Sec-
tion 5.08-F, Fan Assembly Only Replacement. To replace
the Pump, follow the procedures outlined in Section 5.08-
G, Pump Assembly Replacement.
1. Remove the Right Panel per Section 5.04-A.
2. Disconnect the following:
NOTE
Coolant may drain from the hoses. It is recom-
mended that a bucket, rags or towels be placed be-
low the hose prior to removing.
a. Radiator to In-Line Filter Hose - disconnect
at Filter.
b. Radiator to Torch Hose - disconnect at Bulk-
head.
c. Pump to Coolant Filter Hose - disconnect at
Pump.
d. Pump to Torch Hose - disconnect at Bulkhead.
e. Remove tie wraps as necessary.
3. Note connection of all wires to Motor then dis-
connect wires.
4. Remove four nuts and washers securing the Mo-
tor Mount to the base, and remove Motor/Pump/
Fan Assembly.
5. Replace Fan and Pump per procedures in Sections
5.09-F and 5.09-G respectively, if required.
6. Install the replacement Motor with pump and fan
by reversing the above procedure (see NOTE).
NOTE
Before installing the replacement Motor, check that
the internal wiring of the Motor is set for the proper
input voltage per the information on the Motor
nameplate.