DirectFlo DF1400
Chapter 5: Trouble-Shooting and Repair
Comco Inc.
5-15
Issue Date: January 2009
Inspecting and Repairing the Modulator
(refer to Figure 5-3)
Proceed as far as necessary according to the problem.
1.
Turn the power OFF and unplug the unit.
2.
Remove the tank lid and the powder basket from the tank.
3.
Remove the cabinet cover. See instructions above.
4.
Detach the air hose from the modulator.
5.
Using a 3/4" open-end wrench, remove the coil retaining coupler from the
modulator housing. Slide the coil and 1" washer off the modulator
housing.
Save the washer
.
6.
With a 7/16" open-end wrench across the two flats of the modulator nose,
remove the modulator nose from the stainless steel body.
7.
Examine the polyurethane seat cemented on the modulator nose. It
should be smooth and unmarked except for a faint ring (impression)
matching the ring seat on the core.
8.
Tip the DirectFlo onto its left side and allow the core to slide out. Note the
core’s orientation, the cross-holes must be nearest the tank.
9.
Examine the edges and ring seat of the core. They must be smooth and
even. If it has any scratches or roughness that can be felt with a
fingernail replace the entire Modulator Housing Assembly PF2040. If
neither the nose seat nor the core is worn, reassemble the modulator
housing assembly and skip to step 13.
Note:
Make sure the core is inserted properly into the housing. The cross-holes
must be nearest the tank.
10.
Using a 5/8" open-end wrench remove the modulator housing from the
tank. Access the housing through the opening in the bottom of the
chassis.
11.
Use a vacuum to remove any residual powder from inside the tank-mixing
chamber (at the modulator connection).
12.
Make sure threads are clean and abrasive free. Install the new Modulator
Housing Assembly (PF2040) to the tank.
13.
Slide the 1" washer over the modulator housing and then slide the
modulator coil over the modulator housing.
14.
Replace the retaining coupler.
15.
Install the air hose.
16.
Replace the DirectFlo cover and install the tank cover.
