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Repair and Repl acement Procedures 7-18 ProMa ster 25 00 U ser Ma nual Replacing the Programming Module Clamp Air Cylinder If the programming m odule clamp air cylinder f ails, follow the steps below to replace it. 1. Tu…

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Repair and Replacement Procedures
ProMaster 2500 User Manual 7-17
11. Carefully pull the input orbital assembly off the motor spindle and
then slide the assembly to the left, until the right side of the assembly
is free.
12. Install the repaired input orbital assembly and re-assemble all of the
disconnected cables and components.
Replacing the
Output Orbital Tube
Clamp
If an orbital tube clamp on the output orbital tube clamp assembly needs
to be repaired, follow the steps below to remove and reinstall it.
1. Turn off the 2500 and remove the power cord.
2. Remove the PE assembly, as described on page 7-3.
3. Lift the main plate and locate the round input orbital motor clamp.
Loosen the set screw and remove the motor clamp.
4. Remove the two 3/32-inch hex screws that hold the right orbital
alignment block to the underside of the main plate. Slide the right
orbital retaining block off the dowel pin and let the block dangle from
the cables.
5. Remove the two 3/32-inch hex screws that hold the left orbital
alignment block to the underside of the main plate. Remove the left
orbital alignment block.
6. Remove the 3/32-inch hex screw that holds the grounding strap to
the underside of the main plate.
7. Use a needle nose pliers to remove the track springs.
8. Remove the four 3/32-inch hex screws on the underside of the output
orbital plate.
9. Cut the tie wraps and disconnect the four optic cable connectors and
the single microswitch cable connector.
10. Carefully pull the output orbital assembly off the motor spindle.
11. Install the repaired output orbital assembly and re-assemble all of the
disconnected cables and components.
Figure 7-14
Remove the Track Springs
2309-1
OUTPUT ORBITAL
ASSEMBLY
SPRING (1 of 4)
CENTER POST (1 of 2)
Repair and Replacement Procedures
7-18 ProMaster 2500 User Manual
Replacing the
Programming
Module Clamp Air
Cylinder
If the programming module clamp air cylinder fails, follow the steps
below to replace it.
1. Turn off the 2500 and remove the power cord.
2. From above the main plate, remove four of the six 7/64-inch hex
screws (two front ones and two back ones) holding the programming
module clamp assembly to the main plate.
3. Holding the PE from the bottom (below the main plate), remove the
other two screws. Lower the programming module clamp assembly
and let it rest on the black protective shield.
4. Remove the two blue and two red air lines from the four quick
connects, noting their positions for reinstallation.
5. Remove the retaining bar. This bar holds the programming
electronics assembly in place on the underside of the main plate. Use
a 7/64-inch hex wrench to remove the two hex screws that hold the
bar in place. Set them in a safe place to use when you reinstall the
assembly.
6. Use a wrench to remove the air cylinder nut, then pull the air cylinder
away from the programming module clamp assembly.
7. Install the new air cylinder.
8. Ensure that the clamps pull back far enough to clear the inside wall
when retracted. If not, loosen the locking nut attaching the cylinder
shaft to the back of the clamp. Using a small pair of needle-nose
pliers, turn the shaft further into the clamp. Tighten the locking nut
when the clamps pull back far enough.
9. Reinstall all of the removed components.
10. Reinstall the programming module clamp assembly and reconnect
the air lines.
Repair and Replacement Procedures
ProMaster 2500 User Manual 7-19
Solenoid Replacement
This procedure describes the steps required to remove and replace a
solenoid. You can use this procedure to replace any of the solenoids in the
2500.
Replacing a Solenoid
If a solenoid fails, follow the steps below to replace it.
1. Turn off the 2500 and remove the power cord.
2. Disconnect the source air line and the input air line from the 2500 (as
described on page 2-6).
3. Disconnect the signal cable from the solenoid.
4. Use a small Phillips screwdriver to remove the two screws that
connect the solenoid to the manifold.
Note: As you remove the solenoid, make sure you don’t drop or lose the gasket
that is mounted between the solenoid and the manifold.
5. When you install the new solenoid on the manifold, make sure the
gasket stays in place between the solenoid and the manifold, then
reconnect the signal cable.
Power Supply Replacement
These procedures describe the steps required to remove and replace a
failed power supply.
Figure 7-15
Removing the Air Cylinder
2312-1
AIR CYLINDER NUT
AIR CYLINDER