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Repair and Repla cement Procedures ProM aster 25 00 User Manua l 7-19 Solenoid Replacement This procedure describes the steps req uired to remove and replace a solenoid. You can use th is procedure to replace any of the …

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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
Repair and Replacement Procedures
7-20 ProMaster 2500 User Manual
Replacing the PE
Power Supply
If the programming electronics power supply fails, follow the steps below
to replace it.
1. Turn off the 2500 and remove the power cord.
2. Disconnect the two cable connectors.
3. Remove the four 1/4-inch hex nuts at the corners of the assembly.
4. Carefully lift out the PE power supply assembly.
5. Install the new PE power supply and reconnect the cables.
Replacing the Toroid
Transformer
If the Toroid transformer fails, follow the steps below to replace it.
1. Turn off the 2500 and remove the power cord.
2. Disconnect the two cable connectors J1 and J3.
3. Remove the single 3/16-inch hex mounting screw.
4. The Toroid transformer is heavy; lift it out carefully.
5. Install the new Toroid transformer and reconnect the cables.
Replacing the Toroid
PCB
If the Toroid PCB fails, follow the steps below to replace it.
1. Turn off the 2500 and remove the power cord.
2. Disconnect the four cables in connectors J-1 through J-4.
3. Remove the four 1/4-inch hex nuts at the corners of the board.
4. Hold the edges of the board, do not touch the capacitors, and lift the
board straight up. You may damage the capacitors if you apply
pressure to them.
5. Install the new Toroid PCB power supply board and reconnect the
cables.
6. Check the voltage selection switch.
Replacing the
Controller Power
Supply
If the controller power supply fails, follow the steps below to replace it.
1. Turn off the 2500 and remove the power cord.
2. Disconnect the two cable connectors.
3. Remove the four 1/4-inch hex nuts at the corners of the board.
4. Carefully lift out the controller power supply board.
5. Install the new controller power supply and reconnect the cables.
6. Check the voltage selection jumper.