Repair Procedures; Rp1 General; Rp2 Shroud Assembly Rr; Rp3 Condensation Bottle Bracket Rr - CAIRE Liberator G4 Series Technical & Service Manual

XII

Repair Procedures

RP1 – General
The following procedures have been carefully prepared to allow
proper removal and replacement of defective components and
should be used in conjunction with the Troubleshooting Chart and
the tests in this section. All repair procedures and specifications
in this manual supersede those in previous revisions of the
manual and are valid for all G4 Liberators.
WARNING: Make sure the unit is empty and vent valve is open
before replacing any component, except shroud assembly compo-
nents or Lip Seals.
WARNING: The technician's hands, tools, and clothing should be
free of all oils and greases.
WARNING: Parts that are welded in place must not be replaced
in the field. Should these parts fail, return complete assembly or
sub-assembly to factory for repair. DO NOT use solder or silver
solder to repair broken welds.
WARNING: The manufacturer of fluorolubricant warns users not
to allow fluorolubricant to contaminate tobacco products. Wash
fluorolubricant from hands before smoking.
WARNING: Do not use glue type thread locking compounds or
unapproved sealants on any repairs.
CAUTION: When replacing components, make sure the new part is
oriented exactly the same as the original part prior to installation.
CAUTION: Some components require a specific amount of torque
when assembling. Follow torque requirements where specified.
NOTE: All replacement parts must be factory approved, cleaned
for oxygen service, and stored in sealed plastic bags. The repair
area must be clean and separate from other areas. Room air should
be filtered, and free from dust, soot, and other contaminants.
NOTE: When replacing components with pipe threads, use PTFE
tape thread sealant. Apply two rounds of PTFE tape to threads
near end of component, avoiding first thread.
NOTE: When assembling new compression fittings, tighten 1/8",
1/4" and 1/2" nuts eight flats past finger tight and 3/16" nuts five
flats past finger tight. When reassembling previously used com-
pression fittings, tighten nuts one to two flats past finger tight.
RP2 – Shroud Assembly RR (Figure 9)
a. Remove humidifier adapter (Item 26) and FCV extension (Item
25) from FCV (Item 24).
b. Remove shroud mounting screw (Item 13).
c. Remove shroud (Item 7) by lifting up and moving sideways to
clear the QDV on side fill models, or by lifting straight up top
fill models.
d. To replace shroud assembly, reverse above procedure. Torque
FCV Extension (Item 25) onto FCV to 45 N-m (4 in-lb).
RP3 – Condensation Bottle Bracket RR
a. Remove condensate drain tube (Item 58) from bottle (Item
56) and remove bottle from bracket (Item 57).
b. Remove condensate bottle bracket (Item 57) by squeezing legs
together and pulling straight down.
c. To replace bracket, reverse above procedure.
RP4 – Liquid Level Meter RR
a. Remove shroud (See RP2).
b. Remove two screws attaching liquid level meter to the bracket,
being careful not to pull on the meter wires.
c. Detach JST connector (red signal wire) and spade connector
(black ground wire).
d. To replace meter, screw new meter into place using the top set of
holes on the meter and reattach wires.
e. Calibrate meter per RP6.
RP5 – Liquid Level Meter Battery RR
NOTE: Tampering with meter battery housing will void the bat-
tery's 2-year warranty.
If meter battery failure occures while the battery is under war-
ranty, contact customer service to obtain a replacement meter.
If meter battery is no longer under warranty, the CR2032 coin cell
battery may be replaced following the steps below.
a. Remove liquid level meter (See RP4).
b. Using a pair of pliers, grasp the battery cover on the back of the
meter. Twist counter-clockwise and pull the cover away from the
meter, removing the battery cover.
c. Slide the tip of a flathead jeweler's screwdriver beside the battery
and carefully pry out the battery.
Liberators Technical Service Manual • PN 13350704 Rev K
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