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Repair
NOTE: Do not apply thermal grease to the heater
cartridge.
7. For 25B021 and 25B024 applicators only, inspect
the cover gasket for damage and replace it if
necessary. For application environments where seal
integrity is important, it is recommended that the
gasket is replaced each time the cover is removed
to service the applicator. See Replace Cover
Gasket on this page.
8. Reinstall the manifold cover plate (18).
9. Reconnect the cordset to the heated hose.
10. Reconnect the M8 solenoid electrical connector (N).
Replace Heater Plug
NOTE: Depending on the model, the heater may be
retained by a stainless steel plug pressed into the
applicator body. You must remove this plug before the
heater can be accessed and removed.
1. Disable the applicator. See Before Beginning
Repair on page 19.
2. Securely clamp the applicator in a vise or clamp.
3. Drill a hole through the plug using a no. 27 (.144)
drill bit. The plug is approximately 1/8 in. thick.
4. Turn an 8-32 self-tapping screw into the plug.
5. Pull out the screw and plug with a claw or slide
hammer. If using a claw hammer, place a piece of
cardboard between the hammer and the surface of
the applicator to prevent damage to the applicator.
6. After the heater is replaced, place the tapered end
of a new plug into the heater cavity.
7. Lightly tap the plug into the applicator body with a
hammer until flush.
To prevent damage to the valve body, it is recom-
mended that you use the hammer to tap a flat piece
of aluminum scrap rather than striking the plug
directly with a hammer.
20
NOTICE
Replace Cover Gasket
NOTE: This is only required for 25B021 and 25B024
applicators.
1. Peel the used gasket away from the cover plate.
2. Remove any excess adhesive from the plate.
3. Remove the paper backing from the new gasket.
4. Apply the new gasket to the plate and press it lightly
into place.
NOTE: Make sure the holes in the gasket are aligned
with the holes in the plate.
Replace RTD
The RTD is replaced by replacing the entire cordset.
See Replace Cordset on page 22 for instructions.
Replace Thermal Cutoff
1. Disable the applicator. See Before Beginning
Repair on page 19.
2. Use a Phillips screwdriver to remove the four screws
(15) and manifold cover plate (18).
3. Remove the butt splices (4) from the heater wires
(3) and cordset wire leads (17).
To prevent a short to ground and blowing a MZLP
fuse, ensure bare wires are covered and fiber glass
tape (32) and sleeves (30) are centered over the butt
splices (4).
4. Crimp the wires. See Wiring Diagram on page 21.
a. Crimp the butt splice on the cordset heater
wires (17) and heater wires (3). Lightly pull on
the splice to ensure it is crimped.
b. Slide the sleves (30) over each pair of wires
before crimping.
c. Crimp the white wire to one of the thermal cutoff
leads (29).
NOTICE
334627K
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