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AK and 3K Series Installation and Service Instructions
4211-139-A 08-14-2009
C. WATER SOLENOID REPLACEMENT:
Disconnect power from the unit. Turn the water
supply OFF. Disconnect the water supply from the
water solenoid valve. Remove the front cover. Re-
move the two blue wires from the water solenoid
valve. Rotate the self-tightening hose clamp so it can
be loosened with a pair of pliers. Squeeze the clamp
and move it down towards the shelf and off the valve
outlet tube. Remove the two 1/4" - 20 hex head bolts
and lock washers that attach the valve to the chassis.
Pull the valve off the rubber fill hose. To install the
valve, reverse these instructions. Test the unit per
SECTION 7: OPERATIONAL TEST.
D. LEVEL PROBE REPLACEMENT:
Disconnect power from the unit. Remove the front
cover. Note where the blue wire is connected to the
triple pronged water level probe. Disconnect all three
wires from the water level probe. Using a 32 mm box
wrench, remove the level probe. Install a new level
probe. Use Teflon Tape on threads of probe if re-
quired. Tighten until the bottom of the plastic nut is
3 to 9,5 mm above the top of the port. See diagram
17. Reattach the three wires. Test the unit per
SECTION 7: OPERATIONAL TEST.
IMPORTANT
The blue wire connected to “L” on the
PCA must be connected to the shortest of the
three level probes.
IMPORTANT
The level probe may be extremely tight. Damage
to the insulation or chassis may result unless the
tank is properly blocked or supported during
probe removal or installation. It may be neces-
sary to completely disconnect and disassemble
the generator.
SEE DIAGRAMS
SECTION 8: SERVICE (continued)
6. Allow the unit to drain completely. When the water
stops, close the manual drain valve.
3. REPAIR OF AK SERIES GENERATORS
A. ELEMENT REPLACEMENT:
Disconnect power from the unit. Drain the tank. Open
the front and HEATING ELEMENT ACCESS covers.
Note the wire connections. See diagram 15. Remove
the element wires. Using a 1-1/2" (38 mm) hot water
element socket, remove the element. To install a new
element, mount a new element gasket on the ele-
ment. Clean the element port and add a light coat of
Rectorseal No. 5 pipe thread compound to the threads.
Insert and hand tighten the element-gasket combina-
tion. Notice the element end orientation as shown in
diagram 16. Tighten the element until the orientation
is the same as diagram 16, ± 15°. The gasket should
be set and tight but not deformed to a rounded or
bulbous appearance. If the drain valve was removed
reinstall it. Reconnect the wiring. Test the unit per
SECTION 7: OPERATIONAL TEST. Check for leaks at
the element. Replace the front cover and the HEAT-
ING ELEMENT ACCESS cover.
B. PRINTED CIRCUIT REPLACEMENT:
Printed circuit assembly (PCA) removal and replace-
ment must be performed in the sequence described
below. Any other method can damage the PCA.
IMPORTANT
The PCA’s contain static sensitive devices.
Static electricity may damage PCA’s. Handle
accordingly.
Disconnect power from the unit. Note and tag the
positions of all wires that plug into the printed circuit
assembly mounted relays. Remove all the wires from
the relays and water valve. When removing these
wires, pull on the connector, not the wire. Remove
the drain valve wires, if installed, from terminal block
TB2. Press down the orange tabs with a small screw-
driver until the drain wires can be easily pulled out of
the terminal block.Note the blue wire connected to
the shortest of the triple pronged water level probe.
Disconnect all three wires from the water level
probe.Note and tag the positions of all control and
temperature sensor cables. Remove the wire nuts
from the temperature limit switch cable and separate
the wires. Remove PCA from all seven standoffs.
When it is completely disconnected, it may be lifted
out of the enclosure. See diagram 20. To install the
board, reverse this procedure. Test the unit per
SECTION 7: OPERATIONAL TEST.
IMPORTANT
The blue wire connected to “L” on the
PCA must be connected to the shortest of the
three level probes.
All electrical supplies should be
disconnected when servicing
generator.
Electrical Shock Hazard. PCA’s have
exposed 230V ~ on them. Disconnect
ALL~ power to the generator before
servicing.
The relays may be damaged if the
correct orientation of the connectors
is not observed. See diagram 19.
WARNING
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