3800

Maneuvering the Assembly Documentation
1. Select your bookmark of

interest
2. Click on the (+) to expand
your selection and select the
submenu
3. Navigate through the

document with these buttons
DOC: 03-925914-01/02 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Micro - TCD Installation
PAGE: 1 of 3
1
INSTALLATION OF MICRO-TCD
STATION #3, ASSEMBLY PROCEDURES
TEE (SEE NEXT PAGE)
ADAPTER (SEE NEXT PAGE)
PREPARED BY: Sax Makthepharack REVISED BY: Michael Slaughter CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 03 - 10 - 00 - SHOWN
DOC: 03-925914-01/02 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 3
1
CLICK HERE FOR
MICRO-TCD ASSEMBLY
SCHEMATIC OF MICRO-TCD WITH ADAPTOR REFERENCE

SCHEMATIC OF MICRO-TCD WITH INJECTOR REFERENCE
MICRO-TCD CELL (REF.) INJECTOR (REF.)
28-694581-00
CP-470100 FERRULE
FERRULE, Ø0.32 COLUMN
03-949551-00
CP-085887
NUT NUT
DETAIL “A” DETAIL “B”
EFC CARRIER
03-925910-01 16-000589-00
BALANCE ADAPTOR TEE
(03-925916-01)
MICRO-TCD REF. SIDE, ADAPTOR FACTORY
INJECTOR (REF.)
SEE DETAIL “B”

SEE DETAIL “A”
REFERENCE COLUMN (CP-735732) SEE DETAIL “B”
ANALYTICAL COLUMN (CP-7758)
DOC: 03-925914-01/02 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 3
1
INSTALLATION OF MICRO-TCD:
1. ENSURE GC OVEN INSULATION IS CAREFULLY WRAPPED UNDER AND

AROUND, THE MICRO-TCD TO PREVENT COLUMN OVEN CONDITIONS
COUPLING WITH DETECTOR.
2. FEED HEATER AND PROBE TO LOCATION ON PWA’S

- HEATER TO ZONE ON POWER PWA.
- PROBE TO ZONE ON MAIN PWA.
3. INSTALL MICRO-TCD PWA BOARD (03-925904-01) AND SECURE. ROUTE FLAT,

RIBBON CABLE FROM MICRO-TCD ALONGSIDE PNEUMATICS BULKHEAD AND
AROUND TO MICRO-TCD PWA BOARD. SECURE WITH CABLE CLAMP.
03-925904-01
MICRO-TCD PWA
03-925914-11/12
MICRO-TCD SUB-ASSEMBLY
HEATER CONNECTOR ZONE
PROBE CONNECTOR ZONE
DOC: 03-925914-01/02 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 3
1
DOC: 03-925862-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 3800GC W/DEFC Leak Test Procedure
PAGE: 1 of 2
1
INJECTOR EFC LEAK TEST PROCEDURE
1. Install ETS software Version 1.6.2 or newer. (be sure to discharge yourself before touching ROM pwa.)
2. Set the DIP Switches on the main board as shown:
3. Turn on power and connect Carrier Gas inlet tube.
4. Make sure jumpers on EFC board are in the correct position.
5. Cap off all unused gas inlet fittings and the Injector column out fitting.
6. Press MENU key.
7. Check com board if installed (under AOC cont.) pg.2.
8. Check Detector Electrometer pwa’s, (3) are they present?.
9. Check EFC’s, (5) are they present? Are they good?
10. If EFC’s are present and good, press Enter Key and set to Pressure DAC 5.00 and Flow DAC to 3.00.(Left blue toggle key below display 3
times to pressure up instrument).
11. After completing items 1 thru 10, turn on Carrier Gas.
12. When the pressure is stable, turn OFF Carrier Gas and press LEAKSTOP Key. (blue key below display)
13. The leak test procedure will run for 5 minutes then stop and display the leak value for the 5 min. period. (< .30 + .10 for each EFC installed is
the acceptance criteria, (if the test fails, retest and measure the flow at the EFC Vent tube. If a leak is detected and is less than .10 ml/min.
subtract the amount from your total leak value. If that value is less than the spec (above), the instrument passed the test. If over, the
instrument Fail and the leak must be found and corrected. Retest as above until a pass condition is reached.
14. Record the resulting value of the leak test on the QC Record Sheet.
15. Press Menu Key, go to TEMPERATURE MENU (4) check and press Enter.
16. Set all Temp zones to NOT USED and press Enter. (use decrease key)
17. Go to Pg.2 of 3, check Vent Doors for unrestricted opening and closing. (toggle ON enter, OFF enter)
18. If any Cryo is installed, go to pg. 3. Select the proper external event then activate to assure opening and closing. (blue Time Off/On key
under display)
19. Go back to pg. 1 and Enable those zones used. Observe temperature go to 50 deg. and hold stable.
20. Press CONTACTOR key.
21. If Fan is running, go back to pg. 2 and turn off Fan.
22. Go to EFC Control (5) enter, select flow key and measure each Inj/Det. for some amount of flow.
23. Go to Main Menu, select EFC Control, press enter, go to EFC location (front, middle, rear) then go to pg. 6. In lower right corner of display
see EFC type, is it correct? (type 1,3,4,5, etc.) Turn Instrument Off, replace ROM board and restart instrument. Initial Display should
appear.
DOC: 03-925862-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 3800GC W/DEFC Leak Test Procedure
PAGE: 2 of 2
1
DETECTOR EFC LEAK TEST PROCEDURE

1. Connect Helium to makeup line for FID, TSD, ECD and TCD. Connect Helium to H2 line for PFPD and TCD(H2).
2. Cap off all other gas inlets
3. Make sure DEFC position jumpers in correct position.
4. Cap all other inlets (Top and bottom of Detector)
5. Plug in customer software.
6. Turn on the power
7. Press ∞ to go to local mode.
8. From the “Instrument Setup” menu, Enter the IEFC type(s) in the appropriate positions in the “Heated Zones” screen
9. Save and Exit
10. When the GC is done initializing (~2 minutes), Press ∞ to go to local mode.
11. Press “Detector” button to get to the Detector Menu
12. For each detector:
* Pick Detector
* Go to the “adjustments” screen, page 2
* Turn on the gas
* Within 2 minutes, the flowrate of the Helium channel (1) should go to 0. In the case of PFPD, channel 2 is used. In the case of
TCD(H2), Channel 1 is used.
* If flowrate does not go to 0, fix leaks and retest. (.1 is acceptable for PFPD with manufacture engineer approval).
* Turn off gas and GC
DOC: 03-925709-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Column Oven Cryogenics, (CO2)
PAGE: 1 of 3
1
ASSY, COLUMN OVEN CRYOGENICS, (CO2)

3800GC SUB-ASSEMBLIES STATION, ASSEMBLY PROCEDURES
DOC: 03-925709-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 3
1
03-925497-01 2
CO2 OUTLET TUBE
03-925567-01
3800 CO2 VALVE FACTORY INSTALL
CO2 OUTLET TUBE (REF.)
60° (REF.) 1
28-609966-00
3800 CO2 VALVE ADAP, COMP., 1/8 X 1/8 SST
FACTORY INSTALL
28-694205-00
1/8IN ADAPTER 1
FLOW DIRECTIOIN
CRYO VALVE BRACKET (REF.)
03-925261-01
BRACKET, CRYO VALVE
FRONT VIEW (REF.)
12-222060-04, 2 PLCS
SCREW, 10-32 X 1/4 PAN, SS
NOTES:
1. INSTALL TEFLON TAPE ON FITTING THREADS AS REQUIRE AND
1-1/2 - 2 TURNS IN THE DIRECTION OF THREADS.
2. WHEN INSTALLING THE CO2 OUTLET TUBE (03-925497-01) MAKE COLUMN OVEN CRYOGENICS EXPLODED VIEW
SURE TUBING TOWARD THE FAN SHAFT INSIDE THE OVEN
DOC: 03-925709-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 3
1
03-925489-01
ASSY, CABLE, CRYO EXTENSION
NOTE:
CONNECT CRYOU EXTENSIO
WIRES PIN TO (J-47) ON PWA
7 (J-47)
9
22-799995-00
BUSHING, STRAIN REL. CONNECTOR (REF.)
COLUMN OVEN 12-901163-00, 2 PLCS

CRYOGENICS ASSEMBLY (REF.) SCREW, 8-32 X 3/8 SEM
DOC: 03-925709-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 3
1
DOC: 03-925708-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Column Oven Cryogenics
PAGE: 1 of 4
1
ASSY, COLUMN OVEN CRYOGENICS (LN2 VERSION)

3800GC STATION #3, ASSEMBLY PROCEDURES
PREPARED BY: Sax Makthepharack REVISED BY: Micheal Slaughter CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 25 - 00 - SHOWN
DOC: 03-925708-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 4
1
SEE NOTE #2
03-925378-01 2
LIQUID NITROGEN OUTLET TUBE
OUTLET SIDE
03-925557-01
3800 LN2 VALVE
28-691979-00 1 OUTLET TUBING (REF.)

1/4 T X 1/8 P BR MALE CONN. INLET SIDE
28-695130-00
B-4-TA-1-2 ADAPTER, COMPRESSION 1/4 TUBE
FOR REFERENCE ONLY

REFER TO NEXT PAGE FOR CONFIGURATION
03-925489-01
ASSY, CABLE, CRYO EXTENSION
03-925261-01
BRACKET, CRYO VALVE
14-312010-00, 2 PLCS
WASHER, EXT LOCK, #10
NOTES:
1 INSTALL TEFLON PIPE TAPE (88-189669-00) FITTING THREADS PRIOR TO INSTALLATION.
12-222010-06, 2 PLCS 2 WHEN INSTALLING LIQUID NITROGEN OUTLET TUBE (03-925378-01) INTO THE 1/4 T X 1/8 P
10-24 X 3/8 PH PAN BR MALE CONNECTOR (28-691979-00), MAKE SURE HOLES ON THE END OF OUTLET TUBE
IS UPWARD PRIOR TO TIGHTENING. SEE DETAIL “A”.
DOC: 03-925708-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 4
1
BULK ISSUE ITEMS (03-925515-XX)
3 INJECTORS 2 INJECTORS 1 INJECTOR NO INJECTOR
03-925651-01
TUBE, 1/4” CROSS, TEE, CONNECTOR
03-925654-01
DEFLECTOR, AIR FLOW
LN2 OVEN CRYO
28-691946-00
TEE, UNION 1/4” TUBE BRASS 1
57-000235-00
PRESSURE RELIEF VALVE 1
28-695036-00
SWAGELOK #B-4-TA-7-4
NO OVEN CRYO
DOC: 03-925708-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 4
1
88-494510-00, 5” LG 12-901163-00, 2 PLCS

PIPE INSULATION 3/8” ID .42” SCREW, 8-32 X 3/8, SEM
23-230938-00
COVER, SQUARE
VALVE ARRANGEMENT (REF.)
DOC: 03-925632,633,634&635-XX REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, 1177 Manual and Type 5 EFC Installation
PAGE: 1 of 4
1
ASSY, 1177 MANUAL AND TYPE 5 EFC INSTALLATION

PREPARED BY: Sax Makthepharack REVISED BY: Steve Swihart CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 12 - 03 - 99 - SHOWN
DOC: 03-925632,633,634&635-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 4
1
03-917142-00 03-918853-07
03-917142-00
PEEK TUBING 1/8” NAT. 03-925467-01
VITON FERRLE 03-918853-03 VITON FERRLE 3EA
SOLENOID VALVE 3- WAY
28-849067-00 PEEK TUBING, GREEN
03-917157-00 12-901162-00 03-917157-00
WASHER , VITON FERRLE 10-32 ADAPTER HOSE SCREW (2 PL) WASHER , VITON FERRLE 3EA
03-917084-00 03-917084-00
03-918853-07 03-918853-03
NUT, VITON FERRULE NUT, VITON FERRULE 3EA
PEEK TUBING 1/8” NAT. PEEK TUBING, GREEN
28-691944-00
12-222008-04
TEE, 1/16” BRASS
SCREW, 8-32,X 1/4” LG PH,
28-849067-01 03-918853-03
SST 2EA
BESWICK FITTING PEEK TUBING, GREEN
03-925469-01
BRACKET, SPLIT VLV. MTG. 03-917128-00
NUT, 1/6 NPS-”O” RING
03-918959-02 03-918853-03
NOTE: DETAIL OF SOLENOID VALVE PENCIL FILTER PEEK TUBING, GREEN
CLICK HERE TO SEE SOLENOID CONNECTION TO J42 ON POWER BD.
03-917157-00
SEE ADJ.
WASHER , VITON NOTE/ DETAIL 03-918853-07
FERRLE 2EA PEEK TUBING, NATURAL
03-917142-00 03-917084-00
VITON FERRLE 2EA NUT, VITON FERRULE
3EA
FROM INJECTOR 03-917157-00
WASHER , VITON FERRLE
27-239921-00 3EA
03-917084-00
GAGE PRESSURE, 0-60 PSI
NUT, VITON FERRULE 2EA 03-917142-00
03-917157-00 VITON FERRLE 3EA
WASHER , VITON FERRLE 2EA
03-918174-00 28-158923-00
BACK PRESSURE REGULATOR TYGON TUBING, CLEAR.VENT
03-917142-00
VITON FERRLE 2EA
27-180135-00
KOJIMA FLOW CONTL.
28-694302-00 “CARRIER GAS IN” 12-901132-00
ADAPTER 1/8” UNION
SCREW 8-32 X 3/8” LG EXT STL. 2EA
BRS. COMP. FTG.
03-918853-03
PEEK TUBING, GREEN
03-918853-03
PEEK TUBING, GREEN
DOC: 03-925632,633,634&635-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 4
1
NOTE:
1 BE SURE INJ. IS IN ONE OF THE (4) A/S LOCATIONS. SEE INJ. COVER
FOR ALIGNMENT.
03-925996-XX 1
1177 INJECTOR, EFC
03-918532-01
VAR SEPTUM PURGE
12-901163-00
SCREW, 8-32 X 3/8” EXT.
4 ON EFC, 2 INJ., 6 TOTAL
03-925110-01
EFC TYPE 1 03-925987-01
120V HTR. CART., 100V
03-925987-02 03-925374-01
220V HTR. CART., 100V TEMPERATURE PROBE
03-925987-03
101V HTR.CART., 100V
DOC: 03-925632,633,634&635-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 4
1
PRESSURE
SENSE (TO 1177)
CARRIER IN FROM
CROSS FITTING
SPLIT
VENT
SEPTUM PURGE
TO SPORT VALVE
(NO COLORED MARKER)
CARRIER IN - FROM EFC CARRIER

(GREEN COLORED MARKER) OUT
VENT THRU
PNEU. PANEL
SPLIT VENT
G.C. FRONT
G.C. BACK
INJ DET. INJ DET. INJ DET.
FRONT FRONT MIDDLE MIDDLE REAR REAR
1177 INJECTOR SPARE

EFC TYPE 5
CLICK HERE OR ON PICTURE CARRIER IN CLICK HERE OR ON PICTURE
TO SEE S/A EXPLOSION (GREEN) TO SEE S/A EXPLOSION
INJECTOR
SPLIT VENT SPARE
INJECTOR SIDE MANIFOLD PLUMBING
DOC: 03-925630&631-XX REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, 1177 EFC Injector Installation
PAGE: 1 of 4
1
ASSY, 1177 EFC INJECTOR INSTALLATION

DOC: 03-925630&631-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 4
1
3800 TWIN 8200 A/S

INJ. & DET. LOCATION & ORIENTATION
NOTE: DETECTORS MOUNTED IN LOCATION

CLOSEST TO PNEUMATICS COMPARTMENT.
INJ. POSITION 1 & 3
DOC: 03-925630&631-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 4
1
NOTE:
FOR ALIGNMENT.
03-925996-XX 1
03-918532-01 1177 INJECTOR, EFC
VAR SEPTUM PURGE
12-901163-00
SCREW, 8-32 X 3/8” EXT.
4 ON EFC, 2 INJ., 6 TOTAL
03-925987-01
03-925110-01 120V HTR. CART., 100V
EFC TYPE 1
03-925987-02
220V HTR. CART., 100V
03-925374-01
TEMPERATURE PROBE
03-925987-03
101V HTR.CART., 100V
DOC: 03-925630&631-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 4
1
PRESSURE
SENSE (TO 1177)
CARRIER IN FROM
CROSS FITTING
SPLIT
VENT
PRESSURE SENSE - TO EFC
(YELLOW COLORED MARKER)
SEPTUM PURGE
TO SPORT VALVE
(NO COLORED MARKER)
CARRIER IN - FROM EFC CARRIER
(GREEN COLORED MARKER) OUT
VENT THRU
PNEU. PANEL
SPLIT VENT
G.C. FRONT
G.C. BACK
1177 INJECTOR PRESS. SENSE EFC TYPE 1

CLICK HERE OR ON PICTURE CARRIER IN (YELLOW) CLICK HERE OR ON PICTURE
TO SEE S/A EXPLOSION (GREEN) TO SEE S/A EXPLOSION
INJECTOR
SPLIT VENT SPARE
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assembly Procedure Station #3
PAGE: 1 of 11
1
TCD (H2) EFC INSTALLATION
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 11
1
12-901163-00
SCREW, 4EA
03-925607-01
MANIFOLD PLUMBING ASSY., TCD AND OVEN, 120V
03-925607-02
ASSY., TCD AND OVEN, 230V
NOTE: 03-925607-03
SEE PAGE 10 ASSY., TCD AND OVEN, 101V
FOR PWA
CONNECTION
03-925607-11
ASSY., TCD AND OVEN, W/
TRANSFER LINE 120V
03-925607-12
REFERENCE TRANSFER LINE 220V
NOTE: MAKE UP
03-925607-13
TOP OF THE COLUMN
OVEN, CUT AWAY FOR CLARITY
TRANSFER LINE 101V
NOTE:
SEE MOTHER
BD. FOR HTR.
PROBE CONN.
12-901163-00
SCREW, 4EA
03-917145-09
TRANSFER LINE
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 11
1
CABLE INSTALLATION
CABLE PLUG-IN
TO MAIN BOARD
03-925798-01
CABLE, FLAT FOR
DETECTOR EFC
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 11
1
INLET MANIFOLD SUBASSEMBLY
03-925842-24
TUBING, PEEK 1/8 26” (NATURAL)
03-917084-00, 3 PLCS
NUT, VITON FERRULE
03-917157-00, 3 PLCS
WASHER, FERRULE
03-917142-00, 3 PLCS
VITON, FERRULE
03-918153-00
INLET MANIFOLD
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 11
1
MODULE INSTALLATION
12-901163-00, 2 PLCS
SCREW, 6-32
24-389051-00
GROMMET, FLEXIBLE 7”
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 11
1
INLET MANIFOLD INSTALLATION
NOT USE (REF.)
(03-925839-22, RED)
H2 INLET (NOT USE REFERENCE ONLY)
(03-925842-24, 1/8” NATURAL)
CARRIER INLET
NOT USE (REF.)
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 11
1
MODULE INSTALLATION
NOTES:
1. CONNECT CABLE TO MODULE, THEN MOUNT MODULE TO FRONT PANEL.
2 MOVE MODULE LOCATION JUMPER TO SPECIFY FRONT, MIDDLE, OR REAR.
3. ADD CABLE HOLDER WHEN NO REAR MODULE PRESENT.
NOTE MOUNTING LOCATION
12-901163-00, 4 PLCS
SCREW, 6-32
DET. FRONT
DET. MIDDLE
DET. BACK
2
JUMPER LOCATION (REF.)
03-925609-06
EFC MODULE, TCD (H2)
22-119757-00
CABLE HOLDER 3
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 11
1
ADDITIONAL MODULE CABLEING (IF REQ’D)
NOTE CABLE SERVICE

LOOP FOR ADDITIONAL
DETECTOR EFC MODULE
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 11
1
PNEUMATICS SIDE MANIFOLD
REFERENCE ONLY
MODULE PNEUMATICS CONNECTIONS
PNEU. MANIFOLD
REFERENCE LINE FROM NOTES:

MODULE TO DETECTOR RED (26”)
1. DRESS PLUMBING IN PNEUMATICS
MAKE UP LINE FROM COMPARTMENT USING CABLE TIE. INSPECT
MODULE TO DETECTOR RED (26”) TO ENSURE PNEUMATICS PANEL SWINGS FREELY.
03-917142-00
VITON FERRULE
12-901150-00
SCREW
REF. ONLY
03-917141-00
CONDYNE PLATE
REFERENCE MODULE,
RED (16”) CHANNEL 2
MAKEUP LINE TO MODULE,

RED (16”) CHANNEL 1
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of 11
1
NOTE: POSITION & ROUTING OF
CABLE AND TIES NOT NESS. AS SHOWN.
DRESS CABLE W/ QTY. NEEDED
USING AVAILABLE SPACE.
03-925037-01
ASSY., TCD, PCB
CONNECTION TO TCD PWA

CLICK HERE FOR HEATER
CLICK HERE CONNECTION J41 ON POWER BOARD
FOR PROBE
CONNECTION TO
J7 ON MAIN BD. 03-925648-01
LABEL
TCD PWA INSTALLATION

14-112007-00
FLAT, WASHER
12-901163-00
SCREW, 6-32 X 1/4
14-998237-00, 2 PLCS
SET SPRING WASHER
22-300001-00
CLAMP, CABLE , STANDOFF
MOUNTING SCREWS DETAIL
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 11 of 11
1
TCD DETECTOR LOCATION
1. TCD (4) IS FRONT
(5) IS MIDDLE
(6) IS REAR
TCD WITH ONE OTHER

DETECTOR USE (4) AND (5)
DOC: 03-925615-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 12 of 11
1
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 1 of 15
1
PFPD EFC INSTALLATION
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 15
1
03-925194-01
SCREW, CAP 8-32X 3/4” LG, CLEANED 2EA
03-925134-00
ASSY., IGNITOR CAP
03-925461-01
ASSY., IGNITOR CABLE, PFPD
15-003347-00
WASHER CRUNCH, .040 THK, ALUM
NOTE: SEE P.5
FOR CABLE CONNECTION
TO PFPD PWA
03-925194-02
SCREW, CAP 8-32X1 1/2”LG, CLEANED 2EA
NOTE: INSTALL FOR

SULFER TEST
03-925133-01
ASSY., PFPD TOWER, N. MODE
03-925178-00 03-925176-00
HOLDER , COMBUSTER COMBUSTER
2MM SULF. QUARTZ 2MM SULF. 03-925133-00
ASSY., PFPD TOWER
03-925177-00 03-925179-00
COMBUSTER, QUARTZ HOLDER, COMBUSTER
3MM 3MM
03-925490-01
NOTE: INSTALL FOR NITROGEN ASSY., CABLE HIGH VOLT.
OR PHOSPHORUS
15-003347-00
WASHER CRUNCH, TOP LINE AIR
.040 THK, ALUM
BOT. LINE H2
03-925138-00
SEAL COMBUSTER HOLDER NOTE:
FOR CABLE
CONNECTIONS TO
PWA SEE P.5
03-925476-01
DETECTOR BASE PFPD 03-917830-00
ASSY., CABLE SIGNAL 18”
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 15
1
HEAT ZONE 1 INJECTOR 1
AIR H2 HEAT ZONE 4 DETECTOR 1
HEAT ZONE 5 DETECTOR 2
JUMPER
SPARE
J41
PFPD
ALIGN TOWER MOUNTING HOLES IN LINE J7
MANIFOLD PLUMBING WITH BASE CLIP SCREWS (HEATER IN BACK)
03-917142-00
VITON FERRULE
REF
12-901150-00
03-925374-01
ONLY SCREW
TEMPERATURE PROBE
03-917141-00
CONDYNE PLATE
03-925396-01
AIR TOP 03-925476-01
120V HTR. ION
DETECTOR BASE PFPD
LINE FROM
03-925396-02
DET. BASE, 220V HTR. ION
BLACK
03-925326-01
03-925396-03
DETECTOR MOUNTING BASE
101V HTR. ION
03-918663-06
SCREW
12-901163-00
SCREW, 4EA
12-901163-00
SCREW, 2EA
DETECTOR
SIDE MANIFOLD H2 BOTTOM -03-925526-01
LINE FROM CLICK HERE CLICK HERE FOR DETECTOR BASE CLIP
DET. BASE, RED FOR PROBE HEATER CONNECTION
CONNECTION TO J41 ON POWER BOARD
J7 ON MAIN BD.
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 15
1
CABLE INSTALLATION
CABLE PLUG-IN
TO MAIN BOARD
03-925798-01
CABLE, FLAT FOR
DETECTOR EFC
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 15
1
03-925839-22
TUBING, PEEK 22” (RED)
03-925840-21
TUBING, PEEK 21” (BLACK)
03-917084-00, 3 PLCS
NUT, VITON FERRULE
03-917157-00, 3 PLCS
WASHER, FERRULE
03-917142-00, 3 PLCS
VITON, FERRULE
03-918153-00
INLET MANIFOLD
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 15
1
MODULE INSTALLATION
12-901163-00, 2 PLCS
SCREW, 6-32
24-389051-00
GROMMET, FLEXIBLE 7”
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 15
1
(03-925840-21, BLACK)
AIR INLET
(03-925839-22, RED)
H2 INLET
NOT USED (REF.)
NOT USED (REF.)
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 15
1
MODULE INSTALLATION
NOTES:
3. ADD CABLE HOLDER WHEN NO MODULE PRESENT.
12-901163-00, 4 PLCS
SCREW, 6-32
DET. FRONT
DET. MIDDLE
DET. BACK
2
03-925609-01
EFC MODULE, FID
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 15
1
NOTE CABLE SERVICE

LOOP FOR ADDITIONAL
DETECTOR EFC MODULE
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of 15
1
MODULE PNEUMATICS CONNECTIONS PNEUMATICS SIDE MANIFOLD 03-917142-00
VITON FERRULE
REFERENCE ONLY (REF.) 12-901150-00
NOTES: PNEU. MANIFOLD ONLY SCREW
03-917141-00
CONDYNE PLATE
COMPARTMENT USING CABLE TIE. INSPECT
TO ENSURE PNEUMATICS PANEL SWINGS FREELY.
AIR LINE FROM TEE, SST
TO DETECTOR NATURAL (3”)
HYDROGEN LINE
FROM VALVE TO
DETECTOR NATURAL (12”)
AIR 1 LINE TO MODULE CHANNEL 1 BLACK (16”)
H2 LINE TO MODULE CHANNEL 2 RED (16”)
AIR 2 LINE TO MODULE CHANNEL 3 BLACK (16”)
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 11 of 15
1
PNEUMATIC PFPD SHEMATIC
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 12 of 15
1
DETAIL A
12-901163-00, 2 PLCS
SCREW, 6-32
ASSEMBLY VIEW
03-925799-01
BRACKET, VALVE
03-917142-00, 2 PLCS
VITON, FERRULE
03-917084-00, 2 PLCS
NUT, VITON FERRULE
57-000028-00
NEEDLE VALVE 03-925841-12, 2 PLCS
TUBING, PEEK NATURAL
03-917157-00, 2 PLCS
WASHER, FERRULE
EXPLODED VIEW
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 13 of 15
1
22-119650-00 DETAIL B
TIE WRAP
17-699907-00
RIVET, BLIND
ASSEMBLY VIEW
ORANGE TUBING
TO NEEDLE VALVE
22-130018-00, 2 PLCS
CLIP, COMPONENT
28-691944-00 FROM DETECTOR MODULE

TEE
EXPLODED VIEW
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 14 of 15
1
INSTALLATION OF CHECK VALVE
22-130017-00, 2 PLCS
CLIP, COMPONENT, .640 DIA.
27-180166-00, 2 PLCS
CHECK VALVE, 1/8
17-699907-00
RIVET, BLIND
(IF REQUIRED)
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 15 of 15
1
PFPD PWA INSTALLATION
03-917830-00
ASSY., CABLE SIGNAL 18”
03-925066-01
PFPD PWA
03-925461-01
03-908339-02
ASSY., CABLE HIGH
VOLT.,34” LG.
14-112007-00
FLAT, WASHER
12-901163-00
SCREW, 6-32 X 1/4
14-998237-00, 2 PLCS
SET SPRING WASHER
DOC: 03-925614-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 16 of 15
1
DOC: 03-925613-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 1 of 10
1
TSD EFC INSTALLATION
DOC: 03-925613-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 10
1
JUMPER
BLANK BLANK
J41
TSD
J7
MANIFOLD PLUMBING 03-925374-01
TEMPERATURE PROBE
03-917142-00 12-901163-00
VITON FERRULE SCREW, 4EA
REF
12-901150-00
ONLY SCREW
03-917141-00
CONDYNE PLATE
AIR TOP
LINE FROM
DET. BASE, 03-925396-01
120V HTR. CART.
BLACK 12-901165-00
2 SCREW
03-925396-02
230V HTR. CART.
03-925396-03 03-918663-06
101V HTR. CART. SCREW, 2EA
03-925526-01
DETECTOR BASE CLIP
2 03-925326-01
H2 BOTTOM 1 DETECTOR MOUNTING BASE
DETECTOR
SIDE MANIFOLD LINE FROM
DET. BASE, CLICK HERE CLICK HERE FOR
RED 1 FOR PROBE HEATER CONNECTION
J7 ON MAIN BD.
DOC: 03-925613-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 10
1
CABLE INSTALLATION
CABLE PLUG-IN
TO MAIN BOARD
03-925798-01
CABLE, FLAT FOR
DETECTOR EFC
DOC: 03-925613-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 10
1
03-925838-23
TUBING, PEEK 23” (BLUE)
03-925842-24 03-925839-22
TUBING, PEEK 1/8 26” (NATURAL) TUBING, PEEK 22” (RED)
03-925840-21
03-917084-00, 3 PLCS
NUT, VITON FERRULE
03-917157-00, 3 PLCS
WASHER, FERRULE
03-917142-00, 3 PLCS
VITON, FERRULE
03-918153-00
INLET MANIFOLD
DOC: 03-925613-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 10
1
MODULE INSTALLATION
12-901163-00, 2 PLCS
SCREW, 6-32
24-389051-00
GROMMET, FLEXIBLE
DOC: 03-925613-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 10
1
(03-925840-21, BLACK)
AIR INLET
(03-925839-22, RED)
H2 INLET
(03-925842-24,, 1/8” NATURAL)
CARRIER INLET
(03-925838-23, BLUE)
MAKEUP INLET
DOC: 03-925613-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 10
1
MODULE INSTALLATION
NOTES:
3 ADD CABLE CLAMP WHEN NO REAR MODULE PRESENT.
12-901163-00, 4 PLCS
SCREW, 6-32
03-925609-02
EFC MODULE, TSD
2
22-119757-00
3 CABLE CLAMP
DOC: 03-925613-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 10
1
NOTE CABLE SERVICE

LOOP FOR ADDITIONAL
DETECTOR EFC MODULE
DOC: 03-925613-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 10
1
REFERENCE ONLY
PNEU. MANIFOLD
AIR LINE FROM MODULE MAKEUP LINE TO MODULE, BLUE (16”)

TO DETECTOR BLACK (26”)
H2 LINE TO MODULE, RED (16”)
HYDROGEN LINE
AIR LINE TO MODULE, BLACK (16”)
FROM MODULE TO
DETECTOR RED (26”)
03-917142-00
VITON FERRULE
12-901150-00
SCREW
REF. ONLY
03-917141-00
CONDYNE PLATE
NOTES:

DOC: 03-925613-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of 10
1
03-925487-01
IGNITOR CABLE
03-925070-01
TSD PWA
03-917830-00
SIGNAL CABLE 18”
SIGNAL & IGNITOR CABLE CONNECTION
14-112007-00
FLAT, WASHER
12-901163-00
SCREW, 6-32 X 1/4
TSD PWA INSTALLATION 14-998237-00, 2 PLCS

SET SPRING WASHER
DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 1 of 11
1
TCD EFC INSTALLATION
DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 11
1
12-901163-00
SCREW, 4EA
03-925607-01
MANIFOLD PLUMBING ASSY., TCD AND OVEN, 120V
03-925607-02
NOTE: 03-925607-03
SEE PAGE 10 ASSY., TCD AND OVEN, 101V
FOR PWA
CONNECTION
03-925607-11
TRANSFER LINE 120V
03-925607-12
REFERENCE TRANSFER LINE 220V
NOTE: MAKE UP
03-925607-13
TOP OF THE COLUMN
TRANSFER LINE 101V
NOTE:
SEE MOTHER
BD. FOR HTR.
PROBE CONN.
12-901163-00
SCREW, 4EA
03-917145-09
TRANSFER LINE
DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 11
1
CABLE INSTALLATION
CABLE PLUG-IN
TO MAIN BOARD
03-925798-01
CABLE, FLAT FOR
DETECTOR EFC
DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 11
1
03-925842-24
TUBING, PEEK 1/8 26” (NATURAL)
03-917084-00, 3 PLCS
NUT, VITON FERRULE
03-917157-00, 3 PLCS
WASHER, FERRULE
03-917142-00, 3 PLCS
VITON, FERRULE
03-918153-00
INLET MANIFOLD
DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 11
1
MODULE INSTALLATION
12-901163-00, 2 PLCS
SCREW, 6-32
24-389051-00
GROMMET, FLEXIBLE
DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 11
1
NOT USE (REF.)
NOT USE (REF.)
(03-925842-24,, 1/8” NATURAL)

CARRIER INLET
NOT USE (REF.)
DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 11
1
MODULE INSTALLATION
NOTES:
12-901163-00, 4 PLCS
SCREW, 6-32
03-925609-01
EFC MODULE, FID
2
22-119757-00
3 CABLE CLAMP
DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 11
1
NOTE CABLE SERVICE

LOOP FOR ADDITIONAL
DETECTOR EFC MODULE
DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 11
1
REFERENCE ONLY
PNEU. MANIFOLD
MAKEUP LINE TO MODULE, BLUE (16”)

REFERENCE LINE FROM
MODULE TO DETECTOR BLUE (26”)
REFERENCE MODULE, BLUE (16”)
MAKE UP LINE FROM
MODULE TO DETECTOR BLUE (26”)
03-917142-00
VITON FERRULE
12-901150-00
SCREW
REF. ONLY
03-917141-00
CONDYNE PLATE
NOTES:

DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of 11
1
03-925037-01
ASSY., TCD, PCB
CLICK HERE CLICK HERE FOR

FOR PROBE HEATER CONNECTION
J7 ON MAIN BD.

14-112007-00
FLAT, WASHER
12-901163-00
SCREW, 6-32 X 1/4
14-998237-00, 2 PLCS
SET SPRING WASHER
22-300001-00
DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 11 of 11
1
TCD DETECTOR LOCATION
1. TCD (4) IS FRONT
(5) IS MIDDLE
(6) IS REAR
TCD WITH ONE OTHER

DETECTOR USE (4) AND (5)
DOC: 03-925612-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 12 of 11
1
DOC: 03-925611-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 1 of 10
1
ECD EFC INSTALLATION
DOC: 03-925611-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 10
1
03-917142-00
VITON FERRULE
12-901150-00
REF
SCREW
ONLY
BOTTOM
LINE FROM
CONDYNE PLATE
DET. BASE,
TOP BLUE 2
LINE FROM
DET. BASE,
(BLANK) 1 DETECTOR SIDE MANIFOLD
03-925374-01
TEMPERATURE PROBE
03-925396-01
120V HTR. CART.
03-925396-02
230V HTR. CART. 03-918663-06
SCREW
03-925396-03
101V HTR. CART.
12-901163-00
SCREW, 2EA
03-925526-01
12-901163-00
REF. OUTER DETECTOR BASE CLIP
SCREW, 4EA
OVEN TOP
03-925326-01
1 2 DETECTOR MOUNTING BASE
DETECTOR BASE MOUNTING CLICK HERE CLICK HERE FOR

J7 ON MAIN BD.
DOC: 03-925611-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 10
1
CABLE INSTALLATION
CABLE PLUG-IN
TO MAIN BOARD
03-925798-01
CABLE, FLAT FOR
DETECTOR EFC
DOC: 03-925611-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 10
1
03-925842-24 03-925838-23
TUBING, PEEK 1/8 26” (NATURAL) TUBING, PEEK 23” (BLUE)
03-917084-00, 3 PLCS
NUT, VITON FERRULE
03-917157-00, 3 PLCS
WASHER, FERRULE
03-917142-00, 3 PLCS
VITON, FERRULE
03-918153-00
INLET MANIFOLD
DOC: 03-925611-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 10
1
MODULE INSTALLATION
12-901163-00, 2 PLCS
SCREW, 6-32
24-389051-00
GROMMET, FLEXIBLE
DOC: 03-925611-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 10
1
(03-925842-24,, 1/8” NATURAL)

CARRIER INLET
(03-925838-23, BLUE)
MAKEUP INLET
DOC: 03-925611-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 10
1
MODULE INSTALLATION
NOTES:
12-901163-00, 4 PLCS
SCREW, 6-32
03-925609-03
EFC MODULE, ECD
2
22-119757-00
3 CABLE CLAMP
DOC: 03-925611-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 10
1
NOTE CABLE SERVICE

LOOP FOR ADDITIONAL
DETECTOR EFC MODULE
DOC: 03-925611-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 10
1
PNEUMATICS SIDE MANIFOLD MODULE PNEUMATICS CONNECTIONS
PNEU. MANIFOLD (REF.)
MAKE UP LINE FROM MODULE

TO DETECTOR BLUE (26”) TO LEFT
TOP POSITION BLANK OF RIGHT TOP MAKEUP LINE TO MODULE, BLUE (16”)
03-917142-00
VITON FERRULE
12-901150-00
SCREW
REF. ONLY
03-917141-00
CONDYNE PLATE
NOTES:

DOC: 03-925611-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of 10
1
03-925487-01
IGNITOR CABLE
03-925041-01
ECD PWA
03-917830-00
SIGNAL CABLE 18”
14-112007-00
FLAT, WASHER
12-901163-00
SCREW, 6-32 X 1/4
ECD PWA INSTALLATION 14-998237-00, 2 PLCS

SET SPRING WASHER
DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 1 of 11
2
FID EFC INSTALLATION
PREPARED BY: Sax Makthepharack REVISED BY: Bob Vickroy CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 29 - 98 - SHOWN
DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 11
2
3800 TWIN 8200 A/S

DET. POSITION 4 & 6
INJ. POSITION 1 & 3
DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 11
2
JUMPER
BLANK BLANK
J41
FID
J7
TEMPERATURE PROBE
03-917142-00 12-901163-00
VITON FERRULE SCREW, 4EA
REF
12-901150-00
ONLY SCREW
03-917141-00
CONDYNE PLATE
AIR TOP
LINE FROM
DET. BASE, 03-925396-01
120V HTR. CART.
BLACK 12-901165-00
2 SCREW
03-925396-02
230V HTR. CART.
03-925396-03 03-918663-06
101V HTR. CART. SCREW, 2EA
03-925526-01
DETECTOR BASE CLIP
2 03-925326-01
H2 BOTTOM 1 DETECTOR MOUNTING BASE
DETECTOR
SIDE MANIFOLD LINE FROM
DET. BASE, CLICK HERE CLICK HERE FOR
RED 1 FOR PROBE HEATER CONNECTION
J7 ON MAIN BD.
DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 11
2
CABLE INSTALLATION
CABLE PLUG-IN
TO MAIN BOARD
03-925798-01
CABLE, FLAT FOR
DETECTOR EFC
DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 11
2
03-925838-23
TUBING, PEEK 23” (BLUE)
03-925842-24 03-925839-22
TUBING, PEEK 1/8 26” (NATURAL) TUBING, PEEK 22” (RED)
03-925840-21
03-917084-00, 3 PLCS
NUT, VITON FERRULE
03-917157-00, 3 PLCS
WASHER, FERRULE
03-917142-00, 3 PLCS
VITON, FERRULE
03-918153-00
INLET MANIFOLD
DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 11
2
MODULE INSTALLATION
12-901163-00, 2 PLCS
SCREW, 6-32
24-389051-00
GROMMET, FLEXIBLE
DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 11
2
(03-925840-21, BLACK)
AIR INLET
(03-925839-22, RED)
H2 INLET
(03-925842-24,, 1/8” NATURAL)
CARRIER INLET
(03-925838-23, BLUE)
MAKEUP INLET
DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 11
2
MODULE INSTALLATION
NOTES:
3 ADD CABLE HOLDER WHEN NO REAR MODULE.
12-901163-00, 4 PLCS
SCREW, 6-32
DET. FRONT
DET. MIDDLE
DET. BACK

2 03-925609-01
EFC MODULE, FID
22-119757-00
CABLE HOLDER 3
DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 11
2
ADDITIONAL MODULE CABLING (IF REQ’D)
NOTE CABLE SERVICE

LOOP FOR ADDITIONAL
DETECTOR EFC MODULE
DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of 11
2
REFERENCE ONLY
PNEU. MANIFOLD
AIR LINE FROM MODULE MAKEUP LINE TO MODULE, BLUE (16”)

TO DETECTOR BLACK (26”)
H2 LINE TO MODULE, RED (16”)
HYDROGEN LINE
AIR LINE TO MODULE, BLACK (16”)
FROM MODULE TO
DETECTOR RED (26”)
03-917142-00
VITON FERRULE
12-901150-00
SCREW
REF. ONLY
03-917141-00
CONDYNE PLATE
NOTES:

DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 11 of 11
2
03-925487-01
IGNITOR CABLE
03-925021-01
FID PWA
03-917830-00
SIGNAL CABLE 18”
14-112007-00
FLAT, WASHER
12-901163-00
SCREW, 6-32 X 1/4
FID PWA INSTALLATION 14-998237-00, 2 PLCS

SET SPRING WASHER
DOC: 03-925610-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 12 of 11
2
DOC: REF 03-925604-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: PFPD Installation
PAGE: 1 of 5
3
PFPD
Installation
PREPARED BY: MICHAEL HARRAL REVISED BY: Sax CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 09 - 22 - 99 - SHOWN
DOC: REF 03-925604-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 5
3
03-925194-01
SCREW, CAP 8-32X 3/4”LG, CLEANED 2EA
03-925134-00
ASSY., IGNITOR CAP
03-925461-01
15-003347-00 ASSY., IGNITOR CABLE, PFPD
NOTE: SEE P.5

FOR CABLE CONNECTION
TO PFPD PWA
03-918663-07
SCREW, CAP 8-32X1 1/2”LG, MICROSEAL 2EA
NOTE: INSTALL FOR

SULFER TEST
03-925133-01
03-925178-00 03-925176-00
HOLDER , COMBUSTER COMBUSTER
2MM SULF. QUARTZ 2MM SULF. 03-925133-00
ASSY., PFPD TOWER
03-925177-00 03-925179-00
COMBUSTER, QUARTZ HOLDER, COMBUSTER
3MM 3MM
03-925490-01
NOTE: INSTALL FOR NITROGEN ASSY., CABLE HIGH VOLT.
OR PHOSPHORUS
15-003347-00 TOP LINE AIR

BOT. LINE H2
03-925138-00 NOTE:
SEAL COMBUSTER HOLDER FOR CABLE
CONNECTIONS TO
PWA SEE P.5
03-925476-01
DETECTOR BASE 03-917830-00
PFPD ASSY., CABLE SIGNAL 18”
DOC: REF 03-925604-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 5
3
03-925476-01
DETECTOR BASE PFPD
03-917142-00
VITON FERRULE REF. ONLY
12-901150-00
SCREW
REF.
03-917141-00 ONLY
CONDYNE PLATE
H2 BOTTOM
AIR TOP LINE FROM
12-901163-00 LINE FROM DET. BASE,
SCREW, 4EA DET. BASE, RED\BLACK
BLACK\RED DETECTOR SIDE MANIFOLD \CLEAR
03-925396-01
120V HTR. ION 03-925133-01
03-925396-02
220V HTR. ION OR
03-925133-00
03-925396-03 ASSY., PFPD TOWER
101V HTR. ION
22-300000-00
STANDOFF WIRE
03-925374-01
TIE
TEMPERATURE PROBE
03-918663-06
SCREW, 3EA
03-925526-01
DETECTOR BASE CLIP
03-925326-01
12-901165-00
SCREW,SEMS, 8-32 1/4” LG. EXT., SST
DOC: REF 03-925604-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 5
3
03-918853-02
PEEK TUBING , NATURAL, H2
03-918853-13
03-925469-01
PEEK TUBING , ORANGE 30”LG
BRACKET, SPLIT VALVE MOUTING
16-000589-00 RED/CLR/BLK
1/16” TEE TUBE, SST 03-918959-01
FILTER, FLOW MODULE
57-000028-00
NEEDLE VALVE
03-917146-03
FLOW CONTROLLER, 60CC/MIN.
03-917146-04, 2 PLCS
FLOW CONTROLLER, 25CC/MIN
03-918853-05
PEEK TUBING , RED, H2 23-599813-00
03-918853-06
PEEK TUBING , BLACK, AIR DIAL, TURNS COUNTER 3EA
FROM MANIFOLD
27-180166-00, 2 PLCS 28-691944-00, 3 PLCS

CHECK VALVE TEE, 1/8 TUBE ,BRASS
FROM MANIFOLD
RED
NOTE: 03-917084-00
AT BOTH ENDS OF TAN
ALL PEEK TUBING USE: VITON FERR., NUT 23EA.
03-917142-00 03-917157-00 BLACK
VITON FERRULE 23EA. WASHER, FERRULE CLEANED 23EA PNEUMATICS PANEL OVERLAY
ORANGE REFERENCE ONLY
DOC: REF 03-925604-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 5
3
03-917830-00
03-925461-01 ASSY., CABLE SIGNAL 18”
03-925066-01
PFPD PWA
03-908339-02
ASSY., CABLE HIGH VOLT.,34”LG.
PFPD PWA INSTALLATION
DOC: 03-925603-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: TSD Detector Installation, 3800
PAGE: 1 of 5
2
TSD Detector
Installation
PREPARED BY: MICHAEL HARRAL REVISED BY: HCP CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 8/20/97 - SHOWN
DOC: 03-925603-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 5
2
03-917142-00
VITON FERRULE REF. ONLY
12-901150-00
SCREW REF.
AIR H2
03-917141-00
ONLY
CONDYNE PLATE
H2 BOTTOM
LINE FROM
AIR TOP DET. BASE,
BLANK LINE FROM RED
BLANK
DET. BASE,
TSD BLACK DETECTOR SIDE MANIFOLD
MANIFOLD PLUMBING
03-925374-01
TEMPERATURE PROBE
03-925396-01
120V HTR. ION
03-925396-02
220V HTR. ION 03-918663-06
SCREW, MICROSEAL, 8-32
03-925396-03
101V HTR. ION
12-901163-00
SCREW, 2EA
-03-925526-01
DETECTOR BASE CLIP
03-925326-01
12-901163-00
SCREW, 4EA FOR PROBE HEATER CONNECTION
DETECTOR BASE MOUNTING J7 ON MAIN BD.
DOC: 03-925603-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 5
2
89-999028-00
STOPPER
12-142008-04
08-000229-00
SCREW, 8-32 X 1/4” ,
TOP CLAMP
PH, HD, SST 2EA.
REF ONLY
27-409282-00 03-917151-01
21-000031-00
O-RING, .487 ID X .103 WIDE INSULATOR, UPPER
TSD ASSY.
03-906079-00
S/A, COLLECTOR ,TSD
21-000032-00
INSULATOR, LOWER FID
03-917830-00
SIGNAL CABLE 18” 03-918663-01
SCREW, MICROSEAL, 8-32 X
03-925488-01 1/4”PH. HD., SST 2EA.
TSD BEAD CABLE
34-000731-00
PLATE, TOP, TOWER
03-906074-01
ASSY. BEAD PROBE, (TESTED)
02-001938-00
03-906076-00 ASSY., FLAME TIP FID, .020 ID
ASSY, SIGNAL PROBE, TSD 03-906077-00
S/A DETECTOR BODY TSD
15-003347-00 03-925475-01
WASHER, FID, SEALING ASSY., DETECTOR BASE
AIR FROM
PNEU. PANEL
H2 LINE
FROM PNEU. PANEL 03-908361-00
FERRULE
MARKED RED
03-949551-00
INJECTOR, NUT
DOC: 03-925603-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 5
2
03-917065-00
03-918853-06 VALVE, AIR , 450 cc/min., BLACK
PEEK TUBING, BLACK, AIR IN
12-222008-05 23-599813-00 03-917065-01
SCREWS 2EA DIAL, TURNS COUNT- VALVE, H2 , 60 cc/min., RED
VALVE ING, 10 TURNS 03-918853-06
PEEK TUBING, BLACK, AIR-
03-918853-04
OUT TO MANIFOLD
PEEK TUBING, BLUE,
MAKE-UP IN
03-918853-05
PEEK TUBING, RED
H2 TO FILTER
03-918853-04
PEEK TUBING,BLUE,
H2 OUT JUMPER
TO MANIFOLD 03-917146-01
SEE FIG. BELOW FLOW CONTRLLER
03-917142-00
VITON FERRULE
FILTER FLOW 20%

2X 03-917157-00
MS, 80% CHAR.

FLAT WASHER
03-918959-01
REF: PNEUMATICS 03-917084-00
PANEL OVERLAY NUT, VITON FERRULE
03-917147-00
ASSY., CONNECTOR W/FRITT
03-918853-05
PEEK TUBING, RED H2 IN
NOTE:
ATTACH PENCIL FILTER 03-918959-01
TO EXTRA EFC FILTER CLIP PNEU. MANIFOLD
HYDROGEN LINE, RED,

Notes: 03-917142-00
FROM PENCIL FILTER
VITON FERRULE REF. TO DETECTOR
1. DRESS PLUMBING IN
PNEUMATICS COMPARTMENT
USING CABLE TIES. INSPECT TO 12-901150-00 AIR LINE, BLACK ,
ENSURE PNEU. PANEL SWINGS SCREW REF. FROM PNEUMATICS
FREELY.
ONLY PANEL TO DETECTOR
03-917141-00
CONDYNE PLATE
DOC: 03-925603-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 5
2
03-917830-00
SIGNAL CABLE 18”
03-925070-01
TSD PWA
03-925488-01
TSD BEAD CABLE
12-901163-00
SCREW, SEMS 8-32 X 3/8
SIGNAL & BEAD CABLE CONNECTION
TSD PWA INSTALLATION
PARTS NOT SHOWN

22-300001-00 NOTE: POSITION & ROUTING OF
CLAMP, CABLE , STANDOFF CABLE AND TIES NOT SHOWN.
DOC: 03-925602-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: TCD Detector Installation
PAGE: 1 of 3
2
TCD DETECTOR
Installation
DOC: 03-925602-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 3
2
R
12-901163-00
SCREW, 4EA
Notes: 03-925607-01
NOTE: ASSY., TCD AND OVEN, 120V
1. FOR OPTIONS WITH SEE PAGE 3
TRANSFER LINE ONLY. FOR PWA 03-925607-02
CONNECTION
03-925607-03
NOTE:
NOTE: 03-925607-11
SEE MOTHER ASSY., TCD AND OVEN, W/
TOP OF THE COLUMN
BD. FOR HTR. TRANSFER LINE 120V
PROBE CONN.
03-925607-12
TRANSFER LINE 220V
SEE NOTE 1 03-925607-13
(FOR REF. ONLY) ASSY., TCD AND OVEN, W/
28-693995-00 CONNECTION TO TRANSFER LINE 101V
FID
FERRULE, 1/8”SST
28-693998-00
FERRULE, BACK, 1/8”, SST
14-312008-00
WASHER, EXT. #8 4EA.
28-693989-00
NUT, 1/8” SST
12-90116300
SCREW, SEMS, 8-32 X 3/8, 4EA
28-694201-00
ADAPTER, 1/16” TO 1/8”
SEE DETAIL ‘A’
03-917145-09
DETAIL ‘A’
TRANSFER LINE
DOC: 03-925602-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 3
2
03-925037-01
ASSY., TCD, PCB

J7 ON MAIN BD.

22-300001-00
DOC: 03-925601-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: ECD Detector
PAGE: 1 of 5
3
ECD DETECTOR
Installation
PREPARED BY: MICHAEL HARRAL REVISED BY: HCP CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 03 - 13 - 98 - SHOWN
DOC: 03-925601-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 5
3
03-917142-00
VITON FERRULE
PRESS. 12-901150-00
AIR H2 CARR. SENSE SCREW REF.
AIR H2
03-917141-00
CONDYNE PLATE ONLY
BOTTOM
LINE FROM
TOP DET. BASE,
MAKE MAKE SPARE
REF UP SPARE UP LINE FROM
SPLIT DET. BASE,
ECD, FID, TSD PFPD INJECTOR
DETECTOR SIDE MANIFOLD
MANIFOLD PLUMBING
03-925374-01
TEMPERATURE PROBE
03-925396-01
120V HTR. ION
03-925396-02 03-918663-06
220V HTR. ION SCREW
03-925396-03
101V HTR. ION
12-901163-00
SCREW, 2EA
-03-925526-01
DETECTOR BASE CLIP
03-925326-01
12-901163-00 CLICK HERE CLICK HERE FOR

SCREW, 4EA FOR PROBE HEATER CONNECTION
DOC: 03-925601-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 5
3
01-001023-00
S/A, COVER, TOP, ECD TOWER
24-000732-00
INSUL, CVR, ECD TOWER
12-142008-04
03-918663-00
SCREW, 8-32 X 1/4” LG., PH. HD, SST.
SCREW, 8-32 X 3 1/8” MICROSEAL
02-001972-00
ASSY., 63Ni, ECD GEN. LIC.
02-001972-01
ASSY., 63Ni, ECD SPEC. LIC. 02-001974-00
ASSY., POWER PROBE, ECD
34-000731-00 02-001973-00
TOP PLATE , TOWER ASSY., SIGNAL PROBE ECD
03-908376-03
ASSY., CABLE PULSER
01-001028-00
CELL ECD (SPEC LIC.)
03-925768-01 AIR FROM

SHIM, ECD, 3800 PNEUMATICS
PANEL 03-917830-00
ASSY., SIGNAL CABLE
03-925475-01 H2 FROM
S/A DETECTOR BASE PNEUMATICS
PANEL
03-908361-00
FERRULE
03-949551-00
INJECTOR, NUT
DOC: 03-925601-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 5
3
03-917142-00
03-918853-04 VITON FERRULE
PEEK TUBING, BLUE, MAKE UP IN
REF.
12-901150-00
ONLY
SCREW
12-222008-05
SCREW 2EA. 03-917141-00 REFERENCE ONLY
CONDYNE PLATE PNEU. MANIFOLD
03-918853-04
PEEK TUBING, BLUE, MAKE-UP TO MANIFOLD
HYDROGEN LINE
MAKE-UP
INLET FROM PNEU PANEL
TO DETECTOR RED
03-918853-04
PEEK TUBING, BLUE MAKE-UP
03-917065-01
VALVE, COMB-S, RED, HYDROGEN
PNEUMATICS PANEL
DOC: 03-925601-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 5
3
03-908376-03
ASSY., CABLE PULSER
03-925041-01
ECD, PWA
03-917830-00
ASSY., SIGNAL CABLE
PARTS NOT SHOWN

CABLE AND TIES NOT SHOWN.
22-300001-00
DOC: 03-925600-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: FID Installation
PAGE: 1 of 6
4
FID INSTALLATION
Subassembly
DOC: 03-925600-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 6
4
3800 TWIN 8200 A/S

DET. POSITION 4 & 6
INJ. POSITION 1 & 3
DOC: 03-925600-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 6
4
03-917142-00
VITON FERRULE
12-901150-00
SCREW REF.
AIR H2
03-917141-00
CONDYNE PLATE ONLY
AIR TOP
LINE FROM
H2 BOTTOM DET. BASE,
BLANK BLANK LINE FROM BLACK
DET. BASE,
FID RED DETECTOR SIDE MANIFOLD
MANIFOLD PLUMBING
03-925374-01
TEMPERATURE PROBE
03-925396-01
120V HTR. ION
03-925396-02 03-918663-06
220V HTR. ION SCREW
03-925396-03
101V HTR. ION
12-901163-00
SCREW, 2EA
03-925526-01
DETECTOR BASE CLIP
03-925326-01
12-901163-00
REF. OUTER
SCREW, 4EA
OVENTOP FOR PROBE HEATER CONNECTION
DOC: 03-925600-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 6
4
NOTE:
21-000032-00
FOR SIGNAL & IGNITER INSULATOR, LOWER FID
CABLE CONNECTION 03-949587-00
TUBE, COLLECTOR FID
TO DET. PCB SEE P.5
12-142008-04
SCREW, 8-32 X 1/4” , FILL HD, SST 2EA.
03-918663-02
03-917830-00 SCREW, MICROSEAL, 8-32 2EA.
SIGNAL CABLE 18”
03-925487-01
IGNITOR CABLE
02- 001873-00
ASSY, SIGNAL PROBE, FID
34-000731-00
PLATE, TOP, FID, TOWER
02-001872-00
ASSY. IGNITER, PROBE, FID
01-000993-00
S/A DETECTOR BODY
02-001938-00
ASSY., FLAME TIP FID, .020 ID
15-003347-00
WASHER, FID, SEALING
03-925475-01
ASSY., DETECTOR BASE
AIR FROM
PNEU. PANEL
H2 LINE
FROM PNEU. PANEL
03-908361-00
MARKED RED
FERRULE
03-949551-00
INJECTOR, NUT
DOC: 03-925600-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 6
4
REFERENCE ONLY 03-917065-00
PNEU. MANIFOLD VALVE, COMB-S, BLACK, AIR
03-918853-06
12-222008-05
PEEK TUBING, BLACK, AIR IN
8-32 X 3/8” LG. SCREW 6EA
HYDROGEN LINE
03-917065-01
FROM PNUE PANEL VALVE, COMB-S, RED, HYDROGEN
TO DETECTOR RED
03-918853-06 MAKE-UP
03-917142-00 PEEK TUBING, BLACK, AIR INLET
VITON FERRULE OUT TO MANIFOLD
REF.
ONLY 12-901150-00 03-918853-04
SCREW PEEK TUBING, BLUE, M/U IN
03-917141-00
CONDYNE PLATE
03-918853-02
PEEK TUBING, CONNECTOR, BLUE
03-918853-05
PEEK TUBING, RED, H2 IN 03-917065-01
VALVE, COMB-S, RED, HYDROGEN
03-918853-05
PEEK TUBING, RED, H2 OUT TO FILTER
DOC: 03-925600-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 6
4
03-925487-01
IGNITOR CABLE
03-925021-01
FID PWA
03-917830-00
SIGNAL CABLE 18”
FID PWA INSTALLATION
DOC: 03-925517-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 1079/Manual Pneu. Installation
PAGE: 1 of 3
3
1079/Manual Pneu. Installation
PREPARED BY: MICHAEL HARRAL REVISED BY: Sax Makthepharack CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 26 - 00 - SHOWN
DOC: 03-925517-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 3
3
03-925516-01
S/A 1079 INJ. MOD. MANUAL 120v
03-925516-02
S/A 1079 INJ. MOD. MANUAL 230v
03-918532-00 03-925516-03
VAR SEPTUM PURGE S/A 1079 INJ. MOD. MANUAL 101v
CLICK HERE FOR

PROBE CONNECTION
TO J7 ON MAIN BOARD
REFERENCE
03-925374-01
TEMPERATURE PROBE
12-901163-00
SCRW., SEMS 8-32 X 3/8 LG. EXT. STL 4EA
03-925425-01
120V HTR. CART.
CLICK HERE FOR 03-925425-02 REF

HEATER CONNECTION 230V HTR. CART
TO J41 ON POWER BD.
03-925425-03
101V HTR. CART.
PARTS NOT SHOWN
28-694581-00
FERRULE # 100 / 0.5
03-949551-00
NUT, CAPILLARY, INJ
DOC: 03-925517-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 3
3
03-917142-00 03-918853-07
03-917142-00
PEEK TUBING 1/8” NAT. 03-925467-01 03-918853-03
VITON FERRLE VITON FERRLE 3EA
SOLENOID VALVE 3- WAY PEEK TUBING, GREEN
03-917157-00 28-849067-00 12-901162-00 03-917157-00
WASHER , VITON FERRLE 10-32 ADAPTER HOSE SCREW (2 PL) WASHER , VITON FERRLE 3EA
03-917084-00 03-918853-07
03-917084-00
PEEK TUBING 1/8” NAT. 03-918853-03
NUT, VITON FERRULE NUT, VITON FERRULE 3EA
PEEK TUBING, GREEN
28-691944-00
12-901162-00
TEE, 1/16” BRASS
SCREW, 8-32,X 1/4” LG PH,
28-849067-01 03-918853-03
SST 2EA
BESWICK FITTING PEEK TUBING, GREEN
03-925469-01
28-849968-00
BRACKET, SPLIT VLV. MTG.
ADAPTER, HOSE ELBOW
03-918959-02 03-917128-00
NOTE: DETAIL OF SOLENOID VALVE PENCIL FILTER NUT, 1/6 NPS-”O” RING
CLICK HERE TO SEE SOLENOID CONNECTION TO J42 ON POWER BD.
03-917157-00 03-918853-03 03-917084-00
SEE ADJ.
WASHER , VITON NOTE/ DETAIL PEEK TUBING, GREEN NUT, VITON FERRULE
FERRLE 2EA 3EA
03-917142-00 03-917157-00
VITON FERRLE 2EA WASHER , VITON
FERRLE 3EA
FROM INJECTOR 03-917142-00
VITON FERRLE 3EA
27-239921-00 03-917084-00
GAGE PRESSURE, 0-60 PSI
NUT, VITON FERRULE 2EA 03-918853-07
03-917157-00 PEEK TUBING, NATURAL
WASHER , VITON FERRLE 2EA
03-918174-00 28-158923-00
BACK PRESSURE REGULATOR 03-917142-00 TYGON TUBING, CLEAR.VENT
VITON FERRLE 2EA
27-180135-00
KOJIMA FLOW CONTL.
28-694302-00 “CARRIER GAS IN” 12-901132-00
ADAPTER 1/8” UNION
SCREW 8-32 X 3/8” LG EXT STL. 2EA
BRS. COMP. FTG.
03-918853-03
PEEK TUBING, GREEN
03-918853-03
PEEK TUBING, GREEN
DOC: 03-925502-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 1061 Injector/EFC
PAGE: 1 of 4
2
1061 Injector With EFC
Installation
DOC: 03-925502-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 4
2
03-908127-00
ASSY., INJECTOR NUT HEATED
03-908206-01 00-997628-00
ASSY., ACTUATOR SWITCH SEPTA
03-918339-00
03-925458-01 INSERT, MEGABORE INJ.
03-917204-00
INSJECTOR SWITCH CABLE
SPRING
CLICK HERE 03-925483-01

S/A 1061 INJ. EFC
OR ON PICTURE
TO SEE 1061 SUB-ASSEMBLY
03-925512-01
1041 INJECTOR OVEN
TO MANIFOLD
03-925374-01
TO MANIFOLD
PROBE, TEMPERATURE
03-925396-01
29-694523-00
120V HTR. CART.
FERRULE, GRAPHITE
03-925396-02
230V HTR. CART. 28-693985-00
NUT, 1/4” SST
03-925396-03
101V HTR. CART.
PARTS NOT SHOWN
22-012004-00
CABLE CLAMP
12-901165-00
SCREW
DOC: 03-925502-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 4
2
03-925502-01
1061 INJECTOR, 3800
03-925502-02
1061 INJECTOR, 3800
03-925502-03
1061 INJECTOR, 3800
12-901163-00
SCREW, 8-32 X 3/8” EXT.
LW 4EA. 8 TOTAL
03-925374-01
PROBE, TEMPERATURE
03-925458-01
03-925396-01
120V HTR. CART.
03-925396-02
230V HTR. CART.
03-925396-03
101V HTR. CART.
INSTALLATION OF 1061 W/EFC
03-925110-03
EFC TYPE 3
INSTALLATION OF EFC TYPE 3
DOC: 03-925502-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 4
2
CLICK HERE
TO MANIFOLD / PRESSURE SENSE
OR ON PICTURE TO SEE
1061 INJECTOR EFC SUB-ASSEMBLY
CARRIER IN
TO MANIFOLD /
CARRIER OUT TO MANIFOLD /
PRESSURE SENSE
CARRIER OUT
1061 EFC INJECTOR, 3800

G.C. FRONT

G.C. BACK
PRESS.
CARR. SENSE
TYPE 3 EFC, 3800

SPARE SPARE CLICK HERE
OR ON PICTURE TO SEE
INJECTOR TYPE 3 1079 EFC SUB-ASSEMBLY

DOC: 03-925501-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 1 of 4
2
1041 Injector With EFC
Installation
DOC: 03-925501-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 4
2
03-908127-00 03-918204-00
ASSY., INJECTOR NUT HEATED BAKE-OUT SEPTA
00-997628-00
03-908206-01
SEPTA
ASSY., ACTUATOR SWITCH
03-917204-00 03-925482-01
REFERENCE:
SPRING S/A 1041 INJ. EFC
03-925458-01
CLICK HERE
OR ON PICTURE TO MANIFOLD
TO MANIFOLD
03-925512-01
1041 INJECTOR OVEN
29-694523-00
03-925374-01
FERRULE, GRAPHITE
PROBE, TEMPERATURE
03-925396-01
120V HTR. CART.
28-693985-00
03-925396-02 NUT, 1/4” SST
230V HTR.CART.
03-925396-03
101V HTR.CART.
03-925431-01
PARTS NOT SHOWN INSERT, INJ.
22-012004-00 03-949551-00
CABLE CLAMP NUT, INJ., CAPILLARY
12-901165-00
SCREW
DOC: 03-925501-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 4
2
12-901163-00
SCREW, 8-32 X 3/8”
EXT. LW 4EA. 8 TOTAL
03-925374-01
PROBE, TEMPERATURE
REFERENCE
03-925458-01
INJECTOR SWITCH CABLE
03-925396-01
120V HTR. ION
03-925396-02
220V HTR. ION
03-925396-03
101V HTR. ION
03-925110-03
EFC TYPE 3
DOC: 03-925501-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 4
2
TO MANIFOLD / PRESSURE SENSE
CARRIER IN
TO MANIFOLD /
CARRIER OUT TO MANIFOLD /
PRESSURE SENSE
CARRIER OUT
1041 INJECTOR, 3800

G.C. FRONT

G.C. BACK
PRESS.
CARR. SENSE
SPARE SPARE
INJECTOR TYPE 3 EFC, 3800
DOC: 03-925500-2X REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 1079/EFC/CO2 CRYO Installation
PAGE: 1 of 4
3
1079 W / CO2 CRYO & EFC, Installation
PREPARED BY: MICHAEL HARRAL REVISED BY: AJB CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 03 - 13 - 98 - SHOWN
DOC: 03-925500-2X REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 4
3
03-925445-01
1079 INJECTOR W/ EFC
03-918532-01
VAR SEPTUM PURGE
12-901163-00
SCREW, 8-32 X 3/8”
28-211457-00
1/16-1/16 VALCO UNION
88-48071-00
1/18” INSULATION TUBING
03-925110-01
EFC TYPE 1
03-918853-00
PEEK TUBING
03-925396-01
120V HTR. CART.
03-925396-02 REF.
220V HTR. CART.
REF.
03-925396-03 03-925374-01
101V HTR.CART. TEMPERATURE PROBE
CLICK HERE FOR

CLICK HERE FOR HEATER CONNECTION
PROBE CONNECTION TO J41 ON POWER BD.
TO J7 ON MAIN BOARD
DOC: 03-925500-2X REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 4
3
88-189609-00
TEFLON TAPE
28-694205-00
APADT, COMP 1/8” X 1/8”
NOTE: PORT FACING INJECTOR

TO BE ARROW DIRECTION.
28-695110-00
ADAPT, COMP 1/16” X 1/8”
88-189609-00 03-925567-01
TEFLON TAPE CO2 CRYO VALVE
03-925562-01
CO2 CRYO BRKT
12-222060-04
SCREW 10-32 X 1/4” 2EA
14-312010-00
#10 EXT LOCK WASHER 2EA.
03-918853-00 12-901163-00
PEEK TUBING 8-32 X 3/8” EXT SIMS 2EA.
DOC: 03-925500-2X REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 4
3
PRESSURE
PRESSURE SENSE SENSE (TO 1079)
(TO EFC)
CARRIER IN FROM
CROSS FITTING
TO SEPTUM PURGE
(TO SPORT VALVE)
CARRIER IN SPLIT
(FROM EFC) VENT
SPLIT VENT
CARRIER
OUT
VENT THRU
PNEU. PANEL
G.C. FRONT
EFC TYPE 1
G.C. BACK
1079 INJECTOR FRONT FRONT MIDDLE MIDDLE REAR REAR
CLICK HERE OR ON PICTURE CLICK HERE OR ON PICTURE
TO SEE S/A EXPLOSION TO SEE S/A EXPLOSION
CARR. PRESS.
SENSE
INJECTOR
SPLIT
VENT SPARE
DOC: 03-925500-1X REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 1079/EFC/LN2 CRYO Installation
PAGE: 1 of 5
3
1079 W / LN2 CRYO & EFC, Installation
DOC: 03-925500-1X REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 5
3
03-925445-01
03-918532-01 1078 INJECTOR W/ EFC
VAR SEPTUM PURGE
88-489071-00
1/8” INSUL. CRYO TUBE
12-901163-00
SCREW, 8-32 X 3/8”
TOP (SHORT)
03-925110-01 TUBE - INLET
EFC TYPE 1
28-993105-00
5/32” CLAMP 2EA
03-925396-01
120V HTR. CART.
REF.
03-925396-02 REF.
220V HTR. CART. 03-925374-01
TEMPERATURE PROBE
03-925396-03
101V HTR.CART.
CLICK HERE FOR
HEATER CONNECTION
CLICK HERE FOR TO J41 ON POWER BD.
PROBE CONNECTION
TO J7 ON MAIN BOARD
DOC: 03-925500-1X REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 5
3
PRESSURE
(TO EFC)
CARRIER IN FROM
CROSS FITTING
TO SEPTUM PURGE
(TO SPORT VALVE)
CARRIER IN SPLIT
(FROM EFC) VENT
SPLIT VENT
CARRIER
OUT
VENT THRU
PNEU. PANEL
G.C. FRONT
EFC TYPE 1
G.C. BACK
CARR. PRESS.
SENSE
INJECTOR
SPLIT
VENT SPARE
DOC: 03-925500-1X REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 5
3
28-695130-00
ADAP., COMP. 1/4” X 1/8”
AS REQ.
28-691946-00
1/4” TEE #B-400-3
VENT / CONDENCE’
88-489071-00
1/8” TEFLON CRYO TUBE
UNDER INSULATION
88-489071-00
1/8” TEFLON CRYO TUBE
88-494510-00
3/8” PIPE INSULATION
28-695130-00
ADAP., COMP. 1/4” X 1/8”
28-691946-00
1/4” TEE #B-400-3
INSULATION LENGTHS
CRYO TUBING LENGTHS
COMMON
PIPE INSUL PIECE USED PIPE INSUL. TEFLON TUBING, VENT
TOP BY EACH INJ. BACK INJECTOR IN
FRONT 7” + 3” 18” + 3 1/2” 16.0” / 16.5” 3’-0”
MIDDLE 4” + 6.5” 7” 18” + 3 1/2” 16.0” / 16.5” 3’-0’

+3 1/2”
REAR 2” + 10” 18” + 3 1/2” 3’-0”

+3 1/2” +3 1/2” 17.5” / 18.0”
DOC: 03-925500-1X REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 5
3
CLICK HERE
TO SEE CONNECTION TO
J44 ON POWER BOARD
03-925557-01
CRYO VALVE
SHOULD HAVE
GROUND WIRE CUT.
(GREEN & YELLOW)
03-925562-01 23-230938-00
CO2 CRYO BRKT NOTE FLOW DIRECTION,
CRYO DRIP TRAY
PORT FACING INJECTOR
TO READ “OUT”, OTHER
12-222060-04
PORT (FACING REAR OF
SCREW 10-32 X 1/4” 2EA
INSTRUMENT) TO READ
14-312010-00 “IN”.
#10 EXT LOCK WASHER 2EA.
12-901163-00
8-32 X 3/8” EXT SIMS 2EA.
DOC: 03-925500-0X REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 1079/EFC Installation
PAGE: 1 of 5
5
1079/EFC Installation
DOC: 03-925500-0X REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 5
5
3800 TWIN 8200 A/S

NOTE: DETECTORS MOUNTED IN LOCATION

CLOSEST TO PNEUMATICS COMPARTMENT.
INJ. POSITION 1 & 3
DOC: 03-925500-0X REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 5
5
3800 TWIN 8200 A/S

MOVE CABLE CLIP

TO LOCATION SHOWN.
INJ. POSITION 1 & 4
NOTE: FRONT INJECTOR ROTATED 180 FROM O
STANDARD AND MOUNTED IN FRONT MOST HOLES.
DOC: 03-925500-0X REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 5
5
NOTE:
FOR ALIGNMENT.
03-925445-00
1 1079 INJECTOR W/ EFC
03-918532-01
VAR SEPTUM PURGE
12-901163-00
SCREW, 8-32 X 3/8” EXT.
LW 4EA. 8 TOTAL
03-925110-01
EFC TYPE 1
03-925396-01
120V HTR. CART.
REF.
03-925396-02
220V HTR. CART. REF.
03-925374-01
03-925396-03 TEMPERATURE PROBE
101V HTR.CART.
DOC: 03-925500-0X REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 5
5
PRESSURE
(TO EFC)
CARRIER IN FROM
CROSS FITTING
TO SEPTUM PURGE
(TO SPORT VALVE)
CARRIER IN SPLIT
(FROM EFC) VENT
SPLIT VENT
CARRIER
OUT
VENT THRU
PNEU. PANEL
G.C. FRONT
EFC TYPE 1
G.C. BACK
CARR. PRESS.
SENSE
INJECTOR
SPLIT
VENT SPARE
DOC: 03-925500-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 1041 Manual Pneumatics
PAGE: 1 of 3
3
1041 Injector With Manual Pneumatics
Installation
DOC: 03-925500-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 3
3
03-908127-00
ASSY., INJECTOR NUT HEATED
00-997628-00
03-908206-01 SEPTA
ASSY., ACTUATOR SWITCH
03-917204-00 03-925482-01
REFERENCE S/A 1041 INJ. MANUAL
SPRING
03-925458-01
INJECTOR SWITCH CABLE
CLICK HERE
OR ON PICTURE TO MANIFOLD
03-925512-01
1041 INJECTOR OVEN
29-694523-00
03-925374-01
FERRULE, GRAPHITE
PROBE, TEMPERATURE
03-925396-01
120V HTR. CART.
28-693985-00
03-925396-02 NUT, 1/4” SST
230V HTR.CART.
03-925396-03
101V HTR. CART.
03-925431-01
PARTS NOT SHOWN INSERT, INJ.
22-012004-00
03-949551-00
CABLE CLAMP
NUT, INJ., CAPILLARY
12-901165-00
SCREW
DOC: 03-925500-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 3
3
FROM BULKHEAD
TO MANIFOLD/
INJECTOR
03-917084-00
27-239920-00 NUT, VITON FERRULE
GAGE, PRESSURE, 0-30
03-917146-00
03-918959-01 FLOW CONTROLLER, PORTER
FILTER, FLOW MODULE
03-917130-00
ASSY., FLOW CONTROL
OUT TUBE
23-599813-00
DIAL TURNS COUNTER
03-905960-09
O-RING
03-925529-01
PNEUMATICS OVERLAY
G.C. FRONT
G.C. BACK

CARR. SPARE
PARTS NOT SHOWN

03-917157-00
SPARE SPARE WASHER, FERRULE 4EA. 03-917142-00
VITON FERRULE 4EA.
INJECTOR 03-918052-00
SEAL .375”
DOC: 03-925321-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: FAST G.C.
PAGE: 1 of 4
1
Fast G.C. Side Cover & Cryo Mixer Sub.
Subassembly
PREPARED BY: MICHAEL HARRAL REVISED BY: MH CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 4-11-96 - SHOWN
DOC: 03-925321-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 4
1
20
03-918860-00
SIDE PANEL, FAST GC.
28-247071-00
CAP, PLUG, 1/8” BRASS
03-905960-09
O-RING, VITON 28-996044-00
CAP 5/16 - 20 #C-2
OUTPUT
03-917130-03 PORT
ASSY, DUAL TUBING
INPUT PORT
03-917128-00 01-001047-00
REGULATOR, PORTER,100 # 03-918886-00
NUT, GAGE GAGE
PORT
LABEL, FAST G.C.
03-917142-00
FERRULE, VITON
03-917157-00
WASHER, VITON FERRULE
NOTE:
USE T-4343 FOR
LABEL PLACEMENT
24-000741-00
27-239934-00 INSULATION 10”
GAGE, 100 P.S.I. NOTE:
INSULATION AND
TIE WRAP NOT SHOWN 22-119651-00
FOR CLARITY. TIE WRAP 2EA.
DOC: 03-925321-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 4
1
88-494510-00
PIPE INSULATION (LOCATION ONLY,
INSULATION NOT SHOWN. INSUL. TO
COVER ALL FITTINGS)
28-691946-00
1/4” BRASS TEE
28-995808-00
VINYL CAP .250 DIA.
28-995813-00
VINYL CAP .625 DIA.
28-995806-00
VINYL CAP, .125 DIA.
28-694540-01
REDUCING FERRULE, 22-119650-00
1/4 NUT TO 1/8 TEE TIE WRAP
NOTES
1. FOR SHIPPING WITH
03-925325-00
FAST G.C. , DETACH
CRYO MIXER ASSY.
MIXER FROM BASE &
INSTALL CAP
( 28-995806-00) OVER
TUBE END & PLACE
BOTH PIECES IN
SHIPPING BOX
(INTEGRATOR), &
12-222060-10 23-608980-00
SCREW, PHM 10-32 X 5/8 LG. SST ADHEASIVE BACKED BUMPER 4EA RE-SEAL
DOC: 03-925321-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 4
1
27-239934-00
GAUGE, 100PSI
03-925322-00 03-917128-00
MIXER ASSY. BASE NUT, 1/8”NPS - O-RING
03-917142-00
VITON FERRULE
SEE NOTE 2
03-917157-00
88-189609-00 WASHER, FERRULE
TFE TAPE, 1/4” WIDE 2X
28-849718-00
FITTING, 1/16 BARB TO
1/8 NPT, 90DEG.
03-947137-00
TUBE, GAGE ASSY.
NOTES
1. LOCATE FITTING
SUCH THAT THE
BARB PLUG (28-
849973-00) POINTS
DOWN.
2. POSITION REGULA-
TOR SUCH THAT
28-158923-00 27-189315-00
INLET PORT IS
TYGON TUBE 1/8’ O.D. REGULATOR, 1/8”, 2 WAY
LOCATED ON THE
RIGHT SIDE AS YOU
28-849973-00
LOOK AT THE GUAGE PLUG, BARB 1/16 W/POLY TUBE
FACE AND THE REG-
ULATOR KNOB. SEE NOTE 1.
DOC: INSPECTION REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: O-RING
PAGE: 1 of 1
1
O-RING INSPECTION
O-RINGS
PEEK TUBING
OPERATION NOTES
1. DO NOT TOUCH BAKED O-RINGS AT ANY TIME.
2. REMOVE BAKED O-RINGS FROM STORAGE JAR WITH

TWEEZERS.
3. INSPECT BOTH SIDES OF THE BAKED O-RING FOR

CRACKS UNDER A MICROSCOPE.
4. CLEAN BAKED O-RINGS BY INSERTING A PIECE OF

PEEK TUBING THRU CENTER OF O-RING AND
SPRAY THOROUGHLY WITH “DUST OFF” (AS SHOWN).
5. ONLY CLEAN WHAT WILL BE IMEDIATELY USED.
6. WHENEVER O-RINGS ARE USED, USE “DUST-OFF”

TO CLEAN PART SURFACE BEFORE AND AFTER
ADDING O-RINGS.
“DUST-OFF”
PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 6-9-97 - SHOWN
DOC: INSPECTION REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: O-RING
PAGE: 2 of 1
1
PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 6-9-97 - SHOWN
DOC: FILTER REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: FLOW MODULE
PAGE: 1 of 1
2
FILTER SUB-ASSEMBLY
03-917084-00
BESWICK FITTING
FILTER ASSY.
03-918959-01
FILTER, FLOW MODULE 4
3
FLOW
03-917084-00
BESWICK FITTING
2 PARTS LIST FOR: EFC 1079 TYPES I, III, IV, V

1
1 4 03-917157-00
2 3 03-917142-00
FERRULE, VITON
PREPARED BY: HOWIE PLITSCH REVISED BY: AJB CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 5/14/98 - SHOWN
DOC: FILTER REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: FLOW MODULE
PAGE: 2 of 1
2
DOC: 03-925996-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, 1177 Injector, W/Pressure Sense
PAGE: 1 of 9
1
ASSY, 1177 INJECTOR, W/PRESSURE SENSE

STATION #3 3800GC, ASSEMBLY PROCEDURES
DOC: 03-925996-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 9
1
03-925975-01
ASSY, INJECTOR NUT, 1177
03-925971-01 INJECTOR SWITCH
ACTUATOR KNOB, 1177 ASSEMBLY (REF.)
03-925989-01
SEPTUM, HI-TEMP, 9MM THERMOGREEN
03-925998-01 SEE STEPS 1.2.16 THRU 1.2.18

ASSY, INJECTOR SWITCH TO BEND TUBING TO REQUIRED
CONFIGURATION
15-999802-00
COUP., Q.D. TERM, 22-18
ABOUT 1/4” FROM
TOP OFF BRACKET 2
END CAP (REF.)
03-925981-01
ACTUATOR SPACER, 1177
03-925978-01, 3 PLCS
ΙΝΣΥΛΑΤΙΟΝ, 1177 ΙΝϑΕΧΤΟΡ
1
SEE FIGURE 1:
1”
UT 22-119727-00
FOR 1177 INJECTOR WITH A BO
03-925987-01 4” CABLE TIE, .10W
W/PRESSURE SENSE HEATER, CARTRIDGE, 100W, 120V
HAVE TWO TEES PANDUIT PLT1M76
HAVE ONE TEE 03-925374-01

SEE FIGURE 2: 13-312004-00, 2 PLCS PLATINUM PROBE
NUT, 4-40 KEPS, 18-8
FOR 1177 INJECTOR
NO PRESSURE SENSE 03-925964-02
INJECTOR HEATER BLOCK
(HAS HOLES IN TOP/BOTTOM)
INJECTOR SWITCH ASSEMBLY INSTALLATION

03-925964-01
INJECTOR HEATER BLOCK 12-312004-14, 2 PLCS
NOTES: SCREW, 4-40 X 7/8 SOC CAP, 18-8
1. INSTALL TIE WRAP ABOUT WIRES FROM BOTH THE HEATER AND THE
PLATINUM PROBE, ABOUT 1” FROM THE MIDDLE OF THE INJECTOR.
2. AFTER THE INSULATION COVER IS INSTALLED, USE A SCREWDRIVER OR

ALLEN WRENCH TO PUSH THE INSULATION DOWN SO THAT IT DOESN’T
COME UP PAST THE TOP OF THE HEATER BLOCKS. SEE STEP 1.2.15. 03-925967-01
INJECTOR INSULATION COVER
3. BEND TUBING AS DESCRIBED IN STEPS 1.2.16 THRU 1.2.18.
HEATER INSTALLATION/EXPLODED VIEW
DOC: 03-925996-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 9
1
03-925994-01 03-925995-01
ASSY, 1177 INJ., W/PRESS. SENSE ASSY, 1177 INJ.,
NO PRESSURE SENSE
03-925994-11
ASSY, 1177 INJ., W/PRESS. SENSE, 03-925995-11
SILCOSTEEL (BLUE COLOR) ASSY, 1177 INJ., NO PRESSURE
SENSE, SILCOSTEEL (BLUE COLOR)
FIGURE 1 FIGURE 2
03-925994-01 03-925995-01
ASSY, 1177 INJECTOR, W/PRESSURE SENSE ASSY, 1177 INJECTOR, NO PRESSURE SENSE
03-925994-11 03-925995-11
ASSY, 1177 INJECTOR, W/PRESSURE SENSE, SILCOSTEEL (BLUE COLOR) ASSY, 1177 INJECTOR, NO PRESSURE SENSE, SILCOSTEEL (BLUE COLOR)
1177 INJECTOR BODY REFERENCE
DOC: 03-925996-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 9
1
1. 1177 INJECTOR W/PRESSURE SENSE, ASSEMBLY PROCEDURES
1.1 INJECTOR SWITCH ASSEMBLY INSTALLATION
1.1.1 Place an Injector Actuator Spacer, (03-925981-01) on the stud protruding from the top of the Injector assembly.
1.1.2 Place the Injector Switch Assembly (03-908206-01) over the 1177 Injector W/Press. Sense (03-925994-01) purge head.
1.1.3 Install one Actuator Knob (03-925971-01) over the Injector Switch.
1.1.4 Insert a Septum (03-925989-01) into the recess in the top of the purge head.
1.1.5 Install an Injector Nut Assembly (03-925975-01) over the purge head. Carefully tighten the nut with your fingers without damaging the
thread.
1.2 INJECTOR BODY ASSEMBLY
1.2.1 Bend the leads from a 100W Heater Cartridge (03-925987-01) around a screwdriver or other shaft of approximately Ø1/4” and 90 degrees
about 1/8" from the body of the cartridge. Do not bend the leads sharply.
1.2.2 Insert the heater cartridge between the tubing

and bracket as shown.
DOC: 03-925996-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 9
1
1.2.3 Bend the leads from a Platinum Probe (03-925374-01), 90 degrees about 1/4” from body.
1.2.4 Insert the probe end between the tube and the injector bracket.
1.2.5 Place the Platinum Probe into a Heater Block (03-925964-02).
1.2.6 Place a Injector Heater Block (03-925964-01) under the body of the Injector, and make sure the thin tube sits in the slot.
1.2.7 Set the Heater Cartridge in the slot in the block.
1.2.8 Set the -02 Heater Block in place on the lower block. It may help to put the top of the -02 Heater Block in place about 3/4” below the top of
the lower block , so you can hold the heater in place with your thumb and then slide the -02 Heater Block up until they‘re even.
1.2.9 Place a 4-40 x 7/8 Soc Cap Screw (12-312004-14), through the top hole in the both heater blocks and install a 4-40 KEPS Nut
(13-312004-00) as shown. It is easiest to install the screws from underneath.
DOC: 03-925996-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 9
1
1.2.10 Repeat the previous step with the lower hole.
1.2.11 Orient the Heater Blocks so they're straight. Make sure the heater blocks still touch the tubing coming out of the side of the body near the
top. Tighten the screws with a 3/32" allen wrench and a 1/4” nut driver. Allow the Heater to protrude 1/32” below the bottom of the block.
1.2.12 Install a blue .10w Panduit PLT1M76 4” Cable Tie (22-119727-00), about 3/4” away from the heater blocks around the wires from
both the Heater Cartridge and the Platinum Probe.
1.2.13 Set 3 pieces of Injector Insulation (03-925978-01), over the body of the injector, and slide them up to the bottom of the tubing. If the
insulation will not slide all the way up, it is likely hitting the tubing leaving the injector body (see Fig 1.2.13a). Hold the line coming out
of the lower tee to move the tubing out of the way and push the insulation upwards as shown. (see Fig 1.2.13b).
TUBING
PULL UP HERE TO ALLOW INSULATION
TO SLIDE UP, THEN PUSH INSULATION UP
INSULATION IS BLOCKED BY TUBING
Fig 1.2.13a Fig 1.2.13b
DOC: 03-925996-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 9
1
1.2.14 Install the Insulation Cover (03-925967-01), over the injector and
snap in place. If the injector cover doesn’t snap in place, the legs
of the injector need to be bent outward. Bend either leg, or both
legs, outward as shown.
PULL AND BEND LEGS OUTWARD

TO MAKE COVER SNAP IN PLACE
1.2.15 Make sure there is a gap between the insulation and the top
of the block, using an allen wrench or small screwdriver top
push the insulation down.
INSULATION SHOULD COVER

STICK UP ABOVE COVER
USE ALLEN WRENCH OR

SMALL SCREWDRIVER TO
PUSH INSULATION DOWN
DOC: 03-925996-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 9
1
1.2.16 Bend the lowest tubes coming out of the slot in the injector
bracket down, then out, so that they are parallel to the base
of the injector and as close to it as possible.
BEND THESE LINES SO THEY ARE AS

NEAR THE DOTTED LINE AS POSSIBLE
TUBING MUST NOT INTERFERE WITH SWITCH
1.2.17 Bend the tubing from the purge head tubes down to the base
of the injector, then out, watching purge head to be sure it
doesn’t move and thus damage the glass insert. The lines
should not interfere with the inject switch and should be as
close to the base of the injector as possible.
2 LINES FROM PURGE HEAD
BEND TUBING CLOSE

TO INJECTOR BASE
DOC: 03-925996-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 9
1
1.2.18 Rotate the body of the tee fitting so that the line coming out the side of it points horizontally, as shown.
THIS LINE MUST COME OUT HORIZONTALLY
DOC: 03-925996-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of
1
DOC: 03-925914-11/12 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Sub-Assembly Micro - TCD
PAGE: 1 of 3
1
SUB-ASSEMBLY MICRO - TCD

SUB-ASSEMBLIES STATION, ASSEMBLY PROCEDURES
PREPARED BY: Sax Makthepharack REVISED BY: Seamus Flanagan CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 02 - 05 - 99 - SHOWN
DOC: 03-925914-11/12 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 3
1
NOTES:
1. DEPENDING ON APPLICATION USE 120V AC 50W HEATER (03-925899-01) OR
230V AC 50W HEATER (03-925899-02).
2. MAKE SURE HEATER AND PLATINIUM TEMP PROBE ARE FULLY SEATED.
CP-738632 3. ORIENT MICRO-TCD CELL ON BASE WITH FLAT CABLE AT FRONT.

MICRO TCD CELL
SEE NOTE #1
03-925374-01
TEMP PROBE, PLATINIUM
12-901163-00, 2PLCS
SCREW, SEMS, 8-32 X 3/8”, SS
CP-739415
BRACKET MICRO-TCD
CP-84723, 2 PLCS
SCREW, M4 X 8
22-119650-00, 2 PLCS
CABLE TIE, 3-5/8”
03-925913-01
DETECTOR BASE, DUAL TCD
MICRO-TCD EXPLODED VIEW MICRO-TCD ASSEMBLY VIEW
DOC: 03-925914-11/12 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 3
1
CLICK HERE FOR
MICRO-TCD INSTALLATION
CP-847232, 2 PLCS
CP-738640
SCREW, M3
FRONT COVER
CP-738563
INSULATION UPPER
12-901164-00, 2 PLCS
SCR, SEMS, 8-32 X 1/4”, SS
738948, 2 PLCS
INSULATION L/R
NOTE:
CP-738641
1. PLACE THE MICRO -TCD ON FIXTURE T-4310 TO INSTALL INSULATION.
738565, 4 PLCS TOP COVER
INSULATION LOWER
DOC: 03-925914-11/12 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 3
1
DOC: 03-925844-91 REV
CHG PARTS
chromatography
HISTORY
ICONS TOOLS
LIST MENU DESC: Assembly Procedure
PAGE: 1 of 2
Pr
ASSY, KIT, DETECTOR EFC INLET PLUM
DOC: 03-925844-91 REV
CHG PARTS
chromatography
HISTORY
ICONS TOOLS
PAGE: 2 of 2
Pr
03-925842-24
NOTES:
TUBING, PEEK 1/8” X 26”
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
DETAIL B
03-917142-00, 4 PLCS
DETAIL A VITON FERRULE
DOC: 03-925702-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, 3800GC Keyboard/Button-up
PAGE: 1 of 6
3
ASSY, 3800GC KEYBOARD/BUTTON-UP

SUB-ASSEMBLY STATION, ASSEMBLY PROCEDURES
DOC: 03-925702-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 6
3
WARNING:
1. Be careful around the high voltage area PS1 on (03-925800-01) PWA you could receive
an electrical shock. Remove all jewelry while performing adjustments. Be careful with tools
you could cause a short circuit. 12-222002-04, 4 PLCS
SCREW, 2-56 X 1/4, PAN
2. When positioning the LCD Display make sure not to use any metal material device, you 03-925359-01
could receive an electrical shock or short circuit. 3800 LCD DISPLAY
03-925276-00 12-901163-00, 2 PLCS

GROUND STRIP RIGHT SCREW, 8-32 X 3/8 SEMS, EXT
22-431139-00, 2 PLCS
STANDOFF, HEX 4-40 X 7/16
MENU LABEL 12-222004-04, 2 PLCS

SCREW, 4-40 X 1/4, PAN
14-312004-00, 2 PLCS
WASHER, #4 EXT LOCK, SST
03-925275-00
GROUND STRIP LEFT
12-901134-00, 5 PLCS
SCREW, 6-32 X 3/8 SEM, EXT
03-925800-01
3800 FRONT PANEL PWA
13-312004-00, 4 PLCS
NUT, KEPS, 4-40, SS
03-925207-01
HOUSING, KEYBOARD DISPLAY
03-925277-01
3800 KEYBOARD OVERLAY
DOC: 03-925702-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 6
3
1. 3800GC KEYBOARD/BUTTON-UP, ASSEMBLY PROCEDURES
1.1 KEYBOARD HOUSING ASSEMBLY
1.1.1 Feed Keyboard Overlay (03-925277-01) connector through slotted hole on Keyboard Housing Display (03-925207-01), using two 4-40 x 7/16 Hex Standoffs
(22-431139-00) and four 4-40 Keps Nuts (13-312004-00) secure in place as shown. Finger tighten only.
1.1.2 Remove adhesive backing paper from Menu Label and apply into indented part on Keyboard Housing Display where shown.
1.1.3 Place Keyboard Housing Display face down and install PWA Front Panel (03-925800-01), using three 6-32 x 3/8 Sems Ext. Screws (12-901134-00) as shown.
1.1.4 Install Ground Strip Left (03-925275-00), using one 6-32 x 3/8 Sems Ext. Screw (12-901134-00), one 8-32 x 3/8 Sems Ext. Screw (12-901163-00) and one
4-40 x 1/4 Pan Screw (12-222004-02) with #4 Ext. Lock Washer (14-312004-00) as shown.
1.1.5 Repeat previous Step 1.1.4 for Ground Strip Right (03-925276-00) on opposite side.
1.1.6 Install LCD Display (03-925359-01), using four 2-56 x 1/4 Pan Screws (12-222002-04) and leave the screws loose.
1.1.7 Connect the connector from the Keyboard Overlay to (J-101) and connect connector from LCD Display to (J-102) on PWA Front Panel.
1.2 ADJUSTMENT AND TEST
1.2.1 Assemble the keyboard and display, leave all 11 screws installed but not tightened.
1.2.2 Adjust R2, contrast control on the bottom of the display housing to approximately mid point.
1.2.3 With the power off (red light off), install the unit on the alignment fixture. Make sure the hold down clamp does not run into the two black twisted wires
or the power supply PS1 on the board.
1.1.4 Plug in the flat ribbon cable with the red wire toward the left.
1.1.5 Turn on the main power switch. The display takes a moment to come on.
1.1.6 Looking directly over the center of the keyboard/display into the mirror carefully align the display as described in figure #1.
1.1.7 Using the insulated plastic prying tool align the display as shown in attached photos.
1.1.8 Tighten only two diagonally positioned screws when alignment seems complete.
1.1.9 Turn the main power off to tighten the remaining screws. If your screwdriver slips it could destroy the fixture or the display.
DOC: 03-925702-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 6
3
1.1.10 Un-clamp the display and turn it so it is facing you.
1.1.11 Turn the power back on being careful not to touch any circuitry.
STEP 12 STEP 14 STEP 15
2 OF 2
1 KEYBOARD TEST
2 DISPLAY TEST
3 CLOCK TEST START/STOP
STEP 16 STEP 16 STEP 16
CHECKER
CLEAR DARK
BOARD
1.1.12 Go to the instrument menu page, select page 2 of 2.
1.1.13 Select the Keyboard Test press at random any keys except “menu”, make sure they all match their printed description. When complete press “menu” to return
to the main menu of page 2.
1.1.14 Scroll to the display test, press the blue “Enter”. (Lower left hand side)
1.1.15 Press the blue “START/STOP” softkey to “START”. (Lower left hand side)
1.1.16 Press the center softkey to turn all pixels on (black display) and look for any pixels not on.
1.1.17 Press the center softkey again passed the checkerboard pattern to the white screen. Look for any pixels which may be struck on. If any pixels are stuck on
or off the display must be rejected. (A pixel is the smallest dot visible on the display).
DOC: 03-925702-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 6
3
The Object is to align Left, Right, Up and Down Margins

equally with the edge of the housing. The display should show
no tilt. Note: Avoid touching the high voltage supply behind the clamp.
Prior to adjusting the LCD Display make sure to clamp

the Keyboard Display Assembly down into the fixture.
Attach the Ribbon Cable from the fixture to the
connector on the Keyboard Display Assembly
as shown.
Figure #1
DOC: 03-925702-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 6
3
Figure #2 Figure #3 Figure #4
Pry against the standoff to move the display left. Pry here to move both boards to the right. Pry here, between the two boards to tilt the right side of the
display up. Stay away from the high voltage supply behind the
clamp
Figure #5 Figure #3
Pry here to move only the display board to the right To move both boards up pry here.
DOC: 03-925700-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Main Door
PAGE: 1 of 2
2
Main Door Assembly
PREPARED BY: MICHAEL HARRAL REVISED BY: AJB CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 1/29/98 - SHOWN
DOC: 03-925700-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Main Door
PAGE: 2 of 2
2
03-925311-01
PIN, HINGE, 2EA.
03-925208-01
MAIN DOOR
14-112007-00 NOTES:
WASHER, FLAT, 2EA.
1. USE LOCTITE #222 ON
BOTH SCREWS OF
12-901163-00 RETAINER LATCH.
R SCRW, 8-32 X 3/8, EXT.,LW, PH 2EA. TIGHTEN SCREWS UNTIL

SNUG OR LATCH PLATE
MOVES. STOP IF PLATE
MOVES.
2. ATTACH WIDE FLANGEOF

OVEN DOOR SPRING ON
LATCH SIDE.
3. FOR LATCH ROD ASSY.

USE T# 4340
03-925283-01 NOTE:
PLATE, LATCH TO ENSURE PROPER
SEAL WHEN DOOR IS
CLOSED, HANDLE DOOR
03-925284-01
DOOR, RETAINER LATCH
ASSY. SUCH THAT NO
DEPRESSION IS MADE
IN INSULATION
03-925286-01
LATCH ROD
03-925448-01
INNER COL. OVEN DOOR ASSY.
88-299284-00 12-222008-08
LOCTITE #222 SCRW,8-32 X 1/2” SST, PH 2EA 12-901132-00
SEE NOTE 1
SCREW, 8-32 X 3/8, EXT., PH, 4EA.
17-699907-00
RIVET, 1/8 X1/8, AL / AL 4EA.
03-925287-01
SPRING, OVEN DOOR, 2EA.
DOC: 03-925697-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: AUTODRIVE
PAGE: 1 of 6
2
AUTODRIVE
SUB-ASSEMBLY
DOC: 03-925697-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 6
2
03-925670-01
ROD, CYLINDER SUPPORT
03-925663-01
BLOCK 3
03-925598-01
SHAFT, SLED
03-925665-01
STOP “A/B”
2 PLACES
21-179882-00
PRECISION BALL BUSHING
2 PLACES
03-925667-01
SLED
CLEAN GREASE OFF BUSHING
AND ADD LOCTITE RC/609 TO
OUTSIDE OF BUSHING AND INSIDE
HOLES OF SLED, 4 PLACES
03-925661-01
BLOCK 1
11-999961-00 12-212008-08
SET SCREW SCREW #8-32 x 1/2”
6 PLACES 4 PLACES
03-925597-01
BASEPLATE
12-212008-06
SCREW #8-32 x 3/8”
2 PLACES
DOC: 03-925697-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 6
2
12-901163-00 28-849074-00
SCREW 8-32 x 3/8” SEMS BARB FITTING, 2 PLACES
2 PLACES 28-849066-00
SWIVEL - ELL, 2 PLACES
27-300063-00
12-222060-10 PNEU. ACTUATOR
SCREW 10-32 x 5/8”
03-925658-01
2 PLACES
PUSHER
03-925657-01 12-312004-04
BRACKET, CYLINDER SCREW #4-40 x1/4” SOC HD
03-925707-00
28-993060-00
1/8” HOSE CLAMP RIVET, 2 PLACES
2 PLACES 03-925660-01
11-999961-00
SET SCREW 03-925599-01 LINK
FLAT
3 PLACES SHAFT, CAM
TIGHTEN SET SCREWS IN THE 03-925656-01
CENTER OF THE FLAT SECTION STOP, ROTOR
ON THIS CAM SHAFT.
03-925659-01
SADDLE
03-925666-01
STOP, “C”
21-139806-00
BRONZE BEARING
03-925662-01
BLOCK 2
03-925655-01
WASHER
22-678311-00
RETAINING RING
2 PLACES
12-212008-06
SCREW #8-32 x 3/8”
2 PLACES
12-212008-08
SCREW #8-32 x 1/2”
2 PLACES
DOC: 03-925697-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 6
2
12-901163-00
28-849817-00 SCREW #8-32 x 3/8 SEM
#10-32 BULKHEAD FITTING W/ HARDWARE
NOTES: (UNLESS OTHERWISE SPECIFIED) 2 PLACES
SEE NOTE 2
1. REPLACE THE 1/8” BARB FITTINGS ON THE 03-918707-01 SEE NOTE 1
PRESSURE REGULATOR WITH 5/32” BARB PRESSURE REGULATOR
5”
FITTING P/N 28-849074-00. REGULATOR IS PRESET
DO NOT MODIFY
2. USE ONE OF THE 1/8” BARB FITTING REMOVED WIRES FROM
12-222004-24 SOLENOID
FROM THE PRESSURE REGULATOR HERE . SCREW #4-40 x 1 1/2” PHMS, 2 PLACES VALVES
3. USE P/N 03-918707-00 PRESURE REGULATOR 27-180510-00
SOLENOID VALVE, 2 PLACES
AND SET TO 25 PSI TO MAKE 03-918707-01. 03-925762-01
NO VMS TRANSACTIONS REQUIRED. 28-849795-00 9” REAR PANEL
SWIVEL - TEE
27-300064-00
CYLINDER
REMOVE NUT THAT COMES W/CYLINDER 712”
03-925669-01 27-180282-00
ROD, CYLINDER SUPPORT FLOW RESTRICTOR
4 PLACES
28-849074-00
BARB FITTING 10-32 x 5/32 TUBE
8 PLACES 5”
28-849066-00
SWIVEL - ELL
3 PLACES
03-925668-01
CYLINDER
9”
SUPPORT 9”
13-312060-00 13 12 “
#10 KEP NUT
03-925664-01
SPACER, VALVE
28-158630-00
11-999961-00 95 PUR 4MM x 2.4MM TUBING
SET SCREW 7 PLACES
2 PLACES
DOC: 03-925697-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 6
2
ADD RELAY WIRE SET LABELS,
88-488028-00 SEE WIRING SCHEMATIC
ADD SHRINK TUBING 4 PLACES
22-119650-00 TO END OF SLEEVE
CABLE TIE
H1
24-799873-00
5/8” GROMMET
88-360032-00
1/4” I.D. x 3’ POLY SLEEVE
TEST PER PROCEDURE #03-914203-00

PAGE 11 OF THE OPERATORS MANUAL.
WIRING SCHEMATIC RELAY WIRE SET LABEL,

4 PLACES
H1
DOC: 03-925697-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 6
2
03-925763-01
COVER
03-925760-01
LABEL, VARIAN AUTODRIVE
03-925764-02
CAP, END, LEFT HAND
03-925765-01
BRACKET, COVER
3 PLACES
03-925764-01
13-312008-00 CAP, END, RIGHT HAND
#6 KEP NUT
6 PLACES
12-901164-00
SCREW #8-32 x 1/4 SEM
7 PLACES
MAKE SURE THE INSET

NUT IS UPWARD.
DOC: 03-925693-11/12 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Big Valve Oven
PAGE: 1 of 5
2
Assy, Big Valve Oven
PREPARED BY: Sax Makthepharack REVISED BY: AJB CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 12 - 15 - 99 - SHOWN
DOC: 03-925693-11/12 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 5
2
NOTES:
1. PLACE THE HEATER PLATE AS SHOWN ON A FLAT, STEADY SURFACE.
2. INSTALL CLAMP RING SIX PLACE WITH 6-32 X 3/8 SCREWS. (CLAMP RING ORIENTATION AS SHWON).
3. INSTALL OVEN HEATER CABLE AND SECURED WITH TWO SET SCREWS.
(SEE SPECIFICATION FOR OPTION 120V & 230V)
4. TURN HEATER PLATE OVER, INSTALL OVEN CHANNEL WITH 6-32 X 3/8 SCREW.
5. INSTALL CHANNEL COVER WITH 6-32 X 7/8 SCREWS. 22-119918-00
CLAMP, CABLE, 5/16 DIA, 2EA
12-222006-06, 14 PLCS
SCREW, 6-32 X 3/8, PHMS, SST
03-925682-03, 7 PLCS
CLAMP RING, VALCO #CR2
03-925553-01, (OPTION)
CABLE, VALVE OVEN HTR 120V
03-925553-02, (OPTION)
CABLE, VALVE OVEN HTR 230V
03-925547-01
PLATE, HEATER, VALVE OVEN
11-622008-03, 2 PLCS
SCREW, SET, 8-12 X .19
03-925549-01
CHANNEL, VALVE OVEN
12-900307-00
SCREW, 6-32 X 3/4”, SSFH
03-925692-01
COVER, CHANNEL
12-222006-14, 2 PLCS
SCREW, 6-32 X 7/8, PHMS, SST
DOC: 03-925693-11/12 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 5
2
NOTES:
03-925550-01 1. PLACE THE OVEN BRACKET AS SHOWN ON A FLAT,
INSULATION, BRKT STEADY SURFACE.
12-903134-00, 4 PLCS VALVE OVEN 2. ALIGN FOUR HOLES WITH INSULATION TO STANDOFFS ON BRACKET
8-32 X 5/8, KNLD THUMB AND GENTLY PRESS INSULATION INTO BRACKET. THEN NEATLY
SCREW FOLD TOP & 2 SIDE EDGES OF BRACKET INSULATION TOWARD
OVEN BRACKET.
3. ALIGN HEATER PLATE ASSY WITH FOUR (4) STANDOFFS IN VALVE
OVEN BRACKET AND HEATER WIRES WITH PRE SLOTTED INSULA-
TION. PRESS PLATE ASSEMBLY INTO INSULATION AND SECURE
WITH FOUR (4) SCREWS AND EIGHT (8) WASHERS AS SHOWN.
4. ATTACH INJECTOR COVER SUPPORT TO THE OVEN BRACKET,
WITH 8-32 X .38 SCREWS.
03-925545-01
BRACKET, VALVE OVEN
ORIENT WASHER
14-998237-00, 4 PLCS
WASHER, B’VILLE,
.365 OD X .173 ID
12-222008-10, 4 PLCS
SCREW, 8-32 X 5/8,
PHMS, SST
12-901163-00, 4 PLCS
03-925548-01 SCREW, 8-32 X .38 LG, SEMS
SUPPORT, INJECTOR COVER
DOC: 03-925693-11/12 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 5
2
NOTES:
1. SECURE HEATER WIRE CABLE CLAMP (2) TO OVEN BRACKET.

2. POSITION HEATER ASSEMBLY AND OVEN BRACKET AS SHOWN.
3. PLACE THE COVER INSULATION OVER THE OVEN COVER AND A FIRMLY PRESS
DOWN INTO COVER. NEATLY DRESS FOUR (4) CORNERS.
4. INSTALL OVEN COVER ASSEMBLY TO THE HEATER ASSEMBLY. MAKE SURE THE SLOTS
ON THE OVEN COVER ALIGN WITH FACED THUMB WASHERS AND FINGERTIGHT, SECURE.
03-925551-01
INSULATION, COVER, VALVE OVEN
03-925546-01
COVER, VALVE OVEN
DOC: 03-925693-11/12 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 5
2
Typical Installation of Big Valve Oven
DOC: 03-925693-11/12 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 5
2
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 1 of 17
3
ASSY, DETECTOR EFC
PREPARED BY: Sax Makthepharack REVISED BY: Sax Makthepharack CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 02 - 03 - 00 - SHOWN
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 17
3
O-RING INSPECTION
O-RINGS
PEEK TUBING
NOTES: (UNLESS OTHERWISE SPECIFIED)

1. DO NOT TOUCH BAKED O-RINGS AT ANY TIME.
2. REMOVE BOTH TYPES OF BAKED O-RINGS FROM STORAGE JAR WITH

TWEEZERS.
3. INSPECT BOTH SIDES OF THE BAKED O-RING FOR CRACKS UNDER

UNDER A MICROSCOPE.
4. CLEAN BAKED O-RINGS BY INSERTING A PIECE OF PEEK TUBING

THRU CENTER OF O-RING AND SPRAY THOROUGHLY WITH
“DUST OFF” (AS SHOWN).
5. ONLY CLEAN WHAT WILL BE IMEDIATELY USED.
6. WHENEVER O-RINGS ARE USED, USE “DUST-OFF” TO CLEAN PART

SURFACE BEFORE AND AFTER ADDING O-RINGS.
“DUST-OFF”
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 17
3
1. INSTALL FRITT INTO BLOCK WITH ARBOR PRESS TOOL. PRESS UNTIL FRITT IS FULLY
SEATED AGAINST BLOCK FACE.
2. FRITT TABLE 1 BLOCK LABEL
FRITT P/N (03-9256XX-01) LABEL

03-925568-01
CHANNEL BLOCK EFC DETECTOR
DASH NO. NAME 1 2 3
01 FID 79/100 79/100 81/1000

FRITT RESTRICTOR
02 TSD 79/100 78/25 81/1000 SEE TABLE 1
03 ECD 80/250 --------- ---------
04 TCD 79/100 80/250 ---------

FRITT INSTALLATION
05 PFPD 79/100 79/100 79/100
06 TCD (H2) 79/100 79/100 ---------

BOTTOM VIEW
3. FRITT HANDLING
- CLEAN 1 PACKAGE (25 EA.) AT A TIME
- KEEP IN CLEAN GLASS VIAL
- HANDLE ONLY WITH TWEEZERS

4. LABEL BLOCK
BLOCK EFC
DETECTOR (REF.)
03-930109-15, 2 PLCS
O-RING

1. SEE O-RING PRE-ASSEMBLY INSPECTION PROCEDURE OR CLICK ON IMAGE.
2. AFTER CLEANING O-RING & MATING SURFACE, SET O-RINGS IN PLACE WITH
TWEEZERS. (DO NOT TOUCH O-RINGS). 03-905960-10, 2 PLCS
3. FIRMLY SEAT O-RINGS IN BLOCK. O-RING
4. INSPECT SEATING OF O-RINGS, IF NECESSARY PRESS TO SEAT USING TWEEZERS.

O-RING INSTALLATION
5. AFTER O-RING PLACEMENT, “DUST OFF” AGAIN.
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 17
3

1. ASSEMBLE PART AS SHOWN. START SCREWS (3 TURNS) BUT DO NOT TORQUE
COMPLETELY.
2. REPEAT FOR EACH CHANNEL WITH BLOCK PER TABLE 1.
3. FOR CHANNELS WITH OUT BLOCK, INSTALL RESISTOR (P/N 31-408353-00 NOT SHOWN)
INTO J6 AND/OR J4 AS REQUIRED.
03-925812-01
ASSY, EDC PWA
CHANNEL 2 (REF.)
CHANNEL 3 (REF.)
12-222006-04, 2 PER BLOCK

SCREW, 6-32 X 1/4
03-925570-01, 3 PLCS
14-202006-00, 2 PER BLOCK
SPACER (ONE SHOWN)
WASHER, SPLIT #6
BLOCK EFC DETECTOR

(REF.) SEE SHEET #3
03-925961-01, 3 PLCS
TRANSDUCER (ONE SHOWN)
CHANNEL 1 (REF.)
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 17
3

1. ORIENT VALVE CABLES. LABEL
2. MOUNT VALVES & MOUNTING PLATE TO BLOCK ONE AT A TIME.
3. ASSEMBLE PWA TO MOUNTING PLATE SCREWS.

TIE WRAP
4. AFTER VALVES & MOUNTING PLATE ASSEMBLED TO BLOCK,
TORQUE SCREWS FROM PREVIOUS SHEET HAND TIGHT..
5. INSTALL COVER (WITH TIE WRAP) AND LABEL FOR J8.
6. MOUNT CATIPILLAR STRIP TO BRACKET.
03-925569-01
PLATE, MTG
03-925695-01
VALVE, PROPORTIONAL 12-222006-04, 2 PLCS
SCREW, 6-32 X 1/4
14-202006-00, 2 PLCS
WASHER, SPLIT #6
14-202004-00, 2 PLCS
WASHER SPLIT #4
12-222004-22, 2 PLCS
24-389071-00, 2-1/2” LG
SCREW, 4-40 X 1-1/4
GROMMET GTRIP
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 17
3

1. ASSEMBLE TUBING/MANIFOLD/FERRULE AND 28-691944-00
SCREWS TO BLOCK. (SEE TUBING TABLES) HAND TIGHT.
TEE
2. CONNECT PIN OUT AS REQUIRED. (-01, -02 & 05 ONLY)
2 4 6 8 10 12 14 16
J8
1 3 5 7 9 11 13 15
CHANNEL 1 VALVE
CHANNEL 2 VALVE
(IF PRESENT)
CHANNEL 3 VALVE
(IF PRESENT)
JUMP FOR -03, -04,-05 & -06 12-222004-08, 6 PLCS
SCREW, 4-40 X 1/2
JUMP FOR -01 & 02
3. TIE WRAP VALVE CONNECTORS TOGETHER.

SEE DETAIL A.
TUBING, PEEK
4. TIE WRAP TEE TO COVER IF PRESENT. (SEE TABLE SHEET #7)
03-925107-00
PLATE, MANIFOLD MOUNTING
03-917142-00, 6 PLCS
FERRULE, VITON
22-119650-00
TIE WRAP
DETAIL A.
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 17
3
TUBING TABLES
3
4 2
7
1
3 1 1
4 2
NOTE: ITEM 1, 3 & 5 ARE INLET TO BLOCKS
TABLE FOR -01, -02 & -05 TABLE FOR -04 & -06 TABLE FOR -03
ITM TUBE P/N -01 TUBE P/N -02 TUBE P/N -05 ITM TUBE P/N -04 TUBE P/N -06 ITM TUBE P/N
(FID) (TSD) (PFPD) (TCD) (TCD/H2) (ECD)
03-925838-16 03-925838-16 03-925840-16 03-925838-16 03-925839-16 03-925838-16
1 1 1
(BLUE) (BLUE) (BLACK) (BLUE) (RED) (BLUE)
03-925838-02 03-925838-02 03-925840-02 03-925838-26 03-925839-26 03-925838-26

2 2 2
(BLUE) (BLUE) (BLACK) (BLUE) (RED) (BLUE)
03-925839-16 03-925839-16 03-925839-16 03-925838-16 03-925839-16

3 3
(RED) (RED) (RED) (BLUE) (RED)
03-925839-04 03-925839-04 03-925839-04 03-925838-26 03-925839-26

4 4
(RED) (RED) (RED) (BLUE) (RED)
03-925840-16 03-925840-16 03-925840-16

5
(BLACK) (BLACK) (BLACK)
03-925840-26 03-925840-26 03-925840-23

6
(BLACK) (BLACK) (BLACK)
03-925839-26 03-925839-26 03-925841-17

7
(RED) (RED) (NATURAL)
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 17
3
TEST AND CALIBRATION PROCEDURE DETECTOR EFC
3
4 2
7
1
3 1 1
4 2
NOTES: (UNLESS OTHERWISE SPECIFIELD

1. CONNECT FLAT CABLE. ITM DEFC P/N CARRIER IN CARRIER OUT
(03-925609-XX)
2. CONNECT DEFC CARRIER INLET(s) TO TEST BENCH CARRIER INLET (MANIFOLD WITH CROSS
“T” IF REQUIRED) 1 -01, -02 & -05 1, 3 & 5 4, 6 & 7
(FID, TSD, PFPD)
3. CONNECT DEFC CARRIER OUTLET(S) TO TEST BENCH CARRIER OUTLET (MANIFOLD WITH
CROSS OR “T”, IF REQUIRED). 2 -04 & -06 1&3 2&4
(TCD, TCD(H2))
4. PLUG PRESSURE SENSOR ON TEST STAND.
3 -03 1 2
5. JUMP SPLIT VALVE TO VENT ON TEST STAND. (ECD)
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 17
3
LABVIEW TEST AND CALIBRATION PROGRAM DETECTOR EFC
1. IN THE PROGRAM MANAGER LAB

VIEW WINDOW, DOUBLE CLICK ON
LAB VIEW ICON. A WINDOW WITH
HEADING “ UNTITLED 1” WILL
APPEAR, CLOSE IT.
2. CLICK ON THE OPEN VI BUTTON.
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of 17
3
3. HIGHLIGHT AND OPEN
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 11 of 17
3
09
4. HIGHLIGHT AND OPEN
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 12 of 17
3
5. HIGHLIGHT AND “OK”
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 13 of 17
3
7. CLICK ON ARROW TO GO TO “QUICK

TEST”.
9.02
6. FROM FUNCTIONS PULLDOWN

MENU, SELECT “QUICK TEST”.
CURRENT REVISION IS 9.02

DO NOT RUN FIXTURE W/WRONG SOFTWARE REVISION
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 14 of 17
3
1. REFER TO THE DEFC TROUBLESHOOTING FLOW CHART TO TEST ERRORS. 10. IN THE GRP BOX, INDICATE THE
TYPE CODE OF THE DEFC IN EACH
2. IF NOT TEST ERRORS, GO TO WINDOWS AND SELECT 1MODTEST. GROUP ( CODES IN LOWER LEFT
HAND CORNER OF DISPLAY).
11. CLICK ON THE ARROW TO BEGIN

“QUICK TEST”.
9. FROM THE “QUICK TEST SETUP”

PULLDOWN MENU, SELECT FULL
TEST.
8. INPUT FLOW SENSOR NUMBER

(LOCATED ON FLOW SENSOR)
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 15 of 17
3
1. REFER TO THE DEFC TROUBLESHOOTING FLOW CHART TO TEST ERRORS.
2. IF NO TEST ERRORS, ENTER DEFC TYPE AND PWA REV. ON APPRORIATE LABEL.
14. INPUT FLOW SENSOR NUMBER
16. CLICK ON ARROW TO

BEGIN “TEST AND
CALIBRATE”.
13. ENTER THE DEFC

TYPES CONNECTED
IN EACH GROUP
AND THE PWA REV.
(TYPE CODES IN
LOWER RIGHT COR-
NER OF DISPLAY).
15. ENTER THE FIXTURE

NUMBER.
9.02
12. FROM FUNCTIONS

PULLDOWN MENU,
SELECT “TEST AND
CALIBRATION.
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 16 of 17
3
17. APPLY LABEL.
NOTES: (UNLESS OTHERWISE SPECIFIELD

1. AFTER LABEL APPLIED, BAG & SEAL IMMEDIATELY.
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 17 of 17
3
DEFC Trouble-shooting Flow Chart Conduct Full
Test or
Calibration
Diagnostic Rules:
NO YES
1. Always investigate Leak and Flow Label and Package Error
Sensor Errors first DEFC Module Message
2. Always Verify Detector type.

3. If "Channel X Not Operating" with "Fritt
out of Tolerance" message, ignore fritt YES
Channel X not
message. operating
NO
YES NO
Leak Test Error
Decision
Most likely NO
problem: Flow Sensor
Overrange
YES
Fritt out of
Tolerance
NO Test P
NO NO Test P LT NO
LT 85 and/or
Voltage LT .5VDC Voltage GT 3VDC 85 and Leak error
Leak error GT
LT .500 Psi
.500 Psi
YES YES YES
YES
Downstream Restriction
YES Transducer YES Use Controller test to Normal Leak, Fritt out of Tolerance
Blockage Valve Connection Test Flowrate Test Flowrate Missing Fritt
LT Expected Connection LT Expected Flowrate diagnosis problem Severe Leak Check O-Rings and Wrong Type #
Blockage Transducer backwards
Flowrate Board Fittings Bad PWA
Bad Board
Bad Transducer
NO NO
Transducer NO In
YES Valve or PWA
backwards or shorted Test Flowrate Controller Test,
No Fritt GT Expected Valves shut off
Flowrate
NO YES
Transducer Bad
Transducer
Backwards
Short to Block
Blockage
PWA
Bad Transducer
Bad PWA
DOC: 03-925609-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 18 of 17
3
DOC: 03-925607-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: TCD Detector
PAGE: 1 of 3
2
TCD DETECTOR
Subassembly
DOC: 03-925607-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 3
2
03-925333-01
-01, -02, & -03 STANDARD LID, OUTER OVEN
-11, -12, & -13 W/ TRANSFER LINE 24-000739-00
INSULATION TOP & BOTTOM
24-000741-00
INSULATION, SIDE, TCD
Notes:
1. CUT OFF EXISTING CONNECTOR
AND PREPARE WIRES TO
RECEIVE THE WIRE PINS AND
NOTE:
CONNECTOR SHOWN BELOW IN WRAP SIDE INSULATION EVENLY
DETAIL ‘A’. PINS MUST BE SOL- NOTE:
AROUND TCD CELL BY STARTING ON
THESE TWO PARTS TO BE USED
DERED TO WIRES. SURFACE INDICATED FINISH WRAP
WITH TRANSFER LINE VERSION
MUST BE TWO THICKNESSES ON
ONLY. (REF. 03-925607-11, -12, -13)
INDICATED SIDE.
2. LENGTH OF CABLE AFTER ADDI-
TION OF NEW CONNECTOR 28-693976-00
UNION, COMPRESSION 1/16” SST
SHOULD BE 24”.
03-917145-09
TUBING, SST, 1/16” 18”LG.
51-411022-00 SEE DETAIL ‘A’
CONNECTOR, MOLEX, & NOTE 2
SIGNAL CABLE 24-00741-01
INSULATION LOWER CAVITY,TCD
3EA. ,
NOTE: CUT ONE PIECE IN HALF

SEE PHOTO @ LEFT
95 03-925459-01
26 51-411004-00
HEATER, TCD, 120V
25 PINS, MOLEX 5EA.
X-
SEE NOTE 1.
M
03-925459-02
HEATER, TCD, 220V
03-925459-03
03-908280-00
HEATER, TCD, 101V
ASSY., TC CELL STANDARD
R
ED
BL
G AC
R K
W EE
YE H N
IT
LL E
O
W 03-925263-01
COVER, OUTER OVEN
17-699907-00
RIVET AL 2EA.
24-000739-00
PARTS NOT SHOWN
Detail ‘A’ INSULATION TOP & BOTTOM 22-119918-00
5/16” ALUM. CLAMP
DOC: 03-925607-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 3
2
03-925333-01
LID, OUTER OVEN
-21, -22, & -23 DUAL TCD 24-000739-00
INSULATION TOP & BOTTOM
Notes:
1. CUT OFF EXISTING CONNECTOR
AND PREPARE WIRES TO
RECEIVE THE WIRE PINS AND 24-000741-00
NOTE:
CONNECTOR SHOWN BELOW IN WRAP SIDE INSULATION EVENLY
INSULATION, SIDE, TCD
DETAIL ‘A’. PINS MUST BE SOL- AROUND TCD CELL BY STARTING ON
DERED TO WIRES. SURFACE INDICATED FINISH WRAP
MUST BE TWO THICKNESSES ON
INDICATED SIDE.
2. LENGTH OF CABLE AFTER ADDI-
TION OF NEW CONNECTOR
SHOULD BE 24”.
ATTACH LABELS
TO CABLE
51-411022-00, 2 PLCS REAR

CONNECTOR, MOLEX, 24-00741-01
FRONT INSULATION LOWER CAVITY,TCD
SIGNAL CABLE
3EA. ,
SEE DETAIL ‘A’ NOTE: CUT ONE PIECE IN HALF

SEE PHOTO @ LEFT
2X & NOTE 2
95
26 51-411004-00 03-925374-01
25 PINS, MOLEX 5EA. PROBE, TEMPERATURE
X-
SEE NOTE 1.
M
REAR
ATTACH LABELS
TO CABLE
03-925778-01
ASSY., TC CELL DUAL FRONT 03-925459-01
R
ED HEATER, TCD, 120V
BL
G AC
R K 03-925459-02
W EE
YE H N HEATER, TCD, 220V
IT
LL E
O
W 03-925263-01 03-925459-03
COVER, OUTER OVEN HEATER, TCD, 101V
17-699907-00
RIVET AL 2EA.
24-000739-00
PARTS NOT SHOWN
Detail ‘A’ INSULATION TOP & BOTTOM 22-119918-00
5/16” ALUM. CLAMP
DOC: 03-925512-04 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Oven Single Catalyst
PAGE: 1 of 2
1
ASSY, OVEN SINGLE CATALYST

DOC: 03-925512-04 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Oven Single Catalyst
PAGE: 2 of 2
1
1. OVEN SINGLE CATALYST, ASSEMBLY PROCEDURES
03-925499-01
COVER, 1041 INJ OVEN BLOCK
1.1 OVEN BLOCK ASSEMBLY
1.1.1 Assemble the 1041 Oven Block Assembly (03-918648-00) and two
Injector Mounting Brackets (04-000994-00), using four 8-32 x 3/8 Sems
Screws (12-901163-00) to secure in place as shown.
1.1.2 Install the 1041 Injector Insulation (03-925539-01) into the 1041
Injector Oven Block Cover (03-925499-01). Cut Insulation on leg
shown to 1/2 thickness and discard. Make sure the hole on Insulation
03-925539-01
INSULATION, 1041 INJ and Injector Oven Block Cover are lining up.
CUT MATERIAL TO
1/2 THICKNESS
ALONG DOTTED LINE.
03-918648-00
ASSY, OVEN SINGLE CATALYST
12-754015-24
BOLT, 5/16-18 X
1-1/2, HEX HD, BRS
03-918481-00
SPACER, 1/2 OD X .323 ID .12 THK
13-112015-00
NUT, 5/16-18, HEX, SST
03-917588-00, 2 PLCS
BRKT, MTG, HTD INJ
12-901163-00, 4 PLCS
SCREW, SEMS, 8-32 X 3/8, SST
DOC: 03-925512-03 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Oven Dual Valve
PAGE: 1 of 2
1
ASSY, OVEN DUAL VALVE

DOC: 03-925512-03 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Oven Dual Valve
PAGE: 2 of 2
1
03-925676-01 1. OVEN DUAL VALVE, ASSEMBLY PROCEDURES
COVER, VALVE OVEN, DUAL
1.1.1 Assemble Dual Valve Block (03-917170-00) to Injector Mounting

Brackets (04-000994-00), using four 8-32 x 3/8 Sems Screws
(12-901163-00) to secure in place.
1.1.2 Install the Dual Valve Oven Insulation (03-925683-01) into the Dual
Oven Valve Cover (03-925676-01). Make sure the hole on Insulation
and Injector Oven Block Cover are lining up.
1.1.3 Install one 8-32 x 3/16 Set Screw (11-622008-03) into the Dual Valve
Block where shown.s
03-925683-01
INSULATION, VALVE OVEN, DUAL
11-622008-03
SCREW, 8-32 X 3/16, SET
03-917170-00
BLOCK, DUAL VALVE
04-000994-00, 2 PLCS
BRACKET, INJECTOR MOUNTING
12-901163-00, 4 PLCS
SCREW, SEMS, 8-32 X 3/8, SST
DOC: 03-925512-02 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Oven Injector/Valve
PAGE: 1 of 2
1
ASSY, OVEN INJECTOR/VALVE

DOC: 03-925512-02 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Oven Injector/Valve
PAGE: 2 of 2
1
1. OVEN INJECTOR/VALVE, ASSEMBLY PROCEDURES
03-918442-00 1.1 OVEN BLOCK ASSEMBLY

COVER, HTD, INJ-VLV, OVEN
1.1.1 Assemble the Injector/Valve Block Assembly (03-917174-00) and two
Injector Mounting Brackets (04-000994-00), using four 8-32 x 3/8 THD
Cutting Screws (10-351308-06) to secure in place.
1.1.2 Install the INJ-VLV HTD Oven Insulation (03-917673-00) into the Oven
INJ-VLV HTD Cover (03-918442-00). Make sure the hole on Insulation
and Injector Oven Block Cover are lining up.
Note: Use fixture T-8634 to form the Insulation before insert to Oven
Cover.
03-917673-00
INSULATION, OVEN, HTD, INJ-VLV
12-754015-24
BOLT, 5/16-18 X 1-1/2, HEX HD, BRS
03-917174-00
BLOCK, INJECTOR/VALVE 03-918481-00
13-112015-00
04-000994-00, 2 PLCS
BRACKET, INJECTOR MOUNTING
10-351308-06, 4 PLCS
SCREW, 8-32 X 3/8, THD CUTTING, SST
DOC: 03-925512-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Oven Single Injector
PAGE: 1 of 2
1
ASSY, OVEN SINGLE INJECTOR

DOC: 03-925512-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Oven Single Injector
PAGE: 2 of 2
1
1. OVEN SINGLE INJECTOR, ASSEMBLY PROCEDURES
03-925499-01
COVER, 1041 INJ OVEN BLOCK
1.1.1 Assemble the 1041 Oven Block Assembly (03-925548-01)

and two Injector Mounting Brackets (03-917588-00), using
four 8-32 x 3/8 Sems Screws (12-901163-00) to secure in
place as shown.
1.1.2 Insert the 1041 Injector Insulation (03-925539-01) into the

1041 Injector Oven Block Cover (03-925499-01). Make sure
03-925539-01
INSULATION, 1041 INJ the hole on Insulation and Injector Oven Block Cover are
lining up.
13-112015-00
03-925498-00
ASSY, OVEN BLOCK, 1041
03-918481-00
12-754015-24
BOLT, 5/16-18 X
1-1/2, HEX HD, BRS
12-901163-00, 4 PLCS
SCREW, SEMS, 8-32 X 3/8, SST 03-917588-00, 2 PLCS
BRKT, MTG, HTD INJ
DOC: 03-925445-03 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 1079 INJECTOR SUBASSEMBLY
PAGE: 1 of 2
2
1079 INJECTOR W\CO2 CRYO
03-925445-11 (120v CO2) Subassembly

03-925445-12 (230v CO2)
03-925445-13 (101v CO2)
PREPARED BY: MICHAEL HARRAL REVISED BY: Sax Makthepharack CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 05 - 07 - 98 -11,12,13SHOWN
DOC: 03-925445-03 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 2
2
TOOLS LIST 03-925575-01
TOP COVER
1. T-3734 OTHER PARTS NOT
ASSY. FIX. 03-949666-01 SHOWN.
INJECTOR NUT ASSY 03-925572-01
CLAMP, TUBING
03-908206-01
ACTUATOR SWIT. ASSY.
14-920005-00
WAVE SPRING 2 EA.
03-918679-00 03-925374-01
INSULATION PROBE
INSERT FULLY INTO HOLE
OF CLAMSHELL
00-997630-00
SEPTUM 03-925425-01
HEATER 120V
03-925425-02
HEATER 230V
03-925425-03
HEATER, 101V
12-901165-00
SCREW 8-32 X 1/4
12-312004-12
SOCKET HEAD, CAP
SCREW 2 EA.
22-119918-00
CABLE CLAMP 03-925573-01
CRYO BRACKET 2EA
03-925440-01
BRAZED ASSY.
03-925579-01
13-312004-00 CRYO TUBE,CO2
SST KEP NUT #4 2 EA. (ALIGN WITH TOP & BOTTOM
OF CLAMSHELLS SO CRYO
03-918997-00 03-918998-00 TUBE DOESN’T EXTEND
CLAMSHELL SIDE A CLAMSHELL, SIDE B BEYOND CLAMSHELLS).
NOTE:
OPERATION SEQUENCE
1. HEATER CARTRIDGE & PROBE CONTAINED BY CLAMSHELLS. END OF HEATER CARTRIDGE TO BE
FLUSH WITH THE BOTTOM OF CLAMSHELLS.
2. CRYO TUBE & CLAMSHELL ASSY TO BE MOUNTED AS FAR UP THE CHAMBER TUBE AS POSSIBLE.
DOC: 03-925445-02 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 1 of 2
2
1079 INJECTOR WITH LN2 CRYO
03-925445-21 (120v LN2) Subassembly

03-925445-22 (230v LN2)
03-925445-23 (101v LN2)
DOC: 03-925445-02 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 2
2
TOOLS LIST 03-925575-01
TOP COVER
ASSY. FIX. 03-949666-01 SHOWN.
INJECTOR NUT ASSY 03-925572-01
03-908206-01 CLAMP, TUBING
ACTUATOR SWIT. ASSY.
14-920005-00
WAVE SPRING 2 EA.
03-925374-01
03-918679-00 PROBE
INSULATION INSERT FULLY INTO
HOLE IN CLAMSHEELL
00-997630-00
SEPTUM 03-925425-01
HEATER 120V
03-925425-02
HEATER 230V
03-925425-03
HEATER, 101V
12-901165-00
SCREW 8-32 X 1/4
12-312004-12
SOCKET HEAD, CAP
SCREW 2 EA.
22-119918-00 03-925573-01
CABLE CLAMP CRYO BRACKET 2EA
03-925440-01
BRAZED ASSY. 03-925579-02
CRYO TUBE, LN2
13-312004-00 (ALIGN WITH TOP & BOTTOM OF
SST KEP NUT #4 2 EA. CLAMSHELLS SO CRYO TUBE
DOESN’T EXTEND BEYOND
03-918997-00 CLAMSHELLS).
CLAMSHELL SIDE A
03-918998-00
CLAMSHELL, SIDE B
NOTE:
OPERATION SEQUENCE
DOC: 03-925445-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 1079 Injector Subassembly
PAGE: 1 of 2
2
1079 INJECTOR
03-925445-01 (120v NO CRYO) Subassembly

03-925445-02 (230v NO CRYO)
03-925445-03 (101v NO CRYO)
PREPARED BY: MICHAEL HARRAL REVISED BY: Sax makthepharack CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 05 - 07 - 98 - 00 SHOWN
DOC: 03-925445-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 2
2
TOOLS LIST 03-925575-01
TOP COVER
03-949666-01
ASSY. FIX. INJECTOR NUT ASSY SHOWN.
03-908206-01 03-925572-01
ACTUATOR SWIT. ASSY. TUBING CLAMP
14-920005-00
WAVE SPRING 2 EA.
03-925374-01
PROBE
INSERT FULLY INTO HOLE
03-918679-00 OF CLAMSHELL
INSULATION 00-997630-00
SEPTUM
03-925425-01
HEATER 120V
03-925425-02
HEATER 230V
03-925425-03
HEATER, 101V
12-901165-00
SCREW 8-32 X 1/4
22-119918-00
CABLE CLAMP 12-312004-10
SOCKET HEAD, CAP
03-925440-01 SCREW 2 EA.
BRAZED ASSY.
13-312004-00 03-918998-00
SST KEP NUT #4 2 EA. CLAMSHELL, SIDE B
03-918997-00
CLAMSHELL SIDE A
NOTE:
OPERATION SEQUENCE
2. CLAMSHELL ASSY. TO BE MOUNTED AS FAR UP THE CHAMBER TUBE AS POSSIBLE.
PREPARED BY: MICHAEL HARRAL REVISED BY: Sax makthepharack CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 05 - 07 - 98 - SHOWN
DOC: 03-925250-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Rear Panel Assy.
PAGE: 1 OF 2
1
Rear Cover
Subassembly
DOC: 03-925250-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Rear Panel Assy.
PAGE: 2 OF 2
1
R NOTE:
CLICK HERE TO SEE
CONNECTION TO J 51
ON POWER BOARD
13-312008-00
KEPNUT, #6 , SST 4EA.
20-839825-00
03-925305-01
BEZEL, CHASSIS FAN 2ea.
ASSY., CHASSIS FAN
12-222008-24
03-925250-01 SCREW, 6-32 X 5/8” SSPH 4EA
PANEL, REAR A
CS
NOTE:
COVER CSA ON
101V. VERSION
03925689-01
BLANK LABEL
DOC: 03-925211-01/-02 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Pneumatic Bezel Assembly
PAGE: 1 of 2
1
3800 GC Pneumatics Bezel Assembly
PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 16 - 99 - SHOWN
DOC: 03-925211-01/-02 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Pneumatic Bezel Assembly
PAGE: 2 of 2
1
23-620818-00
BALLSTUD, 2 EA.
03-925405-01
BRACKET, PNEUMATICS
DOOR PIVOT
12-901134-00
SCREW, SEMS, 6-32 X 3/8, 2 EA. !
! 03-925415-01
RIVET, LATCHING
03-925211-01
BEZEL, PNEUMATICS, FRONT
! NOTE:
FOR -02 3380 VERSION,
12-901163-00
SCREW, SEMS, 8-32 X 3/8, 2 EA.
DELETE THE FOLLOWING:
03-925405-01
BRACKET, PNEUMATICS DOOR PIVOT
12-901134-00
SCREW, SEMS, 6-32 X 3/8, 2 EA.
03-925415-01
RIVET, LATCHING
03-925274-01
BRACKET, PNEUMATIC
BEZEL MOUNTING
PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 16 - 99 - SHOWN
DOC: 03-925133-00 REV
CHG PARTS
HISTORY LIST MENU DESC: PFPD Assembly
PAGE: 1 of 4
1
PFPD
Subassembly
DOC: 03-925133-00 REV
CHG PARTS
PAGE: 2 of 4
1
12-901131-00
NITROGEN MODE SCREW, SEMS, INT., 8-32 X 3/8” LG, STL 4EA
03-925120-00
SOCKET ASSY., PMT, N MODE
CLICK HERE FOR

03-925128-00
INSTALLATION PMT TUBE, NITROGEN MODE
INSTRUCTIONS
11-622004-03
SET SCREW, 4-40 X 3/16” LG., SST
27-402361-00
O-RING, .987 ID X .103 WALL, VITON
27-402826-00
12-212004-03 O-RING, 1.487 ID X .103 WALL, SLCN
SCREW, FLAT HD., 4-40 X 5/16”LG. SST 3EA
03-925169-00
03-925119-01
LABEL, HIGH VOLTAGE WARNING
FILTER ASSY., N MODE RG9
03-925155-00 03-925126-00
QUARTZ, ROD, LIGHT PIPE HOUSING, PMT, NITROGEN MODE
03-925194-03 12-222008-12
SCREW, CAP, 6-32 X 3/8 LG., CLEANED SCREW,8-32 X 3/4” LG, PHMS, SST 2EA
27-402826-00
14-202006-00
O-RING, 1.487 ID X .103 WALL, SLCN
SPLIT WASSHER,#6, .236 OD X
.141 ID, SST 3EA.
03-925156-00
03-925145-00 LIGHT PIPE, END CAP
SAPHIRE WINDOW, ASSY. 20
03-925147-00
LIGHT PIPE ASSY.
03-925139-00
TOWER, BODY 12-901131-00 OPERATION SEQUENCE
SCREW, SEMS, INT., 8-32 X 3/8” LG, STL, 2EA. 20 INSPECT:
03-925146-00
BRACKET, SUPPORT
03-925143-00
WASHER, SAPHIRE WINDOW
DOC: 03-925133-00 REV
CHG PARTS
PAGE: 3 of 4
1
SULFER
PHOSPHEROUS 03-925147-00
ASSY., LIGHT PIPE 03-925139-00
TOWER, BODY
MODE 12-901131-00
03-925145-00
SCREW, SEMS, INT, 8-32 X 3/8” LG, STL 4EA
ASSY, SAPHIRE WINDOW
03-925143-00
DETAIL ‘A’
03-925169-00
LABEL, HIGH VOLTAGE, WARNING
03-925173-00 03-925168-00
SOCKET ASSY., PMT HOUSING, PMT
27-402826-00 03-925171-00
O-RING, 1.487 ID X .103 WALL, SLCN PHOTOMULTIPLIER TUBE, PMT
03-925151-02
12-903134-00 ASSY, FILTER
SCREW, THUMB, 8-32 X 5/8” LG. SST 12-212004-03
SCREW, FLAT HD, 4-40 X 5/16 LG, SST 3EA.
27-402924-00
O- RING .530 ID X .103 WALL, SLCN 03-925155-00
ROD, QUARTZ, LIGHT PIPE
27-402826-00
O-RING, 1.487 ID X .103 WALL, SLCN 03-925194-03
SCREW, CAP, 6-32 X 3/8” LG, CLEANED 3EA.
03-925156-00
END CAP, LIGHT PIPE
12-901131-00 03-925145-00
SCREW, SEMS, INT, 8-32 X 3/8” LG, STL 2EA ASSY, SAPHIRE WINDOW
03-925146-00 03-925139-00
BRACKET, SUPPORT TOWER, BODY
14-202006-00
WASHER, SPLIT, #6, .236 OD X .141 ID SST 3EA.
03-925147-00
ASSY., LIGHT PIPE
03-925143-00
SEE DETAIL ‘A’
DOC: 03-925133-00 REV
CHG PARTS
PAGE: 4 of 4
1
12-901131-00
SCREW, SEMS, INT., 8-32 X 3/8” LG, STL
UPGRADE TO 03-925120-00
SOCKET ASSY., PMT, N MODE
N2 MODE
27-402826-00
O-RING, 1.487 ID X .103 WALL, SLCN
11-622004-03
SET SCREW, 4-40 X 3/16” LG., SST
03-925128-00
PMT TUBE, NITROGEN MODE
03-925169-00
LABEL, HIGH VOLTAGE WARNING
03-925126-00
HOUSING, PMT, NITROGEN MODE
27-402361-00
O-RING, .987 ID X .103 WALL, VITON
DOC: ATP-03-925110-XX REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: TEST & CALIBRATION
PAGE: 1 of 16
2
24 VOLT SHORT TEST

FOR EFC TYPES I, III, IV, AND 5
METER READING SHOULD BE

O.L. OR IN THE MEGA OHMS
METER SET TO OHMS
BLACK PROBE TO
MANIFOLD BLOCK
RED PROBE TO
TRANSISTOR TAB

1. THIS TEST MUST BE DONE BEFORE
RIBBON CABLE IS ATTACHED.
PREPARED BY: HOWIE PLITSCH REVISED BY: Sax Makthepharack CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 08 - 01 - 00 - SHOWN
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 16
2
TRANSDUCER SHORT TEST

FOR EFC TYPES I, III, IV, AND 5
METER READING BE O.L.

OR IN THE MEGA OHMS
METER SET TO OHMS
CHECK ALL 13
TRANSDUCER HOLES
BLACK PROBE TO
TRANSDUCER HOLE

1. THIS TEST MUST BE DONE BEFORE RED PROBE TO A
RIBBON CABLE IS ATTACHED. GROUNDED SURFACE
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 16
2
TEST FIXTURE CONNECTIONS
GROUP 0 GROUP 1 GROUP 2

1. EFC TYPES CANNOT BE MIXED WITHIN A
GROUP.
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 16
2

FOR EFC TYPE I

1. EFC CALIBRATION WILL BE ADVERSLY
AFFECTED IF THE TUBING IS SHORTENED.
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 16
2

FOR EFC TYPE III

CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 16
2

FOR EFC TYPE IV

CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 16
2

FOR EFC TYPE V

CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 16
2
EFC Fixture Startup Procedure
* Turn on the computer Power.
* Enter password, "PASSWORD" to get logged on to the network if you intend to transfer files, then Press "OK". If no files are going to be transferred, press
"CANCEL".
* If "Cancel" is chosen in previous step, the following box will appear, Press "cancel" and proceed.
* The program will automatically startup. Note: If the software is revised, the windows startup menu must be modified to point to the correct version of the
execuatable file.
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 16
2
The following is the main menu that should be in the middle of the screen.
ACTIVE INACTIVE
* Fields that are required to go to any other screen are as follows. After
required fields are filled in, press RUN to invoke:
1. Function pull down menu
2. Fixture #
3. Ref Flow Sensor #
4. At least one Type in a Group with Revision
Using the Main Menu
Note: For more detailed Procedures regarding fixture maintenance and diagnostics, see the EFC Fixture Maintenance Binder.
* The main menu can be one of two states, Active (as shown with the upper left hand arrow) or Inactive as shown above right. In order to go to the next
screen or activity, you must first be in the ACTIVE screen.
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of 16
2
General Description of Functions
No Function - Default
Serial # and Config Changer - Only use the Serial Number function of this utility. Other settings to be set by the Manufacturing Engineer.
* Set Function to "Change Det Serial Number" or "Change Inj Serial Number"
* Input the new Serial Number in the "New EFC Seriall Number" block.
* Press "Run"
* Change Function to "No Function"
* Press Exit
Exit - Press Run and you will exit the EFC Calibration program.
Test and Calibrate - Routine used after Quicktest to create and write calibration data to memory of EFC modules.
* Fixture # is indicated on Fixture.

* Reference Flow Sensor Number is indicated on Flow Sensor
* Type and Revision reflect the configuration and PWA revision respectively.
CHG PARTS
HISTORY
TOOLS
PAGE: 11 of 16
2
Module Leak - Tool used to pressurize individual modules and test manually for leaks.
* Set Function to "Pressurize"
* Select the "Type", "Module" and "Gas"
* Press "Run". The Mensor Pressure should increase to about 90 psig.
* In the Function, Select "Isolate", Press "Run". This will close off all of the valves to the EFC so a pressure degradation test can be observed (Mensor gage)
* When test is over, Select "Vent" from the Function Menu and press "Run". This will depressureize the system.
* When the system is fully vented, select "exit" from the function menu and press "Run". This will get you back to the main menu.
CHG PARTS
HISTORY
TOOLS
PAGE: 12 of 16
2
Detector Controller - Used to control individual gasses in any channel for a given calibrated DEFC.
* Enter the Module #, Gas Type and Function (Run Controller).

* Enter the desired flow and channel
* Press the "Valve Power" and "Controller on" Buttons to Green.
* Press the arrow in the upper left hand corner to start.
* To turn off, Press the "Valve Power" and "Controller on" Buttons to Red. And press the Function to "exit".
* Press the arrow in the upper left hand corner.
* Close the window by pressing on the X in the upper right hand corner.
CHG PARTS
HISTORY
TOOLS
PAGE: 13 of 16
2
Print Memory - Used to print out the contents of the memory of any EFC, calibrated or not
* Enter the appropriate Type in the Function pull down menu.
* Enter the Module #
* Press the arrow in the upper left hand corner to start.
* To exit, select the Function "Exit" and "Run". This gets you back to the main menu
CHG PARTS
HISTORY
TOOLS
PAGE: 14 of 16
2
Quick Test - A Pre-Calibration test designed to weed out bad EFC modules. Other more advanced functions of this module are to "Test Controller" of individual
EFC’s. This is the "Controller" part of the screen and not covered in this section.
* In the Group box, indicate the type of EFC’s in each group.
* Set the Warm up Time to 1 minute.
* Set the Flow Sensor Serial Number.
* From the Quick Test Setup Pulldown menu, Select "Full Test". If IEFC’s are being tested, Set "Mux Test" button to on.
* Click on the arrow in the upper left hand corner to start.
* When finished, click the upper right hand arrow to return back to the main menu.
CHG PARTS
HISTORY
TOOLS
PAGE: 15 of 16
2
Fixture Leak - Used to diagnose fixture leaks.
* By jumping Carrier in to Carrier out, blocking off Pressure Sense and Jumping Split Vent to Vent and Capping off the Low and High vent of the Master Flow
Sensors, Leaks to the atmosphere can be determined.
* Works similar to Module Leak, except it is used for fixture diagnostics.
* Click on the arrow in the upper left hand corner to start.
* When finished, click the upper right hand arrow to return back to the main menu.
CHG PARTS
HISTORY
TOOLS
PAGE: 16 of 16
2
Reference Flow Sensor Calibration - Used to facilitate and check Master Flow Sensor calibration.
* From the Pull down menu, select High or Low Sensor to check.
* Enter the Password of "1951"
* Push the Botton of "Read Low Flow" or "Read High Flow" as is appropriate.
* Select a gas type.
* Select a module (Typically a Type 1) to run.
* Set the Master Flow Sensor "Serial Number"
* Press "Run " to start.
* To end, Set the Pull down to "exit" and press "run"
DOC: 03-925110-BX REV
CHG TOOLS PARTS
HISTORY LIST MENU DESC: Assy, Shipping Container, EFC Module
PAGE: 1 of 4 1
FIGURE 1 FIGURE 2a FIGURE 2b
FIGURE 3 FIGURE 4
PREPARED BY: Sax Makthepharack REVISED BY: Michelle Wu CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 08 - 23 - 00 - SHOWN
DOC: 03-925110-BX REV
CHG TOOLS PARTS
PAGE: 2 of 4 1
1. SHIPPING CONTAINER EFC MODULE ASSEMBLY PROCEDURES
1.1 BAGGING THE EFC MODULE
1.1.1 Determine EFC Type (Detector EFC 03-925609-XX, Injector EFC 03-925110-XX or Type 21/25 03-933016-XX).
1.1.2 Install one each Short Natural Nylon Typ-Wrap (22-119650-00) to tubing as shown in Figure 1.
1.1.3 Assemble EFC onto a EFC Module Shipping Support Plate (03-925920-01), using four 8-32 x 3/8 Sems Screws
(12-901163-00) as shown in Figure 2a & 2b. Use the Plate Configuration Table for reference shown below.
1.1.4 Place the EFC Module Assembly with plate in Anti-Static Bag shown in Figure 3.
1.1.5 Seal the Anti-Static Bag, using Seal Machine as shown in Figure 4.
PWA THIS SIDE
PWA THIS SIDE PWA THIS SIDE
DEFC IEFC IEFC

(03-925609-XX) (03-925110-XX) (03-933016-XX)
EFC MODULE SHIPPING SUPPORT PLATE CONFIGURATION
DOC: 03-925110-BX REV
CHG TOOLS PARTS
PAGE: 3 of 4 1
FIGURE 5 FIGURE 6 FIGURE 7
FIGURE 8 FIGURE 9a FIGURE 9b
DOC: 03-925110-BX REV
CHG TOOLS PARTS
PAGE: 4 of 4 1
FOAM CAP 2 EA.
1.2 SHIPPING BOX ASSEMBLY & PACKING INSTRUCTIONS
1.2.1 Assemble the Inner Box by taping bottom of inner box, using Tape Gun to seal
one end. See Figure 5.
1.2.2 Obtain the Inner Sleeve and fold into square shape, then insert to the inner box
INNER SLEEVE
as shown. See Figure 6.
1.2.3 Place the Bagged EFC Module into the Box with the Support Plate side up. Close
top end of the inner box with tape gun. See Figure 7.
1.2.4 Assemble the Outter Box by taping bottom of inner box, using Tape Gun to seal
one end and place one each of Foam Cap with the indent side up. See Figure 8.
INNER BOX
1.2.5 Place the inner box inside the outer box and place second Foam Cap on top of
the inner box. Seal the outer box with tape gun as shown in Figure 9a & 9b.
1.2.6 Mark EFC Part Number on outside of the box.
OUTER BOX
BOX EXPLODED VIEW (REF.)
DOC: 03-925110-05 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: EFC 1079 TYPE V
PAGE: 1 of 4
3
EFC MODULE V
24” SUB-ASSEMBLY
10”
8”
6”
8”
22” NATURAL
22”
12”
DOC: 03-925110-05 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 4
3
12-222006-04
SCREW, 6-32 X 1/4” PHMS
4 PLACES
03-918853-03
TUBING, PEEK, .062 X .030 ID, GREEN 14-202006-00
03-917157-00 8” WASHER, LOCK, #6
WASHER, 6 PLACES
VITON FERRULE
28-849067-00 03-925013-01 PIN-1
03-917142-00 BESWICK FITTING, 1/8” VITON EIC PWB SEE DETAIL
FERRULE, VITON 3 PIECES A
03-925114-00
SPACER, TRANSDUCER
MANIFOLD ASSY. 76-998815-00

VACUUM, TRANSDUCER, 30 PSI
GOTO PAGE 3 76-998816-00
V3
COVER, EIC PCB
GOTO PAGE 4
03-925407-01
INSULATION, EIC PCB
12-222006-08
SCREW, 6-32 X 1/2”, 2 PLACES
62-899654-00 62-600876-00
V2 INSULATOR REGULATOR, LM317T
2 PLACES
NOTE: PRIOR TO SOLDERING
03-905960-10 BEND LEDS 90 DEG.
BAKED O-RING
4 PLACES
SEE NOTE 1 12-222004-05
03-925105-00 14-998043-00
03-918959-02 SHOULDER WASHER, 2 PLACES
VALVE, PROPORTIONAL 03-925112-00 FILTER
2 PLACES NOTE: SHOULDER FITS INSIDE
FRIT, MOTT 5000-1/ 8-2500 V1 TRANSISTER HOLE
TOOL: USE T-8909 FRIT TOOL: USE MILWAKEE POWER
POSITIONING TOOL SCREW DRIVER WITH CLUTCH
SETTING AT #2
62-989652-00
TRANSISTOR, TIP141
NOTE: SOLDER TO PWA AFTER
MOUNTING TO MANIFOLD
03-918959-01 DETAIL A
FILTER PWA JUMPER SETTINGS
FILTER ASSY. PIN-1

SEE FILTER SUB-ASSEMBLY
POSITION
NOTE: FLOW ARROW ORIENTATION
1- JUMPER
WHEN INSTALLING PENCIL FILTERS 2- N/O
NOTES: (UNLESS OTHERWISE SPECIFIED) 03-925109-00 3- N/O
4- V3 (SPLITLESS)
BRACKET, MANIFOLD MOUNTING 21 5- N/O
1. SEE O-RING PRE-ASSEMBLY INSPECTION 43 6- V2
12-222004-22 5
6 7- V1
PROCEDURE. SCREW, 4-40 X 1-1/4”, 4 PLACES 8 7 8- JUMPER
DOC: 03-925110-05 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 4
3
DETAIL A
WIRE TERMINATION
A 03-918853-03
TUBING, PEEK, .062 X .030 ID, GREEN, 8” 1/8”
FROM MANIFOLD MOUNTING PLATE POSITION A
REFERENCE PAGE 1 OR PAGE 4 TAB LOCKS IN
OPENING CUT SOLENOID
WIRES TO 6”
51-190316-00
CONN. SOCKET 22-24 AWG
2 PLACES
TOOL: USE MOLEX CRIMP GUN
03-917142-00
FERRULE, VITON
4 PLACES 51-190315-00
28-849067-00
MANIFOLD ASSY. BESWICK FITTING, 1/8” VITON HOUSING, 2 POSITION
GOTO PAGE 2 FOR 3 PIECES, 4 PLACES
INSTALLATION

03-918853-03 1. SEE O-RING PRE-ASSEMBLY INSPECTION
TUBING, PEEK, .062 X .030 ID,
GREEN, 8” FROM BOTTOM
PROCEDURE.
PENCIL FILTER POSITION B
REFERENCE PAGE 1 OPERATION NOTES, SOLENOID VALVE ASSY.
03-925106-00
BLOCK, MANIFOLD, BACK PRESSURE
2. THE SOLENOID VALVE MIDDLE RING MUST
BE LOOSE BEFORE ASSEMBLY.
SEE NOTE 1, 4 PLACES
3. AFTER CLEANING O-RINGS, MANIFOLD AND
SEE DETAIL A SOLENOID VALVE MATING SURFACES, HAND
TIGHTEN SOLENOID VALVE TO MANIFOLD
TOOL HOLE BLOCK.
28-849969-00 MIDDLE RING 4. INSERT SPECIAL TOOL IN TOOL HOLE AND
ADAPTER, HOES, ELBOW
HAND TIGHTEN FURTHER.
5. POSITION VALVE OUTLET (ELBOW FITTING)

IN VERTICAL POSITION AND TIGHTEN MIDDLE
RING.
03-917157-00
4 PLACES
28-849969-00
BESWICK FITTING,
ELBOW
03-925103-00
VALVE, SOLENOID, 3 WAY
SEE OPERATION NOTES
C
28-158923-00 03-918853-03
TUBING, 1/8” OD X 1/16 ID TUBING, PEEK, .062 X .030 ID, GREEN, 14”
POLYURETHANE, CLEAR, 12” FROM MANIFOLD MOUNTING PLATE POSITION C
REFERENCE PAGE 1 OR PAGE 4
DOC: 03-925110-05 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 4
3
C A 03-925783-06
03-925783-24 (USE 03-918853-03)
(USE 03-918853-03) TUBING, PEEK, .062 X .030 ID, GREEN, 6”
TUBING, PEEK, .062 X .030 ID, GREEN, 24” FROM BACK PRESSURE MANIFOLD BLOCK POSITION A
03-925783-10
12-222004-08 (USE 03-918853-03)
SCREW, 4-40 X 1/2”, 2 PLACES TUBING, PEEK, .062 X .030 ID, GREEN, 10”
FROM BACK PRESSURE MANIFOLD BLOCK POSITION C
03-925107-00
SEE DETAIL A
MANIFOLD ASSY.
GOTO PAGE 2 FOR
INSTALLATION
03-925102-00
BLOCK, MANIFOLD, FLOW CONTROL
03-905960-10
BAKED O-RING
3 PLACES
SEE NOTE 1
DETAIL A
NOTES: (UNLESS OTHERWISE SPECIFIED) PEEK TUBING ASSEMBLY
1. SEE O-RING PRE-ASSEMBLY INSPECTION
PROCEDURE.
OPERATION NOTES
2. AFTER CLEANING O-RINGS AND MANIFOLD PEEK TUBING
3 PLACES
MATING SURFACE, SET O-RINGS IN PLACE
WITH TWEEZERS (DO NOT TOUCH O-RINGS).
3. FIRMLY SEAT O-RINGS IN THE MANIFOLD

BLOCK.
4. INSPECT SEATING OF O-RINGS, IF

03-917142-00
NECESSARY PRESS TO SEAT USING FERRULE, VITON
TWEEZERS. 3 PLACES
5. AFTER O-RING PLACEMENT “DUST-OFF” MANIFOLD PLATE

AGAIN.
DOC: 03-925110-04 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 3800GC EFC 1079 TYPE IV
PAGE: 1 of 3
4
EFC MODULE IV
SUB-ASSEMBLY
4” 6”
17” 24”
4” 22”
1.75”
6”
DOC: 03-925110-04 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 3
4
03-918853-12 12-222006-04
03-917142-00 SCREW, 6-32 X 1/4” PHMS
FERRULE, VITON .062 X .015 ID X 17”
PEEK TUBING 4 PLACES
8 PLACES
14-202006-00
03-917157-00 WASHER, LOCK, #6
WASHER, PEEK TUBING, 6”
(TO PENCIL FILTER) 6 PLACES
VITON FERRULE
6 PLACES SEE NOTE 2
03-925013-01 PIN-1
EIC PWB SEE DETAIL
A
03-925114-00
SPACER, TRANSDUCER
28-691944-00
1/8” BRASS TEE 76-998815-00
PEEK TUBING, 6” 2 PLACES VACUUM, TRANSDUCER, 30 PSI
SEE NOTE 2 76-998816-00
VACUUM, TRANSDUCER
PEEK TUBING, 6” 5 PSI
PEEK TUBING, 6” SEE NOTE 2
SEE NOTE 2 03-925406-01
PEEK TUBING, 12” COVER, EIC PCB
SEE NOTE 2 03-925407-01
12-222004-08 INSULATION, EIC PCB
SCREW, 4-40 X 1/2” MANIFOLD ASSY.
2 PLACES GOTO PAGE 3 12-222006-08
03-925107-00 62-899654-00 62-600876-00
PLATE, MANIFOLD MNTG INSULATOR REGULATOR, LM317T
2 PLACES
BEND LEDS 90 DEG.
03-925108-00 12-222004-05
BLOCK, PROPORTIONAL VALVE SCREW, 4-40 X 5/16”, 2 PLACES
V2 03-925112-00
FRIT, MOTT 5000-1/ 14-998043-00
03-905960-10 8-2500 SHOULDER WASHER, 2 PLACES
BAKED O-RING TOOL: USE T-8909 FRIT NOTE: SHOULDER FITS INSIDE
4 PLACES POSITIONING TOOL V1 TRANSISTER HOLE
SEE NOTE 1 TOOL: USE MILWAKEE POWER
SCREW DRIVER WITH CLUTCH
SETTING AT #2
03-925105-00
VALVE, PROPORTIONAL 62-989652-00
2 PLACES TRANSISTOR, TIP141
FILTER ASSY.
DETAIL A
WHEN INSTALLING PENCIL FILTERS PWA JUMPER SETTINGS
PIN-1
NOTES: (UNLESS OTHERWISE SPECIFIED) POSITION
1- JUMPER
1. SEE O-RING PRE-ASSEMBLY INSPECTION 2- N/O
3- N/O
PROCEDURE. 03-925109-00 1 4- N/O
BRACKET, MANIFOLD MOUNTING 2
43 5- N/O
5 6- V2
2. ALL PEEK TUBING IS .062 X .030 ID, GRN 12-222004-22 6
7- V1
SCREW, 4-40 X 1-1/4”, 4 PLACES 87 8- JUMPER
P/N 03-918853-03.
DOC: 03-925110-04 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 3
4
A 03-925783-04
03-925783-24
(USE 03-918853-03) (USE 03-918853-03)
TUBING, PEEK, .062 X .030 ID, GREEN, 4”
TUBING, PEEK, .062 X .030 ID, GREEN, 24”
FROM BACK PRESSURE MANIFOLD BLOCK POSITION A
03-925783-04
12-222004-08 (USE 03-918853-03)
SCREW, 4-40 X 1/2”, 2 PLACES TUBING, PEEK, .062 X .030 ID, GREEN, 4”
03-925107-00
SEE DETAIL A
MANIFOLD ASSY.
GOTO PAGE 2 FOR 03-925102-00
INSTALLATION BLOCK, MANIFOLD, FLOW CONTROL
03-905960-10
BAKED O-RING
3 PLACES
SEE NOTE 1
DETAIL A
PROCEDURE.
OPERATION NOTES
3 PLACES

BLOCK.

03-917142-00
TWEEZERS. 3 PLACES

AGAIN.
DOC: 03-925110-03 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 3800GC EFC 1079 TYPE III
PAGE: 1 of 3
4
EFC MODULE III
SUB-ASSEMBLY
4”
24”
22”
28”
YELLOW
DOC: 03-925110-03 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 3
4
12-222006-04
4 PLACES
NOTES: (UNLESS OTHERWISE SPECIFIED) 14-202006-00

WASHER, LOCK, #6
1. SEE O-RING PRE-ASSEMBLY INSPECTION 6 PLACES
PROCEDURE.
03-925013-01 PIN-1
EIC PWB SEE DETAIL
A
03-925114-00 03-925406-01
SPACER, TRANSDUCER COVER, EIC PCB
76-998815-00
76-998816-00
03-925407-01
MANIFOLD ASSY. INSULATION, EIC PCB
GOTO PAGE 3 12-222006-08
62-899654-00 62-600876-00
INSULATOR REGULATOR, LM317T
2 PLACES NOTE: PRIOR TO SOLDERING
BEND LEDS 90 DEG.
03-925113-00 12-222004-05
FRIT, MOTT 5000-1/ 8-500 SCREW, 4-40 X 5/16”, 2 PLACES
TOOL: USE T-8909 FRIT
POSITIONING TOOL 14-998043-00
SHOULDER WASHER, 2 PLACES
NOTE: SHOULDER FITS INSIDE
V1 TRANSISTER HOLE
03-905960-10 TOOL: USE MILWAKEE POWER
BAKED O-RING SCREW DRIVER WITH CLUTCH
2 PLACES SETTING AT #2
SEE NOTE 1
62-989652-00
TRANSISTOR, TIP141
03-925105-00 NOTE: SOLDER TO PWA AFTER
VALVE, PROPORTIONAL MOUNTING TO MANIFOLD
FILTER ASSY.
NOTE: FLOW ARROW ORIENTATION DETAIL A
WHEN INSTALLING PENCIL FILTERS PWA JUMPER SETTINGS
POSITION PIN-1
1- JUMPER
2- N/O
3- N/O
03-925109-00 4- N/O
BRACKET, MANIFOLD MOUNTING 5- N/O
6- N/O 2
1
7- V1 43
8- JUMPER 5
12-222004-22 7
6
SCREW, 4-40 X 1-1/4”, 2 PLACES 8
DOC: 03-925110-03 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 3
4
03-925783-24 03-925783-04
(USE 03-918853-03) (USE 03-918853-03)
TUBING, PEEK, .062 X .030 ID, GREEN, 24” TUBING, PEEK, .062 X .030 ID, GREEN, 4”
03-925851-28
12-222004-08 (USE 03-918853-14)
TUBING, PEEK, .062 X .030 ID, YELLOW, 28”
03-925107-00
SEE DETAIL A
03-925102-00
BLOCK, MANIFOLD, FLOW CONTROL
MANIFOLD ASSY.
GOTO PAGE 2 FOR
INSTALLATION
03-905960-10
BAKED O-RING
3 PLACES
SEE NOTE 1
DETAIL A
PROCEDURE.
OPERATION NOTES
3 PLACES

BLOCK.
4. INSPECT SEATING OF O-RINGS, IF 03-917142-00

TWEEZERS. 3 PLACES

AGAIN.
DOC: 03-925110-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 3800GC EFC 1079 TYPE I
PAGE: 1 of 4
4
Peek Tubing
EFC MODULE I 1. 03-925783-06
5.
24” SUB-ASSEMBLY 2. 03-925783-08
3. 03-925783-12
2. 4. 03-925783-22
8” 28” YELLOW 7.
5. 03-925783-24
1.
6” 6. 03-925841-22
7. 03-925851-28
2. 8”
22” NATURAL 6.
22” 4.
3. 12”
DOC: 03-925110-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 4
4
12-222006-04
4 PLACES
14-202006-00
03-917157-00 WASHER, LOCK, #6
WASHER, 6 PLACES
VITON FERRULE
28-849067-00 03-925013-01 PIN-1
03-917142-00 BESWICK FITTING, 1/8” VITON EIC PWB SEE DETAIL
FERRULE, VITON 3 PIECES A
03-925114-00
SPACER, TRANSDUCER

GOTO PAGE 3 76-998816-00
V3
COVER, EIC PCB
GOTO PAGE 4
03-925407-01
INSULATION, EIC PCB
12-222006-08
62-899654-00 62-600876-00
V2 INSULATOR REGULATOR, LM317T
2 PLACES
03-905960-10 BEND LEDS 90 DEG.
BAKED O-RING
4 PLACES
SEE NOTE 1 12-222004-05
03-925105-00 14-998043-00
03-918959-02 SHOULDER WASHER, 2 PLACES
VALVE, PROPORTIONAL 03-925112-00 FILTER
2 PLACES NOTE: SHOULDER FITS INSIDE
FRIT, MOTT 5000-1/ 8-2500 V1 TRANSISTER HOLE
TOOL: USE T-8909 FRIT TOOL: USE MILWAKEE POWER
POSITIONING TOOL SCREW DRIVER WITH CLUTCH
SETTING AT #2
62-989652-00
TRANSISTOR, TIP141
03-918959-01 DETAIL A
FILTER PWA JUMPER SETTINGS
FILTER ASSY.
SEE FILTER SUB-ASSEMBLY PIN-1
WHEN INSTALLING PENCIL FILTERS POSITION
03-925109-00 1- JUMPER
BRACKET, MANIFOLD MOUNTING 2- N/O
NOTES: (UNLESS OTHERWISE SPECIFIED) 3- N/O
21
43 4- V3 (SPLITLESS)
1. SEE O-RING PRE-ASSEMBLY INSPECTION 6 5 5- N/O
PROCEDURE. 12-222004-22 8 7 6- V2
SCREW, 4-40 X 1-1/4”, 4 PLACES 7- V1
8- JUMPER
DOC: 03-925110-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 4
4
DETAIL A
WIRE TERMINATION
A 03-918853-03
TUBING, PEEK, .062 X .030 ID, GREEN, 8” 1/8”
FROM MANIFOLD MOUNTING PLATE POSITION A
REFERENCE PAGE 1 OR PAGE 4 TAB LOCKS IN
OPENING CUT SOLENOID
WIRES TO 6”
51-190316-00
CONN. SOCKET 22-24 AWG
2 PLACES
TOOL: USE MOLEX CRIMP GUN
03-917142-00
FERRULE, VITON
3 PLACES 51-190315-00
28-849067-00
MANIFOLD ASSY. BESWICK FITTING, 1/8” VITON HOUSING, 2 POSITION
GOTO PAGE 2 FOR 3 PIECES, 3 PLACES
INSTALLATION

03-918853-03 1. SEE O-RING PRE-ASSEMBLY INSPECTION
TUBING, PEEK, .062 X .030 ID,
GREEN, 8” FROM BOTTOM
PROCEDURE.
PENCIL FILTER POSITION B
REFERENCE PAGE 1 OPERATION NOTES, SOLENOID VALVE ASSY.
03-925106-00
BLOCK, MANIFOLD, BACK PRESSURE
2. THE SOLENOID VALVE MIDDLE RING MUST
BE LOOSE BEFORE ASSEMBLY.
SEE NOTE 1, 4 PLACES
3. AFTER CLEANING O-RINGS, MANIFOLD AND
SEE DETAIL A SOLENOID VALVE MATING SURFACES, HAND
TIGHTEN SOLENOID VALVE TO MANIFOLD
WRENCH HOLE BLOCK.
28-849969-00 MIDDLE RING 4. INSERT SPECIAL TOOL IN WRENCH HOLE AND
ADAPTER, HOES, ELBOW
HAND TIGHTEN FURTHER.
5. POSITION VALVE OUTLET (ELBOW FITTING)

IN VERTICAL POSITION AND TIGHTEN MIDDLE
RING HAND TIGHT.
03-917157-00
3 PLACES
28-849969-00
BESWICK FITTING,
ELBOW
03-925103-00
VALVE, SOLENOID, 3 WAY
28-158923-00 SEE OPERATION NOTES
TUBING, 1/8” OD X 1/16 ID
POLYURETHANE, CLEAR, 12”
DOC: 03-925110-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 4
4
A
03-925783-24 03-925783-06
(USE 03-918853-03) (USE 03-918853-03)
TUBING, PEEK, .062 X .030 ID, GREEN, 24” TUBING, PEEK, .062 X .030 ID, GREEN, 6”
FROM BACK PRESSURE MANIFOLD BLOCK POSITION A
12-222004-08 03-925851-28
SCREW, 4-40 X 1/2”, 2 PLACES (USE 03-918853-14)
TUBING, PEEK, .062 X .030 ID, YELLOW, 28”
03-925107-00
SEE DETAIL A
03-925102-00
MANIFOLD ASSY. BLOCK, MANIFOLD, FLOW CONTROL
GOTO PAGE 2 FOR
INSTALLATION
03-905960-10
BAKED O-RING
3 PLACES
SEE NOTE 1
DETAIL A
PROCEDURE.
OPERATION NOTES
3 PLACES

BLOCK.
NECESSARY PRESS TO SEAT USING 03-917142-00
FERRULE, VITON
TWEEZERS. 3 PLACES

AGAIN.
DOC: 03-918800-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 3800GC, Installation, Basic, SPT (LN2)
PAGE: 1 of 2
1
Installation, Basic, SPT (LN2)

03-925541-01
SPT ADAPTER
USE #3 POSITION
POWER PLUG
INLET CONN. & CHECK VALVE

NOT SHOWN
LN2 VALVE
SHEET METAL CUT OUT

REMOVEAL NOT REQ’D
03-918713/714-XX
TRAP ASSEMBLY
DUAL VALVE OVEN OR INJECTOR VALVE OVEN
DOC: 03-918800-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 3800GC, Installation, Basic, SPT (LN2)
PAGE: 2 of 2
1
03-925542-01
HARNESS PCB
CONNECT TO J52
03-925305-01
ASSY, FAN 24V
CONNECT TO J51
03-918795-00
TRANSFORMER CABLE
HARNESS SPT
TO THE SPT
CONNECT TO TRANSFORMER
DOC: 03-918681-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 1 of 2
2
1078 INJECTOR
Subassembly
PREPARED BY: MICHAEL HARRAL REVISED BY: MH CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 03 - 26 - 98 - 00 SHOWN
DOC: 03-918681-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 2
2
TOOLS LIST 03-918678-00
TOP COVER 03-949666-01
1. T-3734 INJECTOR NUT ASSY
OTHER PARTS NOT
1078 ASSY. FIX. SHOWN.
03-908206-01
ACTUATOR SWIT. ASSY. 03-918334-00
HTR., HARNESS ASSY.,
14-920005-00 120V. ( -01 ONLY)
WAVE SPRING 2 EA.
03-918334-01
00-997630-00 HTR., HARNESS ASSY.,
SEPTUM 220V. ( -02 ONLY)
03-918679-00
INSULATION
17-699907-00
22-119918-00 ALUM POP RIVET 4 EA.
CABLE CLAMP
12-222006-05
CLAMPSCREW
12-312004-12
SOCKET HEAD, CAP
SCREW 2 EA.
03918675-00
03-918680-00 CRYO BRACKET
BRAZED ASSY. 03-918673-00
CRYO TUBE
03-918998-00
13-312004-00 CLAMSHELL, SIDE B
SST KEP NUT #4, 2 EA. 03-918997-00
CLAMSHELL SIDE A
NOTE:
OPERATION SEQUENCE
3. INSURE HEATER PROBE WIRES ARE NOTE CROSSED AND CERAMIC BOTTOMS‘‘‘ OUT.
PREPARED BY: MICHAEL HARRAL REVISED BY: MH CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 03 - 26 - 98 - SHOWN
DOC: 03-918153-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Inlet Manifold
PAGE: 1 of 2
1
ASSY, INLET MANIFOLD

SUB-ASSEMBLY STATION, ASSEMBLY PROCEDURES
DOC: 03-918153-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Inlet Manifold
PAGE: 2 of 2
1
NOTES:
1. ASSEMBLE THE FERRULE HOLDER PLATES IN ORDER SHOWN AND FINGERTIGHT

THE 8-32 X 1/2 SEM SCREW.
03917084-00, 3 PLCS
2. OBTAIN FOUR EACH MALE CONNECTS AND ASSEMBLE TO THE COMPLETE INLET CAPILARY COLUMN FITTING NUT
MANIFOLD AS SHOWN. REPLACE NUT/FERRULE WITH VITON FERRULE, FERRULE
HOLD WASHERAND CAPILARY COLUMN FITTING NUT THREE PLACE.
3. PACKAGE INDIVIDUALLY IN PLASTIC BAG.
03-917157-03 PLCS
03-917159-00, 4 PLCS WASHER, FERRULE HOLD
CONNECTOR, MALE, 1/8OD
03-905960-09, 4 PLCS
O-RING BAKED .176 OD
03-917142-00, 19 PLCS
VITON FERRULE
03-917143-00, 8 PLCS
12-901150-00, 4 PLCS 03-918148-00
PIN, CLEAN 1/16 X 3/4
SCREW, SEM, 8-32 X 1/2 INLET MANIFOLD, COMPLETE
03-917141-00, 4 PLCS
PLATE, FERRULE HOLDER
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: BASIC ASSEMBLY
PAGE: 1 of 18
6
ASSY, BASIC
PREPARED BY: MICHAEL HARRAL REVISED BY: Sax Makthepharack CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 31 - 00 SHOWN
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 18
6
22-799995-00
GROMMET
ROUTE TRANSFORMER AND

FAN MOTOR WIRES (PAGE 7)
THROUGH GROMMET.
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 18
6
03-925307-01
FAN MOTOR 120V. & 101V
03-925307-02
FAN MOTOR 230V
FOR ASSEMBLY OF
MOTOR TO TO MOTOR
MOUNT USE FIXTURE:
T-8989
13-122060-00
NUT, HEX 10-32, SST. 4EA.
12-222008-14
SCREW,8-32 X 7/8 SST.PH, 4EA.
88-299284-00
LOCTITE #222
ALL 4 SCREWS
14-312008-00
WASHER, LOCK 4EA
13-312060-00
NUT,KEP 10-32 SST 4EA.
14-901074-00
WASHER, PLAIN, #6 4EA.
03-917058-00
NOTE: S/A MOTOR MOUNT
ATTACH MOTOR PINS TO
MULTI-PURPOSE CONNECTOR THEN TO
J47 ON THE POWER BOARD
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 18
6
03-917946-01
BLADES
FOR BLADE PLACEMENT ON
MOTOR SHAFT USE TOOL
T-8915, P/N 03-917887-00.
NOTE: TEST FAN PER “FAN
BALANCE TEST” PRIOR TO INSTALLATION
FAN MOTOR ASSEMBLY
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 18
6
230V 120V
03-925294-01
MAIN HARNESS 03925295-01
MAIN HARNESS
BLUE
BLUE FROM BLUE MAIN WHITE
POWER CORD MAIN HARNESS FROM
HARNESS HARNESS PWR.
CORD
SRE
BROWN
L L BROWN MAIN D E
I 03-925594-01 O MAIN HARNESS A 03-925594-01 N
LINE FILTER HARNESS
N A O LINE FILTER I
BROWN FROM E D L L
POWER CORD BLACK
HARNESS FROM
PWR.
SRE CORD
GREEN/YEL
YELLOW/GREEN
FROM PWR.
MAIN
CORD HARNESS
HARNESS YELLOW/GREEN
MAIN
HARNESS
03-918655-00 CHASSIS
HARNESS GRN/YEL CHASSIS
GROUNDING CHASSIS GROUNDING
LUG (14-312008-00)
FROM PWR.
51-340093-00 GROUNDING LUG
LUG
CORD
RECEPTACLE (14-312008-00)
HARNESS
81-821554-00 03-925581-01 03-925473-01

POWER CORD 230V. POWER CORD OR POWER CORD 120V
BACK OF G.C. 110V BACK OF G.C.
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 18
6
101V
BLUE
MAIN
03-925294-01 HARNESS BROWN
MAIN HARNESS MAIN
HARNESS
LOAD
CORCOM
03-925595-00
LINE FILTER
LINE
BLACK
FROM
PWR.
CORD
YELLOW/GREEN
MAIN
HARNESS CHASSIS
GROUNDING
LUG
WHITE GRN/YEL
CHASSIS
GROUNDING FROM FROM PWR.
LUG PWR. CORD
CORD HARNESS
03-925581-01
POWER CORD ,101V BACK OF G.C.
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 18
6
FILTER WIRING DETAIL
WHITE
FROM BLUE
POWER FROM
CORD MAIN
HARNESS
BROWN
BLACK FROM
FROM MAIN
POWER HARNESS
CORD
12-901161-00
SCREW, #6-32,x 3/8” SEM,
4 PLACES (101V)
12-901163-00
SCREW, SEM, 8-32 3/8”
2 PLACESS (230V AND 120v)
03-925595-01
LINE FILTER, 101V
03-925594-01
LINE FILTER, 120V
03-925594-01
LINE FILTER, 230V
03-925581-01
POWER CORD, 101V,
(INSTALL IN ROUND HOLE)
03-925473-01
POWER CORD, 120V,
(INSTALL IN ROUND HOLE)
81-821554-00
POWER CORD, 230V,
(INSTALL IN RECTANGULAR HOLE)
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 18
6
KNURLED PASTIC NUT

INCLUDED WITH
SWITCH.
Note:
1. Finger tight First
WIRING SCHEME. FOR 230V & 101V

CIRCUIT BREAKER
2 4
03-925210-01
POWER SWITCH HOUSING 120V, 230V,
BLUE BROWN & 101V
1 3 NOTE: ALIGN FLAT ON BREAKER

SWITCH WITH FLAT ON HOUSING
FIGURE A. HOLE (O=OFF, I=ON)
03-925622-01
CIIRCUIT BREAKER 101V
55-700701-00
CIRCUIT BREAKER 120V.
55-700702-00
CIRCUIT BREAKER 230V.
NOTE: HITACH GC (03-925620-03/04) Note:

USE CIRCUIT BREAKER (03-925622-01)
3. Wrench tighten using tool
T-8922 circuit breaker wrench
Note:
4. Connect to Main Harness
P/N 03-925295-01 120V
P/N 03-925294-01 230V SAME HARNESS
Hitachi 101V
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 18
6
CIRCUIT BREAKER ASSEMBLY
12-901163-00
SCREW #8-32 x 3/8 SEMS
2 PLACES
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of 18
6
03-925209-01
POWER BOARD SUPPORT
12-901161-00
SCREW, SEM 6-32 X 3/8 4EA.
51-408925-00
TERM, BLK, PLUG 8C
03-925480-01
ASSY., CONNECTOR, HEATER
51-408923-00
TERM, BLK, PLUG68C
03925082-01
51-406933-00 POWER BOARD
CONN. HOUSING PLUG
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 11 of 18
6
VENT DOOR
J42
1 2 3 4 5 6 7 8
BLACK/WHITE BLUE/WHITE
HEAT ZONE 2 INJECTOR 2 BLUE RED
HEAT ZONE 3 INJECTOR 3 FRONT MID REAR WHITE BLACK
HEAT ZONE 4 DETECTOR 1 CRYO 1 CRYO 1
HEAT ZONE 5 DETECTOR 2 9 10 11 12 13 14
OVEN
LOCKING CRYO 2 CRYO 2 CRYO
HEAT ZONE 6 DETECTOR 3 RAMP
J43 CRYO 3 CRYO 3
JUMPER COL. CRYO COL. CRYO
J41 GREEN/YELLOW
J42 BLACK WHITE
1 2 3 4 5 6 7 8
9 10 11 12 13 14
J45 J46 COLUMN OVEN
CONNECT TO J10 FAN
J43 J44 J47
ON THE MAIN BD. EXTERNAL
CLICK HERE TO SEE J41 EVENTS
MAIN BD. ASSY. J51
PROCEDURES
CHASSIS FAN
JACK
03-925296-01
ASSY., CBLE, PWRCTRL. VENT DOOR/
OVEN CRYO &
OVEN MOTOR
POWER BOARD JACK.
03-925082-01
J40 J47
CRYO 1 CRYO 1
CRYO 2 TRANSFORMER JACK
CRYO 2
CRYO 3 CRYO 3 MAIN POWER J50 COLUMN OVEN
HARNESS JACK HEATER
VENT MOTOR /CRYO/
J44 J49 OVEN FAN MOTOR
COLUMN OVEN
INJECTOR CRYO HEATER JACK J48
TRANSFORMER
MAIN POWER
HARNESS
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 12 of 18
6
12-901163-00
SCREW #8-32 x 3/8 SEMS
2 PLACES
POWER BOARD ASSEMBLY
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 13 of 18
6
NOTE: RED LINE ON ALL
CABLES FACE UP.
03-925111-01
EFC FLAT CABLE
03-925296-01
ASSY., CBLE, PWRCTRL.
NOTE: NOT INSTALLED FOR

FACELESS SATURN
03-925450-01
ASSY., CABLE FRONT PANEL
NOTE: USE T-XXXX

(CABLE FOLDING FIXTURE)
FOR FRONT PANEL CABLE
22-120322-00
FLAT CABLE CLAMP 2EA
NOTE: NOT INSTALLED

FOR FACELESS
SATURN
CABLE LAYOUT FOR

PNUEMATICS COMPARTMENT
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 14 of 18
6
OPTION 03-925300-01 START
OPTION ANALOG IN/OUT
OPTION
COL. OVN. PROBE
DET. 3
SAMPLE INTRODUCTION 51-408783-00 DET. 2
PROBE CONNECTOR DET. 1
INJ. 3
INJ. 2
INJ. 1
J7
J8 CONNECT TO INJ. EFC

UP TO THREE
03-925111-01
EFC, CABLE 120 V
OPTION
03-925805-01 J10 03-925296-01 TO J40

ASSY., COM BD. 03-925086-01 ASSY., CBLE, PWRCTRL.
MAIN BD.
ON THE
POWER BD.
CONNECT
J12
TO J14
J13
J17
J14
03-925450-01
03-925049-01 ASSY., CABLE FRONT PANEL
ASSY., ROM BD.
CONNECT
TO J15
CONNECT TO
J15 FRONT PANEL
KEYBOARD
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 15 of 18
6
51-959920-00
SCREW, LOCK SET 6EA
NOTE: USE SCREW
ONLY
12-901165-00
SCREW 8-32 X 1/4,
INT LW 12 EA
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 16 of 18
6
REF:
03-925235-02
BAFFLE, INNER OVEN, W/O
LOGO
04-000200-00
INSULATOR CLIP, 12 EA.
21-000017-00
INSULATOR, HEATER COIL, 12EA.
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 17 of 18
6
03-925233-01
HEATER COIL,COL. OVN. Note: 12-222006-05
1500W. (120 V) SCREW, 6-32 X 5/16, SS, PH.
See note 3
2EA.
03-925412-01
HEATER COIL,COL. OVN.
(230 V)
03-925411-01
NOTES HEATER COIL,COL. OVN.
(101 V)
NOTE: 03-925376-01
1. RELAXED OR RETRACTED NOTE: PRE-STRETCH
CABLE, HEATER
HEATER COIL TO THE
LENGTH OF HEATER COIL FOLLOWING LENGTHS
IS 27 1/4” TO 27 1/2”. BEFORE INSTALLING: Note:
220V - 4’ CONNECT HEATER
2. CAUTION: CERAMIC OVEN 120V - 3’3” CABLES TO J48 ON
HEATER STANDOFFS ARE 101V - 3’ POWER BOARD
UPSIDE
FRAGILE. OVER TIGHTEN- DOWN
ING OF SCREWS WILL 24-811803-00
CAUSE BREAKAGE. CERAMIC STANDOFF 2EA
13-312006-00
KEPNUT #6, SST 2EA.
3. TIGHTEN NUT ONTO SCREW
Note: 14-202006-00
FIRST, CLAMPING RING #6 SPLIT WASHER 2EA
TERMINALS. TO ENSURE See note 4.
PROPER CONTACT.
4. ATTACH STANDOFF TO
TERMINAL ASSY. FINGER-
TIGHT.
SEE NOTE 2.
03-925235-01
COL. OVEN BAFFLE
5. ATTACH COMPLETED ASSY
TO BAFFLE LAST.
6. COIL HEATER CABLE SUCH NOTE:

THAT NO SHORTING TAKES 12-222006-03 USE T-8921 HEATER ALIGN-
PLACE SCREW, 6-32 3/16 SST. PH 2EA. MENT TOOL FOR CORRECT
INSTALLATION OF COLUMN
HEATER TO COLUMN OVEN
BAFFLE.
Note:
See note 5.
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 18 of 18
6
22-119785-00
12-901163-00 12-901163-00
CLAMP, CABLE 03925375-01
SCREW, 8-32 X 3/8 SCREW, 8-32 X 3/8
COLUMN OVEN PROBE ASSY
EXT. SST 4EA
COLUMN OVEN BAFFLE

AND HEATER ASSEMBLY
DOC: 03-925001-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 19 of 18
6
DOC: 03-917946-02 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Fan Balance Test
PAGE: 1 of 1
2
Fan Balance Test

3800 GC Station 2
TEST
1. Mount fan blade (PN 03-917946-01) on test fixture with set screws at 12 o’clock on shaft flat and 3 o’clock on shaft diameter.
Use the grooved end of tool PN 03-917887-00 to set the back spacing of the fan and to counter the torque of the hex wrench.
Close safety door.
2. Set the meter to AC volts and turn on the power and fan switch.
3. The meter should read less than 4.5 volts. Reject any fans that read more that 4.5 volts. Divide the volts by 100 to get oz-in of
unbalance. For example: 5 volts = .05 oz-in of unbalance.
4. If the reading is greater than 4.5 volts, check the motor speed by pressing the Hz button on the meter and read the frequency.
The frequency should be 26.9 to 27.3 Hz (If the signal is less than 2 volts, it may not be stable enough to get a frequency
reading). Switch back to voltage measurement by pressing the Hz button twice.
5. At the end of the shift, turn the power off to the voltmeter.
6. All discrepant fans must have voltage, fan number, and Hz written on one of the fan blades with a marker. Re-box fan in original
container.
7. Circle the fan number on the Vendor Data Sheet.
8. Copy the Data Sheet. Send the original back to the vendor with DR file copy in Fan Data Binder.
PREPARED BY: Sax Makthepharack REVISED BY: Arden Yambao CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 11 - 22 - 00 - SHOWN
DOC: 03-917946-02 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Fan Balance Test
PAGE: 2 of 1
2
CALIBRATION
1. Mount the 4.6 oz-in calibration weight to the motor shaft with the set screw closer to the end of the motor shaft. Use the
grooved end of the tool PN 03-917887-00 to position the weight and counter the torque of the hex wrench.
2. Connect a variac to the fan motor. Adjust the motor speed to 26.9 to 27.3 Hz.
3. Adjust the potentiometer located on the amplifier board below the motor so that the voltage reads 4.6 volts AC.
PREPARED BY: Sax Makthepharack REVISED BY: Arden Yambao CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 11 - 22 - 00 - SHOWN
DOC: 03-925794-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Chassis, Twin Towers
PAGE: 1 of 10
3
ASSY, CHASSIS, TWIN TOWERS

DOC: 03-925794-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 10
3
23-622018-00
03-925315-02 FOOT, LEVELER
FOOT, .87” x .87” 2 PLACES
2 PLACES
13-111114-00
12-222008-12 HEX NUT
SCREW #8-32 x 7/8” 12-901163-00 2 PLACES
2 PLACES SCREW #8-32 x 3/8”
2 PLACES
17-699938-00
RIVET, LARGE
4 PLACES
03-918199-00
SUPPORT, FOOT
2 PLACES
03-925238-01
CHASSIS BOTTOM
NOTES:
1. ALL PARTS MARKED WITH AN ASTERISK (*) ARE

PART OF (03-925700-70) CHASSIS KIT.
28-995808-00
2. ADJUST FEET ON ONE SIDE W/RED CAP 2 OR 3 CAP, VINYL, RED
THREADS SHOWING. “TIGHTEN JAM NUT ON 2 PLACES
ADJUSTABLE FEET TO PREVENT FEET FROM
LOOSENING”, USING 7/16” WRENCH. CUT THE
OPEN END OF THE RED CAP JUST ENOUGH TO
COVER THE REMAINING SCREWS THREADS.
DOC: 03-925794-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 10
3
17-699907-00
RIVET
4 PLACES
03-925246-01
CHASSIS BULKHEAD (*)
USE TEMPORARY
RIVET HERE
03-925242-01
PARTITION (*)
17-699907-00
RIVET
DOC: 03-925794-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 10
3
17-699907-00
RIVET
3 PLACES
03-925466-01 03-925245-01
SUPPORT AND PANEL MOUNTING. MAIN PCB (*)
STIFFENER (*)
17-699907-00
RIVET
2 PLACES
ASSEMBLY
PANEL MNTG.,
MAIN PCB
DOC: 03-925794-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 10
3
17-699907-00
RIVET
4 PLACES
03-925239-01
PANEL, REAR (*)
03-925241-01
PLATFORM, MOUNTING (*)
17-699907-00
RIVET
11 PLACES
DOC: 03-925794-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 10
3
03-925240-01
BRACE, TOP LEFT (*) COUNTERSINK THESE
TWO HOLES TO 1/4” DIA.
AT 82 AND USE
COUNTERSINK RIVETS
P/N 17-699961-00
17-699907-00
RIVET
4 PLACES
03-925237-01
PANEL, FRONT (*)
17-699907-00
RIVET
6 PLACES
DOC: 03-925794-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 10
3
17-699907-00
RIVET 03-925262-01
6 PLACES BRACKET, FAN MOTOR (*)
03-925793-01
OVEN ASSEMBLY (*)
12-222006-06
SCREW, 6-32 X 3/8
17-699907-00 6 EA.
RIVET
20 PLACES USE 13-312006-00
#6 KEP NUT W/SCREW
(NOT SHOWN)
DOC: 03-925794-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 10
3
17-699907-00 12-901165-00
RIVET SCREW #8-32 x 3/16”, SEMS
8 PLACES
17-699907-00
RETAINER CLIP
4 PLACES
12-901163-00
SCREW #8-32 x 3/8”
7 PLACES
03-925285-01
HOOK LATCH (*)
ALIGN TOP HINGE PLATE

UP AGAINST OUTER
OVEN TOP
03-925290-01
HINGE PLATE
2 PLACES (*)
12-901165-00
SCREW #8-32 x 3/16”, SEMS
4 PLACES
RETAINER CLIP
NOTE: USE THESE SCREWS AND RIVETS HERE
TO ADJUST HOOK LATCH
DOC: 03-925794-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 10
3
03-925565-01
COUPLING, FLEXIBLE
03-925314-01
ASSY, VENT DOOR
21-128961-00
BEARING, NYLON SLEEVE
12-901161-00
SCR, SEM, 6-32 X 3/8
NOTES:
1. WHEN ASSEMBLE THE FLEXIBLE COUPLING
(03-925565-01) ONTO THE VENT DOOR ASSEMBLY
(03-925314-01) SHAFT, MAKE SURE IS FLUSH
AGAINST SHOULDER OF SHAFT. TIGHTEN
SCREW ON COUPLING TO 10 IN-LB TORQUE.
03-925306-01
2. WHEN INSTALLING VENT MOTOR INTO THE 3800 VENT MOTOR
FLEXIBLE COUPLING, MAKE SURE MOTOR
SHAFT END TOUCHES VENT SHAFT END. PRIOR
TO TIGHTEN THE SCREW ON COUPLING CHECK
TO MAKE SURE THE SCREW IS ON THE FLAT
SURFACE OF THE VENT MOTOR SHAFT. TIGHTEN
SCREW ON COUPLING TO 10 LB-LB TORQUE. 03-925332-01
PARTITION, VENT (*)
03-925229-01
DUCT, VENT (*)
17-699907-00
RIVET, 1/8 X 1/8 AL/AL
DOC: 03-925794-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of 10
3
28-693973-00
WITH END CAP, 1 ONLY 4 PLACES
17-699907-00
RIVET 6 PLACES
23-620801-00
RETAINING CLIP
2 PLACES
NOTE:
FOR 101V &120V VERSIONS
COVER SQUARE HOLE.
FOR 230V VERSION COVER

ROUND HOLE.
FOR HITACHI, ADD COVER

AT BUTTON UP.
12-901163-00
SCR, SEM, 8-32 X 3/8
11 PLACES 24-389051-00
GROMMET
2 PLACES
VENT DUCT ASSEMBLY (REF.)

SEE SHEET 9 OF 10
03-925310-01
COVER PLATE 17-699907-00
SEE NOTE. (*) RIVET
DOC: 03-925794-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 11 of 10
3
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Chassis
PAGE: 1 of 12
5
ASSY, CHASSIS (STANDARD)

PREPARED BY: HOWIE PLITSCH REVISED BY: Arden Yambao CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 10 - 27 - 00 - SHOWN
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 12
5
23-622018-00
03-925315-02 FOOT, LEVELER
FOOT, .87” x .87” 2 PLACES
2 PLACES
13-111114-00
12-222008-12 HEX NUT
SCREW #8-32 x 7/8” 12-901132-00 2 PLACES
2 PLACES SCREW #8-32 x 3/8”
2 PLACES
17-699938-00
RIVET, LARGE
4 PLACES
03-918199-00
SUPPORT, FOOT
2 PLACES
03-925238-01
CHASSIS BOTTOM
NOTES:
1. ALL PARTS MARKED WITH AN ASTERISK (*) ARE

PART OF (03-925700-70) CHASSIS KIT.
2. ADJUST FEET ON ONE SIDE W/RED CAP 2 OR 3 28-995808-00

THREADS SHOWING. “TIGHTEN JAM NUT ON
CAP, VINYL, RED
ADJUSTABLE FEET TO PREVENT FEET FROM
2 PLACES
LOOSENING”, USING 7/16” WRENCH. CUT THE
OPEN END OF THE RED CAP JUST ENOUGH TO
COVER THE REMAINING SCREWS THREADS.
3. ASSEMBLE FOOT SUPPORT (03-918199-00) WITH

HOLE PATTERN AS SHOWN. (2 PLCS)
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 12
5
17-699961-00
COUNTER SINK RIVET
17-699907-00
RIVET
3 PLACES
03-925246-01
CHASSIS BULKHEAD (*)
USE TEMPORARY
RIVET HERE
03-925242-01
PARTITION (*)
17-699907-00
RIVET
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 12
5
17-699907-00
RIVET
3 PLACES
03-925466-01 03-925245-01
SUPPORT AND PANEL MOUNTING. MAIN PCB (*)
STIFFENER (*)
17-699907-00
RIVET
2 PLACES
ASSEMBLY
PANEL MNTG.,
MAIN PCB
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 12
5
17-699907-00
RIVET
4 PLACES
03-925239-01
PANEL, REAR (*)
03-925241-01
PLATFORM, MOUNTING (*)
17-699907-00
RIVET
13 PLACES
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 12
5
03-925240-01
BRACE, TOP LEFT (*)
17-699961-00
COUNTER-SINK RIVET
17-699907-00
RIVET
4 PLACES
03-925237-01
PANEL, FRONT (*)
17-699907-00
RIVET
6 PLACES
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 12
5
17-699938-00
RIVET, SST 17-699907-00 RIVET, 2 PLACES
4 EA.
03-925251-01 AFTER INSTALLING 03-925251-00
PAINTED GRILL PAINTED GRIL
17-699907-00
RIVET 03-925262-01
8 PLACES BRACKET, FAN MOTOR (*)
03-925701-01
OVEN ASSEMBLY (*)
12-222006-06
SCREW, 6-32 X 3/8
17-699907-00 6 EA.
RIVET
20 PLACES USE 13-312006-00
#6 KEP NUT W/SCREW
(NOT SHOWN)
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 12
5
DOOR HEIGHT ADJUSTMENT:
17-699907-00 1. TIGHTEN LOWER AND UPPER HINGE PLATE WHILE PULLING
RIVET UP AND ALIGNING NOTCH IN HINGE PLATE WITH OUTER PNEU-
8 PLACES MATICS BOX. LEAVE SCREWS ITEM (1) LOOSE.
2. LEAVE SCREWS 12-901165-00 FOR BASIC 2 DOOR ASSEMBLY

(2 PCS) (USE THESE SCREWS TO ADJUST HOOK LATCH)
23-620801-00
RETAINER CLIP
4 PLACES
12-901132-00
1 SCREW #8-32 x 3/8”
7 PLACES
03-925285-01
HOOK LATCH (*)
ALIGN TOP HINGE PLATE

UP AGAINST OUTER
OVEN TOP
03-925290-01
2 HINGE PLATE
2 PLACES (*)
12-901165-00
SCREW #8-32 x 1/4”, SEMS
2 PLACES
03-925447-01
RETAINER CLIP HINGE PIVOT BLOCK
AND RIVETS HERE 2 PLCS.
(USE 12-901165-00
SCREW, 8-32 X 1/4
TO SECURE)
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 9 of 12
5
4
03-925565-01
COUPLING, FLEXIBLE
03-925314-01
SCREWS SHOULD
ASSY, VENT DOOR
FACE OUT.
21-128961-00
BEARING, NYLON SLEEVE
12-901161-00
SCR, SEM, 6-32 X 3/8
NOTES:
1. WHEN ASSEMBLE THE FLEXIBLE COUPLING (03-925565-
01) ONTO THE VENT DOOR ASSEMBLY (03-925314-01) SHAFT,
MAKE SURE IS FLUSH AGAINST SHOULDER OF SHAFT.
TIGHTEN SCREW ON COUPLING TO I0 IN-LB TORQUE.
2. WHEN INSTALLING VENT MOTOR INTO THE FLEXIBLE

COUPLING, MAKE SURE MOTOR SHAFT END TOUCHES VENT 03-925306-01
SHAFT END. PRIOR TO TIGHTEN THE SCREW ON COUPLING 3800 VENT MOTOR
CHECK TO MAKE SURE THE SCREW IS ON THE FLAT SUR-
FACE OF THE VENT MOTOR SHAFT. TIGHTEN SCREW ON
COUPLING TO 10 IN-LB TORQUE.
3. INSPECT CONNECTORS FOR BROKEN TEETH.

03-925332-01
4. FOR FIELD SERVICE ACCESS MAKE SURE SCREW ON PARTITION, VENT (*)
COUPLING IS FACING OUT.
03-925229-01
DUCT, VENT (*)
17-699907-00
RIVET, 1/8 X 1/8 AL/AL
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 10 of 12
5
28-693973-00
WITH END CAP, 1 ONLY 4 PLACES
17-699907-00
RIVET 6 PLACES
23-620801-00
RETAINING CLIP
2 PLACES
NOTE: 6 14/16” LONG GROMMET

FOR 101V &120V VERSIONS
COVER SQUARE HOLE.
FOR 230V VERSION COVER

ROUND HOLE.
FOR HITACHI, ADD COVER

AT BUTTON UP.
2 PIECES OF GROMMET:
-12 11/16” LONG
- 7 1/8” LONG
12-901132-00
SCR, SEM, 8-32 X 3/8
11 PLACES 24-389051-00
GROMMET
2 PLACES
VENT DUCT ASSEMBLY (REF.)

SEE SHEET 9 OF 10
03-925310-01
COVER PLATE 17-699907-00
SEE NOTE. (*) RIVET
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 11 of 12
5
PFPD CHASSIS: CLIP INSTALLATION 22-130017-00 17-699961-00

1. USE MEDIUM CLIP (22-130017-00) W/ RIVET (17-699961-00) MEDIUM CLIP RIVET
2. USE SMALL CLIP (22-130018-00 W/ RIVET (17-69907-00)
22-130018-00 17-69907-00
SMALL CLIP RIVET
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 12 of 12
5
03-925291-01
TRANSFORMER,120V
03-925292-01
TRANSFORMER, 230V
03-925293-01
TRANSFORMER, 101V
14-122010-00
WASHER,FLAT, #10 SST. 4EA
12-222060-40
SCREW 4EA
SEE CONNECTION TO
POWER PCB, J50 ON NOTE: USE
PAGE 14 88-299284-00
LOCTITE #222
ON ALL FOUR
SCREWS
NOTE: VERIFY
SCREWS ARE TIGHT
24-389956-00
BUSHING 4EA
DOC: 03-925700-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 13 of 12
5
TRANSFORMER ASSEMBLY
DOC: 03-925461-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, PFPD Ignitor W/Cable
PAGE: 1 of 7
1
ASSY, PFPD IGNITOR W/CABLE

GC PROBE AREA, ASSEMBLY PROCEDURES
DOC: 03-925461-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 7
1
NOTE:
03-925166-00, 2 PLCS
1. NOTE THAT THE.200 INCH DIMENSION IS ESTABLISHED WITH A SPECIAL TOOL AND ASSY, PIN TUBE
IS DIFFERENT FROM THE ONES USED FOR THE MODEL 3500 TSD/FID PROBES.
58-200020-00
CONNECTOR
03-925164-00
INSERT, IGNITOR PROBE
T - 8876
IGNITOR ASSEMBLY HOLDING TOOL
T - 4161
HOLDING TOOL
DOC: 03-925461-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 7
1
1. PFPD IGNITOR W/CABLE ASSEMBLY PROCEDURES
1.1 IGNITOR CONNECTOR ASSEMBLY - (03-925162-00)
1.1.1 Place Ignitor Probe Insert (03-925164-00) into the holding tool T-8876. Obtain Connector (58-200020-00), screw onto the
holding tool T-8876 until it bottoms out. Insert two Pin Tube Assembles (03-925166-00) through the Connector into two holes on
the Ignitor Probe Insert.
Caution: Make sure the Pin Tube Assembly does not contact the Connector. If necessary, swag top of connector to provide
additional clearance for Pin Tube Assembly. Place the assembly into the holding fixture tool T-4161.
1.2 FIXING/EPOXY IN PLACE
1.2.1 Using a digital Scale, turn on scale, place 100ml beaker on scale and zero. Using metal spatula, place 50g of Duralco 4700 Ultra
Hi-temp Epoxy (88-900909-00) resin into beaker. Clean spatula with Kim-Wipe. Zero scale. Add 14g of Duralco 4700 hardener
to beaker containing Duralco 4700 resin. Mix (fold) to avoid entrapment of air until completely mixed. Place dispensing tip onto
30cc disposable barrel. Using glass spatula (or glass stirring rod) as an aid, transfer epoxy into 30cc disposable barrel of
previous step 1.1.7. Set pneumatic dispenser to 10psi, and back pressure regulator to 1/4 turn (adjust as required), set timer to
off.
Caution: Do not allow epoxy to back flow into adapter tubing.
1.2.2 Epoxy Ignitor Probe Insert and Pin Tube Assembly in place, cure it. Curing: Place fixture T-4161 and assembled parts in oven
start at 50°c and raise at 5°c per minute until part gets to 105°c for 2 hours followed by 4 hours at 175°c.
Continue next page...
DOC: 03-925461-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 7
1
NOTES:
1. USE WHITE NYLON ON GLOVES WHEN HANDLING CERAMIC PARTS.
2. SOLDER BLACK AND CLEAR WIRES TO PINS IN PLACE INDICATED. DO NOT ALLOW SILVER
SOLDER BETWEEN GAPS IN COIL. PREVENT FLUX FROM FLOWING BETWEEN TUBE AND HOLE
IN CONNECTOR CERAMIC.
3. HANDLE IGNITOR COIL (03-925167-00) WITH CARE. SOLDER AND CRIMP AFTER OTHER PARTS
HAVE BEEN ASSEMBLED.
4. ATTACH GLS TUBE NATURAL INSULATION TUBING (88-459904-00) TO PFPD IGNITOR 03-925460-01
ASSEMBLY WITH FIXTURE T-8958. S/A, CABLE, PROBE, 31” LG
5. CURE, HIGH TEMP EPOXY (88-900909-00) AT 150°C FOR 40 MINUTES WITH FIXTURE T-8959.
88-459904-00, 8” LG
TUBING, INSUL, GLS, #7, NATURAL
22-119650-00
TIE, CABLE, 4” LG
03-925193-00
SLEEVE
ASSY, PFPD IGNITOR (REF.)
88-900909-00, A/R
EPOXY, HIGH TEMP
1.4 IGNITOR W/CABLE PFPD ASSEMBLY - (03-925461-00)
1.4.1 Complete the assembly of the PFPD Ignitor with Cable (03-925461-00) by placing 8” Natural #7 GLS Insulation tubing
(88-459904-00) over the 31” Probe Cable S/A (03-925460-01) and Sleeve (03-925193-00) over exposed clear wire.
1.4.2 Insert both Black/Clear wires into the Pin Tube Assembly and solder in place indicated.
Continue next page...
DOC: 03-925461-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 7
1
1.4.3 Slide the Sleeve over the Pin Tube Assembly and heatshrink in place not shown.
1.4.4 Place the PFPD Ignitor with Cable into a fixture T-8958 and apply epoxy where indicated with the Ignitor Coil pointed downward.
While the epoxy is not yet cured, slide the 8” Natural #7 GLS Insulation tubing until it flush with the Ignitor Connector.
1.4.5 Remove the PFPD Ignitor With Cable from fixture T-8958 and place into fixture T-8959 to bake for approximately 40 minutes.
1.4.6 Remove the PFPD Ignitor With Cable from fixture T-8959, then fold (tuck) the end of 8” Natural #7 GLS Insulation tubing into
itself and install 4” LG Cable Tie (22-119650-00) where shown.
1.4.7 Obtain Label with completed PFPD Ignitor with Cable Assembly part number (03-925461-00) and placed over the existing label
on the 31” Probe Cable S/A. Write 3800 on the new label for reference.
1.5 IGNITOR COIL INSTALLATION - (03-925161-00)
1.5.1 After the PFPD Ignitor with Cable Assembly is completed, weld Ignitor Coil (03-925167-00) to the Ignitor Connector Assembly.
1.5.2 Check and make sure the setting on the Synchronous A.C. Welding Control as indicated: Set Timing switch to 1-99
Cycles/Spot, Repeat Rate to 10, Current 50 and Transformer Tap High.
1.5.3 Insert Ignitor Coil (03-925167-00) into the PFPD Ignitor with Cable Assembly Pin Tube Assembly. Insert the Ignitor through the
large block of the fixture and place the Ignitor Coil over the Pin of the fixture.
Note: Prior to welding check to make sure that the Ignitor Probe Insert is aligned with the outer edge of the fixture.
1.5.4 After applying weld on both of the Ignitor Coil, remove the assembly from the fixture and apply weld on each of the Pin Tube
Assembly/Ignitor Coil separately on opposite side of the fixture.
DOC: 03-925461-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 7
1
IGNITOR W/CABLE ASSEMBLY (REF.)
DOC: 03-925461-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 7
1
TIMING 1-99 CYCLES
TIMING 50
PFPD IGNITOR W/CABLE

NOTE: COIL TO PINS ALIGNMENT
TO BE WITH ± TO EACH OTHER
ESTABLISH DIMENSION
WITH FIXTURE T-3740
CURRENT 50
TRANSFORMER TAP
HIGHT (MAX)
REPEAT RATE 10 MAX FIXTURE CLOSE-UP

TIMING SPOT
SYNCHRONOUS A.C. WELDING CONTROL
03-925167-00
COIL, IGNITOR
PFPD IGNITOR W/CABLE
IGNITOR COIL INSTALLATION (REF.) COIL POSITION SIDE VIEW (REF.)
DOC: 03-925461-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 7
1
DOC: 03-925721-XX REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Button-up, Twin Towers
PAGE: 1 of 5
2
BUTTON-UP, TWIN TOWERS

3800GC BUTTON-UP STATION, ASSEMBLY PROCEDURES
DOC: 03-925721-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 5
2
03-925702-01
KEYBOARD, ASSY.
NOTE:
CLICK ON S/A PICTURES 12-901163-00 OPERATION SEQUENCE
SHOWN TO SEE S/A SCREW, 8-32, X3/8 EXT.SST., SEM 2EA
INSTRUCTIONS 1. THE MAIN DOOR IS
DESIGNED TO SEAL PROP-
03-925700-01 ERLY, HOWEVER SOME
CHASSIS ADJUSTMENT MAY NEED
TO BE MADE FOR
ASTHETIC PURPOSES.
03-925703-01
ASSY., MAIN DOOR
03-925244-01 03-920011-13
LEFT SIDE COVER 3800 , NAME PLATE
03-925211-01
PNEUMATICS BEZEL
03-925711-01
FOAM STRIP
NOTE:
FOAM TO BE ADDED TO LEFT SIDE
PANEL (P/N 03-925244-01) REQUIRES
T-7110 TOOL TO ALIGN FOAM
(P/N 03-925711-01)
12-901131-00 03-925213-01
SMOKED PNEUMATIC DOOR
SCREW, 8-32 X 3/8” INT LW 7 EA.
DOC: 03-925721-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 5
2
03-925243-01
TOP COVER
23-620803-00
STUD, BALL 6-32 X .437 CS
03-925700-01
CHASSIS
12-901131-00
SCREW, 8-32 X 3/8” INT LW 4EA. 12-901132-00
SCREW, 8-32 X 3/8” EXT. LW 9
03-925250-01
03-925248-01 REAR PANEL
RIGHT SIDE COVER
DOC: 03-925721-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 5
2
03-925788-01
DETECTOR, COVER 22-120209-00, 2 EA.
CABLE, CLAMP, 3/4
12-902733-00, 4 EA.
SCREW, 8-32 X 3/8” INT LW
23-620795-00, 2 EA.
FASTENER, BALL STUD
03-925790-01
INJECTOR, COVER
REAR VIEW REF.
DOC: 03-925721-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 5
2
GENERAL PLUMBING & WIRING LAYOUT
(EXCEPTIONS TCD & PFPD)
CRYO
VLV1 NOTE:
USE BOW TIE MAIN DOOR
WRAPS TO ANCHOR 3 2 1
AND ORGANIZE CABLE
CRYO ROUTINGS AS NEC.
VLV2
INJECTOR SWITCH
NOTE:
CRYO TIE WRAP ALL 1
3 2
VLV3 CABLES AND NOTE:
WIRES EVERY 4” ANGLE DETECTOR
TOWERS AS
SHOWN WHEN
EVER POSSIBLE
J44 J7 MANIFOLD
J41 PNEUMATICS
COMPARTMENT KEYBOARD
NOTE:
NEATLY BUNDLE PEEK
& TIE WRAP WITH AT
LEAST TWO CABLE TIES
DETECTOR BOARDS
DOC: 03-925721-XX REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 5
2
DOC: 03-925620-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: Assy, Hitachi Button-up
PAGE: 1 of 3
1
ASSY, HITACHI BUTTON-UP

GC3800 BUTTON-UP STATION, ASSEMBLY PROCEDURES
DOC: 03-925620-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 3
1
OPERATION SQUENCE
1. THE MAIN DOOR IS DESIGNED TO

SEAL PROPERLY, HOWEVER SOME
ADJUSTMENT MAY NEED TO BE MADE 03-925700-01, (REF.)
ASSY, CHASSIS
FOR ASTHETIC PURPOSES.
036-925619-01
NAMEPLATE, HITACHI G-7000 GC
036-925619-02
NAMEPLATE, HITACHI G-7000M GC
03-925211-11
BEZEL, PNEUMATICS,
FRONT, HITACHI COLOR
I
CH
I TA
H
03-925711-01
FOAM STRIP
NOTE:
(P/N 03-925711-01) 03-925213-11
03-925244-11
3800 PNEUMATICS DOOR - HITACHI
LEFT SIDE COVER
12-901131-00, 7 PLCS
DOC: 03-925620-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 3
1
03-925212-11
DETECTOR, COVER
23-620795-00, 3 PLCS
12-902733-00, 4 PLCS FASTENER, BALL STUD
03-925243-11
TOP COVER
03-925267-11 23-620803-00
INJECTOR, COVER STUD, BALL 6-32 X .437 CS
OPERATION SQUENCE
1. REMOVE THE REAR PANEL FROM THE
INSTRUMENT AND PLACE FOUR EACH BLANK FOIL
LABELS TO COVER FOUR SYMBOLS ON LOWER
CENTER OF REAR PANEL.
2. REPLACE EXISTING 101 POWER CORD WITH NEW

HITACHI CALBE PWR CORD 11FT. 3-12 WIRE
03-925250-01
(03-925621-01) NOT SHOWN. USE 11/32
REAR PANEL
RATCHETING BOX WRENCH.
3. RE-INSTALL THE REAR PANEL BACK ONTO

INSTRUMENT.
NOTES: 12-901132-00, 9 PLCS
SCREW, 8-32 X 3/8” EXT. LW
1. USE LABEL 7000 OR 7000M.
2. NO BOX SET AND NO INSTALLATION

QUALIFICATION CHECK LIST REQUIRE.
3. CHECK TO MAKE SURE THE ADJUSTABLE FEET

ON ONE SIDE W/RED CAP 2 OR 3 THREADS
SHOWING AND JAM NUT IS TIGHT.
SEE OPERATION SQUENCE #1
4. ALL HITACHI UNITS REQUIRE FILTER KIT
(03-925944-91).
REAR PANEL SYMBOL (REF.)

DOC: 03-925620-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 3
1
DOC: 03-925012-01 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: ASSY, LOW COST GC
PAGE: 1 of 4
1
ASSY, LOW COST GC

3800GC BUTTON-UP STATION, ASSEMBLY PROCEDURES
DOC: 03-925012-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 4
1
23-620803-00
03-925243-01 STUD, BALL 6-32 X .437 CS
COVER, TOP, ELECTRONIC
12-902733-00, 6 PLCS
03-925861-01
COVER, INJECTOR, WIDE
12-901131-00, 9 PLCS
12-901132-00, 9 PLCS
SCREW, 8-32 X 3/8” EXT. LW
03-925244-01, 16 PLCS
COVER, LEFT SIDE
03-925250-01
REAR PANEL
03-925854-01
03-925248-02
FACE
RIGHT SIDE COVER
03-925700-02
CHASSIS
03-920011-15 SAME SCREWS AS
NAME PLATE, SAT2000R G LEFT SIDE COVER
03-925703-01
ASSY, MAIN DOOR
DOC: 03-925012-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 4
1
1. LOW COST GC, SATURN 2000R GC (03-930090-01, -02 & -03), ASSEMBLY PROCEDURES
1.1 This is a Saturn GC shipped with a large face replacing the keyboard and the pneumatics bezel alone with no detector cover. The
following is a summary of the differences to a regular Saturn GC:
1.1.1 BASICS
Leave off 3 ball stud receptacles for detector cover.
Leave off hinge pivot blocks (normally used for pneumatics sub panel).
Do Not install Keyboard Cable.
1.1.2 FINALS
Install “Capital” keyboard housing & keyboard cable for the purposes of leak check, burn-in, and test. This will beremoved
from instrument and returned to assembly after test.
Install 1079 EFC on chassis front panel, behind keyboard housing, in right-hand location.
Do not include pneumatics panels.
Install pneumatics manifold block in lower position.
Only 1 1079 Injector and no detectors allowed.

Install only “flangeless” version of 1079 Injector; EFC is only type 21 or type 25.
1.1.3 TEST
Test per new ATP. Detlim sample is 10 pg (03-920274-00).
When test is complete shut down instrument, remove keyboard, and plug in power indicator cable (03-925855-01).
Switch instrument back on just to prove light works.
Return “Capital” keyboard with its cable to Assembly.
DOC: 03-925012-01 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 4
1
1.1.4 BUTTON UP
Using 2 Cable Clamps (22-120202-00), retain the Ribbon Cable (03-925855-01) along the Chassis walls. Feed light through
Face and install using Clip (67-599272-00).
Attach the Face Panel (03-925854-01) to left side of the Chassis, using four Washer (14-3023006-00) and four Screws
(12-312006-04). Screws not shown.
Place Wide Injector Cover (03-925861-01) on top of the Chassis Injector side, using six Screws (12-902733-00) as shown.
Use Saturn 2000R Nameplate (03-920011-15).
DOC: 03-925001-XX REV
CHG PARTS
HISTORY
TOOLS
LIST
MENU DESC: Button-up
PAGE: 1 OF 4
2
Covers, Door, Pneumatics Bezel & Keyboard

Installation
DOC: 03-925001-XX REV
CHG PARTS
HISTORY
TOOLS
LIST
PAGE: 2 OF 4
2
03-925702-01
KEYBOARD, ASSY.
NOTE:
CLICK ON S/A PICTURES 12-901163-00 OPERATION SEQUENCE
SHOWN TO SEE S/A SCREW, 8-32, X3/8 EXT.SST., SEM 2EA
INSTRUCTIONS 1. THE MAIN DOOR IS
DESIGNED TO SEAL PROP-
03-925700-01 ERLY, HOWEVER SOME
CHASSIS ADJUSTMENT MAY NEED
TO BE MADE FOR
ASTHETIC PURPOSES.
03-925703-01
ASSY., MAIN DOOR
03-925244-01 03-920011-13
LEFT SIDE COVER 3800 , NAME PLATE
03-925211-01
PNEUMATICS BEZEL
03-925711-01
FOAM STRIP
NOTE:
(P/N 03-925711-01)
12-901131-00 03-925213-01
SMOKED PNEUMATIC DOOR
SCREW, 8-32 X 3/8” INT LW 7 EA.
DOC: 03-925001-XX REV
CHG PARTS
HISTORY
TOOLS
LIST
PAGE: 3 OF 4
2
03-925212-01
DETECTOR, COVER
23-620795-00
03-925243-01
FASTENER, BALL STUD, 3EA.
TOP COVER
12-902733-00
SCREW, 8-32 X 3/8” INT LW 4EA. 23-620803-00
STUD, BALL 6-32 X .437 CS
03-925700-01
CHASSIS
03-925267-01
INJECTOR, COVER
12-901131-00
SCREW, 8-32 X 3/8” INT LW 4EA. 12-901132-00
SCREW, 8-32 X 3/8” EXT. LW 9
03-925250-01
03-925248-01 REAR PANEL
RIGHT SIDE COVER
DOC: 03-925001-XX REV
CHG PARTS
HISTORY
TOOLS
LIST
PAGE: 4 OF 4
2
GENERAL PLUMBING & WIRING LAYOUT
(EXCEPTIONS TCD & PFPD)
CRYO
VLV1 NOTE:
USE BOW TIE MAIN DOOR
WRAPS TO ANCHOR 3 2 1
AND ORGANIZE CABLE
CRYO ROUTINGS AS NESS.
VLV2
INJECTOR SWITCH
NOTE:
CRYO TIE WRAP ALL 1
3 2
VLV3 CABLES AND NOTE:
WIRES EVERY 4” ANGLE DETECTOR
TOWERS AS
SHOWN WHEN
EVER POSSIBLE
J44 J7 MANIFOLD
J41 PNEUMATICS
COMPARTMENT KEYBOARD
NOTE:
NEATLY BUNDLE PEEK
& TIE WRAP WITH AT
LEAST TWO CABLE TIES
DETECTOR BOARDS
DOC: 03-925880-00 REV
CHG PARTS
HISTORY
TOOLS
LIST MENU DESC: 3800GC, Burn-In Test Procedure
PAGE: 1 of 7
2
1. 3800GC BURN-IN PROCEDURE
1.1 TOOLS AND EQUIPMENT REQUIRED:
1.1.1 Flow meter

1.1.2 Injector nuts/seals T-8941
1.1.3 Torque wrench, 15 in/lbs with 3/32 hex tip
1.1.4 Test column, 6 ft. long (cut to three Feet long) P/N 03-912403-35)
1.1.5 #2 Philips screw driver
1.1.6 Straight Slot screw driver
1.1.7 Open end wrench, 5/16-1/4
1.1.8 Open end wrench, 7/32
1.1.9 Open end wrench, ¾
1.1.10 Plug, detector base
1.1.11 Packed Column adapter, 03-918631-00
1.1.12 Adapter Seal, 03-925132-00
1.1.13 Voltmeter
1.1.14 Capillary Pick
1.1.15 Ground Strap
1.1.16 Gases, N2, He, Air, H2
1.1.17 Injector Nut wrench
1.1.18 Tweezers
1.1.19 Hy-Pot Tester
1.1.20 Quad fitting, 1/8” (with 3 pieces of peek tubing & manifold plate)
1.2 Verify G.C. to S/O & Specials Documentation if Applicable
1.3 Hy-Pot Instrument (observe safety precautions)
1.3.1 Display Safety Chain in front of Instrument.

1.3.2 Attach Ground Cable to the Instrument Frame.
1.3.3 Display a Red Safety Cone on top of the unit being tested..
PREPARED BY: Sax Makthepharack REVISED BY: F.Faili/M.Slaughter CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 07 - 30 - 99 - SHOWN
DOC: 03-925880-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 2 of 7
2
1.3.4 Remove J-41 Harness from power PWA (03-925082-01) & install into Analyzer cable.
1.3.5 Install Analyzer Cable into J41.
1.3.6 Connect Instrument Power Cable to correct Voltage (101,120,220) Adapter made for Hy-Pot Tester.
1.3.7 Turn on Instrument Power Switch.
1.3.8 Make sure Continuing Light/Function is activated.
Warning: NEVER TOUCH INSTRUMENT DURING HY-POT TEST
1.3.9 Depress TEST MODE key on Analyzer.

1.3.10 Observe Pass/Fail condition on Analyzer.
1.3.11 If FAIL, Trouble Shoot Instrument to determine defect (refer to Troubleshooting chart).
1.3.12 If PASS, proceed with Burn-in Procedure. (observe Safety Precautions during disconnect, make sure voltage indicator on the
Analyzer is reading Zero).
1.3.13 Remove Ground Cable, Analyzer Cable and re-install J41 Harness into Power PWA.
1.3.14 Sign off Data Record Sheet under “HY POT”.
1.4 Instrument Burn-in Procedure
Warnings & Precautions:

* When heating Injectors/Detectors, make sure one of the specified gases is flowing through them.
* Make sure all heat sensitive materials are removed from heated zones.
* Burn-in PFPD’s with the proper combustor holder and washer (see Sales Order).
* For GS Valves, be sure Temperatures on Injector/Column Oven are NOT set higher than the Valves will allow.
1.5 Set up & Connection
1.5.1 Connect Instrument to correct Voltage (101,120,220).

1.5.2 Connect Appropriate Gases to Instrument rear panel (type and location of Gases determined by Detector type).
1.5.3 Install test column w/adapter and seal to each Injector (Column is ≈ 18” x 1/8” packed column).
1.5.4 Install a Plug in each Detector Base.
1.5.5 Power up Instrument.
1.5.6 Press any key to run in local mode, if unit has a COM PWA, & wait for instrument to initialize.
1.5.7 Observe Set Up Menu (see diagram). If Set Up Menu is not displayed, depress the SETUP Key and select “EDIT
DOC: 03-925880-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 3 of 7
2
1.5.8 Verify Time & Date (see diagram).
1.5.9 Edit Heated Zones (type, temp. limit, location, coolant) for GSV’s, see labels & flow diagram for temp. limits (see diagram).
1.5.10 Edit Column Parameters (see diagram).
*NOTE: Use N2 by default, except He must be used as carrier gas in certain applications such as Mass Spec units & TCD.
Carrier* Length Bore

Manual N2 or He 30 320
Type 1 EFC N2 or He 30 320
Type 4 EFC (GSV) N2 or He 30 320
1.5.11 Edit Valves (see labels & flow diagram) (see diagram)
1.5.12 Save & Exit
1.6 1077/1079 INJECTORS
1.6.1 Press Injector key to get to menu (see diagram)

1.6.2 Select Injector
1.6.3 Set temperature to 50° C
1.6.4 Page down & turn oven to ON
1.6.5 Page down & turn Split state to ON
1.6.6 Perform steps 1.6.1-1.6.5 for all 1077/1079 Injectors
1.7 1041/60/61 INJECTORS
1.7.1 Press Injector key to get to menu

1.7.2 Select Injector
1.7.3 Set temperature to 50° C
1.7.4 Set oven power to ON
DOC: 03-925880-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 4 of 7
2
1.7.5 For 1060, install Glass Insert 37-000813-00 in Burn-In. For 1061 install Glass Insert 03-918339-00 in Burn-In.
1.7.6 Remove & replace septum with aluminum seal.
1.7.7 Perform steps 1.7.1-1.7.6 for each 1041/60/61 injector.
1.8 DETECTORS
1.8.1 Press Detector key to get to menu.

1.8.2 Select Detector.
1.8.3 Turn On Detector oven.
1.8.4 Set temp. to 50° C.
1.8.5 Perform steps 1.8.1-1.8.4 for each detector.
1.9 FLOW/PRESSURE
1.9.1 Press Flow/Pressure key to get to menu (see diagram).

1.9.2 Set Pressure or Flow:
TYPE PRESSURE FLOW
Saturn 10 PSI
Manual 10 PSI 30-40mL/min
Type 1,5,21,25 EFC 10 PSI
Type 3,23 EFC 25mL/min
Type 4,24 EFC 25 PSI
1.9.3 For 1079 Injectors:
a. Adjust Sport Valve Flow to 5-10 mL/min.

b.) Verify flow coming from test column is 30-100 mL/min.
c. Measure flow at EFC Vent tube, should be ≈ to Total Flow + Flow @ Sport Valve ± 10%.
d. Press Activate key then Activate Now, (instrument must be in Ready State to Activate).
e. If the above conditions are not met, determine cause and correct.
f. Remove injector nut and Septum & install bake out nut and seal, T-8941.
DOC: 03-925880-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 5 of 7
2
1.10 DETECTOR EFC Flow rate check
1.10.1 Turn on all gas supplies

1.10.2 Plug all other detector inlets (top)
1.10.3 Press “Detector” key to get to the Detector Menu
1.10.4 For each detector:
* Select Detector
* Go to the “adjustments” page (2)
* Set the individual channel flows to 0
* Unplug the Detector Base (@ the column end), attach a flowmeter
* Turn on the gas
* For each channel of each Detector, verify that the flow measured is within the below listed specs:
Flow (cc/min)
Detector Type Channel Gas Min/Max Range
FID 1 He 45/55 Ref. + 10% full scale

2 H 2 45/55 II
3 Air 450/550 II
TSD 1 He 45/55 II
2 H 2 5.4/6.6 II
3 Air2 180/220 II
CONTINUE
DOC: 03-925880-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 6 of 7
2
Flow (cc/min)
Detector Type Channel Gas Min/Max Range
ECD 1 He 90/110 Ref. + 10% full scale
TCD 1 He 45/55 II
2 He 90/110 II
PFPD 1 Air 45/55 II

2 He 27/33 II
3 Air 27/33 II
TCD (H2) 1 H 2 45/55 II

2 H 2 90/110 II
* Unplug the Detector Base (@ the column end), attach a flowmeter

* Turn on the gas
1.11 ENTER TEMPS FOR INJECTORS, DETECTORS & COLUMN OVEN
INJECTORS & DETECTORS TEMPERATURE INJECTORS & DETECTORS TEMPERATURE

1079 INJECTOR 325° C TSD DETECTOR 360° C
1060 INJECTOR 420° C TCD DETECTOR 125° C
1061 INJECTOR 420° C PFPD DETECTOR 400° C
1041 INJECTOR 420° C COLUMN OVEN 350° C (Unless Specified

Otherwise)
(Increments of 10°C
1077 INJECTOR 325° C at a time, 50,60...) VALVE OVEN SEE S/O & LABELS
FID DETECTOR 360° C SPT W/VALVE SEE TRAP FOR SPEC
ECD DETECTOR 400° C METHANIZER 420° C
DOC: 03-925880-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 7 of 7
2
1.5.7 1.5.8 1.5.9
1.5.10 1.5.11 1.6.1
1.9.1
DOC: 03-925880-00 REV
CHG PARTS
HISTORY
TOOLS
PAGE: 8 of 7
2

3800

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

3800

Uploaded by

Copyright:

Available Formats

Maneuvering the Assembly Documentation

1. Select your bookmark of

3. Navigate through the

TEE (SEE NEXT PAGE)

ADAPTER (SEE NEXT PAGE)

SCHEMATIC OF MICRO-TCD WITH ADAPTOR REFERENCE

MICRO-TCD CELL (REF.) INJECTOR (REF.)

DETAIL “A” DETAIL “B”

SEE DETAIL “B”

REFERENCE COLUMN (CP-735732) SEE DETAIL “B”

ANALYTICAL COLUMN (CP-7758)

1. ENSURE GC OVEN INSULATION IS CAREFULLY WRAPPED UNDER AND

2. FEED HEATER AND PROBE TO LOCATION ON PWA’S

3. INSTALL MICRO-TCD PWA BOARD (03-925904-01) AND SECURE. ROUTE FLAT,

HEATER CONNECTOR ZONE

PROBE CONNECTOR ZONE

DETECTOR EFC LEAK TEST PROCEDURE

ASSY, COLUMN OVEN CRYOGENICS, (CO2)

CRYO VALVE BRACKET (REF.)

COLUMN OVEN 12-901163-00, 2 PLCS

ASSY, COLUMN OVEN CRYOGENICS (LN2 VERSION)

28-691979-00 1 OUTLET TUBING (REF.)

FOR REFERENCE ONLY

1 INSTALL TEFLON PIPE TAPE (88-189669-00) FITTING THREADS PRIOR TO INSTALLATION.

BULK ISSUE ITEMS (03-925515-XX)

3 INJECTORS 2 INJECTORS 1 INJECTOR NO INJECTOR

LN2 OVEN CRYO

88-494510-00, 5” LG 12-901163-00, 2 PLCS

VALVE ARRANGEMENT (REF.)

ASSY, 1177 MANUAL AND TYPE 5 EFC INSTALLATION

CARRIER IN - FROM EFC CARRIER

1177 INJECTOR SPARE

SPLIT VENT SPARE

INJECTOR SIDE MANIFOLD PLUMBING

ASSY, 1177 EFC INJECTOR INSTALLATION

3800 TWIN 8200 A/S

NOTE: DETECTORS MOUNTED IN LOCATION

INJ. POSITION 1 & 3

1177 INJECTOR PRESS. SENSE EFC TYPE 1

SPLIT VENT SPARE

INJECTOR SIDE MANIFOLD PLUMBING

TCD (H2) EFC INSTALLATION

INLET MANIFOLD SUBASSEMBLY

INLET MANIFOLD INSTALLATION

NOT USE (REF.)

NOT USE (REF.)

2 MOVE MODULE LOCATION JUMPER TO SPECIFY FRONT, MIDDLE, OR REAR.

3. ADD CABLE HOLDER WHEN NO REAR MODULE PRESENT.

NOTE MOUNTING LOCATION

ADDITIONAL MODULE CABLEING (IF REQ’D)

NOTE CABLE SERVICE

REFERENCE LINE FROM NOTES:

MAKEUP LINE TO MODULE,

CONNECTION TO TCD PWA

TCD PWA INSTALLATION

TCD DETECTOR LOCATION

1. TCD (4) IS FRONT

TCD WITH ONE OTHER

PFPD EFC INSTALLATION

NOTE: INSTALL FOR

INLET MANIFOLD SUBASSEMBLY

INLET MANIFOLD INSTALLATION

NOT USED (REF.)

NOT USED (REF.)