1998 s10e fan buffer

-- Beata Collection --







1998 S-10-E Electric Truck


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EV1 System 110 Inverter

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The first two pictures below show a custom jump-wire modification
that we discovered in the S10Es buffer wiring harness.  This
harness controls the radiator cooling fan.  The 
modification/jump-wire is an indication of a failed fan
buffer assembly.

The assembly is, of course, unobtainium, and has PNs =
(on wire = 711) - (on buffer =  27003265 717_) - ( on wire = 712)

Unfortunately this is a typical failure and the only option is to de-epoxy
the assembly, dianose its failure and repair the original part.

The following are a few pictures of this projects progress.  More
pictures to follow as progress is made.  c2009.01



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--->  Additional pictures below  <---


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S10E

S10E Equilization Charge

S10E Fan Buffer

S10E 'A' Piller Gauges

S10E DTC-279

S10E DTC-104

S10E Library

This shows the unit as found after purchasing the S10E c2007

Note the lower right corner of the unit. It shows an unusual indentation which was later found to be the area of an over-temp failure event

Our initial attempt was to chip away at the epoxy base but we quickly learned that this would not yield acceptable results. We later came across a process to soften the epoxy and successfully cleared the PCB for repair. This process took nearly a week of soaking, removing material, and repeated sessions. Painful but necessary and eventually worth the results seen below.

Top view. Here is the basic board at the final stage of epoxy removal. In this picture the board is missing a number of parts that were removed for replacement

Bottom view

Although difficult to see, note the resistor scales added to this document

On reassembly and testing, we added a good sized aluminum heat sink & ceramic to the original design in hopes of saving it from the previous parts fate.