82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Manual 0-2984
MIJIT 1000
Wire Harness Replacement Kit
Catalog # 831058
Installation Instructions
General Information
This field installable repair kit is intended to replace a
damaged or defective Mijit 1000 wire harness. This is a
directly connected type of wire harness as featured in the
latter model Mijit 1000's or in older units that have been
upgraded from the 19-pin amphenol socket / printed
circuit board type of wire harness.
Refer to catalog number 870538 for the upgrade kit that
changes the amphenol socket / printed circuit board type of
wire harness into a directly connected type of wire harness.
Recommended Tools
(Note: wrench and socket sizes may vary.)
• Medium size flat-blade screwdriver
• Medium size Phillips screwdriver
• 1/4, 11-32, 3/8, 9/16-inch nutdrivers or sockets
• Ratchet wrench
• Slip-joint or channel-lock pliers
Supplied Parts
The following components are included in this kit:
Item # Description Qty Part Number
1 Wire Harness Assembly 1 870513
2 Locknut, steel, 1-inch 1 870467-100
not shown Wire Ties 4
not shown Instruction Manual 1 300x2984
1
Art # A-04564
2
Figure 1: Supplied Parts
© 2005 by Thermadyne Corp.,
March 18, 2005 1 Manual 0-2984
Installation Procedure
:
4
0
9
4
4
6
CAUTION
B. Remove Old Wire Harness
1. Remove the compression fitting nut from the outside of the wire harness. Refer to Figure 3.
Only a qualified technician should perform this procedure. Disconnect all input lines.
A. Dis-assemble The Enclosure
1. Turn the power source and MIJIT 1000 power
switches OFF. Disconnect all input lines. Unlatch
the outside cover and lay the MIJIT 1000 on its
side.
2. Remove the wire spool hub by removing the wire
spool hub nut and hub tension bolt with a
9/16-inch socket. Refer to Figure 2 for location.
3. Remove the 5 screws (A - E) shown in Figure 2 to
detach the sheet metal door panels.
Wire Spool
Hub Nut
A
C
B
Compression Fitting Nut
Art # A-04560
Figure 3: Remove the Compression Fitting Nut
2. Remove (and eventually discard) the 1-inch locknut from the compression fitting where enters the
case. Refer to Figure 4.
Plastic compression fitting
6
4
4
9
0
4
F
G
DE
:
Art # A-04543
Hub Tension Bolt
Sheet Metal Door Panels
Figure 2: Panel Screw And Hub Locations
4. Remove the 2 screws (F - G) shown in Figure 2 to
detach the wire harness entry hole cover panel.
5. Remove panels and hardware and set aside for
re-assembly.
Art # A-04558
Figure 4: Remove Locknut From Compression
Fitting
March 18, 2005 2 Manual 0-2984
3. Remove chassis grounding stud nut and brass
washer using 11/32-inch nut driver or socket and
ratchet and set aside for re-assembly. Pull the greenyellow wire with the ring-lug terminal off the
grounding stud. Refer to Figure 5.
4. Disconnect the two insulated quick-connectors
from the F1 fuse located behind the fuse panel.
Refer to Figure 6.
Chassis Grounding Stud Nut
Art # A-04545
Green-Yellow Wire With Ring-Lug Terminal
Figure 5: Remove Chassis Grounding Stud Nut
And Green-Yellow Wire
F1 Fuse located behind panel here
Art # A-04546
Upper Fuse Connector Lower Fuse Connector
Figure 6: Disconnect The Two F1 Fuse Wires
March 18, 2005 3 Manual 0-2984
5. Disconnect the white 15-pin Molex J2 connector
from the motor control board. Refer to Figure 7.
7. Pull the Molex connector around the back of the
vertical frame member at its base. Refer to Figure 9.
Art # A-04547
J2 Connector
Motor Control
Board
Figure 7: Disconnect Molex Connector From Motor
Control Board.
6. Pull the Molex connector down along the right side
of the vertical frame down to the base of the
enclosure. Clip and remove wire ties as necessary.
Refer to Figure 8.
Art # A-04566
Wire Harness
J2 Molex Connector
Vertical Frame Base
Figure 9: Wire Harness Pulled Around Bottom Of
Vertical Frame Frame
8. Carefully compress the J2 Molex connector and its
wires and pass it through the 1-inch locknut. Pull
the two loose wires through the locknut as well.
Refer to Figure 10.
CAUTION
The white 15 position Molex J2 connector and/or
the insulated quick connectors may catch on and
potentially damage components in the machine
when removing the wire harness.
Art # A-04565
J2 Socket
1-inch Locknut
Art # A-04551
Figure 10: Pass Molex Connector And Wires
Through Locknut
Figure 8: Pull Wire Harness Down Along Vertical
Frame
March 18, 2005 4 Manual 0-2984
9. Carefully compress the J2 Molex connector and its
wires and pass it through the wire harness entry
hole. Pull the two loose wires through the hole as
well. Refer to Figure 11.
J2 Molex Connector
C. Route The New Wire Harness Into The Case
Follow the removal procedure in reverse.
1. Carefully compress the J2 Molex connector and its
wires and pass it through the wire harness entry
hole. Pull the two loose wires through the hole as
well. Refer to Figure 11.
2. Carefully compress the J2 Molex connector and its
wires and pass it through the NEW 1-inch locknut. Pull the two loose wires through the locknut
as well. Refer to Figure 10.
CAUTION
Do not re-use the old 1-inch locknut.
3. Lead the Molex connector around the back of the
vertical frame member at its base. Note the
position of the locknut. Refer to Figure 12.
Art # A-04550
Figure 11: Pass Molex Connector And Wires
Through Hole
10. Carefully remove the old wire harness from the
machine.
Locknut J2 Molex Connector
Wire Harness
Art # A-04552
Vertical Frame Base
Figure 12: Wire Harness Routed Around Bottom
Of Vertical Frame
March 18, 2005 5 Manual 0-2984
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