Step 3: Thermal Fuse Replacement

Once the thermal fuse has been determined to be the cause, here we go...

Removing the Thermal Fuse:

Disconnect power to the fan before proceeding.

1. To make fuse replacement easier, we need to free the motor from the control unit keeping its wiring harness as long as possible. The harness has 5 wires going into the motor housing. By tracing this harness, starting from the motor housing, I found the Ground (green/yellow) and Neutral (blue) wires ending at a terminal block and another three (grey, orange, red) ending at the speed selector.

2. Remove the Ground and Neutral wire (no cutting required) from the terminal block. De-solder  the grey, orange and red wires at the speed selector, note their location first. (You may have noticed that I cut the whole harness about 10cm from the motor…big mistake...but that was way before I decided to do this!!)

3. Using a flat tip screw driver as a lever, pry the motor housing mount rod away from the control unit.

4. Remove the oscillating unit and detach the capacitor.

5. Remove the metal housing screws. Carefully remove the rotor and the windings slowly by giving it enough slack from the harness.
6. The windings are tied by strings and coated with some kind of lacquer. We need to cut some of them (see the “X” points in the picture) using pen-knife or sharp tip scissors. Look for a bulge (where the fuse is) and notice where it ends.

7. Carefully slice open the black sheath cover to expose the brown woven sheaths, also tied with strings.

8. Trace the blue Neutral wire from the harness towards the windings. You will notice it ended inside the biggest sheath which is on top. This is our target. Cut the strings tying this sheath.

9. This big sheath, which is flattened, holds the fuse and another sheathed wire. Use fingers to lift it and press on its sides to form back its tubular shape. 

10. With wriggle, press and pull action, slowly remove this sheath and the thermal fuse will be exposed. Put the removed sheath aside to be reused later.

11. Notice that one of the fuse’s leads is also sheathed to prevent electrical contact. Slice the SIDE of this sheath lengthwise about 10mm. Expose the lead through this cut.

12. With both leads exposed, cut them off as close to the fuse as possible. This will give us enough room to solder the new fuse.

13. Trim the leads of the new fuse to about 10mm and tin them with solder.

14. Solder the new fuse, polarity is not important but you may follow the old fuse direction.

15. Move the cut sleeve to cover back the lead exposed in step #11above.

16. Cover the fuse and its accompanying wire with the big sheath removed in step #10 above.

17. String the new fuse assembly to the windings as neat as you can. Fold back the black cover and string again. Ensure no string or black cover sheath is protruding into the rotor area.

18. Carefully place back the windings and rotor into the motor housing.

19. Secure the housing and mount back the oscillator and the capacitor.

20. Insert the motor housing mount rod to the control unit, a little pressure is needed here.

21. Dress back the wiring harness and reconnect the Ground and Neutral wires to the terminal block. (For me, I had to solder back all the wires and insulate them with heat shrinking tubes. I also had to de-activate the oscillator to prevent them from rubbing against each other)

23. Re-solder the grey, orange and red wires back to the speed selector.

24. Power on the fan to test. Cover back the control unit and you are done.

<p>I have a panasonic table fan.i want to change the bearing of the motor but when i remove the motor i didnt realize there is a connector attached at the coil winding.the connector pulled off from the coil winding.Is there any way to solder them back or dispose the fan? </p>
I have problem, i had a bajaj table fan., fan wings are made of fibre those were broken last time because it fell down from a table, afer that i cuecked with the electrician he told also want to change the capacitor since it's not pushing to rotate, but my issue is wings are breaking all of a sudden during rotation., wat is the reason for this...?
<p>I have a weird problem with my fan. Its panasonic's . There are no problems with the 3A fuse, the capacitor nor the grease. So i thought that maybe the circuit is out so I decided to run this stupid test. I turned the fan on, and touched the fan directly( to check whether there is any flow of current) since i dont have a test pen thaha. So i got shocked by the current! The current is present! SO WHATS THE PROBLEM HERE??? PLEASE HELP!</p>
Any idea on standing fans, that is able to spin briefly for approximately 2 secs and just stops. I have accumulated 3 fans of different makes and brand. They have the same trouble too! Tried replacing the capacitor which doesn't see any improvement. Also tried to short the thermal fuse contact that don't help.
<p>The grease applied to the spindle gets hard by heat and time. Soften it by spraying anti rust oil, scape it, and replace it with soft heat resisting grease.</p><p>Good luck</p>
<p>see if the gear of the fan is not align</p>
<p>i have a problem with the speed of my fan, how can i increase its speed...?</p><p>tri-staterepairs</p>
<p>repalce its capacitor</p>
This instructables program help me so much. I don't have to go every now and then to repair shop.
Great instructable! Without fans the air in my house gets stagnant so I have a fan just like this in every room. Unfortunately two of them are broken and I called someone that does <a href="http://303carefree.com/Services.html" rel="nofollow">electrical repair in Centennial CO</a> to see if it would be cheaper to repair them or just buy new ones. Turns out I was going to buy new ones but I think I'll try this. Might as well, thanks for sharing!
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