Service Manual — Gordak 952

Gordak 952 Service Manual: Comprehensive Maintenance & Repair Guide

The Gordak 952 Service Manual is a critical technical resource for engineers and technicians tasked with the upkeep of this dual-function SMD rework station. Whether you are dealing with a faulty heating element or a complete power failure, understanding the internal schematics and maintenance procedures is essential for safe operation. Overview of the Gordak 952 Rework Station

The Gordak 952 is a versatile soldering and desoldering tool featuring both a hot air gun and a soldering iron.

Dual Functionality: Includes a thermostat-controlled soldering iron and a diaphragm-pump-driven hot air gun.

Safety Features: Anti-static handle materials and a delayed automatic cooling system for the hot air gun to protect the heating element.

Technical Design: Utilizes a diaphragm air pump for stable, high-pressure airflow. Core Technical Specifications & Manual Contents

According to technical documentation found on platforms like Scribd and Elektrotanya, the service manual typically includes: Gordak 952 Service Manual

System Descriptions: In-depth explanations of the electronic control circuits.

Circuit Diagrams: Full schematics showing connections between resistors, capacitors, and ICs like operational amplifiers and triac drivers.

Part Names & Functions: Detailed identification of all internal and external components. Common Maintenance & Repair Procedures

Maintaining the Gordak 952 involves regular checks and occasional part replacements to ensure longevity.

Heating Element Replacement: If the unit blows air but fails to heat, the heating material may be compromised. To replace it, unscrew the handle, release the internal screws, and disconnect the old element from its termination before inserting a genuine replacement.

Fixing Power Problems: A common design quirk in the Gordak 952 is that the transformer remains active even when the front switches are off. Technicians often modify the unit by adding a dedicated primary power switch to fully disconnect it from the mains when not in use. Troubleshooting Failure to Start: Check the 5V supply to the microcontroller. Verify the +/- supplies on the operational amplifiers. Failure 2: Hot Air Heats Continuously (No Regulation)

Inspect the fuse holder; some users recommend upgrading to a more robust holder with a 3A–5A fuse for better reliability. Safety Warnings

Working on a rework station involves high voltages and temperatures.

Unplug Before Service: Always disconnect the power plug before opening the chassis.

Cool Down Period: Wait until the soldering iron or hot air gun has cooled to room temperature before attempting to replace tips or elements.

Flammable Materials: Never use the station near flammable substances, and always place the iron in its anti-static stand. Where to Download the Manual

You can find PDF versions of the Gordak 952 manual and schematic diagrams at several community repositories: Gordak 952 Service Manual Symptoms: Element glows red, plastic melts, but fan runs

Failure 2: Hot Air Heats Continuously (No Regulation)

Symptoms: Element glows red, plastic melts, but fan runs.
Cause: Shorted Triac (BT136) or dead optocoupler (MOC3021).
Test: Power off. Use multimeter in diode mode between A1/A2 of triac. A short means replace.
Service manual reference: Page 12 – Triac snubber circuit (R+C) may also crack.

Part 7: Where to Find Replacement Parts

Using your service manual’s bill of materials (BOM), order from these suppliers:

Triac: BT136-600E (replace with BTA16 for higher durability).
Optocoupler: MOC3021 (non-zero-crossing type – critical).
Air pump membrane: Generic 24V diaphragm pump (size 55x45mm).
Heating element (air): 220V 700W ceramic core (length 52mm, OD 14mm).
Soldering iron heater: A1321 4-wire type (not A1322).

Avoid universal "Gordak 952 repair kits" on AliExpress – they often mismatch voltage.

Failure 3: Soldering Iron Stays Cold

Causes:
- Broken heater element (24V). Resistance should be 12-15 ohms; infinite ohms = broken.
- Broken reed relay (on main PCB) that switches between iron/hot air.
Fix: Replace heating element ($3 part) or resolder relay joints.

Where to Buy Replacement Parts (Referenced by Manual)

The Gordak 952 Service Manual includes a parts list. Here is the modern cross-reference:

Heating Element (Hot Air): "850 Hot air heater" or "Gordak 952 heating core" (usually 220V/500W).
Thermal Fuse: "184°C thermal cutoff" (Must be exactly 184°C, not 200°C).
Fan Motor: "24V Brushless blower 5015" (50x50x15mm).
Soldering Iron Handle: "936 Handle with 5-pin aviation connector".
TRIAC: BT136-600E or BT139-600.
Op-Amp: LM324N (Standard DIP-14 package).

The Ultimate Guide to the Gordak 952: Finding the Service Manual & Schematics

If you work with electronics, specifically soldering stations or hot air rework stations, you know the feeling: a piece of reliable equipment starts acting up, and you can't find the documentation to fix it. For many technicians, the Gordak 952 is a workhorse, but finding a legitimate, readable Gordak 952 Service Manual can feel like searching for a needle in a haystack.

In this post, we’re diving into the Gordak 952. We’ll discuss what this machine is, why the service manual is so hard to find, and what you need to look for when troubleshooting common issues.

Step 4: Check the Op-Amps (IC1/LM324)

The manual’s schematic will label pins.

Pin 3 (Non-inverting): Reference voltage (approx 2.5V from a Zener diode).
Pin 2 (Inverting): Voltage from the thermocouple amplifier. If Pin 3 is missing voltage, the Zener (ZD1) is shorted. If Pin 2 is stuck at 0V, the thermocouple is broken.

Part 1: Gordak 952 Technical Specifications (For Reference)

Before troubleshooting, you must know the baseline specs found in the service manual:

Soldering Iron: 24V AC, 50W (Heater resistance: ~12-15 ohms)
Hot Air Gun: 220V / 110V AC, 700W (Heating element resistance: 50-70 ohms)
Air Pump (Diaphragm): 24V DC, 0.5A (Internal transformer tap)
Temperature Range (Air): 100°C – 480°C (212°F – 896°F)
Airflow: 120 L/min (Max)
Control IC: Typically LM324 (Op-amp) + Dual Triac (BT136/BT138)
Display: Dual LED (Set vs. Actual)