7
Clean or Replace Bypass Poppet
1. Disconnect pump from power and flush.
2. Remove the bypass poppet plug.
3. Remove the bypass poppet. Gently rock it back and forth
as necessary to remove.
4. Wipe the cavity clean and wash the bypass poppet in very
pure deionized water.
5. Examine all components and replace as necessary.
6. To replace the poppet O-ring, carefully remove the O-ring
using a small screwdriver or similar tool. Seat O-ring on
the poppet head.
7. Assemble by placing the bypass poppet assembly in the
cavity. Tighten the plug firmly.
Replace Motor
1. Disconnect pump from power and flush.
2. Remove the screws holding the motor and handle to the
housing.
3. Lift the motor from the housing and drive shaft.
4. Remove the motor shaft adapter from the drive shaft.
5. If replacing the motor only, remove the power cord using
instructions below.
6. Assemble by reversing the steps above. Make sure the
motor is properly seated against the motor adapter seal.
Torque the four screws to 75 to 100 in-lbs.
Replace Switch
1. Disconnect pump from power and flush.
2. Remove the switch coverplate on the side of the motor.
3. Press in on the sides of the switch. Push the switch from
the switch box.
NOTE: Before disconnecting wires, note their positions on the
switch. Connect to the new switch in the same positions.
4. Disconnect the terminal wires from the back of the old
switch.
5. Install the new switch by reversing steps above. Carefully
position wires in switch box before replacing coverplate.
6. Install coverplate and tighten screws until snug. Do not
overtighten.
Replace Power Cord
1. Disconnect pump from power and flush.
2. Remove the switch coverplate on the side of the motor.
3. Remove electrical tape and unscrew the wire nut. Remove
wire from terminal on back of the switch.
4. Remove the old power cord.
5. Install new power cord by reversing steps above.
6. Secure wire nut with two wraps of electrical tape.
7. Install coverplate and tighten screws until snug. Do not
overtighten.
Replace the Drive Shaft or Motor Shaft Seal
Follow these steps to remove the drive shaft and motor
shaft seal.
1. Disconnect pump from power and flush.
2. Remove the motor as described above.
3. Carefully slide the drive shaft from the motor and the hous-
ing. Note the position of the motor shaft washer.
4. Carefully pry the motor shaft seal from the housing with a
flat-bladed screwdriver.
5. Inspect the drive shaft, motor shaft washer, motor shaft
seal, and bearings for wear. Replace, as necessary.
Follow these steps to install the drive shaft and motor
shaft seal.
1. Press the new motor shaft seal into the housing with the
same orientation as the old seal.
2. Position the motor shaft washer on the seal. Slide the
notched end of the drive shaft into place in the housing.
3. Align the drive shaft with the motor adapter or the planetary
gear module. When properly aligned, the drive shaft will
slip into place with the motor against the housing.
4. During assembly, make sure the motor is properly seated
against the motor adapter seal and the housing.
5. Replace the screws fastening the motor and handle to the
housing. Use the two longer screws to secure the handle.
Torque to 75 to 100 in-lbs.
Replace Gears or Drive Key
Follow these steps to remove the gears and drive key.
1. Disconnect pump from power and flush thoroughly.
2. Remove the coverplate and O-ring from the housing.
3. Remove the drive key and gears from the housing.
4. Inspect gears and key for wear or damage. Replace, as
necessary. Clean cavity.
Follow the steps below to install gears and drive key.
1. Place a gear over the drive shaft.
2. Align the slotted drive shaft end with the gear.
3. Place the other gear in the housing. Turn the gears to make
sure they do not bind. Carefully place the key in the slot.
4. Replace the O-ring and coverplate. Torque screws to 25
to 35 in-lbs.
