16
Performance Series 450e
GB
Repairs at the unit
15. Guide piston (3) through the lower packings (9) into the
pump manifold (2) from below. Using a rubber mallet,
lightly tap the piston (3) from below until it can be seen
above the pump manifold.
16. Remove installation tool from piston (3).
17. Carefully tighten retainer nut (6) with adjusting wrench.
18. Slide the top of the piston (3) into the T-slot (10) on the
slider assembly (4).
19. Position the pump manifold (2) underneath the gear unit
housing and push up until it rests against the gear unit
housing.
20. Attach pump manifold (2) to the gear unit housing. Ensure
that the pressure sensor does not damage the pressure
sensor seal (10).
21. Screw pump manifold (2) tightly to gear unit housing.
22. Lubricate O-ring (Fig. 9, Item 6) between pump manifold
(2) and inlet valve housing with machine grease. Screw
inlet valve housing to the pump manifold.
23. Push connection bend of suction hose into the inlet valve
housing (Fig. 9, Item 1) and secure with retaining clip.
Screw on return hose and clamp to suction hose.
24. Install front cover.
11.4 Replacing the motor assembly
1. Open the relief valve, valve position PRIME (
k
circulation), switch the unit OFF, and unplug the power
cord.
2. Remove the four motor cover screws (Fig. 14, Item 1).
Remove the motor cover (2).
3. Remove the four heat sink assembly screws (3). Pull the
heat sink assembly (4) away from the gear box housing
(5).
4. Disconnect the five wires from the relay (6) that is
mounted on the inside of the heat sink assembly.
5. Connect the five wires to the new relay (refer to the
electrical schematic in section 11.8 of this manual).
6. Using the four heat sink assembly screws (3), install the
heat sink assembly (4) onto the gear box housing (5).
Tighten the screws securely.
7. Disconnect the black and red wires coming from the gear
box housing. Disconnect the black and red wires from the
capacitors (8). Disconnect the black and red wires from
the motor (9).
8. Loosen and remove the four motor mounting screws (10).
9. Pull the motor out of the gear box housing.
i
If the motor will not dislodge from the pump
housing:
• Remove the front cover plate.
• Using a rubber mallet, carefully tap on the
front of the motor crankshaft that extends
through the slider assembly.
10. With the motor removed, inspect the gears in the gear
box housing for damage or excessive wear. Replace the
gears, if necessary.
11. Install the new motor into the gear box housing.
i
Rotate the motor fan manually until the armature
gear engages with the mating gear in the gear
box housing.
12. Secure the motor (9)with the four motor mounting screws
(10).
13. Push the new capacitors into their clip (8) on the new
motor.
14. Reconnect the wires (refer to the electrical schematic in
the section 11.8 of this manual).
15. Slide the motor cover (2) over the motor. Secure the
motor cover with the four motor cover screws (1).
1
2
3
4
6
10
5
9
8
11.5 Carbon brushes in motor
1. Remove the four screws (Fig. 15, Item 1) at the motor
cover (2). Remove motor cover.
2. Remove the two screws (3) at the shells (4). Remove
shells.
3. Lift up both covers (5) with a small screwdriver.
4. Pull red wire (6) and black wire (7) out of the respective
carbon brush.
5. Insert new carbon brush and snap cover (5) into place.
6. Insert red wire (6) and black wire (7) onto the respective
carbon brush.
7. Screw down both shells (4).
8. Push motor cover (2) over the motor and fasten with the
four screws (1).
1
2
3
7
4
5
6
