hydraulic pump replacement service instruction

Hydraulic Pump Replacement Service Instruction

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Endless Pools D90006 0616

Section 1: Parts List

Qty Description 1 Replacement Hydraulic Pump

1 Pump Puller Fitting, Large

1 Pump Puller Fitting, Small

1 High-Pressure Hose Fitting

1 Pick-Up Tube Assembly

2 Pump Mounting Bolts

2 Pump Mounting Bolts Washers

2 Pump Mounting Bolts Lock Washers

1 Service Instruction

Section 2: Additional Considerations

Use extreme caution when working in and around the hydraulic power unit. The

unit is heavy. Improperly supporting the unit can cause instability which could

result in bodily injury.

Be sure to disconnect electrical service to the hydraulic pump unit and water

quality system (WQS). Accidental activation of the hydraulic pump during

servicing would result in the loss of hydraulic fluid requiring extensive clean up

and could also promote a chance for bodily harm. Accidental activation of the

WQS without adequate water in the pool can cause the pump motor to burn out.

Section 3: Hydraulic Pump Replacement Instructions 1. Before performing this replacement, turn off the electrical power to the pool equipment.

2. Unthread the four 3/8” reservoir mounting bolts.

3. Place a one gallon paint can (or similar object adjacent to the power unit. If an alternative to the paint can

is being used, it must be able to support the weight of the motor assembly. Tilt the power unit motor

assembly up onto its edge. The reservoir lid should rest on the reservoir. Take care not to damage the

reservoir gasket. The motor assembly must be tilted in this position to protect the float level switch.

WARNING

CAUTION


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4. Unthread the internal high-pressure hose from the hydraulic pump. Hydraulic fluid will escape from the

hose; let it drain into the reservoir before continuing.

5. Disconnect the hydraulic hose fitting from the hydraulic pump. This component will not be re-used. A

new fitting has been provided with the new hydraulic pump.

6. Unthread the compression nut on the pick-up tube and remove the pipe and compression nut assembly.

These components will not be re-used. New components have been provided with the new hydraulic

pump.


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7. Loosen the lock nut on the pick-up tube elbow and then unthread the elbow from the hydraulic pump.

These components will not be re-used. New components have been provided with the new hydraulic

pump.

8. Using a 5/16” Allen key, unthread the hydraulic pump mounting bolts. These components will not be re-

used. New components have been provided with the new hydraulic pump.

9. Attempt to pull the pump off of the motor. If the pump can easily be removed, skip to step 13. If the

pump cannot be easily removed, then go to the next step.

10. Two pump puller fittings have been provided with the replacement pump. Unthread the bolt from each

fitting. Thread each of the pump puller fittings into the hydraulic pump. When the bolts are threaded

back into the fittings, they should sit firmly against the underside of the reservoir lid and NOT the motor.

Align the pump puller fittings with the underside of the reservoir lid as best as possible.


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11. Thread the bolts back into the pump puller fittings. Again, the bolts should be resting firmly against the

underside of the reservoir lid. If the bolt is seated attains the motor, then unthread the bolt and loosen the

pump puller fitting.

12. Take note of the pump’s position as the replacement pump must go back in the same position. Alternate

tightening each bolt equal amounts until the pump disengages from the power unit motor. The pump

puller bolts MUST be tightened at an equal rate. Tightening one of the bolts too much will cause

the pump shaft and the motor shaft to bind, locking the motor in place.

13. Install the new pump. The pump shaft key will align with the notch in the hollow shaft of the power unit

motor.


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14. Push the pump into place. Make sure that it is in the correct position. Install the new pump mounting

hardware.

15. Thread the new high-pressure hose fitting into the new pump. Tighten the fitting with a wrench until it is

just tight, and then tighten an additional 15º-30º (1/4-1/2 flats from wrench resistance).

16. First install the new pick-up tube fitting into the pump.


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17. Next, thread in the new pick-up tube elbow assembly onto the new pump. The elbow should be at a 45º

angle to the pump. Once the elbow is in the correct position, tighten the lock nut with a wrench it is just

tight; then tighten the fitting an additional 15º-30º (1/4-1/2 flats from wrench resistance).

18. Thread the internal high-pressure hose onto the hydraulic pump hose fitting. Tighten the hose fitting with

a wrench until just tight, and then tighten an additional 90º (1-1/2 flats from wrench resistance).

19. Carefully rest the power unit motor assembly back onto the reservoir. Make sure that the reservoir is not

damaged and is in place. Re-install the reservoir lid mounting bolts.

hydraulic pump replacement service instruction

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