INSTRUCTIONS PUMP MOTOR REPLACEMENT KIT PART #69907 COPYRIGHT 998 BY ISCO, INC. P.O. Box 85 Lincoln, NE U.S.A. 6850 PHONE: (800) 8-47 FAX: (40) 465-0 Outside the U.S.A. call (40) 464-0 ISSUED: June 998
900/90 Pump Motor Replacement Kit This instruction sheet will explain how to remove your old pump motor and how to install the replacement. EQUIPMENT NEEDED # Phillips screwdriver # Phillips screwdriver /4 and /8" straight blade screwdrivers /" nut driver or socket /8" open or box-end wrench Wire cutter Wire crimper /4" nut driver. Using the # Phillips screwdriver, remove the ten screws that hold the control panel on the control box (Figure ). Figure Removing the control panel REMOVING THE PUMP ASSEMBLY WARNING REMOVE ALL POWER FROM THE UNIT.. Remove the outer pump housing and pump tube (Figure ). Figure Removing the outer pump housing 4. Disconnect the long connector on the control panel. To prevent damage to the wiring harness, it is important that you grasp the connector instead of the wires while pulling. 5. Remove desiccant bag and place in a sealed bag. The desiccant bag will be reused when the controller is reassembled. 6. Remove the three desiccant tray screws using the # Phillips screwdriver and remove the tray from the unit (Figure 4).. Using /8" wrench and a # Phillips screwdriver, remove the screw that holds the pump rollers on, then remove the rollers (Figure ). Figure Removing the pump rollers Figure 4 Removing the desiccant tray
900/90 Pump Motor Replacement Kit 7. (900 Models Only) If the controller is still mounted on the center section, remove the distributor arm retaining nut and the distributor arm (Figure 5). Figure 5 Removing the 900 distributor arm Figure 7 Removing the distributor assembly() Figure 8 Removing the distributor assembly() Distributor Arm Retaining Nut 8. Remove the three standoffs and disconnect the three connectors with /4" nut driver. Lift the circuit board from the control box (Figure 6). Figure 6 Removing the circuit board 0. Next, remove the four screws using the # Phillips screwdriver that holds the inner pump housing on the unit (Figure 9). This will allow the pump assembly to be removed from the unit (Figure 0). Figure 9 Removing the inner pump housing 4 Figure 0 Removing the pump 9. (900 Models Only) Remove the three screws using the # Phillips screwdriver that holds the distributor assembly in place, then lift out the entire assembly (Figures 7 and 8).
900/90 Pump Motor Replacement Kit DISASSEMBLING THE OLD PUMP MOTOR. Remove and discard the old encoder disk, item, Existing Pump Motor, (Figure ) from the intermediate gear. (The encoder disk is the round disk that is eccentrically mounted). Note Retain all hardware. The hardware will be used to reassemble the gear train.. Remove the pump shaft spacer plate, item 7 from item 4 by removing the two screws, item 4.. Disassemble the pump motor assembly, using /" nut driver. Removing the four long screws, item 5. (Figure ). 4. Remove the two screws, item 6, holding the pump optical sensor in place. 5. Remove the pump motor from the pump support motor plate, item. 6. Discard the three motor plates, motor, and original encoder disk from the existing pump assembly items, 4, 5, and. 7. Cut the black and white wires coming from the motor pump /4" past the ferrite beads. Cut the brown wire /4" from the end of the of the noise filter. ASSEMBLING THE NEW PUMP MOTOR Reassemble the pump motor assembly. An illustration (Figure ), gives an enlargement of the motor and a schematic. Refer to instructions for reassembling the 900/90 controller and Pump Motor Replacement (Figure 4). Notes One set of spacers and long screws will not be used. These can be discarded. Be sure the long screws are installed with the nut (item # 8) on the top of the gear train. Refer to the New Replacement Parts Diagram The new encoder disk must have the flat washer, item # 9, between the disk and the gear shaft. REASSEMBLING THE 900/90 CONTROLLER. Bend the end terminal of the fuse holder straight out (in-line with the body of the fuse holder).. Strip about /4" of the insulation from the black, white, and brown pump motor wires cut in step 7 of Disassembling the Old Pump Motor. Attach the new pump motor leads using the crimp connectors provided, connecting the wires color for color (Figure 4).. Reassemble the unit reversing the Removing the Pump Assembly procedure. Figure Old and New pump assemblies (crimped wire connections not shown.)
900/90 Pump Motor Replacement Kit THIS PAGE IS BLANK INTENTIONALLY 4
900/90 Pump Motor Replacement Kit Figure Existing Pump Motor EXISTING ASSEMBLY DIAGRAM 6 X X 4 X 6.5" X 6 X 0 7 8 4X 4X 5 4X.5" 8 9 EXISTING MOTOR EXISTING ENCODER DISK REF 6 9 4 4X 0 4X 0 0 EXISTING REAR SUPPORT PLATE ASSEMBLY 9 5 4X EXISTING PUMP SUPPORT MOTOR PLATE 4 8 7 9 4 X EXISTING PUMP SUPPORT PLATE ASSEMBLY 5
900/90 Pump Motor Replacement Kit Figure Pump Motor and Schematic BRN 4 X 7 -/" TAB (BLK) TAB (RED) BLK 6 -/" 0 X TAB (BLACK) MOTOR 0 REF 7 -/" BLK WHT WHT BRN 8 5 -/" 5 -/" ITEM INVENTORY NO. DESCRIPTION NOTES: TAB (RED) 9 X X 60904076 4500 40047 4 44080 5 48500900 6 4850000 7 4855000 8 48900600 PUMP MOTOR GEAR ASSY CAPACITOR.047 MFD ZENA DIODE IN4744A BUTT CONNECTOR WIRE WHITE WIRE BROWN WIRE BLACK CABLE TIE USE ITEM 9 TO COVER EXPOSED ELECTRICAL PART AND JOINTS. 9 0 68 000000 SHRINK TUBING /4 FIT FERRITE BEAD THIS DETAIL IS FOR ITEMS 5 AND 7. LOOP ITEM 5 AND 7 FORMING ONE COIL AROUND EACH ITEM 0. 6
900/90 Pump Motor Replacement Kit Figure 4 Pump Motor Replacement NEW REPLACEMENT PARTS DIAGRAM 6 6 REF -/" TAB (RED) 8 BUTT CONNECTORS 4 X X TAB (BLACK) -/" 0 X 6 7 X 0 NEW MOTOR REPLACEMENT ASSEMBLY 9 ENCODER DISK 9 8 X 5 X 6 4 X 7 0 X 7 4 ITEM INVENTORY NO. DESCRIPTION 60904076 PUMP AND GEAR ASSY 6090408 PINION SHAFT ASSY 6090409 PUMP SHAFT ASSY 4 60904074 PUMP SUPPORT PLATE ASSY 5 60904075 REAR SUPPORT PLATE ASSY 6 6090407 WIRING ASSY, PUMP GEAR TRAIN 7 607007 PUMP SHAFT SPACER PLATE 8 6070058 SPCR RND DELRIN.80IDX.060 9 609007 BRG, PUMP SHAFT 0 609008 SPCR, PUMP 609009 SPCR 7/6RND ALUM.5IDX.4L 60906 ENCODER DISK 6090 PUMP SUPPORT MOTOR PLATE 4 0404 SCR M SST FH 00 P 6- X /4 5 0458 SCR MS SST PH P B- X -/4 6 0404 SCR M SST PH P 4-40 X /4 7 8 04405 5000 SCR M SST PH P 6- X 5/6 NUT HEX SST 8-.4B 9 00800 SST FLAT WASHER #6 0 0400 LK WSHR INT SST #4 0800 LK WSHER INT SST #6 00 LK WSHR INT SST #8 4500 CAPACITOR.047 MFD 00V 4 40047 ZENER DIODE N4744A 5V W 5 4890000 CBL TIE.87.9LG WHT 6 80000 LOCTITE # TREADLOCKER - 0 7 800000 COMPOUND OPEN GEAR SYNTHETIC 8 68 SHRINK TUBING /4 IN FIT 9 0600 SST FLAT WASHER #0 REAR SUPPORT PLATE ASSEMBLY 9 0 48900600 485000 4850900 CBL TIE.4LG NAT WIRE STRD GA BLK WIRE STRD GA WHT PUMP SUPPORT MOTOR PLATE 5 X 8 7 INSURE ALL WIRES ARE KEPT AWAY FROM ITEM AND ARE ROUTED THROUGH ITEM 5 ON ITEM 5. 6 4 X PUMP SUPPORT PLATE ASSEMBLY 7