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Perform Pressure Relief Procedure, see page 4. Unplug power cord. 2. Release hopper adapter clamp (158). 3. Loosen rod clamp knob (112) on front of pump module and push rod down. 4. Lift and pull power module (153) off of unit. NOTE: Power module weighs approximately 85 lb. 5. Install hopper plug (117) if needed. Installation 1. Remove hopper plug (117) if installed. 2. Replace power (153) module and insert pump outlet into hopper inlet. 3. Pull rod clamp up and tighten knob (112) on front of pump module. 4. Fasten hopper adapter clamp (158). ti15684a 158 ti11675a 112 ti15623a 153 ti15623a 117 ti15625a 153 ti11678a 112 ti15683a 158 Pump 8 3A0246C Pump Removal 1. Perform Pressure Relief Procedure, see page 4. 2. Remove Power Module, see page 7. 3. Disconnect material hose (79) from pump (18a). 4. Loosen two screws (40) and remove pump rod shield (48). 5. Turn flow control knob to a very low setting and turn prime valve handle to TOOL FILL position (JOG mode will appear in display). Use ON/OFF switch or turn control knob OFF to stop pump when pin is visible. 6. Use screwdriver to press pin (7b) out of pump. NOTE: Pin should be removed by pressing the pin out through the bottom side of the pump. Make sure to control the pump pin when removing so that it does not fall into the pump module. 7. Use hammer to loosen pump retaining nut (22). 8. Unscrew and remove pump (18a) from module. Installation 1. Extend pump piston rod 1.5 in. 2. Install pump pin (7b). Verify retaining spring is in groove of connecting rod. NOTE: Pin should be installed from the top side of the pump. Make sure to control the pump pin when installing so that it does not fall into the pump module. ti15616a 79 18a ti15619a 48 40 ti15620a ti15617a 7b ti15615a 22 ti15618a 18a 1.5 in. ti7171a 7b ti13093a Pump 3A0246C 9 3. Push pump up until pump threads engage. 4. Screw in pump until threads are flush with drive housing opening. 5. Align pump outlet to right side so that hose can be reassembled. 6. Screw jam nut up toward drive housing until nut stops. Tighten jam nut by hand, then tap 1/8 to 1/4 turn with a 20 oz. (maximum) hammer to approximately 75± 5 ft-lb (102 N•m). 7. Replace pump rod shield (48) and torque two screws (40) to 30 - 34 in-lb. 8. Reconnect material hose (79) to pump (18a). 9. Replace Power Module, see page 7. ti15924a ti15621a ti15923a ti15925a ti15619a 48 40 ti15616a 79 18a Motor 10 3A0246C Motor Removal 1. Perform Pressure Relief Procedure, see page 4. 2. Remove Power Module, see page 7. 3. Disconnect material hose (79) from pump (18a). 4. Remove four screws (40) and lift motor shroud (98) off of motor. 5. Disconnect three wire harnesses (see Wiring Diagrams, pages 34-36). 6. Remove two screws (5b) from underneath motor base plate. Lift and remove motor/pump assembly from pump module. 7. Loosen four screws (19) on bearing housing (9), and remove from gear housing. 8. Remove three screws (5c) on motor (8a). Remove motor from gear housing. Installation 1. Apply brown lithium grease supplied with motor repair kit (8) to gear cluster (17a) and inside of motor cavity. 2. Align orientation tab on gear housing with slot on motor and slide gears into motor. 3. Replace three screws (5c) on motor (8a). Torque to 200-220 in-lb. ti15616a 79 18a ti15624a 98 40 ti11734a 5b ti15630a 19 9 5a ti11735a 8a 5c 17a ti15629a ti11735a 5a 5c 8a Motor 3A0246C 11 4. Attach bearing housing (9) to gear housing (5a) (slowly turn motor fan by hand to align gear into pump connecting rod). Torque four bearing housing screws (19) to 25-30 ft-lb. 5. Replace motor/pump assembly into pump module. Replace and torque two screws (5b) underneath motor base plate to 200 - 220 in-lb. 6. Reconnect three wire harnesses (see Wiring Diagrams, pages 34-36). 7. Replace motor shroud (98) and torque four screws (40) to 30 - 34 in-lb. 8. Reconnect material hose (79) to pump (18a). 9. Replace Power Module, see page 7. ti15630a 19 9 5a ti11734a 5b ti15624a 98 40 ti15616a 79 18a Motor Control Board 12 3A0246C Motor Control Board Removal 120V Models: 1. Perform Pressure Relief Procedure, see page 4. Wait 5 minutes before servicing. 2. Remove Power Module, see page 7. 3. Disconnect material hose (79) from pump (18a). 4. Remove four screws (40) and lift motor shroud (98) off of motor. 5. Remove four screws (33b) and display cover (33k). 6. Disconnect display connector (A) from motor control board (24) and remove display. 7. Remove bottom two screws (61) and remove control panel (37). 8. Disconnect Prime/Tool Fill/Recirculate reed switch connector (E) from motor control board (24). 9. Disconnect potentiometer connector (C) from motor control board (24). 10. Disconnect 15/20A switch connector (X) from motor control board (24). ti15616a 79 18a ti15624a 98 40 33b ti15786a 33k ti13569a A 24 ti15795a 37 61 ti13572a E 24 ti15791a C 24 ti15850a X 24 Motor Control Board 3A0246C 13 11. Disconnect white power cord conductor (D) from motor control board (24). 12. Disconnect black power lead (J)...

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