8
Mechanical Maintenance
Assembly
Fitting the Eccentric Bearing
• Remove the Fan Motor Cover 16 by unscrewing the 4 screws using a 6 mm wide screwdriver.
• Place this end of the shaft against a solid base.
• Fit the Eccentric Shaft Bearing 14 onto the shaft.
Note: It is strongly recommended that a small press be utilised for this procedure.
• Replace the Fan Motor Cover 16 and 4 screws using a 4 mm screwdriver.
Installing the Electric Motor
• Ensure that both the Motor Flange 16, the gasket and the Mounting Plate 35* are free from any dirt.
• Smear both sides of the gasket with a non-adhesive sealant.
• Supporting the Electric Motor 16 and ensuring that the Enclosure Assembly 32 is on top, slide the motor Studs 15 through the
holes in the Mounting Plate 35*.
• Secure the Electric Motor 16 to the Mounting Plate 35* from inside the tank with the two M6 socket head cap screws using a 5
mm allen key.
• Feed the solenoid wire through the Gland 29 in the Mounting Plate 35* leaving a little slack between the Enclosure Assembly 32
and the Mounting Plate 35* and tighten the Gland Screw 29 using a 17mm spanner.
Installing the Pump
• Ensure that the 'O' rings are firmly in position on each element's discharge port.
• With the discharge port facing away from the Mounting Plate 35*, lift the piston against the spring and slide the Element 8 over
the Studs 15 and the Eccentric Shaft Bearing 14 until they are up against the Mounting Plate 35*. Repeat for all four Elements.
Note: HP41 and HP51 models have four equal size Elements. The HP21 and HP41 however have two different size elements.
Equal size Elements MUST be assembled so that they are diametrically opposed.
• Slide the Manifold Flange 7 over the Studs 15 ensuring that the ports are facing the Elements and that the symbol 'T' is located
on top.
• Tighten the eight Nyloc Nuts 36 to 30 Nm in an opposing sequence using a 17 mm socket and torque wrench.
Assembling the Combination Valve 4
• Replace the two Plungers 109 in their respective ports.
Note: It is essential for efficient valve functioning that the plungers are placed in their original positions.
• Loosen the two Nuts 105 with a 10mm spanner and a 5 mm allen key and back-off the pressure adjusting screws 104 on top of
the Spring Domes 106 about three turns.
• Insert the Bearing Pads 107 and Springs 108 in that order into the Spring Domes 106.
• Locate the Spring Dome Spigots in the matching recesses in the Combination Valve 4 and secure with the four Screws 103 in
each Spring Dome 106 using a 3 mm allen key.
Assembling the Valve Set 3 and 4
• Ensure that the four 'O' Rings 113 are in place on top of the face of the Combination Valve 4.
• Place the Directional Valve 3 over the Combination Valve 4, locating the Dowel Pin in the recess provided.
• Secure the two valves 3 and 4 with the four M5 Socket Head Cap Screws 102 using a 4 mm allen key.
Installing the Valve Set 3 and 4
• Screw the two nuts on the Bulkhead Adaptors 1 as far on as possible by hand and slide the washers as close as possible to
them.
• Ensuring that the two 'O' Rings 111 are in place over discharge ports in the Combination Valve 4, place the Valve Set 3 and 4
over the two holes provided in the tank.
• Screw the long side of the Bulkhead Adaptors 1 into the ports and tighten using a 24 mm spanner
• Secure the Valve Set 3 and 4 to the tank by tightening the two nuts up against the washers with a 27 mm spanner.
• Looking from the non-motor end of the HydraPac, fit the Male Quick Coupler 2A to the Right Hand Side Adaptor and the Female
Quick Coupler 2B to the Left Hand Side and tighten using a 24 mm spanner for both.
Item numbers in bold refer to the General Assembly and Valve Set drawings and Parts Lists on pages 10 - 16.
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