diy motor unit assembly and disassembly instructionssp.maytronics.com/marcom/0/17054/17054_1.pdf ·...

DIY MOTOR UNIT ASSEMBLY AND DISASSEMBLY INSTRUCTIONS December 2011

DIY Motor Unit

Table of Contents

Introduction .................................................................................................................................. 3

Disassembly Instructions ............................................................................................................. 6

Opening the Motor Unit Cover .............................................................................................. 6

Removing the Drive Motors ................................................................................................... 8

Removing the Impeller Motor .............................................................................................. 10

Removing the Motor Unit PCB Card ................................................................................... 11

Removing the Motor Unit Cable .......................................................................................... 11

Assembly Instructions ................................................................................................................ 12

Assembling the Drive Motor ................................................................................................ 12

Closing the Motor Box Cover .............................................................................................. 13

Assembling the Impeller Motor ........................................................................................... 16

Assembling the PCB Card ................................................................................................... 17

DIY Motor Unit

Introduction Maytronics is now offering certified Maytronics Service Centers the option of repairing DIY motor units. This document provides instructions on how to assemble and disassemble them. Before conducting any repairs, Maytronics requires that you use the new Maytronics Analyzer to determine what is wrong with the motor unit. The Analyzer has been developed especially for this purpose.

Dynamic DIY Motor Unit Parts

Part # Description

9995266 BLACK IMPELLER+SCREW DC 1

9991044-ASSY IMPELLER CYLINDER+SCREWS 2

9991273 RETROFIT FOR CABLE CON. 2010 3

5588901 IMPELLER MOTOR HOLDER 4

9982332 CABLE HOLDER DB 5

9980726 MBU COVER LENGTH LOCKER 6

9980727 MBU COVER LOCKER 7

9991217 MBU COVER DIAG/DYN 2010 ASSY 8

5890051LF CABLE MBU 2010 9

3864202 SEAL 202X4 MBU 2010 10

3862503 SEAL O-RING 25X3 I.M 11

5583323 SEAL O-RING 32X3 12

9991218 IMPELLER MOTOR 2010 ASSY 13

9995009 ELECTRONIC CARD DYN 2010 14

5588900 DRIVE MOTOR HOLDER 15

4850010 DESSICATING BAG 16

3862119 SEAL O-RING 2-119 D.M 17

3861902 SEAL O-RING 19X2 D.M 18

9991219 DRIVE MOTOR 2010 ASSY 19

9980723 MBU BOX DYN 2010 20

3379440A SCREW KA50X12 A2 WN1412 A

3389208A SCREW ZP WN1412 KA30X08 C

DIY Motor Unit

Diagnostic DIY Motor Unit Parts

Part # Description



9991044-ASSY IMPELLER CYLINDER+SCREWS 3






3864202 SEAL 202X4 MBU 2010 9

3861902 SEAL ORING 19X2 D.M 10

5890051LF CABLE MBU 2010 11

3862503 SEAL O-RING 25X3 I.M 12

5583323 SEAL O-RING 32X3 13


3862119 SEAL O-RING 2-119 D.M 15


9995008 ELECTRONIC CARD DIAG 2010 17



9980722 MBU BOX DIAG 2010 20

3379440A SCREW KA50X12 A2 WN1412 A


DIY Motor Unit

Diagnostic Basic DIY Motor Unit Parts

Part # Description



9980720 IMPELLER CYLINDER 3






3864202 SEAL 202X4 MBU 2010 9

3861902 SEAL ORING 19X2 D.M 10

5890051LF CABLE MBU 2010 11

3862503 SEAL O-RING 25X3 I.M 12

5583323 SEAL O-RING 32X3 13


3862119 SEAL O-RING 2-119 D.M 15


9995005 ELECTRONIC CARD DIAG 2010 17



9980722 MBU BOX DIAG 2010 20

3379440A SCREW KA50X12 A2 WN1412 A


DIY Motor Unit

Disassembly Instructions After using the new Analyzer to determine which part of the motor unit is defective, open the motor unit and replace the defective part according to the following instructions:

Opening the Motor Unit Cover

Open the six cover lockers by hand.

Using a small, slotted screwdriver, gently lift open the corners of the motor unit cover.

Motor unit cover lockers x 6 Opening the lockers

Starting from the corner Small, slotted screwdriver

1

Open all 4 corners in the order noted,

before dismantling the cover.

2 3

4

DIY Motor Unit

Note:

o Open the cover gently with the screwdriver to avoid damaging the motor unit box, cover, or seals.

o To open the cover you should always open diagonally opposite corners (see the above picture).

After releasing all four corners, use your hand to lift off the cover. Make sure that the cover seals are not damaged.

An opened motor unit

Checking the seals The two seals on the cover

DIY Motor Unit

Removing the Drive Motors

If, according to the Analyzer, drive motor 1 or drive motor 2 are faulty, replace them as follows:

On the motor unit PCB card, the drive motors are marked with DRV1 and DRV2.

Drive motor 2

Drive motor 1

Pull the drive motor back and then up. The two seals on the motor shaft

After releasing the holder, pull it out

with your hand.

Open the drive motor holder with a

small, slotted screwdriver.

DIY Motor Unit

After removing the drive motor, disconnect the motor wire from the PCB card with needle-nosed pliers.

Note:

o Do not disconnect the motor wire by pulling the wire with your hand. Always use pliers to prevent the wires from breaking off from the wire connector.

The drive motor wire connected to the

motor PCB card

DIY Motor Unit

Removing the Impeller Motor

To replace the impeller motor, do as follows:

Note: o Do not disconnect the motor wire by pulling it with your hand. Always use pliers to

prevent the wires from breaking off from the wire connector.

Pull the impeller motor out. The two seals on the motor shaft

Open the impeller motor

holder with your hand. Dismantle the impeller. Turn the motor box cover upside

down and disconnect the impeller

wire from the PCB card.

DIY Motor Unit

Removing the Motor Unit PCB Card

To remove the motor unit PCB card, first disconnect the motor’s wires from the PCB card and then continue as follows:

Removing the Motor Unit Cable

To replace the motor unit cable between the terminal and the PCB card, do as follows:

Three screws hold the PCB

card on the motor box cover.

Open the PCB card screws using a

small Phillips screwdriver.

The disconnected motor unit cable

The motor unit cable’s connections

Open the motor cable

connector on the terminal.

Open the motor cable

connector on the PCB card.

The motor unit cable between

the terminal and the PCB card

DIY Motor Unit

Assembly Instructions

Assembling the Drive Motor

Clean the seals and sealing surfaces.

Assemble the drive motor as follows:

Motor unit box’s sealing

surfaces

Drive motor seals and

surrounding area

Put the motor in its place. Make sure the seals are

in their correct position.

Make sure the motor holder entry sticks out from the motor

box.

Lock the drive motor in place with the motor

holder.

Connect the motor cable

to the PCB card. Make sure the motor

holder is all the way in

place.

DIY Motor Unit

Closing the Motor Box Cover

To close the motor cover box, do as follows:

Note:

o Clean the seals and sealing surfaces with a soft napkin. If the seals are damaged,

replace them.

o Use only Molicote grease (P/N4830111) to grease the seals.

Make sure the seals have been placed

properly and fit snugly.

Make sure all wires are

connected to the PCB card.

Remove the seals from the cover.

Clean the seals. Grease the seals.

Make sure the desiccating bag sits between

the drive motor and the drive motor box.

DIY Motor Unit

Before closing the motor box cover, make sure the seals and wires are inside the box.

Assemble the cover and close the cover lockers. Note:

o There is only one way to position the cover for closing (see images below).

Seals positioned incorrectly Wires positioned incorrectly

Cover correctly positioned Cover incorrectly positioned

DIY Motor Unit

A closed motor unit

Press down on the cover till

you can close the locker.

Begin by closing the lockers on

the shorter sides.

Continue by closing the lockers

on the longer sides.

DIY Motor Unit

Assembling the Impeller Motor

Note:

o The flat side of the impeller motor connects to the flat side of the box cover. o Always clean the seals and sealing surfaces of the impeller motor and cover before

assembly.

The flat side of the motor connects to the flat side of the cover.

The flat side of the impeller motor

The flat side of the cover

Clean the sealing surfaces on the box cover.

Make sure the motor holder entry

sticks out from the motor box. Plug the impeller motor

wire to the motor PCB card.

Lock the motor in place with the

motor holder. Motor holder entry side Make sure the motor

holder is fully closed.

DIY Motor Unit

After closing the impeller screw, assemble the motor box cover as described above.

Assembling the PCB Card

o o

After screwing on the PCB card to the motor unit box cover, assemble the motor box cover according to the instructions above. Test the Dolphin in a pool or a water tank for one full cycle.

Screw the impeller onto the motor shaft.

The PCB card The PCB card’s space on

the motor box cover

Position the PCB card in

its place.

Close the three screws

on the PCB card.

The three screws holding the

PCB card in place

Connect the wires

to the PCB card.

DIY Motor Unit

Note:

o The assembly/disassembly procedures are the same for Dynamic, Diagnostic and

Diagnostic Basic motor units.

o As spare parts, the impeller and drive motors come with wires and with greased seals.

o As a spare part, the motor box cover comes with seals.

o Check that all seals are in their place and in good condition before assembling motors

and box covers.

o Grease seals before assembling motors and box covers.

o You can order Molicote grease from Maytronics (P/N 4830111, 1kg).

o Remember to stock enough spare parts to service the DIY motor units.

If you have any questions, please contact us. We will be happy to help you. Maytronics Technical Department Team

diy motor unit assembly and disassembly instructionssp.maytronics.com/marcom/0/17054/17054_1.pdf ·...

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