Deck Mount Fastlane Motor Change Service Instruction

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Deck Mount Fastlane Motor Change

Service Instruction Page 1 of 6

Section 1: Parts List Motor Replacement Kit (supplied by EPI) (1) (2) (4) (2)

New hydraulic motor Motor Fitting Caps Hydraulic Hose Plugs Hydraulic Fitting Caps

(4) (2) (1)

Stainless Steel Bolts and Washers White Plastic Guard Strips Roll of Anti-Corrosion Tape

Tools Required (supplied by others) Phillips head screwdriver Paper towels Plastic bags (2) Adjustable Wrenches Duct Tape

Section 2: Additional Considerations WARNING

Use extreme caution when working in and around the front housing. The edges, especially around the propeller cylinder, can be very sharp. Wear protective gloves when removing the motor.

CAUTION

Be sure to disconnect electrical service to the hydraulic pump unit. 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.

NOTICE

If your power unit is at a higher elevation than the Fastlane, disconnect both hydraulic hoses at the power unit. Use the red threaded plugs to cap the end of each hose, making sure to mark each hose so you know to which fitting it needs to be re-connected.

Section 3: Motor Replacement Instructions Removing the Fastlane from the Pool 1. Remove the four screws that attach the deck plate cover to the deck plate and set aside the screws and the escutcheon assembly.

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Deck Mount Fastlane Motor Change

Service Instruction Page 2 of 6

2. Remove the black anti-corrosion tape that is wrapped around the hydraulic fittings. The hydraulic fittings connect the submersible [sub-] hoses (that run through the Fastlane rails to the underwater motor) to the run-hoses (that come from the hydraulic power unit). Note that the sub hose is a smaller diameter hose than the run hose 3. Disconnect the run hose from the sub hose using the two adjustable wrenches. Make sure to leave the adapter connected to the run hose. Thread in the provided plugs into each sub hose fitting. Place the plastic cap over the adapter fitting connected to each run hose.

4. Use the 7/16” socket and 7/16” wrench to remove the two 1/4"-20 bolts and nuts that attach the Fastlane rails to the deck plate.

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Deck Mount Fastlane Motor Change

Service Instruction Page 3 of 6

5. Slowly lift the Fastlane out of the pool, allowing trapped water to drain out of the Fastlane.

6. Note: Placing a suitable shim underneath the front of the Fastlane will prevent it from tipping forward.

Disassembling the Fastlane to Access the Underwater Motor 1. Unthread the screws that secure the throat to the Fastlane and set the throat aside.

2. Slide the horizontal (honeycomb-shaped) conditioning grill out of the upper housing and set it aside.

Fitness Machines, LLC

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Deck Mount Fastlane Motor Change

Service Instruction Page 4 of 6

3. Disconnect the stainless steel rails from the Fastlane body. For Stainless Steel Fastlane:  Lay the Fastlane on its front so that you have access to the backside of the lower housing. Using a Phillips head screwdriver, remove the 12 screws that affix the rear stainless steel perforated grill to the Fastlane, and then the grill can be removed as well.  Stand the Fastlane unit upright again. Remove the bottom bolts on each side that attach the rails to the lower housing of the Fastlane. The 9/16” socket is used to remove the nut that attaches the bottom bolt, and the nut is accessed though the opening in the rear of the perforated steel lower housing.  Remove the remaining bolts that attach the rails to each side of the upper housing of the Fastlane. The 9/16” wrench is used to remove the nuts that are accessed through the throat, and the 9/16” socket is used to remove the top bolt. As the top bolt is removed from each side, set the rails down on the ground so that the rails form a butterfly shape with the Fastlane. At this time the rails are still connected to the Fastlane via the sub-hoses that run through the rails. Be careful not to twist the rails around, as the hoses can be nicked or cut by the sharp edges of the oval-shaped holes in the rails. The hoses exit the rails via these holes, and enter the Fastlane’s perforated steel lower housing where they connect to the underwater motor. For Acrylic Fastlane:  Unthread the nut that is attached to the middle bolt that secures the rail to the housing. Remove the stainless bond wire from the right bolt.  Unthread the top and bottom screw that are threaded directly into the Fastlane housing. 1) Now that the rails are no longer blocking access to the screws that affix the upper housing to the lower housing, use the Phillips head screwdriver to remove the eight (four on each side) screws. 2) The upper housing can now be lifted away and set aside from the lower housing, as the motor replacement only involves the lower housing.

Motor Replacement 1) Remove the bolt on top of the propeller using the 7/16” socket. 2) Remove the propeller from the motor shaft and verify the propeller fits on the new motor shaft. Visually inspect the propeller for any signs of wear. If any cracks or chips are evident, call customer service to order a new propeller. NOTE: The original motor may look different from the replacement that was sent, however, the bolt patterns and fittings on the motors are the same. Please pay special attention to Step 21 when installing the new motor. 3) Take a large plastic bag and spread it out underneath the existing motor so that it can catch any oil that may drip while disconnecting and reconnecting the hydraulic sub-hoses. It may be helpful to spread a layer of paper towels on top of the plastic bag so that any oil that drips will be absorbed. 4) Snap the two white plastic guard strips (that have been provided) over the top edge of the cylinder. This will protect your arms and hands from the sharp edges of the cylinder during motor replacement. 5) Loosen the hydraulic hose fitting with the 15/16”wrench, and hold a paper towel around the hydraulic hose as you loosen it. Once removed, plug the hoses immediately with the provided metal plugs, and cap the motor fittings with the provided metal caps (they are shipped on the replacement motor). Wipe away any excess hydraulic fluid that may have dripped onto the hose while securing the plugs or caps. 6) Using a 9/16” wrench, remove the four bolts that attach the motor to the motor mounting bracket. Take caution so that the motor is not in danger of falling when the last bolt is removed.

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Deck Mount Fastlane Motor Change

Service Instruction Page 5 of 6

7) Wrap the four new stainless steel motor bolts with Teflon tape. Slide the lock washers on each bolt, and then slide the flat washers on each bolt. 8) Remove any debris left behind from the previous motor from the motor mounting bracket. Using the new bolts and washers that were prepared in the previous step, attach the new motor to the mounting bracket, being sure to orient it in the same manner as the old motor. Attach each of the bolts loosely and make certain that the motor shaft is centered on the bracket before tightening the bolts securely. 9) Reattaching the hydraulic hoses:  If the replacement motor looks the same as the original: Make sure that both o-rings are on the motor fittings, and that all dirt and grit has been removed from between the threads before securing in place. These are mechanical o-ring seals so no Teflon tape or sealant should be used. Reattach the hydraulic hoses, and use a paper towel to absorb any residual hydraulic fluid. Tighten the fitting with a wrench until they are just tight, then tighten an additional 30-45 degrees (1/2-3/4 flats past wrench resistance).  If the replacement motor looks different from the original: The hose positions need to be reversed. Make sure that both o-rings are on the motor fittings, and that all dirt and grit has been removed from between the threads. These are mechanical o-ring seals so no Teflon tape or sealant should be used. Reattach the low-pressure sub-hose (with the red tape on the end) to the motor fitting stamped “A”. Reattach the high-pressure sub-hose to the motor fitting stamped “B”. Use a paper towel while tightening the fittings to absorb any residual hydraulic fluid. Tighten the fitting with a wrench until they are just tight, then tighten an additional 30-45 degrees (1/2-3/4 flats past wrench resistance). 10) Remove the white plastic guard strips and carefully remove the plastic bag and paper towels so that none of the spilled oil can find its way into the pool water. 11) Attach the propeller to the motor. Be sure that the edge of the key on the motor shaft is aligned vertically so that it will fit into the key slot on the propeller. The motor was shipped with a red plastic band on the shaft, but the band is only to keep the key attached to the motor shaft during shipment. Remove this band before attaching propeller. If necessary, gently tap the propeller into alignment with a hammer. Set the large fender washer in place and tighten the propeller bolt over the washer with the 7/16” socket. Do not over tighten the bolt to the extent that the large fender washer begins to deform.

Reassembling the Fastlane 1) Slide the upper housing back onto the lower housing and loosely reinstall the eight screws using a Phillips screwdriver. The heads and threads of these screws can be easily stripped if a screw gun is used. Once certain that all of the screws fit properly, then they can be tightened securely. 2) Reconnect the stainless steel rails to the Fastlane body. For Stainless Steel Fastlane:  Reinstall the rails one bolt at a time, but do not tighten the bolts securely yet. Be careful not to have the Fastlane tip over when reinstalling the rails. It may be helpful to lay the Fastlane on its side so that the rail that is facing up can be reinstalled. As a reminder, the top bolt assembly includes a hex head bolt and self-locking nut with the nylon insert. The smooth head bolts go in the lower two holes, and each of those bolts is installed with flat washers against the housing, and then a lock washer in between the flat washers and the plain nuts.  Before tightening all of the bolts securely, check to see that the remaining hose inside the lower housing does not touch any areas of the stainless steel perforated grill. If necessary, feed additional hose from the lower housing into the rail and make sure that the hose clamp on the back of the lower housing is tight. The bolts that attach the rails to the housings can then be tightly secured.

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Deck Mount Fastlane Motor Change

Service Instruction Page 6 of 6

 Reattach the rear stainless steel perforated grill with the 10-32 screws and a Phillips screwdriver. The heads and threads of these screws can be easily stripped if a screw gun is used. Once certain that all of the screws fit properly, then they can be tightened securely.  Visually inspect the horizontal (honeycomb-shaped) conditioning grill for any signs of wear. If it shows any wear or damage, please call customer service to order a new grill. If everything appears to be in good condition, reinstall the grill and attach the throat, again being careful not to strip any parts of the screws.

For Acrylic Fastlane:  Align the rails to the housing and loosely secure the upper and lower bolts of the rail to the Fastlane housing. Make sure the PVC washer is in place between the rail and the housing.  Push the middle bolt thru the hole in the housing; making sure that the PVC washer is between rail and the housing. On the inside of the housing, place the stainless steel washer over each screw and then secure the nut to the bolt. Make sure to wrap the bond wire around the right bolt.  Position the throat in place and then secure with the stainless steel screw.

Reinstalling the Fastlane in the Pool 1) The Fastlane can now be rolled to the pool, lowered into place, and bolted to the deck plate. Be sure that the #8 AWG bare copper bonding wire is still attached to the bonding lug that is mounted on the deck plate. 2) Connect the hydraulic hoses to the same union fixtures to which that they were originally connected. Note that prior to tightening the fittings, one must verify that an o-ring is seated in place in the fitting to avoid leaking of hydraulic fluid. Once certain that the o-rings are in place, use 40 ft-lbs of torque to tighten the fittings. 3) After making the hydraulic hose connections, reconnect electrical service to the power unit, and turn the unit on to check for hydraulic fluid leaks. Once it has been verified that there are no leaks, use the anticorrosion tape to wrap the fittings and union fixtures at the deck plate. 4) Reinstall the escutcheon to the deck plate using the same screws that originally held the escutcheon in place. The Fastlane motor change is complete.

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