Please read the entire replacement guide before proceeding.
Disconnect the wire harness (both connector plugs) from the Helmet Particle Separator before doing any kind of maintenance. Do not work on your Helmet Particle Separator while it is connected to the wire harness.
Use a clean table or a clean flat surface to work on your Helmet Particle Separator as there are small screws and washers that can get lost if you are not careful.
All the small screws used in the assembly are stainless steel button head allen screws. Avoid using ball end hex keys as they will tend to strip the head of the small stainless screws. It is better to use straight hex keys on these small stainless fasteners.
Tools Required: 2.5mm Hex Key.
If you have any questions or need any assistance, call our customer support team at (909) 947-0015.
- 4mm Hex Key
- 5mm Hex Key
- 13mm Wrench or Socket Wrench
There are two fans in the Helmet Particle Separator. The Exhaust Fan (Item 15) is the smaller fan that removes the dust and particles from the air. The Blower Fan (Item 11) blows the cleaned air into the hoses connected to your helmet.
Use your thumb to remove the Blower Fan connector from the Exhaust Cover (Item 16) by pushing and sliding the connector from the Connector Clip (Item 18) as shown.
The connector should be fully removed from the Exhaust Cover.
Using a 2.5mm Hex Key, remove the (4) Screws (Item 20) and (4) Washers (Item 17) from the Blower Outlet (Item 8).
Carefully separate the Blower Outlet (Item 8) from the Main Housing (Item 1).
Using a 2.5mm Hex Key, carefully remove the (4) Screws (Item 13) attaching the Blower Fan (Item 11) to the Blower Outlet (Item 8).
Remove the Blower Fan (Item 11) with plastic Fan Guard (Item 12) from the Blower Outlet (Item 8). Be careful not to lose the (4) Screws (Item 13) that were loosened in the previous Step 5.
Remove the metal Fan Guard (Item 10) from the Blower Outlet (Item 8).
Carefully pull straight and remove the fan wires from the prongs of the Speed Control Knob (Item 9). The prongs are delicate so remove the wires carefully.
Clean the Blower Outlet (Item 8) of any foreign objects or debris. Check that the Plenum Seal (Item 14) is clean, undamaged, and that the start and end of the Plenum Seal coincides with the small notch in the Blower Outlet.
Carefully connect the new Fan wires with the spade terminals to the prongs on the Fan Speed Control Knob (Item 9). One wire to the long center prong and one wire to the right bottom prong. The color of the wire doesn’t matter to which prong it attaches. Make sure to fully insert the terminal on to the prong. Be careful as the prongs are delicate.
Place the metal Fan Guard (Item 10) into the Blower Outlet (Item 8) with the dip facing down towards the outlet ports. Make sure the (4) corner holes of the Fan Guard are aligned with the threaded holes of the Blower Outlet.
Snap the plastic Fan Guard (Item 12) onto the Blower Fan (Item 11). Make sure that the Plastic Fan Guard covers the side without the fan label. Place (4) Screws (Item 13) in the Fan frame and carefully lower the Fan onto the metal Fan Guard. Make sure the Fan wires are facing down towards the bottom right side as shown.
Carefully align and place Blower Fan (Item 11) on top of the metal Fan Guard (Item 10) and secure them both to the Blower Outlet (Item 8) using (4) Screws (Item 13). The plastic Fan Guard (Item 11) should be facing you. Tighten all (4) Screws with a 2.5mm Hex Key.
Tuck the fan wires in between the bottom of the Fan (Item 11) and the Blower Outlet (Item 8) back and forth and leave about 3.50” of straight length coming out of the small notch in the Blower Outlet.
As a precaution, check inside the Main Housing (Item 1) for any large objects or debris. First remove the Fan Chamber Seal (Item 7) from the Main Housing.
Remove the Back Plate (Item 6) from the Main Housing (Item 1).
Remove any large debris inside the Main Housing (Item 1) or inside the Inertial Tubes (Item 4).
Align the cones of the Back Plate (Item 6) that go into the center of the Inertial Tubes (Item 4) and install the Back Plate into the Main Housing (Item 1).
Install the Fan Chamber Seal (Item 7) into the Back Plate (Item 6). Make sure the square pocket on the Fan Chamber Seal is facing you.
Install the Blower Outlet / Fan Assembly to the Main Housing (Item 1) using (4) Screws (Item 20) and (4) Washers (Item 17). Tighten all (4) Screws with a 2.5mm Hex Key.
Make sure the fan wires are coming out of the notch in the Blower Outlet (Item 8) and are not being pinched by the Back Plate (Item 6) or Fan Chamber Seal (Item 7).
Check that all fasteners are tight and there are no gaps between the Main Housing (Item 1) and Blower Outlet (Item 8).
Snap in both fan connectors into the Connector Clips (Item 18).
Plug both Fan Connectors to the Wire Harness and run both fans to verify they are working properly. Adjust the Speed Control Knob both ways to test the variable speed. If you hear any unusual sounds, check for loose fasteners, misplaced components, or any obstructions to the fans and correct as necessary. Call customer service if you have any questions at (909) 947-0015. Enjoy your newly rebuilt Helmet Particle Separator.
