DISASSEMBLE
Pressure Switch
1. Remove switch (9). Disconnect switch wires.
2. Loosen four pump head screws and carefully remove upper
housing assembly (1)
Upper Housing
Follow steps 1 and 2
3. Inspect check valve (2) for debris
4. Reassemble new upper housing (1)
Check Valve Assembly
Follow steps 1 and 2
3. Replace check valve (2)
4. Reassemble upper housing (1)
Lower Housing, Diaphragm, Motor
Follow steps 1 and 2, then remove 2 recessed screws.
3. Rotate lower housing (4) so drain notch opening on lower
housing near baseplate exposes set screw which holds
bearing housing to shaft.
4. Loosen this set screw by inserting wrench 1/8” Allen wrench
into drain notch opening. Then, slide lower housing (4) off
motor shaft.
Diaphragm Cont’d
5. Loosen two cam piston screws with Phillips head screw
driver and pull apart cam from inner pistons. (Pistons should
always be replaced when a new diaphragm is installed.)
Motor Cont’d
5. Replace Motor
REASSEMBLE
Motor
1. Reassemble lower housing assembly (4) to motor. (Follow
steps 4 to 10.)
Diaphragm
2. Lower housing is assembled with:
• Flat side of diaphragm and outer pistons facing motor
• Hex stem of inner pistons must be aligned into hex holes in
outer pistons (4).
• Outer pistons must be aligned with alignment slots on cam
assembly making sure screw holes align in cam assembly,
otherwise diaphragm will leak.
3. Tighten cam piston screws partially, center piston in
diaphragm, then tighten screws securely (18 in. lbs. torque)
Lower Housing
4. Reassemble lower housing assembly (4) to motor.
5. Retighten set screw securely. Set screw head must be
positioned facing motor covering seam (indentation).
(Positioning of this screw is critical to avoid misalignment and
subsequent diaphragm damage.)
Upper Housing, Check Valve
6. Reassemble upper housing (1)
7. Properly seat O-Ring in check valve assembly (2) and check
if ferrules and screen are in place on upper housing (1)
8. Install check valve (2) into upper housing (1) and push in.
9. Assemble on to lower housing (4), align 4 screws on to motor
by rotating lower housing (4) if necessary.
10. Tighten screws evenly to 30 in. lbs. torque.
Pressure Switch
1. Place switch against front of pump (9), insert screws and take
care not to cross thread or strip out threads in housing.
2. Reconnect wires.
TROUBLESHOOTING
WARNING:
BEFORE SERVICING PUMP, TURN OFF PUMP AND DRAIN WATER FROM SYSTEM!!
Pulsating Flow -
Pump cycles on and off
• Restricted pump delivery. Check discharge lines, fittings and
valves for clogging or undersizing.
Failure to Prime -
Motor operates, but no pump discharge
• Restricted intake or discharge line. Open all fixtures, check
for “jammed” check valve poppets and clean clogged lines
• Air leak in intake line
• Punctured pump diaphragm
• Defective pump check valve
• Crack in pump housing
• Debris in check valves
Motor Falls To Turn On
• Pump switch in off position
• Loose wiring connection
• Blown fuse
• Pressure switch failure
• Defective motor
Pump Falls to Turn Off After All Fixtures Are Closed
• Empty water tank
• Insufficient voltage to pump (low battery)
• Discharge line leak
• Defective pressure switch
• Punctured pump diaphragm
Low Flow and Pressure
• Air leak at pump intake
• Accumulation of debris inside pump and plumbing
• Worn pump bearing (excessive noise)
• Punctured pump diaphragm
• Defective motor
4
5
5
7
3
1
9
2
Quite often when a pump is worn or defective the one failed component has overburdened others. To avoid frequent aggravating
repairs, Flojet offers service kit assemblies making repairs as quick and easy as possible.
