SF2 Service manual 2.0

SF2 Pump

Service Manual & Trouble Shooting Guide

6

5

4

3 2 1

2

3

4

5

6

7

B

C

D

ence

al refer

Technic Dept.

E

5 4 3

F 2 1

Dept.

Technical reference

Created by

Joselyn Klupar Document type

Title

SF2 v28

4/20/2017

Approved by

Document status

DWG No.

Service Manual SF2 Pump

SF2 inspection, disassembly, and reassembly

Exploded view of SF2 Pump

Pump Housing

Driveshaft Assembly

Air Vessel Assembly

Motor and Frame Assembly

Solar Panel Assembly

4 5 6 7 8 9

Inspection Guide 10 Dissassembly Guide 14

Reassembly 26

System Specs Flow chart 34 RPM chart 35

Trouble shooting flow chart 58

Trouble shooting guide Pump runs but at a low flow rate

36

System air leak

Leak in suction hose

Leak between suction hose to inlet connection

Leak between air vessel to pump

Air vessel leak

Water too deep to be lifted

Suction valve leaking

Piston valve or seal leaking

Pump operating at low RPM 45

Pully slipping on the wheel Excessive friction of the piston/stuffing box Bad electrical connection Panel capacity too low Motor gets too hot Excessive resistance on outlet Suction inlet blocked

Knocking sound while pump is running

Main shaft bearings worn

Worn or loose stuffing box

54

Excessive leakage at stuffing box 56

Exploded View

SF2 Pump

5

5

6

4

3 2 1

A

2

4 2

1

3

4

5

6

7

B

C

D

al refer

Technic Dept.

E

5

3

F

1

4

3 2

Dept.

Technical reference

1

1

2

4

Created by

Joselyn Klupar

Document type

Title

1

Pump Assembly

Pg 5 SF2 v28

2

Driveshaft Assembly

Pg 6

3

3

4

Air Vessel Assembly

4/20/2017

5

Pg 7

4

Motor and Frame Assembly

Pg 8

5

Solar Panel Assembly

Pg 9

App

Doc

DW

Rev

6

7

A

Pump Assembly

Exploded View Parts List

Item 1

Qty

2

Description

1

Part Number B 0717a

Bottom Cover

2

0724a

Rubber Washer

1

0717a

Valve Insert

4

1

0726

M8 Nut

Steel

5

1

0711

Piston Ring

Rubber, Silicone ABS Plastic

6

1

0712a

7

1

0727

Piston

8

2

0723a

Rubber valve 80x3mm

C

Spacer Tube

9

1

0728

M8 Washer

1

0707a

Cylinder

10

1

0729

11

1

0703

12

2

0704

Graphite Rope

13

1

0702

Stuffing Box Bush

ABS Plastic

14

1

0701a

Yoke

Steel

Guide Bush D Top

Cover

2

Sheet Rev.

7

9 7

12

2/2

issue Date of

8

10

System Specs

6

F

.

DWG No

Do

SF2

nt status

Docume

cument

Title

Reassembly

12

Approv

11

ABS Plastic Canvas

Disassembly

Klupar

Stainless Steel ABS Plastic

14

E

17 6/20/20

Inspection

by

Stainless Steel Rubber, Silicone Steel

10

ed by

Joselytypne

Rubber, Silicone ABS Plastic

3

13

Created

Material ABS Plastic

Exploded View Exploded View

rence

8 7

8

3 1

Trouble Shooting

6

5

4 2 5

33

30

Exploded View

Driveshaft Assembly

31

35

32

33

34

28 22

27

20

26 25

20

21 23

22

22

24

36

Item 20

35

34

27 26

6 25

Qty 4

Part Number 0206

Parts List Description Bearing (17 mm ID 35 mm OD)

Material Steel

20

1

0109

6mm x 20mm Bolt

Steel

21

1

0612

6mm Washer

Steel

23

1

06b03

Main Shaft

Steel

24

1

0602

O-ring

Rubber, Silicone

25

1

0608

8mm Washer

Steel

26

1

0611

8mm locking washer

Steel

27

1

0211

8mmx40 bolt

Steel

28

1

0203

Yoke Guide

30

1

Need Part Number M4 Bolt

Acetal Resin, White Steel

31

1

0201

Post

Steel

32

1

0202

M8 x 20mm bolt

Steel

33

1

0202

M8 x 40mm bolt

Steel

34

1

0401a

Flywheel

35

1

0402a

Flywheel Band

Rubber, Silicone

36

1

0204

Long Bolt

Steel

Air Vessel Assembly

Exploded View

Exploded View Exploded View

46

47

48

Inspection

45

49

Disassembly Reassembly

Parts List Qty

Description

1

Part Number 0503

ABS, molding

46

1

0505

PVC

47

1

0504

Silicone Rubber 50 Shore

48

1

0506

48

1

0508

49

1

0507

Material ABS Plastic

System Specs

Item 45

PVC, Unplasticize d Rubber, Silicone ABS Plastic ABS Plastic

Slicone o-ring

Rubber, Silicone

Trouble Shooting 7

Motor and Frame Assembly

Exploded View

50 7

50

51 52

Item 50

Qty 1

Part Number 0103a

51

1

Pulley

52

1

01

53

3

0104

53

1

0102

55

54

1

0106a

2

0109

M

56

1

0108a

M

56

Parts List Item 50

8

Qty 1

Part Number 0103a

Description M6 x 1.00 x 35mm

Material Steel

51

1

Pulley

52

1

01

53

3

0104

53

1

0102

54

1

0106a

55

2

0109

M6x 1.0mm x 18mm

Steel

56

1

0108a

M8 x 1.0mm x 60mm

Steel

57

1

ABS Plastic M6 Washer

Steel Steel Steel

Frame

M

55

54 53

M

Exploded View Solar Panel Assembly

Inspection Disassembly

Reassembly

System Specs

Trouble Shooting

9

Done

Exploded View

71 68

78

Under constuction

Inspection guide Use one of the inspection guides below to inspect and replace the parts listed.

Piston Ring

11

12 Valve

Stuffing Box 13

10

Piston ring Inspection & Replacement

Inspection

1

Exploded View

Follow disassembly one steps 1-8 in addition to the steps below to inspect and replace the piston ring.

Remove piston from pump cylinder.

Inspection

2

Disassembly Reassembly System Specs

2 Inspect piston ring for damage.

3 Remove piston ring by locating

Trouble Shooting

Seam, and pulling apart. Replace if damaged or worn.

Refer to pg XX for gap tolerances.

Done 11

Inspection

Valve Inspection & Replacement

Follow disassembly steps 1-8 in addition to the steps below to inspect and replace valves.

1

Inspect suction & piston rubber valves

for damage or trapped debris.

suction valve

assembled piston valve

2 Remove suction valve by pulling upward, stretching rubber valve around knob in middle.

SolidWorks Student Edition.

For Academic Use Only.

12

disassembled

3 Remove nut under

piston and unscrew piston from piston rod.

Stuffing box

Inspection 2

1

3

4

Exploded View

Follow disassembly steps 1-8 in addition to the steps below to inspect and replace stuffing box.

A

1

Unscrew the nut.

Inspection

B

Disassembly

C

2 Pull the yoke out from the top housing D

and remove the yoke guide.

2

3

4

5

6

A

Reassembly

1

E

System Specs

B

F

2

3

4

D

Done

13

Trouble Shooting

1 C

Disassembly guide Use one of the disassembly guides below to inspect and replace the parts listed.

Disassembly 15

Pump exploded view 20 Stuffing box 21 Driveshaft 23 Camshaft exploded view 25

Reassembly 26

Cam reassembly 27

Pump housing reassembly 26 Pump housing to frame 28 Driveshaft reassembly 31

14

Disassembly

Exploded View

1 Unplug solar panel 6

5

4

3

2

Inspection

from motor and remove panel.

1

A

Disassembly Disassembly

B

C

D

2

3

4

5

E

6

A

Reassembly

1

7

System Specs

B

C

Trouble Shooting

2 Remove suction

and delivery hoses.

D

E

15 Dept.

Technical reference

Created by

Joselyn Klupar

5/9/201

2

3

4

5

6

Disassembly 3

4

5

3 Twist and pull air vessels from pump housing.

4 Unscrew long bolts.

Dept.

Technical reference

Created by

Joselyn Klup Document type

Title

SF2 2

3

16

4

5

6

Disassembly

Inspection Disassembly Disassembly

Loosen guide pin bolt.

System Specs

Trouble Shooting

17

Reassembly

5

4

3

2

1

Te Dept.

6

6 5 4 3 2

Exploded View

5 Remove long bolts.

Disassembly 1

7

A

2

3

Remove pump.

4

5

6

B

2

C

3

4

5

D

E

Remove bottom housing & cylinder by pulling apart

8 F

1

2

18

3

Dept.

Technical reference

Created by

Joselyn Klupar Document type

Title

SF2 4

5

6

5/17/

Disassembly p housing

Exploded View

9 Remove rubber valve by pulling apart from the insert with force.

1 3

2

2 4

3

4

5

6

Inspection

A

Disassembly Disassembly

B

Dept.

Technical reference

Reassembly

C

10 Remove insert by unscrewing from 3 bottom housing.

2

4

5

6

System Specs

D

E

Technical reference

Created by

Joselyn Klupar

Document type

F

1

2

3

Done

Trouble Shooting

Dept.

Title

4

SF2

19

Dep

6

Exploded view of pump assembly guide bushing yoke guide yoke compression bolt graphite cord guide bushing top cylinder housing cylinder o-ring 1 90965A190:1 rubber piston valve 1 piston seal piston 90576A117:1 pump cylinder rubber piston valve 2 valve insert cylinder o-ring 2 bottom cylinder housing 20

Stuffing box

Disassembly

1

3

2

3

4

4

5

3 Seal replacement : Remove stuffing box

5

6

7

compression bolt by unscrewing from top housing.

A

Exploded View

Follow disassembly steps 1-8 and stuffing box inspection steps 1-2 in addition to the steps below.

Inspection

B

Disassembly Disassembly

C

D

Reassembly

E

4 Pull compression bolt, graphite cord and Dept.

Technical reference

guide bushing out.

Created by

Joselyn Klupar Document type

5/31/2017

Title

Document status

DWG No.

SF2

F

Approved by

System Specs Rev.

1

2

3

4

5

6

7

graphite cord

21

Trouble Shooting

guide bushing

Date of iss

Disassembly

5

2

Stuffing box

To replace, wrap the two graphite cords around the piston shaft. Guide the bushing block, graphite cord, piston rod and compression bolt into the top cylinder 5 4 3 housing, ensuring the graphite cord fits securely.

Dept.

22

6

Technical reference

Done

Driveshaft

Disassembly

1

A

1

2

3

4

5

6

Secure a wrench to the flywheel bolt, holding it in place.

Exploded View

Follow disassembly steps 1-7 in addition to the steps below to remove flywheel to access cam assembly.

7

Inspection

B

C

Disassembly Disassembly

D

2 Unscrew the camshaft bolt, while still Dept.

holding the flywheel bolt steady.

F

2 2

3 3

4 4

Joselyn Klupar

Title

SF2

5 5

Created by

Document type

6 6

7

A

6/22/2017

7

System Specs

1 1

Technical reference

Reassembly

E

8

B

Trouble Shooting

C

D

23 E

Disassembly

Driveshaft

3 Remove flywheel bolt with a wrench, the 2

1

flywheel will need to be held in place, while unscrewing the bolt.

3

4

5

6

7

4 Use very little force to lightly tap flywheel off.

Dept.

3

2

6

5

4

Technical reference

7

Created by

8

Joselyn Klupar

Document type

6/22/2017

Title

SF2

Approved

Document

DWG No.

A

Rev.

1

2

3

4

5

6

7

B

C

D

24 E

D

Disassembly

Driveshaft 3

2

5

4

7

6

5 Lightly tap cam plate to remove cam assembly.

Exploded View Inspection Disassembly Disassembly

Exploded View of Camshaft

Reassembly

Approved by

nce

Technical refere

Dept.

Created by

Joselyn Klupar

6/12/2017

Document type

Document status DWG No.

Title

SF2

3

4

7

6

System Specs

2

5

Rev.

Trouble Shooting

Done

25

Date o

Reassembly

Pump housing

11 Screw piston back onto piston rod and screw locknut back on.

2

1

dent Edition. se Only.

2

26

Replace the rubber suction valve by pressing down on valve insert, stretching the rubber hole around the knob.

Pump housing

Reassembly

3 Slide yoke down through top 1

2

3

4

5

A

Inspection

B

3

4

5

Disassembly

C

2

6

D

Reassembly Reassembly

4 Slide cylinder and bottom E

Exploded View

housing and piston and secure bolt to bottom of yoke.

housing together

Dept.

Technical refer

1

2

3

4

5

System Specs

F

Trouble Shooting

Done

27

Reassembly 2

1

4

5

6

7

1 Put pump housing on frame.

Make sure outlet is positioned toward the right, and inlet facing the left.

Make sure label is visable.

2

1

3

4

5

2 Insert guide pin and tighten.

A

B

3

Pump housing to frame

Dept.

Technical reference

Created by

Joselyn Klupar Document type

5/17/2017

Title

Approv

Docum

DWG N

SF2

Rev.

1

2

C

D

28

3

4

5

6

7

3

Pump housing Reassembly to frame 4

5

6

Exploded View Inspection

2

3

4

Technica

5

Reassembly

1

Disassembly

Dept.

3 Insert long bolt and tighten.

System Specs

Make sure to tighten the wing nuts with EVEN force.

Tighten wing nuts hand tight. To ensure even pressure alternate tightening in cross pattern.

Dept.

Technical reference

29

Trouble Shooting

CAUTION

Crea

Jo

Docu

Reassembly 2

3

4

Pump housing to frame 5

6

4 Twist and push air vessels on. Add a bit

1

of lubricant (oil, grease, or soap) to make assembly easier.

A

B

C

2

1

3

4

5

6

5 Secure suction and delivery hoses.

A

Dept.

7

D Technical reference

Created by

Joselyn Klupar Document type

Title

SF2 B

2

3

4

5

E

6

C

F

D

30 E

1 Done

5

Driveshaft assembly Reassembly 2

Exploded View

4 1 Reassemble3 pump, steps 1-5.

5

Starting on pg 28 Steps 1-5.

Inspection Disassembly Reassembly System Specs

2

3

4

Trouble Shooting

Dept.

Technical reference

C

J

Do

Tit

S

31 5

6

Reassembly

Cam assembly

2 Place flywheel back on camshaft.

5

4

8

7

6

A

B

C

D

E

Approved by ence

Technical refer

Dept.

Created by

Joselyn Klupar

6/1/2017

s

Document statu

Document type

DWG No.

F

Title

SF2

32

4

5

6

Rev.

7

Sheet

Date of issue

1/1

8

Cam assembly

Reassembly

Secure flywheel bolt with wrench.

3

3

4

5

6

Exploded View

2

1

7

8

A

B

Inspection

C

2

1

3

4

B

C

5

D

D

Disassembly

A

E

4

Securing yoke bearing to the camshaft. Hold the flywheel white tightening the camshaft SF2 bolt.

Dept.

Technical reference

Created by

Joselyn Klupar Document type

6/22/2017

Title

B

Document status

DWG No.

Rev.

1

2

3

4

5

6

E

Approved by

Reassembly

F

A

Date of issue

F

Sheet

7

8

System Specs

C

1/1

D

Trouble Shooting

E

Done

33

Dept.

T

System Specs

Flow rate chart

Check the system for low flow rate. Measure the flow rate of the system while the pump is operating in full sunshine and the panel is set to high. To measure the flow rate you will need a bucket of a defined volume, ideally around 20 liter and a stop watch. As the pump is running place the bucket under the outlet and time the amount of time it takes to fill. The flow rate will be the volume of bucket in liter dived by the time in second to fill.

34

RPM chart

System Specs

Exploded View

To obtain the RPM count the number of pump strokes in set time interval. This is best done by identify the highest or lowest pump stroke position, start a stop watch and count each time the pump reaches it’s max or min position. After reaching a count of 20-30 stop the stopwatch and record the time. # of seconds # of strokes

Inspection Disassembly Reassembly System Specs System

Trouble Shooting 35

Pump turns, low flow rate

System air leak

1 Check for system air leaks by running

the pump with outlet hose elevated and observe outlet for air bubbles. If large air bubbles are seen the pumps system has a significant air leak.

2

3

4

5

Dept.

6

Technical reference

Created by

Joselyn Klupar

Document type

7

4/20/2017

Title

Approved by

Document status

DWG No.

SF2 v28

Rev.

2

36

3

4

5

6

Date of issue

7

Done

2

System air leak

Pump turns, low flow rate

Possible air 3leak positions

4

5

Exploded View Inspection

Low flow rate could be caused by air leaking into the pump system. If there is significant amount of air leaking into the system air can be observed discharging out the outlet hose while the pump is running.

Disassembly

air vessel

Reassembly System Specs

inlet connection

Trouble Shooting Trouble Shooting

suction hose

pump Done

37

Pump turns, low flow rate

Air Leak in suction hose

Hold both ends of hose upward, and fill with water to visually inspect suction hose for leak.

1

2

3

4

5

Dept.

6

Technical reference

Created by

Joselyn Klupar

Document type

7

4/20/2017

Title

Approved by Document status DWG No.

SF2 v28

Rev.

2

38

3

4

5

6

Date of issue

7

Done

Leak between suction hose to connection

Visually inspect both rubber washers of the coupling halves.

Exploded View

1

Pump turns, low flow rate

Inspection Disassembly

2

System Specs

Insure that the hose nipple is pushed tightly against the inlet and outlet holes while you screw on the couplers.

Reassembly

Replace if in doubt. Insure coupling is screwed on tight.

Trouble Shooting Trouble

Done

39

Pump turns, low flow rate Pump turns, low flow rate

Leak between air vessel to pump

1 Inspect O-ring in bottom

connection that connects to pump

Replace if damaged.

40

Done

Water too deep to be lifted

Pump turns, low flow rate

Exploded View

1 Measure lift 1 5

4

B

3

2

1

2

3

5

6

7

8

C

Inspection

A

4

1

A

A

D

B

B

B

E

C ed by

Approv

017

d by

Create ce

C

Techn

D

ical

referen

Joselyn

ent type

Docum

Dept.

6/20/2

Klupar

ent status

DWG

C

No.

Rev.

SF2

F

Docum

Title

Sheet

Date

of issue

2/2

8

7

6

E

5

D

D

4

3

2

F

1

E

Technical reference

Created by

Joselyn Klupar

Document type

5/9/2017

Title

Document status

DWG No.

SF2

F

Rev.

1

2

3

4

5

6

E

Approved by

7

F

Date of issue

Sheet

8

1/1

total liftlift total

Disassembly

suction suction liftlift Dept.

Reassembly System Specs

If suction lift is greater than 8 meters a deepset version of the SF2 pump is required.

Trouble Shooting Trouble Shooting

Done

41

Pump turns, low flow rate

Suction Valve Leaking

Follow disassembly one steps 1-8 in addition to the steps below to check the suction valve.

1 Open pump.

2 Attach pump cylinder to bottom cylinder housing and fill with water.

Hold the cylinder and bottom housing firmly to allow no water leakage at that point.

No water should escape the suction value 42

Suction Valve Leaking

Pump turns, low flow rate

Exploded View

3 Check gaskets for damage

Inspection Disassembly Reassembly System Specs

4 Inspect suction valve

and check for dirt or debris.

Done

Trouble Shooting Trouble Shooting

You can lift slightly on the valve, to inspect.

43

Pump turns, low flow rate

Piston seal leaking

Follow disassembly one steps 1-10 in addition to the steps below to check the piston seal.

1 Insert piston into cylinder and inspect the clearance between the seal and the cylinder. Make sure it is no more than .5 mm. Replace piston seal, if worn or damaged.

If piston cylinder is worn replace cylinder.

0 - .5mm 44

Done

Pully slipping on wheel

Pump operating at low RPM

1 Visually check condition

of rubber track on flywheel. If damaged, replace.

2

3

4

5

6

A

7

Inspection

B

Exploded View

1

C

Disassembly

D

from making full contact on wheel and align pully with the rubber track on flywheel. Joselyn Klupar (The cage has been removed from image for SF2 better visual understanding) Dept.

Technical reference

Created by

Document type

Reassembly

2 Check to make sure motor is not restricted

E

6/13/2017

Title

1

2

3

4

5

6

7

Trouble Shooting Trouble Shooting

Done

45

Doc

DWG

System Specs

F

App

Rev

Excessive piston friction

Pump operating at low RPM

Follow disassembly one steps 1-8 in addition to the steps below.

2

1

3

4

5

6

1 Remove pump unit from frame.

Dept.

Technical reference

Created by

Joselyn Klupar

Document type

Title

SF2

1

46

2

3

4

5

Done 6

6/

Excessive piston friction

2

Pump operating at low RPM

2

3

4

Inspection

1

Exploded View

Manually move the piston up and down, holding the yoke. The force required to do this should not exceed 2 kg. If it does, disassemble the pump (refer to page 9) and check for accumulation of dirt around the piston seal (refer to page 18).

5

6

A

Disassembly

B

Reassembly

C

System Specs

D

E

Technical reference

Trouble Shooting Shooting

Dept.

Created by

Joselyn Klu

Document type

Title

SF2

F

1

2

3

4

5

6

47

Pump operating at low RPM

Excessive friction of stuffing box

Follow disassembly steps 1-7 in addition to the steps below.

1 Loosen the stuffing box compression bolt by turning the stuffing box one turn counter clockwise. It may take some time (5-10 mins) before the graphite accommodates to the new situation and the friction is reduced.

48

Done

Bad electrical connection

Pump operating at low RPM

Exploded View

Bad electrical connection between motor and panel. Check the connection points. A bad connection can sometimes be found by feeling for a hot spot.

1

Inspection Disassembly

5

4

3

2

Reassembly

6

1

A

B

System Specs

C

D

Trouble Shooting Trouble

E

Done

49

Pump operating at low RPM

Testing PV panel

Check Panel output

1

Connect the multimeter as shown below to the plug from the panel. To insure proper current, disconnect the motor from the panel. Connect the multimeter as shown below to the plug from the panel. Ensure the multimeter is set at 10A, the measurement should match the panel rating.

2

To insure proper voltage rating, connect the +ve voltmeter to the +ve on the panel and -ve from voltmeter to -ve on panel. Voltmeter should read 21V.

6

6

5

4

3

2

5

4

3

2

1

1

A

A

B

B

C

C

D

D

E

E

ACV

DCV 200

DCV

1000

200

20

DCA

DCA

200

2000µ 20m 200m

Ω

DCA

OFF

C C max

Digital Multimeter

OM

50

10 ADC

ON

10A max

!

!

CAT. II

1

VΩmA 750VAC 1000VDC 200mAmax

COM

2000 m

200µ

200 m

200 m

2000µ 20m 200m

Ω

10A

A

10

20

2000 m

200µ

200 m

mA

DCV

1000

20

2000 m

200µ

2000µ 20m 00m

ACV

Ω

10A OFF

Digital Multimeter

2

10 ADC

ON

10A max

!

!

CAT. II

OFF

VΩmA 750VAC 1000VDC 200mAmax

ON

Digital Multimeter

COM

Done

Motor damaged

Pump operating at low RPM

Exploded View

Replace Motor

Inspection Disassembly Reassembly System Specs

Possible reasons for damaged motor - overheating - worn brushes - faulty components

Trouble Shooting Trouble Shooting

Done

51

Pump operating at low RPM

Testing motor

Measure motor amps under full sun and with the motor detached from the flywheel. Plug the positive side of the multimeter into 10A. To measure, use an extension cable and multimeter.

Follow the diagram below to measure amps(be sure to plug the lead into the 10 AMP plug before measuring). The motor current, running without load, should not exceed 0.4 amps.

1

ACV

DCV 200

1000

20

DCA

2000 m

200µ

200 m

Ω

OFF

200k 20k 2000

2000µ 20m 200m

Digital Multimeter

52

10A

200

10 ADC

ON

10A max

!

!

CAT. II

VΩmA 750VAC 1000VDC 200mAmax

COM

Done

Suction inlet/outlet hose blocked 2

1

3

Pump operating at low RPM

4

5

6

Exploded View

Remove Suction and Delivery Hoses to check for obstruction.

Inspection Disassembly Reassembly

2 Check entire hose for obstruction.

2

3

A

4

1

5

B

6

7

8

C

Dept.

A

A

Technical reference

D

B

B

B

Created by

Joselyn Klupar Document type

E

C

System Specs

5

4

3

2

1

d by

Approve

by ar lyn Klup Jose nt type C

7

/201

6/20

nt status

C

l referenc

Technica

D

DWG

No. Sheet

Docume

Dept.

Rev.

Title

SF2

F

Docume

Created e

Date

of issue

2/2

8

Title

7

6

E

D

4

3

2

F

1

E

E

Dept.

Technical reference

Created by

Joselyn Klupar Document type

5/9/2017

Title

Approved by

Document status

DWG No.

SF2

F

F Rev.

1

2

3

2

3

4

4

5

6

7

Date of issue

Sheet

8

1/1

5

6

Done

53

Trouble Shooting Shooting

SF2

5

D

5

Knocking sound

1

Main shaft bearings worn

Check if flywheel can be tilted more than 1mm at the rim. If yes...

(The cage has been removed from image for better visual understanding)

SolidWorks Student Editio n.

SolidWorks Edition.

For AcademicStudent Use Only.

For Academic Use Only.

54

Done

Main shaft bearings worn

Knocking sound

Exploded View

3 Follow disassembly two, steps 1-5 to remove cam assembly to inspect bearings.

Remove main shaft access bearings Replace if damaged.

2

3

4

5

6

Inspection

6.6

6.4

6.11

6.5

6.10

6.3

Reassembly

6.2

6.8

Disassembly

6.7

6.9

6.1

System Specs

Technical reference

Trouble Shooting Trouble Shooting

Dept.

Created by

Joselyn Klup

Document type

Done

55

Title

SF2

Excessive leakage

Stuffing box

Follow disassembly one: pump housing, steps 1-9 in addition to disassembly one:stuffing box, steps 1-3.

1 Refer to pg 9 to disassemble pump.

Tighten stuffing box.

rks Student Edition. demic Use Only.

2 If the stuffing box cannot be further

tightened, remove the stuffing box (refer to pg 16) and add the graphite cord.

56 SolidWorks Student Edition.

For Academic Use Only.

Done

Notes

Exploded View

Inspection Disassembly

Reassembly

System Specs

TroubleShooting Shooting Trouble

57

Done

Is the pump

yes

yes

no

Is there a low flow rate? (see flow rate chart)

Is th

Is the pump running slowly (low RPMs) Refer to pg. 48 yes

Is the solar panel in full sunshine?

no

yes yes

Is there air coming out of the outlet hose?

system air leak Refer to pg 36 Check leak in suction hose

Check suction & piston valve Refer to pg. 12

Performance will greatly reduce if panel shadows.

Relocate panel to avoid any shadows.

Check leak in pump

Check leak in air vessel leak

Check suction & piston o-ring for damage Refer to pg. 40

no

Damaged PV Panel

Damaged Motor Refer to pg. 51

Possible constricted outlet; Refer to pg.

53

Possible constricted inlet Refer to pg. 53

Pully slipping on wheel Refer to pg. 45

58

p, pumping water? yes

no

Is the pump moving?

here a knocking sound? yes

Check for severe air leak in sucktion hose Refer to pg 38

no

Is the motor too hot?

yes

no

Is the pump running at an irregular speed?

Is the current over 3.8 amps? Refer to pg. 50 Check lift to flow ratio.

Refer to pg. 34

yes

Outlet side airvessel has lost the air and is now filled with water. Fix the leak

yes

If lift is too high use deepset version of pump.

Pully slipping on wheel; Refer to pg. 45

Excessive friction Panel capacity too low; Refer to pg. 50

Refer to pg. 46

Bad electrical connection; Refer to pg. 49

l

Done

59