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
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d by
Approve
by ar lyn Klup Jose nt type C
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nt status
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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