Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Did something go wrong? Ask about it here. Later report and document the resolution here including out of pocket costs for replacement parts.
Post Reply
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by steve96822 »

Heres a brief introduction to cover some fears overcome. not sure if I will manage to post complete step by step with photos at this sitting.

Caveats

My great fear was knowing the internal rebuild components were graphite and I likened it to graphite in a pencil, fragile, break easy. I was worried about snapping the graphite components.

Fact; Graphite comes in various hardness's with a pencil being on the very soft end.

The 3 graphite components of pump are exceedingly strong as it took much fulcrum force with tools to remove the originals. This hardness graphite has a very strong compression tolerance/strength.

Was not that difficult to do. The only time elbow grease was needed was in removing the old graphite flanges albeit the first one came out very easily. The other operation that needed a little force was to compress the cover plate so the C clip could be reinserted.

The exploded view showing the proper assembly of the internal components specifically the pieces that create the watertight seal was not 100% clear on schematic but with some trial and error and great support from Fluid O Tech I figured it out.

Pro's and Con's;

Interesting, educational and fun. Save some money versus buying a new pump. The brass pump housing is not cheap, generally lasts forever and only needs an internal cleaning of debris and minerals. Shipping cost of pump higher due to added weight of housing vs light rebuild components.

Fear of breaking something and being stuck unable to make coffee. Learning curve. Need time to do it.


Step by step with photos to follow
Last edited by steve96822 on Sun Jul 08, 2018 9:20 am, edited 2 times in total.
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Unplug

Turn off water supply
Attachments
Place towel
Place towel
P1050106.JPG (147.02 KiB) Viewed 208479 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Remove 2 screws faceplate and remove faceplate

Turn on back
The attachment P1050107.JPG is no longer available

Pump exposed anterior view
P1050107.JPG
P1050107.JPG (158.1 KiB) Viewed 208476 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Pump exposed on anterior view
P1050109.JPG
P1050109.JPG (110.88 KiB) Viewed 208476 times
Bottom view pump access
P1050110.JPG
P1050110.JPG (122.16 KiB) Viewed 208476 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Remove water inlet connection . 17mm wrench
P1050114.JPG
P1050114.JPG (99.4 KiB) Viewed 208476 times


Remove water outlet connection . 14 mm wrench
P1050115.JPG
P1050115.JPG (96.4 KiB) Viewed 208476 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Remove motor-pump coupling collar
P1050117.JPG
P1050117.JPG (97.92 KiB) Viewed 208476 times
P1050118.JPG
P1050118.JPG (104.89 KiB) Viewed 208476 times

Remove pump. Dont misplace brass coupling that links pump shaft to motor shaft
Last edited by steve96822 on Sun Jul 08, 2018 6:25 am, edited 1 time in total.
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Inspect and clean if need be the bearing area of motor collar. Here can see residue of aluminum corrosion from pump water leak. Ceramic bearing seen.
P1050120.JPG
P1050120.JPG (113.18 KiB) Viewed 208476 times


Water damage on coupling side of pump
P1050122.JPG
P1050122.JPG (101.36 KiB) Viewed 208475 times
Attachments
P1050123.JPG
P1050123.JPG (130.4 KiB) Viewed 208476 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Pump outer housing cleaned
P1050128.JPG
P1050128.JPG (167.94 KiB) Viewed 208474 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Remove C clip . with needle nose plier or C clip tool. Note the clip tool must squeeze inward. I initially used the opposite tool applying inward pressure with a vise grip (not shown in photo).
P1050129.JPG
P1050129.JPG (133.29 KiB) Viewed 208474 times
P1050130.JPG
P1050130.JPG (129.87 KiB) Viewed 208474 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

C clip and metal cover plate removed to expose rubber O ring on front flange and front end of metal rotor
P1050132.JPG
P1050132.JPG (153.71 KiB) Viewed 208474 times

Remove rubber O ring
P1050136.JPG
P1050136.JPG (182.11 KiB) Viewed 208474 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Remove old internal components. I used an motorcycle internal bearing puller and a socket set extension through coupleing side of pump. Rubber mallet helped. Some force required to get out old components most of which broke.
P1050140.JPG
P1050140.JPG (145.61 KiB) Viewed 208474 times
P1050141.JPG
P1050141.JPG (173.38 KiB) Viewed 208474 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Internal bearing puller set for motorcycles
P1050158.JPG
P1050158.JPG (111.23 KiB) Viewed 208474 times
P1050159.JPG
P1050159.JPG (101 KiB) Viewed 208474 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Vinegar water soak to remove minerals. Since I did not mess with adjustment valve nor replace its O ring I just used vinegar rather than a strong de mineralizing chemical.
P1050160.JPG
P1050160.JPG (109.11 KiB) Viewed 208474 times

Old internal components post removal
P1050170.JPG
P1050170.JPG (164.6 KiB) Viewed 208474 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Original internal components that came out intact. Front graphite
P1050154.JPG
P1050154.JPG (203.02 KiB) Viewed 208474 times
flange Metal rotor, 4 graphite vanes, alignment pin and 2 vane pins
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Cleaned brass housing internally
P1050173.JPG
P1050173.JPG (110.6 KiB) Viewed 208474 times
P1050172.JPG
P1050172.JPG (139.44 KiB) Viewed 208474 times
P1050171.JPG
P1050171.JPG (133.54 KiB) Viewed 208474 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

WRONG WAY to install graphite seal ring on rotor shaft. In addition spring is missing.
P1050175.JPG
P1050175.JPG (148.94 KiB) Viewed 208474 times
P1050175.JPG
P1050175.JPG (148.94 KiB) Viewed 208474 times
P1050174.JPG
P1050174.JPG (139.11 KiB) Viewed 208474 times
Last edited by steve96822 on Sun Jul 08, 2018 8:28 am, edited 1 time in total.
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Insertion of white ceramic disk in rubber gasket
P1050177.JPG
P1050177.JPG (98.35 KiB) Viewed 208474 times
P1050178.JPG
P1050178.JPG (97.92 KiB) Viewed 208473 times
P1050180.JPG
P1050180.JPG (100.95 KiB) Viewed 208474 times
Attachments
P1050177.JPG
P1050177.JPG (98.35 KiB) Viewed 208474 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Rotor inserted into back flange. Can see vane pin holes
P1050191.JPG
P1050191.JPG (111.59 KiB) Viewed 208472 times
P1050193.JPG
P1050193.JPG (84.66 KiB) Viewed 208472 times
Last edited by steve96822 on Sun Jul 08, 2018 7:55 am, edited 1 time in total.
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Vane pins correct positioning depicted though not inserted into rotor yet.
P1050190.JPG
P1050190.JPG (128.89 KiB) Viewed 208472 times
Vane pins inserted and in correct position . (flat sides touching. You also see graphite vanes correctly positioned in rotor. Note convex ends face outwards
P1050203.JPG
P1050203.JPG (119.67 KiB) Viewed 208472 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Next place graphite liner (middle graphite component) over rotor vane assembly and than place graphite front flange on top. Rotate 3 graphite components so the 3 alignment slots become one. I used a small amt of scotch tape to hold assembly together. I cleaned any tape residue before final assembly. Fluid O Tech recommends isopropyl alcohol as a cleaner-lubricant for assembly as it leaves virtually no residue.


Carefully install the graphite seal-spring mechanism over the rotor shaft. Seal distance is about 0.72 inches. The small graphite seal ring touches the white ceramic disk to create the pump internal water seal while also allowing the rotor to spin. It is essential the small graphite ring surface be perfectly flat not damaged. Tiny indentations or surface defects can cause water leaks. Should this graphite seal surface become not flat you may fix it by using a #500 knife sharpening stone to eliminate gross imperfections and finish it with #1000 stone. I had a #1000 Japanese water stone available to use.
P1050229.JPG
P1050229.JPG (131.13 KiB) Viewed 208471 times
P1050204.JPG
P1050204.JPG (101.28 KiB) Viewed 208471 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Carefully position the internal assembly into brass housing in the correct position while insuring the flange alignment pin is in place.
P1050207.JPG
P1050207.JPG (124.59 KiB) Viewed 208470 times
P1050206.JPG
P1050206.JPG (148.66 KiB) Viewed 208470 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

I used a gentle combination of hand and rubber mallet to get it in. Was not difficult. Once internal assembly in inserted you can push it in and feel the spring tension and release it and it pops up .
P1050208.JPG
P1050208.JPG (148.4 KiB) Viewed 208470 times
P1050209.JPG
P1050209.JPG (146.7 KiB) Viewed 208470 times
P1050211.JPG
P1050211.JPG (181.99 KiB) Viewed 208470 times
P1050212.JPG
P1050212.JPG (115.39 KiB) Viewed 208470 times
Can see the rubber O ring above front flange and metal cover plate above it
Attachments
P1050213.JPG
P1050213.JPG (144.14 KiB) Viewed 208470 times
Last edited by steve96822 on Sun Jul 08, 2018 8:23 am, edited 2 times in total.
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Here is the action of spring shown in video attachment
https://youtu.be/Jt0m4qqsb28
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

With new rubber O ring on top of front flange and metal cover plate I used a C clamp to compress adequately enabling C ring reinsertion.You may need to squeeze C ring into recess, I used a vice grip.
P1050232.JPG
P1050232.JPG (192.26 KiB) Viewed 208464 times
P1050232.JPG
P1050232.JPG (192.26 KiB) Viewed 208464 times
P1050234.JPG
P1050234.JPG (187.16 KiB) Viewed 208464 times
Last edited by steve96822 on Sun Jul 08, 2018 8:23 am, edited 1 time in total.
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 »

Reattach pump in reverse order, turn on water and plug in power. Test.

Rebuild manual says pumps are typically bench tested so you may need to run it a bit. My pump shaft initiall a bit difficult to turn after cover plate compressed and C ring place but resolving on its own. No visible water leaking.
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos

Post by steve96822 »

Rebuild manual shows pump bearing but the S1 pump does not have a bearing.
Pump Rebuild Manual 1 0 9-29-16.pdf
(2.35 MiB) Downloaded 1400 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by steve96822 »

PS; You do not absolutely need the internal bearing pullers to do this rebuild.

May be possible to remove old graphite components without breaking by soaking in vinegar solution overnight as it may be mineral buildup causing the adhesion.

Can be tapped out from rotor shaft opening also.
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
User avatar
chas
Vivaldi Dreamer
Posts: 3044
Joined: Wed Jun 02, 2004 11:52 pm
Location: Central Maryland
Contact:

Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by chas »

What standard tool that I might already have can be used in place of the internal bearing puller?
Chas
LM GS/3 & LaSpaziale Dream v 1.25 (US 120V)
Mazzer Kony E, Customized Rocky
Hottop P/B
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by steve96822 »

What standard tool that I might already have can be used in place of the internal bearing puller?"
IGNORE BEARING SINCE S1 PUMP HAS NONE
IGNORE BEARING SINCE S1 PUMP HAS NONE
ROTARY PUMP .png (123.98 KiB) Viewed 208197 times
Some options;

Front flange and rotor and rotor components come out easily. Then you are left with #graphite liner and #graphite rear flange, mechanical seal and spring. Using hacksaw blade or equivalent cut into liner until near brass housing but avoid cutting housing. then can use a strong screwdriver or chisel to break graphite. Can also use curved nose pliers for this. Initially even with internal bearing puller it wasnt budging before I cut graphite.

The rotor opening can accept a screwdriver that can be angled to knock out the graphite.

Can also try the "secret bearing removal" trick by packing chosen cloth through shaft hole then using socket extension to tap down thus pushing graphite out. What I did also very helpful was to form a nice cushion cradle using a old bath towel.

https://www.youtube.com/watch?v=ggsEewAg2YM
https://www.youtube.com/watch?v=w62c4NQDwP0
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by steve96822 »

One comment on oil/grease soaked rag trick to remove graphite. I would use a water soaked rag rather than oil/grease because you dont want oil/grease to find its way into the valve.
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
rhinoevans
Vivaldi Dreamer
Posts: 110
Joined: Tue Aug 17, 2004 2:32 pm
Location: Las Vegas

Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by rhinoevans »

Where did you get the parts kit?
steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by steve96822 »

"Where did you get the parts kit?"


Fluid O Tech USA .. about 36 usd plus shipping



Fluid-o-Tech International, Inc. Tel 860-276-9270

161 Atwater Street Fax 860-620-0193

Plantsville, CT 06479 www.fluidotech.com
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
levikoehn
Freeze Dried
Posts: 1
Joined: Sun Feb 25, 2018 3:02 am
Location: US

Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by levikoehn »

Since spanner wrenches are in nobodies tool box here's a simple way to get the pump cover off for those with the threaded coverImage

Sent from my SM-G950U using Tapatalk

steve96822
God Shot
Posts: 135
Joined: Tue May 30, 2006 5:08 pm
Location: US/Asia

Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by steve96822 »

Good idea and fast.

Below also look decent though requires a little time to make.
Screen Shot 2018-10-01 at 12.31.23 PM.png
Screen Shot 2018-10-01 at 12.31.23 PM.png (690.09 KiB) Viewed 206250 times
S1 V1 220volt
Mazzer mini
Ascaso Innova doserless
Simonelli Oscar
Olympia Cremina
Faema lever antique(working)
Post Reply

Return to “S1 Operational Problems”