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

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

Post by steve96822 » Tue Jul 03, 2018 7:53 am

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

Post by steve96822 » Sun Jul 08, 2018 5:32 am

Unplug

Turn off water supply
Attachments
P1050106.JPG
Place towel
P1050106.JPG (147.02 KiB) Viewed 1985 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:15 am

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 1982 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:17 am

Pump exposed on anterior view
P1050109.JPG
P1050109.JPG (110.88 KiB) Viewed 1982 times
Bottom view pump access
P1050110.JPG
P1050110.JPG (122.16 KiB) Viewed 1982 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:18 am

Remove water inlet connection . 17mm wrench
P1050114.JPG
P1050114.JPG (99.4 KiB) Viewed 1982 times


Remove water outlet connection . 14 mm wrench
P1050115.JPG
P1050115.JPG (96.4 KiB) Viewed 1982 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:20 am

Remove motor-pump coupling collar
P1050117.JPG
P1050117.JPG (97.92 KiB) Viewed 1982 times
P1050118.JPG
P1050118.JPG (104.89 KiB) Viewed 1982 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.
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:23 am

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 1982 times


Water damage on coupling side of pump
P1050122.JPG
P1050122.JPG (101.36 KiB) Viewed 1981 times
Attachments
P1050123.JPG
P1050123.JPG (130.4 KiB) Viewed 1982 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:28 am

Pump outer housing cleaned
P1050128.JPG
P1050128.JPG (167.94 KiB) Viewed 1980 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:31 am

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 1980 times
P1050130.JPG
P1050130.JPG (129.87 KiB) Viewed 1980 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:36 am

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 1980 times

Remove rubber O ring
P1050136.JPG
P1050136.JPG (182.11 KiB) Viewed 1980 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:40 am

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 1980 times
P1050141.JPG
P1050141.JPG (173.38 KiB) Viewed 1980 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:41 am

Internal bearing puller set for motorcycles
P1050158.JPG
P1050158.JPG (111.23 KiB) Viewed 1980 times
P1050159.JPG
P1050159.JPG (101 KiB) Viewed 1980 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:45 am

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 1980 times

Old internal components post removal
P1050170.JPG
P1050170.JPG (164.6 KiB) Viewed 1980 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:48 am

Original internal components that came out intact. Front graphite
P1050154.JPG
P1050154.JPG (203.02 KiB) Viewed 1980 times
flange Metal rotor, 4 graphite vanes, alignment pin and 2 vane pins
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:51 am

Cleaned brass housing internally
P1050173.JPG
P1050173.JPG (110.6 KiB) Viewed 1980 times
P1050172.JPG
P1050172.JPG (139.44 KiB) Viewed 1980 times
P1050171.JPG
P1050171.JPG (133.54 KiB) Viewed 1980 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:54 am

WRONG WAY to install graphite seal ring on rotor shaft. In addition spring is missing.
P1050175.JPG
P1050175.JPG (148.94 KiB) Viewed 1980 times
P1050175.JPG
P1050175.JPG (148.94 KiB) Viewed 1980 times
P1050174.JPG
P1050174.JPG (139.11 KiB) Viewed 1980 times
Last edited by steve96822 on Sun Jul 08, 2018 8:28 am, edited 1 time in total.
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 6:56 am

Insertion of white ceramic disk in rubber gasket
P1050177.JPG
P1050177.JPG (98.35 KiB) Viewed 1980 times
P1050178.JPG
P1050178.JPG (97.92 KiB) Viewed 1979 times
P1050180.JPG
P1050180.JPG (100.95 KiB) Viewed 1980 times
Attachments
P1050177.JPG
P1050177.JPG (98.35 KiB) Viewed 1980 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 7:02 am

Rotor inserted into back flange. Can see vane pin holes
P1050191.JPG
P1050191.JPG (111.59 KiB) Viewed 1978 times
P1050193.JPG
P1050193.JPG (84.66 KiB) Viewed 1978 times
Last edited by steve96822 on Sun Jul 08, 2018 7:55 am, edited 1 time in total.
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 7:05 am

Vane pins correct positioning depicted though not inserted into rotor yet.
P1050190.JPG
P1050190.JPG (128.89 KiB) Viewed 1978 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 1978 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 7:21 am

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 1977 times
P1050204.JPG
P1050204.JPG (101.28 KiB) Viewed 1977 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 7:27 am

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 1976 times
P1050206.JPG
P1050206.JPG (148.66 KiB) Viewed 1976 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 7:30 am

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 1976 times
P1050209.JPG
P1050209.JPG (146.7 KiB) Viewed 1976 times
P1050211.JPG
P1050211.JPG (181.99 KiB) Viewed 1976 times
P1050212.JPG
P1050212.JPG (115.39 KiB) Viewed 1976 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 1976 times
Last edited by steve96822 on Sun Jul 08, 2018 8:23 am, edited 2 times in total.
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 7:52 am

Here is the action of spring shown in video attachment
https://youtu.be/Jt0m4qqsb28
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 8:00 am

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 1970 times
P1050232.JPG
P1050232.JPG (192.26 KiB) Viewed 1970 times
P1050234.JPG
P1050234.JPG (187.16 KiB) Viewed 1970 times
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Re: Rotary Pump Rebuild; Finally did it...........

Post by steve96822 » Sun Jul 08, 2018 8:04 am

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

Post by steve96822 » Sun Jul 08, 2018 8:26 am

Rebuild manual shows pump bearing but the S1 pump does not have a bearing.
Pump Rebuild Manual 1 0 9-29-16.pdf
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Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by steve96822 » Mon Jul 09, 2018 1:30 am

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

Post by chas » Tue Jul 10, 2018 1:01 pm

What standard tool that I might already have can be used in place of the internal bearing puller?
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Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by steve96822 » Fri Jul 13, 2018 10:17 am

What standard tool that I might already have can be used in place of the internal bearing puller?"
ROTARY PUMP .png
IGNORE BEARING SINCE S1 PUMP HAS NONE
ROTARY PUMP .png (123.98 KiB) Viewed 1703 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
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Re: Rotary Pump Rebuild; Finally did it.........Updated with step by step how to and photos & video

Post by steve96822 » Mon Jul 16, 2018 5:44 am

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

Post by rhinoevans » Fri Jul 20, 2018 11:26 pm

Where did you get the parts kit?

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

Post by steve96822 » Tue Aug 14, 2018 6:59 am

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

Post by levikoehn » Fri Aug 31, 2018 1:53 pm

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

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