SHURFLO® 4008 RV REVOLUTION™ By-pass pUmp
INSTALLATION & OperATION MANuAL
16 AWG [1.28mm] or heavier wire
Switch
Connector
Ground
Black
Flexible Braided
High Flow Hose
Fuse
Surface Solide
Strainer
Typical Pump Installation
INSTALLATION GUIDELINES
❚ Solid Surface within 6' of tank.
❚ Minimize flow restrictions in the
system.
❚ No Accumulator needed.
❚ Flexible hose on inlet and outlet.
❚ Minimize plumbing elbows and valves.
❚ Accessible location.
❚ Strainer on pump inlet.
❚ Properly Sized wiring.
❚ Properly electrical protection.
❚ Properly sized plumbing.
INSTALLATION PREPARATION
The goal of installation is to provide a
quiet, easy-to-maintain installation with
good flow and low backpressure. This
can be accomplished with the following
guidelines:
❚ Mount on a solid surface in an
accessible location for strainer cleaning
and pump maintenance.
❚ Use flexible high-pressure hose
on the pump inlet and outlet [such
as SHURFLO Kit 94-591-01]. The
pumps ports and strainer should
not be connected to plastic or rigid
pipe, or the pump's normal motion
will transmit through rigid plumbing
causing noise, and possibly loosening
or cracking components.
❚ Pump must use an adequate 50-mesh
strainer [such as SHURFLO 255 series
strainers].
❚ Use a minimum of 1/2" [13mm]
Inner Diameter plumbing. Smaller ID
plumbing will cause cavitation, high
back pressure, low flow and noise.
❚ No need for an accumulator with by-
pass pumps.
❚ Pump is designed for intermittent
duty only: Do not use these pumps
for running a Reverse-Osmosis [RO]
Filtration System. High pressurecontinuous duty usage will shorten
the life of the pump and is not covered
under warranty.
❚ Wire Size is 16 GA MINIMUM, 12GA
is recommended —See Wire Chart in
Electrical Section for minimum sizing.
❚ Minimum power requirement is a 10
Amp circuit.
❚ Reduce restrictions on inlet and
outlet. This includes small inner
diameter shut-off valves, winterizing
valves and elbows.
❚ If the RV has an Intellitec Pump
Controller, it must be rated at 10 or 15
amps; If the controller is rated at 7.5
Amps, a new controller or a high-amp
relay must be used.
MOUNTING
❚ Mount the pump within 6 feet of the
tank for best performance and pump
life. The pump will pull farther, but the
farther it pulls the more work it does,
increasing vibration and noise, and
reducing the output and pump life.
❚ Mount pump in a space of at least 1
cubic foot for adequate ventilation to
prevent overheating.
❚ Pump may be mounted in any position.
❚ Mount pump for easy access for
cleaning strainer, maintenance and
service.
❚ Mount pump on a solid surface to
prevent vibration and noise.
WATER PURFICATION 911-1008 REV.H 1
ELECTRICAL
ABOUT THE BY-PASS
❚ The pump works best on an individual
filtered circuit, protected by the recommended fuse or breaker specified on the
label.
❚ A 15-Amp switch is recommended and
should be on the positive lead (red wire).
❚ Wire Sizing: Proper wire sizing is
required for good pump operation. If the
wire is too small, low voltage will affect the
pump performance and can create a fire
hazard. SHUT OFF POWER TO THE PUMP
WHEN LEAVING THE RV UNATTENDED.
Ft. [m] AWG [mm2]
0-25 [0-7.6] 16 [1.3]
25-50 [7.6-15.2] 14 [2.1]
50-70 [15.2-21.3] 12 [3.3]
70-110 [21.3-33.5] 10 [5.3]
Minimum Wire Size for a 10% voltage drop on a 12VDC, 15 Amp
Circuit. Length is the distance from the power source to pump
and back to ground.
PLUMBING
Installation of a strainer is required to
prevent debris from entering the pump.
For noise and vibration reduction we
recommend at least 18 in. [.5 M] of
1/2" [13mm] I.D. flexible high-pressure
hose to both ports. The pump ports and
strainer should not be connected to
plastic or rigid pipe. This hose should
be anchored where it meets the hard
plumbing to reduce plumbing vibration.
OPERATION
NOTE: By-pass adjustment should only
be performed by a professional technician with proper gauges and equipment.
The by-pass is a spring loaded diaphragm that opens up allowing water
from the discharge side back to the inlet
side. The by-pass is set to begin opening
at about 40 psi and creating full by-pass
at about 62 psi (lower pressure pumps
will vary depending on the by-pass and
pressure shut-off settings). The pressure switch on the pump is set to shut
off at 55 psi. If the switch or by-pass
are adjusted too much, the by-pass and
switch shut-off can overlap and THE
PUMP WILL NOT SHUT OFF. Screw-
SANITIZING
Potable water systems require periodic
maintenance to keep components working properly and deliver a consistent
flow of fresh water. Sanitizing is recommended: prior to storing, after a period
of storage, or any time the system is
opened or contaminated, as follows:
NOTE: Check your Vehicle Owner’s
Manual for specific instructions.
By-pass any filters or remove filter
cartridges.
1. Determine the amount of common
household bleach needed to sanitize the
tank.
A) 2 ounces of bleach per 15 gallons
tank size: 60 gallon tank [15 x 4] = 4 x
2 ounces = 8 ounces of bleach.
B) I ml bleach per 1 liter tank size:
300 liter tank = 300 milliliters of
bleach.
ing the switch screw in clockwise will
raise the shut-off pressure. Unscrewing the switch screw counterclockwise
will lower the pump shut-off pressure.
Screwing the by-pass screw in will raise
the pressure at which the by-pass starts
and raise the full by-pass pressure.
Unscrewing the by-pass screw counterclockwise will lower the pressure at
which by-pass starts and lower the full
by-pass pressure.
WARNING: If full by-pass is reached
before the shut-off setting, the pump
will not shut off. Full by-pass pressure
setting should be at least 10 psi higher
than pump shut off pressure.
2. Mix the bleach with water in a container such as a gallon jug. If tank is
filled through a pressurized fitting, pour
the bleach into the hose before attaching the hose to the city water entry.
3. Pour the bleach solution into the tank
and fill the tank with potable water. Rock
the RV back and forth to coat top and
sides of potable water tank.
4. Open all faucets (Hot & Cold) allowing the water to run until the odor
of chlorine is detected. Allow four (4)
hours of contact time to disinfect completely. Doubling the solution concentration allows for a contact time of one (1)
hour.
5. Drain the tank. Refill the tank and
flush the system once or twice until the
odor has decreased. The residual chlorine odor and taste is not harmful.
This pump is designed for intermittent
duty only. The pump operates normally
up to about 40-psi, where a spring-loaded by-pass valve opens, allowing flow
back from the output side to the input
side, providing smooth, steady flow with
virtually no cycling, all the way down
to a trickle. As a faucet is opened back
up, the pressure will drop, the by-pass
will close and full flow is again obtained. This allows good flow, even with
today’s restrictive showers and pullout
sprayer faucets. Performance will vary,
of course, depending on the voltage to
the pump; lower voltage = lower flow,
higher voltage = higher flow. Remember
your electrical safety: It is always best to
shut power to the pump OFF when leaving the RV unattended.
2
WINTERIZING
Refer to the vehicle owner’s manual for
specific winterizing instructions.
If water is allowed to freeze in the
system, serious damage to the plumbing and pump may occur. Failures of
this type will void the warranty. The best
guarantee against damage is to completely drain the pump and perform the
following:
1. Drain the water tank. If the tank
doesn't have a drain valve, open all faucets allowing the pump to operate until
the tank is empty.
2. Open all the faucets (including the lowest valve or drain in the plumbing), allow
the pump to purge the water from the
plumbing, and then turn the pump OFF.
3. Using a pan to catch the remaining water, remove the plumbing at the
pump's inlet/outlet ports. Turn the
pump ON, allowing it to operate until
the water is expelled. Turn OFF power to
the pump once the plumbing is emptied.
Do not reconnect the pump plumbing.
Make a note at tank filler as a reminder:
"Plumbing is disconnected".
4. All faucets must be left open to guard
against any damage.
5. Potable anti-freeze may be poured
down drains and toilets to protect
p-traps and toilet seals. Sanitize the
plumbing system before putting the
plumbing system back in service.
TROUBLESHOOTING
Vibration induced by driving can loosen
plumbing, strainers and pump hardware. Check for system components
that are loose. Also, refer to the chart
below for trouble-shooting tips.
PUMP WILL NOT START/ BLOWS
CIRCUIT
√ Electrical connections, fuse or
breaker, main switch, and ground
connection.
√ Is the motor hot? Thermal breaker
may have triggered; it will reset
when cool.
√ Is voltage present at the switch?
Bypass pressure sw. Does the pump
operate?
√ Charging System for correct voltage
(±10%) and good ground.
√ For an open or grounded circuit, or
motor; or improperly sized wire.
√ For seized or locked diaphragm as-
sembly (water frozen?).
WILL NOT PRIME/SPUTTERS
(No discharge/Motor runs)
√ Is the strainer clogged with debris?
√ Is there water in the tank, or has air
collected in the hot water heater?
√ Is the inlet tubing/plumbing suck-
ing in air at plumbing connections
(vacuum leak)?
√ Is inlet/outlet plumbing severely
restricted or kinked? Restrictive
valves?
√ Proper voltage with the pump oper-
ating (±10%).
√ For debris in pump inlet/outlet
valves or swollen/dry valves.
√ Pump housing for cracks or loose
drive assembly screws.
RAPID CYCLING
√ For restrictive plumbing and flow
restrictions in faucets/shower
heads.
√ Water filter/purifier should be on
separate feed line.
√ Shut-off pressure set too low.
PUMP WILL NOT SHUT-OFF / RUNS
WHEN NOZZLE IS CLOSED
√ Output side (pressure) plumbing for
leaks, and inspect for leaky valves
or toilet.
√ For air trapped in outlet side (water
heater) or pump head.
√ For correct voltage to pump (±10%).
√ For loose drive assembly or pump
head screws.
√ Are the valves held open by debris
or is the rubber swollen?
√ Pressure switch operation. By-pass
set higher than shut-off.
NOISY OR ROUGH OPERATION
√ For plumbing which may have
vibrated loose.
√ For a restricted inlet (clogged
strainer, kinked hose, restrictive
valves).
√ Is the pump plumbed with rigid pipe
causing noise to transmit?
√ Does the mounting surface amplify
noise (flexible)? Does it bang like a
drum?
√ For mounting feet that are loose or
are compressed too tight.
√ For air in the system. Check all
fixtures for air and bleed system.
√ The motor with pump head re-
moved. Is noise from motor or
pump head?
5
LEAKS FROM PUMP HEAD OR SWITCH
√ For loose screws at switch or pump
head.
√ Switch diaphragm ruptured or
pinched.
√ For punctured diaphragm if water is
present in drive assembly.
MAINTENANCE
Normal pump maintenance is all that
is needed: Checking and cleaning of
the strainer, normal sanitizing and
winterizing and occasionally checking all plumbing hardware and fittings
for tightness. Lack of sanitizing is the
number one reason for premature pump
failure and poor performance over time.
Lack of sanitizing will cause scale buildup on the diaphragm and valves, causing
low flow and leak back [occasional
pump cycling with no faucets open or
tank filling up when hooked up to city
water].
TYPICAL PERFORMANCE
PRESSURE FLOW CURRENT
PSI BAR GPM LPM Amps
0 0 3.0 11.3 2.8
10 0.7 2.3 8.7 3.2
20 1.4 1.9 7.2 4.2
30 2.1 1.6 6.0 5.1
40 2.8 1.4 5.3 6.1
50 3.4 0.8 3.0 6.8
55 3.8 0.0 0.0 7.5
3
2
1
4
REPAIR KITS
ITEM COMPONENT PARTS KIT
1
2, 3
4
5
N/S
1, 2, 3, 4
N/S
Upper Assembly
Valve Assembly
2.5° Drive Assembly
Motor
Check Valve
Pump Head
Pressure Switch
94-800-00
94-800-01
94-800-02
94-11-302-00
94-800-03
94-800-04
94-800-05
3
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